ISHRAE
HAND BOO K
2009
ISHRAE
INDIAN SOCIETY OF HEATIN G
INSTALLATION
REFRIGERATING AN D
GUIDE
AIR-CONDITIONING ENGINEER S
ISHRAE
HEAD QUARTERS : # 502, DDA BUILDING, DIST.CENTRE, DELHI - 110 09 2
CHAPTERS AT : • DELHI • MUMBAI • BANGALORE • AHMEDABAD • PUNE • CHENNAI • MYSOR E
• NAGPUR • RANCHI • CHANDIGARH • COCHIN • INDORE • HYDERABAD • VADODARA • JAIPU R
• KOLKATA • VISHAKAPATANAM • GOA
SUB CHAPTERS AT : • LUCKNOW • BHUVANESHWAR • DEHRADUN • RANCHI • SURAT • HOSU R
• KALPAKKAM • MANGALORE • NASHIK • KOLHPUR SANGALI • JODHPUR • VIJAYAWAD A
• LUDHIANA • TRIVANDRAM
ii
ISHRAE Installation Guid e
DEDICATE D
TO THE ADVANCEMENT O F
THE AC ft R PROFESSION AND INDUSTRIE S
ISHRAE has compiled this publication with care, but the appearance of any technical data o r
editorial material in this publication does not constitute any endorsement, warranty, or guarante e
by ISHRAE of any product, service, process, procedure, design, or the like . ISHRAE does no t
warrant that the information in this publication is free of errors . The entire risk of the use of an y
information in this publication is assumed by the user .
Comments, criticisms and suggestions regarding the subject matter are invited . Any errors of
omissions in the data should be brought to the attention of the Editor .
INSTALLATION GUIDE Committe e
ISHRAE Board of Governors had allocated the Installation Guide project to Bangalore Chapter .
A Committee of following Members of Bangalore Chapter was set-up to formulate and publis h
Guide :
Technical Advisor s
•
S V Venkatachalam (Chairman) • Leslie D' Souza
■ Pankaj Sha h
•
Pandi Murali (Co - chairman) • G V Rao
■ Hari Rao
•
C Subramaniam (Co - ordinator) • B K C Jain
■ Bhagavan S
•
Rakesh Sahay (Editor )
INDIAN SOCIETY OF HEATING, REFRIGERATIN G
ft AIR-CONDITIONING ENGINEER S
Head Quarters : # 502, DDA Building, Dist . Centre, Lakshminagar, New Delhi - 110 092 .
ISHRAE Bangalore Chapter : No . 102, Santa Clara, 2nd Floor, 6th Cross, 100 ft . Road ,
Koramangala, Bangalore - 560 057 . Phone : 4149 5045
ISHRAE Installation Guide
in
Foreword
1 amglad to note that ISHRAE - Bangalore chapter is
publishing an Installation Guide for Airconditioning &
Refrigerating engineers. Installation Guide will prove
to be a handy tool for the practicing engineers to adop t
to the standardized engineering practices . The
handbook encompasses the standard installatio n
procedures for not so standard sites and brings along an uniformity . 'This in
turn eliminates the small mistakes which otherwise could end up to be a long
time pain. The operation and maintenance of the plant, post erection an d
commissioning is smoothened and also ensures efficient running of plant wit h
high up-time and enhances the asset's fife cycle .
Suggestions and inputs from the practicing professionals will always help i n
upgrading this manual.
Best wishes
MP Agarwat
National president -ISHRAE .
ISHRAE Installation Guide
v
Contents
SECTION 1 - DUCTIN G
Duct System Components
Vibration Isolators
Take-off s
Stacks, Boots and Head s
Dampers
Terminal Unit s
Air Terminals
Duct Cleanin g
Duct Fabrication Standard s
Longitudinal Joints (Seams )
Transverse Joints
Cross-breaking or Beading
Leakage and Sealing Duct s
Sealing as per ECBC of BE E
Ducting Standards and Practice s
I5 655 Standard s
Selection of Material and Joints
Selection of Material for Round Duct s
SMACNA Standards
Duct width and Reinforcement Spacin g
Table - Steel Reinforcement Codes for Ducting wor k
DWF 144 Standard s
Equivalent Aluminium Conversions from Stee l
Anciallries - Fabrication and Installatio n
Branch & Take offs
Elbow s
Tunrning Vane s
Branch Connection s
Offsets
Obstructions
Duct Support s
Access Door Arrangemen t
Typical Diffuser&Grille Connection s
Typical Diffuser Collar/ Tap Off
ISHRAE Installation Guide
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Flexible Duct Installation
30
Installation Precautions
30
Joining Requirements
30
Proper Support
30
Air Distribution System Installation and Sealing
31
Sealing Materials
31
Installation Materials
33
Fasteners
33
Duct Leakage Testing
33
Duct Insulation
34
Supply Ai r Outlets
Corrosion Resistant Fume Exhaust Systems and Duct Fittings
35
PVC Ducting
36
35
Suggested Standard Specifications
36
Exhaust Duct
36
36
Round Duct
Welding for Round and Rectangular Duct
37
37
Materials
38
Polyvinyl Chloride (PVC) Flanges
Installation of Flanges
38
39
Installation Tips
39
Torque Table
40
Rectangular Duct
Good Installation Practices
40
Dampers
40
Terminal Devices (Grilles & Diffusers)
41
Mixing Bgxes
44
Duct Testing
45
Test Set Up
45
46
Instrumentation
46
Test Sequence
46
47
Smacna Duct Performance Test Standards
Data to be Included in Reports of Tests
As per DW 144 Standards :
48
49
Air Leakage Table
49
Indian Standards - IS 655
50
Test Set Up
ISHRAE Installation Guide
SECTION 2 - PIPING
Genera l
Shop Fabrication s
Workshop Requirements
Stainless Stee l
Progress Contro l
Spool Size s
Steel Pipin g
Painting the Spool s
Preparations for Weldin g
General Requirement s
Misalignment Toleranc e
Nominal Pipe Size Misalignmen t
Slip on Flanges
Socket Weld
Valve s
Threaded Connections
Flanged Connection s
Branch Connection s
Cold Bendin g
Mitre Bend s
Preheat and Heat Treatmen t
Pipe Supports
Material and Pipe Spool Identificatio n
Storage and Handling of Piping Materials and Piping Spool s
General Storage Requirements
Stainless Steel Materials
Lined Steel Pipes
Factory Acceptance, Inspection and Testing
Inspectio n
Repair of Defect s
Shop Testin g
Installation, Erection, Constructio n
General Requirement s
Installation of Valve s
Piping for Rotating Equipmen t
Flanged Joint Bolt Torque
vii
51
viii
ISHRAE Installation Guid e
Recommended Bolting Torques
61
Pipe Supports
62
Insulated Piping Precaution
62
Stainless Steel Piping
62
62
Plastic Piping
Lined Piping
Underground Piping
Galvanized Piping
63
64
64
Mining Hose
64
Typical Piping Connections
66
Gauge Locations
67
Typical Chiller Connection Detail
Typical Coil Connection Details
69
70
Typical Condenser Water Piping Connection Detail
71
Typical Condenser Connection Detail
71
Typical AHU Connection With 3 Way Diverting Valve
72
Typical AHU Connection With 2 Way Valve
72
Recommended Piping Procedures
73
Avoid Air Traps
74
Avoid Air Locks
74
Avoid Bullheading
75
Avoid Erosion
75
C.I . Pot Strainer
76
Commissioning
77
Pressure Testing
77
Test Requirements
77
Test Media
78
Pneumatic Testing
78
Test Duration
78
Preparation for Testing
Test Equipment
78
79
Completion of Testing
79
Test Records
80
Cleaning and Re-instatement
80
Re-instatement
80
Steel Pipes Dimensions - ANSI Schedule 40
81
Flanges - API Vs . ASME/ANSI
81
Threaded Et Socket Welded Fittings - Pressure Classes and Schedules
82
ISHRAE Installation Guide
ix
Pipe Spacing Chart
Piping Support System s
Selection of Support Types
Refrigerant Pipin g
Leak Testin g
Test Pressure s
The Operating Pressure of an AC & R Syste m
High and Low Side of the Syste m
Procedures Adopted in Pressure Testin g
Methods Adopted for Pressure Testin g
Use Soap Solution to Detect Leaks
Use Halide Leak Detecto r
Use Electronic Leak Detecto r
Vacuum Standing Test
Dos & Don'ts
Vacuumisin g
Extent of Vacuum Require d
Procedures Adopted While Vacuumisin g
Instruments Used for Measuring Vacuum
Methods to Improve Vacuumising Proces s
Good Practise s
Suction Line s
Suction Line Risers
Liquid Line s
Good Engineering Practise s
SECTION 3 - INSULATION
Glass Wool Pipe Thermal Insulatio n
97
99
Precaution s
99
Hot Pipe
99
Cold Pipe
OutsideApplicatio n
99
99
Pipe Sections
99
Fittings and Hangers
10 0
Cautio n
10 0
Application Guideline s
10 0
Storage
100
x
ISHRAE Installation Guid e
Preparation
10 0
General Guidelines
100
Recommended Thicknesses
101
Fiber Glass and Mold
10 1
Heavy Industrial Applications Outdoors
101
Painting
101
Insulated Stand
10 1
Glass Wool Duct Acoustic Insulation
10 2
Typical Performance Chart
102
Limitations
102
Duct Thermal Insulation
Application and Specification Guidelines
104
104
Storage
104
Preparation
10 4
Application
104
Installation Procedures
10 4
Things to think before Installation
106
Underdeck Insulation - Concrete Slab
107
Installation a Design Considerations
107
Synthetic Insulatio n
Piping
107
Ducting
108
Flange Insulation
10 8
Fixing with Transfer Adhesive
109
Application of Insulation Material
109
WRAP - Around System
10 9
Cut Section Installation
11 0
Duct Installation
11 0
Hangers
11 0
Underslab
Installation Method
11 1
11 1
Roof Insulation
11 1
Above Purlin Installation
11 1
Below-Purlin Installation
11 2
Refrigerant Pipe Insulation
11 3
Points to Remember
11 3
Installation
11 3
Fabricating Fitting Covers
114
xi
ISHRAE Installation Guide
P-Trap Fittings
11 5
Insulation on Existing Refrigeration Piping
The Snap-on Method
11 5
11 5
Insulation at Pipe Hanger Locations
11 6
Insulation Pipe Hangers
Traditional Method
11 6
11 7
Correct Use of Synthetic Foam Insulation Adhesive
11 8
Important Installation Considerations
11 8
Engineering Considerations
System Testing
11 9
SECTION 4
EQUIPMENT
11 9
12 1
CHILLER PACKAGE
122
Unit Identification
123
Storage
126
Installation
12 6
Foundation
127
Clearances
127
Ventilation
12 9
Water Drainage
129
Moving and Rigging
129
Heavy Objects
129
Isolation Pads
Spring Isolators
129
Connecting Groove Pipes
Piping damage
13 2
132
Equipment damage
13 2
Vents and Drains
13 2
Evaporator Piping Components
13 2
Equipment damage
Water Treatment
132
13 2
Flow-Sensing Devices
13 3
PUMPS
12 9
13 5
Concrete Foundation
13 7
Base Plate
13 7
Rough checks
137
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ISHRAE Installation Guide
Grout
13 7
Grouting the base
13 8
13 8
Anchoring - Long Coupled
Anchoring - Closed Coupled
Piping
Suction piping
13 8
13 8
Good Practices
13 9
13 9
In-line pumps
140
COOLING TOWERS
14 1
Cooling Towers
142
Tower Location
14 3
Receiving the cooling tower at site
14 4
Foundation Level
14 4
Erection of Cooling Tower
14 4
Water Connections
14 4
Pump Connections
14 4
FANS
Causes of Non-Performing Systems
145
Fan Manufacturer's Responsibility
147
147
System Effect
14 7
Definition of System Effect
148
Causes of Losses
14 8
Inlet vs. Outlet Losses
148
Inlet Flow Conditions for a Fan
14 9
Outlet System Effects
149
For Axial Fans
149
System Effect Factors
Fan Sound Specifications
15 2
15 2
Sound Pressure is NOT Guaranteed
Noise Problems
154
Balance Et Vibration
154
15 4
Static Unbalance
15 5
Dynamic Unbalance
15 5
Vibration Terminology
Vibration Measurement
15 5
15 6
Causes of Vibration
157
ISHRAE Installation Guide
xiii
Rigid and Flexible Operation
15 8
Flexible Foundation Design
158
Drive Arrangements for Centrifugal Fans
160
Motor Positions
162
Fan Rotation & Discharge Positions
163
Good Installation Practices
164
AIR HANDLING UNITS
165
Documentation
Cabinet Installation
167
Coil and Piping Installation
167
Sheet Metal Installation
167
Controls Installation
167
-
168
Fan Installation
168
Electrical Installation
168
Final Installation
Sensor and Actuator Calibration Verification
168
169
Ceiling Suspended Air Handling Unit
170
HEPA FILTER
Special Features
17 1
Dioctylphthalate Gas (DOP Gas) for HEPA Filter Testing
171
171
Applications
172
PACKAGE & SPLIT REFRIGERATION AIR CONDITIONING UNIT
173
General Safety Information
Delivery Inspection
176
Installation Instructions
176
Handling and Placement of Condensing Unit
Space and Location Requirements
176
176
176
Condensing Units and Remote Condensers
Walls or Obstructions
177
Multiple Units
177
Units in Pits
177
Decorative Fences
177
Walls or Obstructions for Horizontal Air Flow
178
Multiple Units with Horizontal Air Flow
178
General Installation
178
177
xiv
ISHRAE Installation Guid e
Typical Arrangements
Water Regulating Valve
Subcooler
Condensing Unit Rigging and Mountin g
Ground Mountin g
Roof Mounting .
Access
Recommended Indoor Unit Placemen t
Minimum Unit Clearances
Indoor Unit Mountin g
Refrigerant Pipin g
Leak Check
Condensate Drain Line s
Evacuation, Dehydration and Start-U p
Evacuation Procedure
Finish Charging Procedures
Built-Up Remote Condensing Unit s
Pre-Charged Remote Refrigeration System s
During the Testin g
Check Lis t
General
Installation Dat a
Piping Connection s
MOTOR
19 1
Receiving and Storin g
19 3
Unpacking and Inspectio n
193
Storag e
19 3
Handlin g
193
Installatio n
19 4
Fitting of Pulleys or Coupling s
Drives-Belt s
194
194
Terminal Marking s
19 4
Wiring
194
THERMAL ENERGY STORAGE TANK S
19 5
VARIABLE AIR VOLUME BOXES Ft SYSTEMS
199
ISHRAE Installation Guide
Before Installing
xv
Mounting the Unit
201
20 1
VAV new Construction Installation
201
New Installation CW or CCW open Damper
201
Connecting the Power
202
Communications Bus Wiring
202
Connecting the Duct Sensor
205
Connecting , the Velocity Sensor
20 6
HEAT RECOVERY WHEEL
207
Installation Instructions for General Equipment
209
Mounting
209
Mounting the Rotation Monitor
209
Maintenance Instructions for Equipment
209
General
209
Procedures .
209
AIR SEPARATOR
21 1
PRESSURISED EXPATION TANK
21 5
Horizontal and Vertical
21 7
Location of Expansion Tanks
21 7
Point of Connection
21 7
21 8
Installation
VIBRATION ISOLATION AND CONTROL
22 1
Vibration Isolators - Materials Et Types
223
Rubber Isolators
223
Isolation Hangers
223
Structural Bases
22 3
Concrete Bases
223
Choice of Isolators
224
RUBBER APPLICATION
226
Anti Vibration Mounts
226
227
Installation of Rubber Expansion Joints
xvi
ISHRAE Installation Guid e
Alignment
227
Anchoring
227
Control Units
227
Bolting
227
Mating Flanges
22 7
Retainer Rings
227
Improper Installation
227
SECTION 5 - ELECTRICAL PANEL AND CABLING
23 1
Classified Locations
23 3
Remember
23 5
23 5
Cabling
SECTION 6 - SAFETY
24 1
Ladders
243
Scaffolding
243
Safety Helmets
243
Safety Shoes
Face Masks
243
Face Shields
243
Protective Goggles
24 3
Safety Belts
243
Hand Gloves
243
Precautions Before / While Welding
Fire Extinguishers
24 4
244
First Aid
244
Handling Gas Cylinders
Other General Safety Considerations
244
24 4
Electrical
244
Safe Working Loads for Chain Slings & Wire Rope Slings
246
Ladder Safety
Portable Ladders
248
Fixed Ladders
249
Cages for Fixed Ladders
250
Wells for Fixed Ladders
250
Use of All Ladders
250
Ladder Climbing and Standing
25 1
Nine Point Electrical Safety Programme
251
243
248
ISHRAE Installation Guide
xvii
Electricity- it is Safe, Don't Misuse it
251
Water + Electricity = Disaster
Fuse
251
25 2
Avoid Extension Cords
Don't be a 'Do-it-yourself' person
252
25 2
Handle an Electrical Emergency
Unable to reach the cable, socket or mains
252
Victim is Unconscious
253
Casualty is Conscious
253
252
Comparison between Temporary and Permanent Electrical Installations
25 3
Checklist on Portable Power Tools
Points to remember while selecting tools
25 5
25 5
Inspection .
25 5
Work Practices
255
Electrical Tools
255
Pneumatic Tools
255
Circular Saws
256
Grinders and Abrasive Wheels
256
Mark Criteria for Fire Extinguishers
257
General Requirements
257
Product Specific Requirements
257
FIRE SAFETY in stores
25 8
Principal Causes
258
258
Storage
Segregation
Stacking
258
Housekeeping
Handling
259
259
Equipment and appliances
25 9
Electrical installations
260
Other Measures
260
Handling Emergencies
26 0
25 9
SECTION 7 - CONVERSIONS 8 TABLES
26 1
SECTION 8 - IS CODES AND STANDARDS
279
SECTION 9 - GLOSSARY
289
Sectio n
DUCTING
Ducting
Ducting is used to distribute, collect transfer air, to & from all zones a s
per the design requirement .
A-Ducting installation is as important as its design . Improper installatio n
leads to lots of leakages at site and the AHU needs to keep pumpin g
that much amount of air resulting in wastage of power as well as therma l
energy.
The duct supports which are generally taken from the ceiling should b e
as liberally sized as possible and the anchoring of the same should b e
carefully done . Load testing of the anchors, though not the norm in ou r
country today, is as important as duct leakage testing .
Care should be taken not to puncture the ceiling in the hollow portion s
as well as non load bearing areas .
Safety measures can never be overemphasized . Safety for the peopl e
operating, handling and erecting the equipment is more important tha n
anything else . Follow all safety codes and more than that follow all logic s
to eliminate possible cause of accidents .
4
Ducting
Today, if we consider all the materials which
allow us to construct ducts in rectangular ,
round, or oval cross-sectional shapes, we wil l
find that the main ones are :
Galvanized stee l
Polyurethane duct board (preinsulate d
aluminum ducts )
Fiberglass duct board (preinsulated no n
metallic ductwork )
Flexible tubin g
Fabric Duct s
Duct system component s
Besides the ducts themselves, complete
ducting systems contain many othe r
components .
Vibration isolator s
A duct system often begins at an air handler.
The blowers in the air handlers can creat e
substantial vibration and the large area of th e
duct system would transmit this noise an d
vibration to the inhabitants of the building .
To avoid this, vibration isolators (flexibl e
sections) are normally inserted into the duc t
immediately before and after the air handler .
The rubberized canvas-like material of thes e
sections allow the air handler to vibrat e
without transmitting much vibration to th e
attached ducts .
Take-offs
Downstream of the air handler, the supply ai r
trunk duct will commonly fork, providing ai r
to many individual air outlets such a s
diffusers, grilles, and registers . When th e
system is designed with a main duct branchin g
into many subsidiary branch ducts, fitting s
called take-offs allow a small portion of th e
flow in the main duct to be diverted into eac h
branch duct . Take-offs may be fitted into
round or rectangular openings cut into the wal l
of the main duct . The take-off commonly ha s
many small metal tabs that are then bent to
ISHRAE Installation Guide
retain the take-off on the main duct ; roun d
versions are called spin-in fittings . Othe r
take-off designs use a snap-in attachmen t
method, sometimes coupled with an adhesiv e
foam gasket to provide improved sealing . Th e
outlet of the take-off then connects to th e
rectangular, oval, or round branch duct .
Stacks, boots :and heads
Ducts, especially in homes, must often allo w
air to travel vertically within relatively thi n
walls. These vertical ducts are called stacks
and are formed with either very wide an d
relatively thin rectangular sections or ova l
sections . At the bottom of the stack, a stack
boot provides a transition from an ordinar y
large round or rectangular duct to the thin wall mounted duct . At the top, a stack head can
provide a transition back to ordinary ductin g
while a register head allows the transition t o
a watt-mounted air register.
Damper s
Ducting systems must often provide a metho d
of adjusting the volume of air flow to variou s
parts of the system. Balancing, flow-control ,
and fire/smoke dampers provide thi s
function . Besides the regulation provided a t
the registers or diffusers that spread air int o
individual rooms, dampers can be fitte d
within the ducts themselves . These damper s
may be manual or automatic . Zone damper s
provide automatic control in simple system s
while VAVs allow control in sophisticate d
systems .
Terminal units
While single-zone constant air volum e
systems typically don't have them, other type s
of air distribution systems often have termina l
units in the branch ducts . Usually there is on e
terminal unit per thermal zone . Some type s
of terminal units are VAV 'boxes' of eithe r
single or dual duct, fan-powered mixing boxes
ISHRAE Installation Guide
Ducting
of either parallel or series arrangement, an d
induction terminal units . Terminal units ma y
also include either, or both, a heating o r
cooling coil .
section length, its inherent stiffness an d
rigidity will be greater and therefore a
lower thickness of sheet metal i s
adequate . SMACNA prescribes the least
thickness of sheet-metal possible as a n
unduly heavier gauge will increase bot h
the self weight of the assembly leadin g
to greater deflection and leakage as wel l
as resulting in greater noise an d
vibration .
Air Terminals
'Air terminals' are the supply air outlets an d
'return' or 'exhaust air inlets' . For supply,
diffusers are most common, but grilles, an d
for very small HVAC systems such as i n
residences, 'registers' are also used widely .
Return or 'exhausrgrilles' are used primaril y
for appearance reasons, but some als o
incorporate an air filter and are known a s
'filter returns' .
Duct Cleanin g
The position of the U .S . Environmenta l
Protection Agency is that "If any one in you r
household or office suffers from allergies o r
unexplained symptoms or illnesses and if,
after a visual inspection of the inside of th e
ducts, you see indications that your air ducts
are contaminated with deposits of dust or mold
(musty odor or visible mold growth), the n
having your air ducts cleaned is probabl y
necessary." Duct cleaning will usually chang e
the quality of the air you breathe, it will not
significantly affect airflows or heating/ coolin g
costs" .
Duct Fabrication Standard s
Comparing the BIS and SMACNA standard s
with reference to the two key performanc e
requirements :
•
Structural Rigidity: Under SMACNA, i n
addition to duct cross section, the shee t
metal gauge is also a function of pressur e
class, spacing between joints ,
reinforcements and type of joints .
SMACNA recognises that the shorter the
5
•
Leakage : Under SMACNA a leakage limi t
of 5% is deemed acceptable for mos t
applications (less than this als o
achievable by greater use of sealants) .
•
Interestingly, While both leakage an d
structural rigidity characteristic s
inevitably deteriorate with an increas e
in the number of longitudinal seams or
joints neither BIS nor SMACNA specify a
limit on the number of such joints in a
duct assembly.
The predominant form of fabrication in th e
West is with coils rather than sheets, seam s
are typically located on the edges (Fig .3) an d
commonly of the "Pittsburgh" or "Snap" loc k
type (Fig .4 & 5) both of which provide fo r
lower leakage and higher reinforced structura l
strengths .
Note : where no pressure classes are specifie d
by the designer, the 1" W .G . (250 Pa) pressure
class is the basis of compliance regardless o f
velocity in the duct . However, all variabl e
volume duct upstream of VAV boxes shoul d
have a 2" W.G . (500 Pa) basis of compliance
when the pressure class is not defined .
6
Ducting
ISHRAE Installation Guid e
IHmmi.
e.
Fig 5
Fµ 1
x I ICO x 2400 mm lg l
Tm
1_`Dun
. _ 11600
.
km 2.4 m x 1 .0 m duc t
BUTTON PUNCH SNAP LOCK
Longitudinal Joints (Seams )
Longitudinal joints though preferred to be onl y
on one side, shall be restricted to maximu m
of two diagonally opposite edges .
These should be machine-formed of any o f
the following types :
a. Pittsburgh lock type .
Fig 2
Acme lock
b. Button Punch Snap lock type .
Joints and seams should be able to withstan d
1 .5 times maximum operating pressur e
without deformation or failure .
Transverse Joints
Transverse joint must be able to withstan d
1 .5 times the maximum operating pressur e
without deformation or failure .
Fig 3
Tm dun 11600c 1100x 1200 mm Ip l
Ixbr'evd fnmw 1 .2 m wide mil s
Where a transverse joint acts as a reinforcin g
member its maximum allowable deflection wil l
be 6 .25 mm for ducts upto 1220 mm width
(W), and W/200 for greater widths .
For the spacing of transverse joints and typ e
of reinforcement refer 'SMACNA' tables fo r
rectangular ducting covering pressure clas s
from 125 Pa W.G . to 2500 Pa W.G .
Cross-breaking or Beadin g
Flg 4
PITTSBURGH LOCK
Cross-breaking or beading are effective way s
in dealing with commercial . tolerances on out of-flatness, natural sag from dead weight an d
ISHRAE Installation Guide
Ducting
7
Table 1 Standard Duct Sealing Requirements
Seal Class
Sealing Requirements
Applicable Static
Pressure
Construction Class
All transverse joints ,
4' (1000 Pal w .g . and
longitudinal seams and duc t
upwards
wall penetrations
B
All transverse joints an d
T(750 Pa)w.g .
longitudinal seams only
C
Transverse joints only
Z (500 Pa) w .g .
In addition to the above, any variable air volume system duct of 1 '
(250 Pal and W (125 Pa) w .g . construction class that is upstream
of the VAV boxes shall be Seal Class C . All Acme joints should b e
seated .
A
n¢ 6 : Cr ... breakin ¢
ducting system can be ensured by makin g
ducts reasonably airtight which can b e
achieved by :
Fr, ]r Ra n F
with the flexure reversals that may result whe n
duct pressure is inadequate to stretch th e
sheet taut . Ducts for 4" W.G . (1000 Pa) o r
more do not require beads or cross-breaks .
Leakage and Sealing duct s
Leakage is largely a function of static pressure
and amount of leakage in a system i s
significantly related to system size .
Economical and quiet performance of the
a)
selecting a static pressure constructio n
class suitable for the operatin g
condition, an d
b)
properly sealing the duct work .
Transverse joints should be sealed wit h
gaskets, and for ease of application, gasket s
should preferably be self adhesive .
Heavy mastic sealants are more suitable a s
fillets in grooves of longitudinal seams .
Mastics having excellent adhesion an d
elasticity are preferred .
8
Ducting
ISHRAE Installation Guid e
Sealing as per ECBC of BEE, Ministry of Power, Government of Indi a
requirements :
Ductwork shall be sealed in accordance with Table belo w
Ductwork Sealin g
•
500 Pa
Duct Location
Supply Duct s
L-500 Pa
Outside Conditioned Space
-
Unconditioned Spaces
t
-
Indirectly Conditioned Space s
-
f
Return Air Plenum s
--
Cooled Spaces
None
Exhaust Ducts
Return Duct s
Non e
Non e
Non e
. 1
Non e
Non e
— All joints and longitudinal seams, and at all duct wall penetrations . Snaplock longitudinal are not allowed .
Pressure sensitive tape shall not be used as the primary sealant .
I All joints and longitudinal seams . Pressure sensitive tape shall nil be used as the primal y
• Transverse Joints only, 1 Ducts within the conditioned space to which limy supply air or from 'which they exhaus t
air need not be seated .
NOTE : Unless otherwise shown in design documents, ductwork between the supply fan an d
variable air volume boxes shall be considered to be in the e"500 Pa (2 in . w.g .) pressur e
classification, while all other ductwork of any application shall be considered 250 Pa ( 1
in . w.g .) pressure classification .
ISHRAE Installation Guide
Ducting
9
DUCTING STANDARDS AND PRACTICE S
IS 655 STANDARD S
Types of Seam and Connection s
111
,c nu,
Selection of Material and Joint s
THICKNESS OF SHEET AND TYPE OF TRANSVERSE JOIN T
FOR RECTANGULAR DUCT CONSTRUCTIO N
(Clauses 3 .1 and 5.2)
MAXIMU M
Sloe
Tiucssrs s
or Snxbr
Tvrr, or Taewevtxe x
Jon.-r CONNtcrioNa
Hnemx e
318hoeta Aluminiu m
Shoots
1q
2)
13)
f41
(5 )
mm
mm
mm
Mon o
0 . 63
0'80
&drive, pocket or bar
Up to 300
slips, on 2-5 m centre
s
Non e
f S-drive. pocket or bar
slips, on 2 . 5 m centre s
301 to 800)
S-drive, 2 .5-mm pnrknt 25 x 25 x 3m m
0 . 63
2:80
angles . 1 . 2 i n
or 25.mm bar slips o n
001 to 750 J
from join t
2 .5 m contras
Drive . 35-mm pocket or 25 x 25 x 3m m
25-nun bar +lipe, o n
angles, 1'2 i n
2'5 m cantina
from joint
i .51 to 7 (7001
40 x 40 mm angle con- 40 x 40 x 3 mm
motions, or 40-m m
angles, 1 . 2 i n
0 . 80
1 . 00
pocket or 40-mm bar
from join t
1001 to 1a00J
slips, with 35 x 3m m
ber reinforcin g
on 2 . 5 m centres
1 . 50
a0 x e0 mm tingle con - 40 x 40 x 3 m m
1501 to .3 230
1•00
nations, or 40-m m
diagonal angles ,
pocket or 40-mm bar
or 40x40x 3m m
slips , 1 in maximum
angles, 80 c m
wit h
from join t
centre',
35 X 3mm bar rein .
lasting
1 . 25
1 . 80
50 x 50 mm angle con - 40 x 40 x 3 m m
2251 and above .
diagonal angle s
neotione or 40.m m
pmket or 40-mm bar
or 40x 40x 3mm
sllpe, 1 mm maximu m
angled, 60 cm
',entree
wit h
from joint
9.5 x 3 mm bar rein forcing
250
mm
and
larger
require
special
Gold study for hanging and supportin g
• Duct, 3- 2
016iivda .
10
Ducting
ISHRAE Installatio n Guide
Selection of Material for Round Duct s
Thickness of Sheet For Round Duct s
Diameter of Duct
Thickness Of Shee t
GI (mm)
Aluminium (mm )
150 to 500
0 .63
0 .90 or 0 .8 0
501 to 750
0 .80
0 .90 or 0 .8 0
751 to 1000
0 .80
1 .25 or 1 .0 0
1001 to 1250
1 .00
1 .60 or 1 .5 0
1251 and above
1 .20
1 .8
SMACNA STANDARD S
Sheet Thickness W/O Reinforcements as per Pressure Clas s
Duct Dimensio n
(mm)
200 and undo
230-250
251-300
301 - 350
351-460
401-450
451-500
501-550
551-600
601-650
651-700
701-750
751-900
901- 1000
1001 -1200
Pressure Class, P a
Positive or Negativ e
500 P a
750 P a
1000 P a 11500 P a
055
0.70
U]U
0 .70
0.55
0]0
0 .85
O.RS
0 .55
0 .70
0.85
Ina
0 .70
0 .85
1 .00
00
070
0 .85
1 .00
1 .31
0 .85
1 .00
1 .31
1 .31
1 .00
1 .31
131
1 .6 1
1 .31
1 .31
1 .31
1 .6 1
1 .31
1-31
1 .31
1 .6 1
IJI
1 .31
1 .6 1
1 .31
1 .11
1b 1
1 .31
1 .31
1 .6 1
1 .61
1 .6 1
125Pa
250 P a
0.5 5
0.55
0 .55
0 .55
0 .55
0.55
0.55
0.55
0.55
0.55
0.55
0.70
0.70
0.70
0.85
0.85
0 .85
0 .85
1 .00
1 .00
1 .31
131
IJI
1 .31
1 .61
131
1 .6 1
1 .61
1 .61
1 .61
. Table 2-47M Unreinforced Duct (Wall Thickness)
2500 Pa
0 .8 5
1 .0 0
1 .3 1
1 .3 1
1 .6 1
1 .6 1
This mblc gives minimum duce wall thickness (mm) foruse of fat type joint syuems . Plain S and Itemmcd S mm.xmr s
am limited to 500 Pa maximum. Slips and drives muss not be less than two gages lighter than the duct voll nor belo w
0 .70 mm. Double S slips must be 0 .70 mm for ducts 762 mm wide or less and 0 .85 mm for sealer width.
Duct Thickness (mm)
Minimum Flot Slip & Drive thickness (mm)
See Figure 2-8 forloint tri m
I 0.55 to 0 .85
0 .70
1,00
085
I
1 .31
1 .00
1 .61
1i 1
ISHRAE Installation Guide
Ducting
11
Duct Width and Reinforcement Spacing
0.70 mm
'
0.80 mm
11.00 mm or Heavie r
.Duct Wall
0 .55 mm
Maximum Duct Width (W) and Maximum Reinforcement Spacing (RS)
Static Pressur e
(Pa)
W (mm) RS (m) W (mm) RS (m) W (mm) RS (m)
W (mm) RS (m )
125
50 8
457
3
250
50 8
356
305
N .R .
500
457
750
305
254
508
N .R
508
N.R.
508
356
2.4
N .R.
508
457
3
N.A.
1.5
457
305
2.4
N .R.
45 7
356
1 .5
457
1 .5
254
N .R .
N .R.
2.4
3
1 .8
1000
Not Accepted
1500
508
N .R.
508
N .R.
3
N .R.
457
N. R
457
1 .5
457
1 .8
356
N.R .
406
203
1 .5
305
305
N.R .
N .R .
254
N.R .
305
N. R
305
1.5
1.5
305
1. 8
203
N .R.
30 5
203
N .R.
254
N .R .
1 .8
Table 2-48M T-1 Flat Drive Accepted as Reinforcement
Table - Steel Reinforcement Codes for ducting wor k
Code
C
D
E
F
G
H
J
K
Steel Angle Size (mm )
25x25x1 .6 1
25x25x3 . 2
31 .8 x 31 .8 x 3 . 2
38 .1 x 38.1 x 3 . 2
31 .8 x 31 .8 x 4 . 8
51 x 51 x 3 . 2
51 x 51 x 4 . 8
51 x 51 x 6 .4
63 .5 x63 . 5x4. 8
Note - To read the tables given for reinforcement code for duct panel thickness, the followin g
procedure to be adopted .
Example - for 6" wc, 2 .5"-2 .6" duct size and spacing option is 4 ft . - you have F-0.85 to F-22 i .e.
"F" type reinforcement as above table and 22G sheet . The table above has sizes for the
reinforcements codesA,B . . . .K.
12
Ducting
I1n . wg
Slali <
Pas. or Na.
Dun
Dimensio n
---
--"
----- Reinforcement Spacing Options -_
Inn
aqn
60
C)
26 ga
11-12 in
36 ga ,
13- 14in.
15-16 in.
268x .
26gn .
1]-18 n.
2A ga,
Ngo.
4 0
0
7
*311`
n
] 11
C)
o,
2
-13-+_6
0-26
C-26
B86
C-26
C-26
G26
G26
C-26
.0
24
.24
0
C-26
0-26
D-26
C .26
C-36
D-26
&20
FIB
G-18
E-22
F-20
0.18
E-24
E-22
F-20
0-24
624
H-18
I-I6
11-18
H-18
G-10
G-20
1-16G
H-18O
1-I8G
71 *.
G29
C-26
G24
21 pp.
25-T6 in .
2]-28 in .
20 pp.
188x.
G24
.22
0
G24
.24
0
29-30 in .
31-36 in .
32-42 in .
IB ga .
18 gv.
D-II
E-23
16 go .
16 8a .
55 -60 in
61-]2 in.
93-84 n.
5 n
_
Not Required
19-20 in
21-22 in.
2]-3d w .
43 -48 in
49-54 in .
---
Itoinfnmemrm Cnde fur IMO Gage Nnni6e r
Na
Ileln(nrcemen l
Required
IO in. anti wtiv
ISHRAE Installation Guid e
Net DeslBOed
85-96 0.
9] -108 10.
1-16H
-
B-26
N4o
D-26
.2 5
0
C-26
C-26
B-26
.26
0
.026
3 .26
11-2 5
0-2 5
C-26
C-26
G36
C-26
C-26
0-26
B-26
C-26
B--25
B-2 5
C-26
0 . 26
C-26
0.26
C-26
C-26
0-26
G2 5
C-2 5
F-22
F-22
G¢2
E-26
E-N
4'-N
F-24
0 . 26
E-26
C'-24
F-2'
H-18G
1-18G
H-22G
1-20G
F-24
H-22G
E-24
F.24
H-22G
E-24
F-24
G-22
1-18H
1-1811
1-200
H-200
1-16H
I-1811
3-1611
I-18G
1-18N
1-180
1-1811
11-2 20
1-18 G
1-18 G
109-120 in
C85
0 .26
0-26
L ^_6
.26
0
'
E24
E-24 -
Table 2-2 Rectangular Duct Reinforcemen t
la
2 in .
Slade
Pos . or Neg.
pur l
Dimension
Reinforcement Code for Duct Gage Numbe r
No
Reinforcement
Required
Reinforcement Spacing Option s
10 n
8D
6n
C
ID in and under
11-12 in,
13- 14 in.
26 gr .
24 ea .
IS-I6 in.
1] -18 in.
24 ga,
22 ga,
19-20b.
20 ga .
21-22 in
18 9 .
16 gx .
3D
©
0
Q
2b fi
2n
10
Not Require d
626
13 .26
1584
626
C-26
G26
C-26
C-24
026
G26
B .26
G26
C86
0-26
G24
G26
0-26
G26
G26
0-26
8-26
C-26
0-24
E-2i
E.22
0-26
0.26
D-26
D-26
G26
0-26
G26
G26
0-16
G26
2-22
E-22
F20
F-20
Edo
F-20
E-24
E-22
E32
D-26
Edo
E-24
D-26
D=M
C-26
D-26
0-16
G26
G26
G26
C-26
C-2 n
G-IB
H-16
G-20
H-10
F22
G-20
FN
G-22
E-16
E-24
F-24
0-26
E-26
C-24
0-26
D-26
C-2 6
D-2 6
43-40 in,
1-18
H-20
11-22
0-22
F-24
E-26
F-14
E-2 6
E-24
49-54 in.
55-60 in.
6160
1-1SO
14-300
11-200
024
F-24
F-24
1-18G
J-16H
1-100
}1811
H-20G
I-20G
G-2
II-22G
0-
F-24
1 .168
IdOG
l-18H
L20G
1-18H
11-22G
1-22G
1-2011
11-2i
1-22 1
1-221 1
K-161
K-ISli
1-1811
1-181 1
K-161
K-181
1-181
2]-28 in .
29-30 in,
31-36 in .
37- 42 in,
j
4D
11 .26
23-24 in .
25-26 in .
I
26ga .
511
61-Rin.
]1-84 in.
05-96 in.
9] -108 in,
109-120 in.
IB Ea .
18 ga
18 ga.
16 ga-
0 .22
0-22
Not Designed
R26
G26
B-26
C-26
0-26
Table 2-3 Rectangular Duct Reinforcemen t
ISHRAE Installation Guide
Jinn ;
Stati c
r6 : . or Nee .
Duc t
Dimension
Reinforcement Code for Duct Gage .'umbe r
N.
ltdnforcemen t
Required
Reinforcement Spacing Option s
1011
8R
6B
5f1
O
O
©
Ili
O
O
10 in, old under
I I -12 in.
13 - IJ in .
15 -16 in .
17 -18 in.
19-20 1n.
21-E2 in.
2J-2J in.
25 ;^_e in .
2]-28 in .
29-20 in,
11-J6 in .
3]-J3 in .
43 .4A i n .
49459i n
55-dl in .
61,02 R.
23-84 in.
85 .i 95 in,
! 108 in.
109-120 in
24 0n.
24 m.
22 p.
22 ga.
20 En,
IB Ea.
180n,
1E 6e.
188a
18 p.
IS B o .
160a_
Not Requital
4 in ..g
Static
Pos. or Neg .
Duct
Dimension
O
13
Ducting
4B
3ft
214a
O
I0
B-26 B-26
B-26
B-26
B-26 R-26
C-26
626 B36
C-26
026 C-26
026 C-26 C-26
D-24
C .26 C-36
D-24
D-26 C-26
E-24
D-26 D-26
E84
D-26 D46
E-24 E .26 D-26
E-24
Ed6
626
F-22
F-24
636
F-24
F-24
G-22
1620 c32 G44
I-10G 11-220 0-24
1-160 H-200 11420
1-1811 1-200 1.226
K-16H RI BH I-70H
L-161 K-181 1 .181
L-161 L-181
L-161 4181
Table 2-4 Rectangular Duct Reinforcemen t
B-26 B-26
B .26 B-26
C-24 624
024
C-24
0-24 D34 C-24
D32 D-22 0-24
E@
E-22 D-21
E-20
E33
E-24
F40
E-22
E-24
F-22
F-20
F-20
G-20 F-20 F .22
111-18G 11-18G H-186 0-20
I .16G II-18G H-20G
1-1611 I-18G 1-180
1-1611 I . 18G
1-16H L16G
Not Designed
3-161
L16I
No
Re inforcemen t
Required
2B
p-2 6
B-26
636
C-2 6
C-26
026
C-2 6
C-1 6
62 6
D-26
D-26_
E-26
E .26
R2 4
624
0-24
1-246
6226
1-2011
K .181
K-18 1
Reinforcement Code for Duct Gage Numbe r
_ 101 ft
0 O
Relnforeement Spacing Option s
6R
0
1 4P
`/ O
55 II
3R
2YaR
O
O
211
10
V
S in . and under
24 8n
I
P36
B-26 B36 p86
036 B-3 6
iot Reyulrtd
9-10 in .
22 FnB-2 .1
R-26 626 B-26
0-26 B-2 6
11-12 i n.
228a
I D34
C-24
C-26 626 026 3-36 B4 6
13 - l in,
20 ccC-22
022
024
C-26 026 C-26 02 6
15-16 in
20 p.
.II D3'_ C-24 026 C3R 036 G2 6
0
17-18 in .
N go,
.22 0
0
.22 D-24 D.26 I C-26 C-26 0'_ 6
19-20 in .
E30
E-32
E24
D-24 D .26 C-26 C-2 6
IBFn,
2 I - 23 in .
IB p.
610
E-20 6-N E-2 .1 D36 D-26 02 6
2G-24 in,
d 0.
F-20
F-20
.33 E-04
1
626
D-26 D26
25-26 in . _ 16_,
G-IB G-I8 F-20
F-22
E34
F.-16
E-26 D-26
27-28 is
168e
II-18G G-18 G-20 F-22
F39 [36
E-26 D . 26
39-JO is
168v.
H-18G ILIBG G .IB G-22 F-24 E-26
E26 F2 6
1-16H 1-16G H .18G M20 G42 P 24
11-16 in.
F'_6 E-2 6
42 in
` 1-1611 li6c 1-180 11-200 G42 G24 F-26
43-4X
1 1 .1611
1-I8G MSG H .22G H24G G-2 4
1-1X11 11-180
49-54 in.
1 1-1611
11-220 1134 6
55-60 in
RIO 1 RIM 1-20 Von 111.14 0
61- P in.
\nl pni¢ned
I K-1611_ 1-181 1 r 1-2011 1320
K-ILI 1, 1X 1 1201 1
75 A4 in.
-ILI K'1NI 130 1
85-94 in
97- IUN in
1 .16 1 I . IXI 1.181
IYI- 120 in .
1 Ld61* L .I81 LI81
Table 2-5 Rectangular Duct Reinforcemen t
1
1
L
1
J
ISHRAE Installation Guid e
Ducting
14
61n. wg
Stalk
or N
;Pa or Neg.
Duet
-Dlmemlo°
-
>
Reinforcement Code for Duct Cage Numbe r
No
Rc3oforceme m
Required
O
0
8 in and under
24 gm
9 - 10 be
11-12 in .
D-14 n
15-16 in.
24 p
O-18 in
18 Rs.
16 ge .
Reb2foreemenl Spocing Option s
1011
8R
611
O
O
O
5R
411
30
21£0
21
1
©
O
O
O
l0
026
0-26
0-26
3-26
616
C-24 C-24
C-24
8-26
C-26
C-26
B-14
626
0-24
L24
D-26
D-26
C-26
0-26
026
626
026
626
E-24
F-24
F-22
Q24
624
624
D-26
.26
0
E36
OM
D-26
.26
0
F-22
022
0-22
1-24
F-24
F-24
E36
E-24
F-24
_ F-24
E36
614
E-24
F.2 4
H-20G
1 . 180
LION
H-22G
HSOG
1-20H
J-1611
116H
85-%w
97-102 n
1-1BH
.1 .18H
' K-161
L161
11-16
.11. 16
109-120 in .
Kt-I6
19-20 m
21-22 n
23-24 n.
23-26 in.
Z2-22 in
Not Required
C-22
D-24
C-22
C-24
C-24
C-22
.0
20
.0
20
.20
0
0-22
0-22
E-20
F-20
F-18
GIB
E-10
F .20
F-20
020
621
E-22
F.22
F-22
11-160
Hd6G
1-160
0-18
H-18G
H-18G
0-20
11-200
11 .180
1-I8H
20 gn
208n .
IB Erg
F-15
F-18
.1g
0
16 g1
16 gn
H-160
-
29-10 in.
I
31- 16 in.
37 -42
L16H
1-1611
43-48 in.
49-54in .
55-60 in
1-16H
3-1611
Not Dmgned
61-Rirt
23-84 in
G-24
11-220
1326
1-200
13011
1-181
L181
11-I6
.11 .16
Kt-I6
F-24
0-22
:-220
1-220
I-22G
1-201
1
K-18 1
LI0 1
L18J
Kt-18
Table 2-6 Rectalgular Duct Reinforcemen t
10 tn. wg
Stati c
Homer Neg.
Duct
Dlmemlon
Reinforcement Spacing Optio n
1011
0 in.md under
9-10 n
11-12 n
I3-14 in
22 gm
200 .
I8 g .
I8 g.
15-16 n
12-18 in
16 so
16 gs
19-20 n
21-22 in .
23-24 in
25-16 .
27-28 in.
29-30 .
Reinforcement Code for Duct Gage Numbe r
No
Rcluforcemen l
Required
8R
Net Required
E .10
C-20
.20
0
618
F-I8
G-16
F18
G-18
H-160 _H-18G
L16G
-
1-18G
L16G
-
5R
411
3fl
2Rn
2a
C-20
610
.20
0
&20
624
C-26
C-26
C-24
.24
0
D-22
E-2D
F-20
C-26
C-26
C-26
D-24
E-24
C-26
022
.22
0
E-20
8-20
C-26
626
.26
0
D-24
E-24
F-22
F.22
0
.22
E-34
684
F-24
F34
C-26
C-26
02 6
D .2 6
62 6
G-22
H-22G
H-22G
1-20G
1-IAG
F-24
6-24
11396
H-22G
130H
G-34
11340
L22 G
1-161
J+101
I-IBH
1 .221
1
L-161
K-181
L161
L-161
1-I5H
K-181
L181
LIW
I .20H
J-201
L10 1
L18 1
E-I8
F-18
G-18
11.18G
I1-10G
1-16G
1.166
1-160
11-36M
F-10
GIB
0-18
11-IBG
H-IBG
HIBG
1.18G
J-1611
1 .161
- 32-42 in.
43-40 in.
49-54 in.
6R
Not Deigned
F-20
0-20
H-20G
H-200
H-18G
I-12G
1-18H
1-181
55-60w
61-72 .
71-84 in.
E-2 4
E2 4
F.2 4
F-2 4
F-2 4
V-I 6
Lt-1 6
Lt-1 6
85-96 n
97-108 in .
109- 120 in
Table 2-7 Rectangular Duct Reinforcement
Ducting
ISHRAE Installation Guide
Iln . rig
Smile
Fos . .. Neg .
- Duel
Dimension
10 in. end under
II -12 in .
13-14 in.
I5-16in .
Ir-18 in.
19-20in .
21-22in .
23-24 in .
25-26 in .
22-28 in .
29-30 in .
31-36 in .
)2-42 in .
43-48 in .
49-54 in.
55-60 in .
61-72
4 it Joints
Mln
go
Join t
RUM:
26
z6
26
26
26
26
26
26
26
26
26
26
24
24
22
22
22
20
NM
NM
NR
NR
NR
NR
NR
NR
NM
NM
NM
NM
NR
NM
NR
MR
JiR
ITR
Alt.
Ada..
15
4 R Joints o/2 IT Rebel Spacin g
JounlsReinf.
Int . RcInf.
joint
Al
t
Agga
Rer.. Joint T1n Rod AIL
Reivf.
ReInf.
NM
NM
NR
N/R
NM
NM
NM
NM
NR
NR
NM
NM
NR
NM
NM
NM
(2)E
(2)H
Use4 RJeln u
26
NM
NM
MPT
C
26
NM
NR
MIT
D
24
N0l
NM
ASPT
E
24
NM
NR
MIT
E
22
NM
NR
MPT
F
22
ITR
(2) E
MPT
G
33-84 in .
20
NM
NM
MPT
G
85-96 in .
18
JTR
(2)H
22
1TR
(2)E
MPT
H
92-108 in .
ITR
(2)H
18
18
fB
(2)H >-<
1
109-120 in .
JTR
(2)11
18
JTR
(2)11
16
I
Table 2-9 4 ft Coll/Sheet SloclS/T25a/T25b (TDC/TDF) Duct Reinforcemen t
4 It Joints w2 D RGnf. Spacing
4 fl Joints
21v . w g
SmDC
J91nts/Relnf.
Inc. RAI L
P os. ar pkg .
Am
Ali n
Join t
Alf.
o
JJoint
Join t
AL
L
min
Rein(
Duel
6a
John Ile Rod Mint.
ReInf.
Rom.
ga
Dimensio n
ReInf.
N/R
WA
IO in. and undcr
26
WA
11-ain.
26
WA
Il-14 in
26
WR
N/A
N/A
I5-I6 in,
26
NM
12-18 in.
26
NR
WA
Use 9 f l J o i n ts
19-30 in .
26
NR
N/A
21-22in .
NM
N/A
26
N/A
23-24 in,
26
WR
25-26 in,
26
NM
N/A
NIA
22-28 in,
26
NM
N/A
NR
N/A
6iPT
C
29-10 in,
24
NM
26
N/A
0
31-36 in .
24
NR
N/A
26
NM
MPT
l]-42 in .
22
NM
NIA
24
NR
WA
MPT
E
(2) C
24
NM
N/A
MPT
E
22
ITR
A-49 in .
20
NR
WA
MPT
F
49-54 in .
l0
JfA
(2)E
22
NM
NIA
MPT
F
55-60 in .
(2)E
22
NR
20
in
11
(2)11
20
ITR
(2)F,
MPT
20
1TR
61-Rin
NIA
MPT
H
I8
WR
2MPT
I
23-84 in.
20
Mt
(2)11
20
1TR _ (2) H
(2)H
1
JTR
(2)II
20
ITR
2MIT
85-96 in.
18
ITR
(2)H f
92- 108 in .
16
31R
(2)1
18
(2)11 j
1
109-120 in .
Not Designed
is
ITR
Table 2-10 4 ft Coll/Sheet SIock/T2Sa/T25b (TDC/TDF) Duct Reinforcemen t
J ln .wg
soni c
Pns or N cg.
Due l
Dimensio n
IO in_ and undo(
II -12 in .
I3 -14 in .
15-16 in.
I7 -I8 in .
i9-20 iry
21-22 in.
21-24 in.
25-26 in.
22-28 in,
29-10 in.
11-16 in .
37-42 in .
4l-I8 in 49 -]9 in .
15-(O in .
61-22 in.
21-84 in.
85-96 in.
92-IO8 in.
109-120 in .
4 RJOinls
AIL
Jalvl
Hann
Mi n
64
Join t
ReinL
26
26
26
26
26
24
24
26
24
24
24
22
22
20
'_0
18
Na
NB
WA
NIR
WA
N/R
N/R
N/A
WA
WA
N/A
N/A
N/A
ITR
N/A
N/A
(2)C
WR
(2) E
(2) H
is
JB
(2)H
18
16
16
fTlf
-(2)1
ITR
(2)1
(2)L
4 IS Joints Iva ft Relnf. SPaclo g
JoinlafReinf.
IIL RAI L
All
.
Jeln t
AI L
rai n
Joint Tie Rod Rani.
RI nf.
Rv
R91nf.
WA
N/R
NM
NIR
N/R
NIR
WA
WR
N/R
JTR
NRl
JTR
MR
Nol Designed
Use4 RJoints
26
26
26
' 26
26
26
24
24
N/R
N/A
N/A
N/R
WA
N/R
N/A
N/A
NIA
NIA
N/A
N/R
N/R
N/R
N/R
WR
NIR
MPT
0
-MPT
2MCI
2MPT
>-<
1
I
I
K
K
(2)C
Na
(2)C
20
JTR
20
18
18
RR
RR
JTR
C
D
D
E
- p)H
(2)1
(2) 1
(2) 1
(2) 1
NIA
JTR
NlR
C
F
G
0
G
NIR
1TR
C
C
MPT
MPT
Mn
MIT
22
22
20
22
2o
20
NIR
MPT
MPF
Mn
MPT
MPT
MPT
MPT
MP T
f
41nm C
Sall e
Pos. ar Pkg.
Auer
Dlmension
8 in W under
9-low .
11-I2 in
13 -14 in,
IS-16 in.
Ix - is in .
19-20 in.
11-22 in.
2] -24 in.
1]-261n
29-28 in
29-10 in
l l -J 6 in
4 2 A - 42 i n
i]-vg in
4 R Joints
mi n
P
Join t
Reins
Ax.
Join )
Re'
16
26
26
26
26
26
2J
N
24
22
22
22
22
20
20
Ifi
16
I8
N/R
NIA
N/R
NM
WA
N/A
WA
N/A
WA
Na
Na
NM
WA
Nra
WA
N/A
WR
N/A
NB
NR
wA
NlA
NIA
(2)C
N/A
(x1E
ITR
NM
JTA
WR
ITR
4 II Joints D/2 R Relnt Spacin g
JoloWRelnf.
Inc Held.
mi n
Pa
Jeln l
Rehr.
AI L
John
RUM.
T1e Rod
,\I1 .
RHO.
D se 4 fl J o hn s
26
26
26
26
26
26
24
NM
WA
WR
NM
N/A
N10.
NIA
N/A
NIA
N/A _
N/A
MPT
AIPT
MPT
MPT
MPT
6PT
MYf
22
NIR
WA
MPT
20
]0
is
20
la
x0
13
IB
NM
1T0.
NR
N/A
(22E
N/A
WR
NM
WR
C
C
D
O
D
E
E
NIA
(2)11
(2111
MPT
a
AfIT
11
\IPT
11
is
fIR
(2)11
ITR
mg
MPT
11
53 - 60 in
WA
N/A
61P5
x
M-, in.
l6
RR
(2)1
RR
(2p
MPr
1
A-64 in
IIIR
G) .
MPT i 1
as-96 in .
)T0.
(2)I
2MPT I
Net Designed
92-108 in .
IA
1 JTR
L
R)K *
IW- no in.
is
ITR
L
(2)K > `
Table 2-12 4 R CoIIISheet SlocR/T2501T25b (T0C/TDF) Duct Reinforcemen t
49 -04 i n.
Jf0.
6ln . svg
Smd c
Pos. or Net.
Duc t
Dimensio n
8 in . and under
9-Io in .
I I -12 in .
I3-lain .
15-161c,.
1] - 18 in
19-^_0 in.
21-'_2 in.
23-24 in .
2546 in .
2]-28 in.
29-]0 in.
31-36 in .
39-42 in.
43-48 in .
4 It Jolnls
Mi n
gin
Join t
ReInL
26
24
NR
NIR
N/R
24
24
24
24
24
22
22
22
20
20
20
IS
18
I
4 ft Joints irQ R ReInL Spacin g
Jolnls/Relnf.
Al t
join t
Int. Relnf.
All.
Join t
ReInL
Nfl n
ga
Ru1nL
N/A
26
We 4 fl Joints
NM
N/A
MPT
N/A
N/A
N/A
NIA
26
N/R
N1R
N/R
NR
N/R
NR
N/A
N/A
N/A
NR
NR
NR
ITR
NIA
NIA
N/A
NR
JTR
Ralf.
N/A
(2)E
N/A
(2)II
(2)11
26
26
26
26
26
21
24
24
24
24
NB
NM
N/A
NIA
WR
NM
NR
NR
N/A
N/A
N/A
WR
NM
WR
WR
NOR
N/A
N/A
N/A
2]-flirt
25 - 26i n.
MPT
MPT
G
(2) H
(2) 11
MPT
MPT
MPT
2MIT
2MPT
K
L
L
31-36 in.
3]-e2 in.
43_49 in
49-54 in.
55-60 in
61-R in.
]]-841n
85-961a
92 -108in .
>J.<
Kt
109-1201¢
18
92-103 in .
18
ITR
(2)K
109- 120 in.
IS
1TR
(2) L
Not Designed
(2)H
C
C
D
D
E
RID
(2)11
1TR
ITA
JDl
JfR
(2)N
MPT
MPT
MPT
C
grow wJund
9-IO in.
11-IJ in
13-14 in
is-16 in
I]-IB in
19-]0 it
21-22 in
NIA
NIA
N/A
20
IB
18
49-54 in
55-Win .
61-]2 in .
]3-S4 in .
85-96 in .
IIR
ITR
MPT
MPT
BIPT
B
C
Duc t
Dlmemlon
E
ITR
SiB
1TR
ITR
MPT
Alt.
Heine
MPT
MET
MPT
MPT
22
20
20
18
16
16
Tie Red
10 In . Dg
Slade
Pa6 or Neg .
(2)H
(2)1
(2) K
F
F
1
I
1
1
able 2-13 4 ft Coll/Sheet StocI/T25B/T25b (TDC/TDF) Duct Reinforcement
39 - 3oin
4 R Joint.
4 n Jamb w/2 R Heine Spacin g
NI'
Jsjn
ReInL
Mi n
ga
Joint
Rant
26
24
24
22
20
20
20
20
0
g
20
19
20
18
is
WR
N/R
WR
WR
N/R
WR
WR
NM
nix
NR
JTR
WR
.1TR
WR
fIR
WA
N/A
WA
WA
WA
WA
(2)e
WA
(2)E
N/A
(2) E
N/A
Q)1!
rm
ITR
rra
nR
(2)11
(2) 11
(2)1
(2) K
18
13
16
16
I
JnlnWRelnf
min
WA
N/A
I
ga
26
26
26
26
26
24
24
22
NB
NIX
W0
.
W0.
NIR
NR
NM
NM
22
wa
WA
WA
F
22
NR
WA
WA
F
22
20
20
20
20
20
18
P%
NR
ITR
(2)E
WA
WA
N/A
WA
WA
WA
WA
WA
WA
WA
0
G
11
1
1
1
I
IB
Not Dcslgned
InL Heine
Jal m
Relnl.
18
16
16
Join t
ReInL
I ➢ N RJOIp U
WA
WA
WA
WA
WA
WA
N/A
WA
WA
WA
N/A
WA
WA
N/A
WA
WA
nit
11R
ITR
2T0
.
rrR
ITR
flR
ITR
QIE
(2)H
(2)11
(2)11
(2)1
(2) L
(2)L
(2) L
(2) L
RA
(2) L
All .
Reed.
Tie ROtl
C
C
C
D
D
I
E
F
L
Li
II
Li
.
Table 2-14 4 ft Coll/Sheet Stocll/f05a/T25b (TDCRDF) D uet Relnrorcemen
16
>J<
v
C
n
W
18
Ducting
ISHRAE Installation Guide
DWF 144 Standards
Constructional Requirements :
. . . . . . . . . . _ . . ._*_
S iz
Maximum Duct Size
400 600 800 1000 1250 1600 2000 2500 300 0
(longer)
A1asimum Shco Thickness 0.6
0A
1 .0
1
"fvpc Rating
Shccl
Maximum S pacing B etween loinls and Slilfcors
_
1
2
3
1
7
5
6
8 I 9
10 _ 11 1 1 2
PS
3000
Al
SS
3000
P
S
3000 200 0 160 0 125 0
8
A''
SS _ 3000 3000 1600 125 0
_
y4*c
PS
300 0 2000 1600 125 0 100 0 800
SS
3000 3000 2000 1600 1'-50 800
P
S
300 0 160 0 1250 625
_ 11/S I _ S8
3000 3000 1250 625
P
S
3000 200 0 160 0 125 0 62 5
123S2
a
SS
3000 3000 1600 1250 625
300 0 200 0 1600 125 0 100 0 SOU
13!S3 _ PSSS
3000 3000 2000 1600 1250 SOD
PS
3000 200 0 160 0 125 0 100 0 80 0
SO O
14 X 54
SS
3000 3000 2000 1600 1250 1000 80 0
PS
300 0 200 0 1600 125 0 100 0 800 800 5011 62 5
J5/S5
SS
3000 3000 2000 1600 1250 1000 Soo g oo go o
PS
300 0 2 00 0 160 0 125 0 100 0 800 80 0 So o 80 0
16 .'56
SS
3000 3000 2000 1600 1250 , 1000 800 800 800
Medium pressure l imited to 100OPa Posi tive an d 750Pa Negative pressure
PS
3000 1 .
__
Al
SS
3000 1
A
- PS
300 0
I SS
3000
-- 'T PS
3000 - —`
1600 C50 IU00 Sou - -' _- --AS
SS
3000 3000 1600 1,50 80 0
3000 1250 625
JI/SI - PS
SS
3000 1250 625
PS
3000 1250 1250 62 5
1>JS2
SS
3000 1600 1250 62 5
PS
3000 1600 1250 1000 800
13/S7
SS
3000 300D 1600 1250 80 0
PS
3000 1600 1250 1000 800 80 0
14154 _ SS
_ 3000 3000 1600 1250 1000 80 0
PS
3000 1600 1250 1000 800 800 Soo 6'- 5 1
E
15/S5
SS
3000 3000 1600 1250 1000 800 800
00
PS
3000
1600
1250
1000
800
800
800
800
62 5
16/$6
SS
3000 3000 1600 1250 1000 800 800 800 62 5
High Pressure limited to 2000Pa Posllive and 750Pa Negative Pressur e
Maximum Shcct Thickness
0 . 80
1 .0
12
I
3000
Al
PS/SS
88
= . 25 .5
PS/SS 300 0
f
1
1
1
-
x
m
'9
I
N"
C
AJ
11/SI
J2/S2
13/S3
J4/S4
15/S5
16/S6 -
PS/SS
PS/SS
PS/SS
25/55
PS/SS
P5/85
P5/35
3000
3000 1 62 5
7000 1_50
3000 1250
3000 1250
3000 1250
3000 1250
All dimensions in "mm "
PS - Plain Sheets, SS - Stiffened Sheet s
80 0
1250
1250
1250
1250
80 0
1000 800
1000 800 800
1000 I 800 I 800
I'
62 5
800
625
ISHRAE Installation Guide
Cress breaking beiwccn joints or
ad(ftmcn
Ducting
Plating (may also be along 0e
duct)
19
Beading (may also be along the
din )
Fig . Illustrations of panel stiffenin g
Equivalent Aluminium conversions from Stee l
Sheet Thickness Adjustment l
Galvanised Steel inGa. (mm)
Min Aluminium Equivalent (mm)
Commercial Aluminium Size (mm)
28
(0 .48)
(0.58)
(0 .60)
L26
(0.55)
(0.69)
(0.80)
24
(0.70)
(0.86)
(1 .00)
22
(0 .78)
(1 .09)
(1 .27)
20
(1 .00)
(1 .32)
(1 .60)
18
(1 .31) _
(1 .70)
(1 .80)
16
(1 .61 )
(2.11 )
(2 .29)
Reinforcement Rigidity Adjustment s
Steel Angle Siz e
(mm)
Code
Equivalent Al . Siz e
(mm)
Steel Ba r
Al . Ba r
(mm)
_ (mm )
25 x 25 x 1 .6 1
38 .1 x 3 .81
C
31 .8 x 31 .8 x 3 .2
25 x 3 .2
31 .8 x 4 .8 o r
25 x25 x3 .2
38 .1 x 3 .81
31 .8 x 31 .8 x 3 .2
D
38 .1 x38 .1 x3 .2
38 .1x3 .2
31 .8x4 .8 or
E
44 .5 x 44 .5 x 3 . 2
38 .1 x 38 .1 x 3 .2
F
63 .5 x 63 .5 x 3 .2
31 .8 x 31 .8 x 4 .8
G
51 x 51 x 6.4
_
51 x 51 x 3 .2- - 51 x 51 x 4 .8
H
I
63 .5 x 63 .5 x 4 . 8
_
51 x 51 x 6 .4
J
63 .5 x 63 .5 x 7 .9 or 76 .2 x 76 .2 x 6 .4
63 .5 x 63 . 5 x 4.8
K
76.2 x 76 .2 x 9 .5 or 88 .9 x 88 .9 x 6 .4
63 .5 x 63 .5 x 7 .9 or 76 .2 x 76 .2 x 6 .4
20
Ducting
ISHRAE Installation Guide
OtSIGH OF SHALL ORAIIUI OUCT TANG Fr FROM MAIN 9UC T
SATISFACTORY FOR NAIR DUC T
VELOCITIES UP TO 'COO FPM .
PooR EL . . . k SPLIT OCSION RESULTING IN
UKAOJUSTAai( AIR CUILOUV IN RIGHT BRANCH
PREFERRED rOP MAIN DUCT VCLOCITIC 3
UP TO IPOO FPM .
PREFERRED CLOOV & SPLIT 0C3 I CH PERMS T T
POLL ADJUSTING AT BRANCH DUCT AIR FLO . .
EXTRACTOR AITM : IcT :OM TYP O
Po3I TION HOLUCA
I
SHORT REGISTER SOOT CONNECTION VILE CREAT E
AIR xOiSE AND cAUSC EXTREMELY SAO AIR PLO W
AdAOBS REGI S T E R PACE .
'W' HININU M
OINC1LIO M
TO EQUA L
RCGI STE . VIO
ISHRAE Installation Guide
OUTSIDE
Ductin g
Ala
[ANIMA', Al .
/unNISNCO vrth
INDICATED DAMPENING
DEVICES PLUS OUTLET DAMPERS . THCR C
ARC OVCR 40 INDIVIDUAL DESIG N
CONY DCRATIONS OVCAiOO D .TIC .
ASSURE UNSATISFACTORY OPERATION O P
THIS STSTCN .
A SYAC: OCSI :l . ::CS P05S10L
AND AIR NOISE LEVt 5 .
:A .MCE J : Tr . ?OASC 10 Al .
PCC- C.AGT :TIE S
22
Ducting
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ISHRAE Installation Guide
Ducting
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ISHRAE Installation Guid e
Ducting
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ISHRAE Installation Guide
Ducting
25
Anciallries - Fabrication and Installation :
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Volume control should be by branch dampers . If a splitter is shown in the design its length shoul d
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28
Ducting
ISHRAE Installation Guid e
BUTT HINGE 25 mm x 25 mm, OR PIANO HING E
LOC K
TYPE 1
FRAME 2
HINGE POS . 2
FRAME 3
HINGE. POS . 3
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VIEW PORT
IF SPECIFIED
FRAME 1
HINGE POSITION 1
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m
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Door
Size (mm)
No.
Hinges
No .
Locks
Frame
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500 Pa
Static and
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305 x 305
406x506
610 x 610
2
2
3
1-S
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0 .85
0 .85
0.55
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0 .5 5
0 .5 5
0 .5 5
750 Pa
Static
305 x 305
408x508
810x810
2
2
3
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305x305
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610x610
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3
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2-S,1-T1-B
2-S .2-T2-B
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S=Side opposite Mopes, T=Top, B = Bottom
ACCESS DOOR ARRANGEMEN T
THE CEILING SUPPORT S139EA MUST SUPPORT DIFFUSER
WEIGHT the FUMBLE CONFESSIONS ARE USED I
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TILE THE DIFFUSER DOES NOT SUPPORT TIE TILE
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TYPICAL DIFFUSERRGRILLE CONNECTIONS
30
Ducting
ISHRAE Installation Guid e
Flexible Duct Installatio n
Installing flexible duct correctly helps ensure
the duct system does its job, withou t
adversely affecting system performance .
The following excerpts from SMACN A
standards will help make sure the flexible duc t
systems you install provide the maximu m
performance for your customers .
To begin, there are four types of flexible duct :
metallic, uninsulated ; metallic, insulated ;
nonmetalic, uninsulated; and nonmetalic ,
insulated (lined) . As with any product you
install, safety is an important consideration .
So, when these ducts must conform to Nationa l
Fire Protection Association (NFPA) Standards
90A or 90B, they must have been tested i n
accordance with Underwriter's Laboratory's
(UL) Standard for Factory Made Duc t
Materials, UL-181, and be installed the way
their UL fisting requires .
Separate installation limitations for flexibl e
connectors and flexible ducts are identifie d
in NFPA Standard 90A . UL Standard 18 1
defines a flexible connector as a flexible ai r
duct that hasn't had certain flam e
penetration, puncture,'and impact tests .
Installation Precaution s
You should always opt for the minimum length
of flexible duct. Any necessary bends shoul d
be made with not less than one duct diamete r
centerline radius . When you do bend the duct,
it should extend a few inches beyond the en d
of a sheet metal connection before you bend
it. When you're bending the duct, be carefu l
not to compress it .
You should locate flexible duct — especially
the nonmetalic, and wrapped metallic flexibl e
duct — away from hot equipment such a s
furnaces and steam pipes .
Joining Requirements
When you're joining lengths of flexible duc t
or attaching duct to air supply or termina l
equipment, make sure the adhesive i s
chemically compatible with the material s
. you're using .
Trim the end of the ducts so they're square
before you begin installing them . Collars tha t
you're attaching the duct to need to be a
minimum of 2 in . long ; therefore, the sleeve s
used for joining two sections of duct shoul d
be at least 4 in . Collars and sleeves need to
be inserted at least an inch into the duc t
before you fasten them .
Use at least three #8 sheet metal screws t o
attach flexible metal duct . These screw s
should be equally spaced around the duct' s
circumference . When installing ducts bigge r
than 12 in . in diameter use five evenly space d
#8 screws . In either case, the screws shoul d
be located at least 1/2 in . from the end of
the duct.
To secure nonmetallic flexible duct to a sleeve
or collar, use a draw band . If the duct is larger
than 12 in . in diameter, the metal collar need s
to have a bead put in it, and the draw ban d
should be located behind that bead .
Insulation and vapor barriers oh factoryfabricated duct needs to be fitted over th e
core connection and then also secured with a
draw band .
Tapes and sealants used on connections shoul d
be listed for UL 181B, Clousre Systems for Us e
with Flexible Air Ducts and Connectors, a
standard out in first edition in 1995.
Proper Suppor t
It's best to follow the manufacturer' s
instructions on how far apart duct supports
ISHRAE Installation Guide
Ducting
can be, but in their absence, support s
shouldn't be more that 5 ft . apart . Th e
maximum sag the calls for is 1/2 in ./ft . o f
spacing between the supports . You ca n
consider the connection to other duct or to
equipment as a support point .
Hanger or saddle material in contact with th e
flexible duct has to be wide enough so i t
doesn't reduce the internal diameter of th e
duct when the supported section rests on th e
hanger or saddle material .
The part of the hanger touching the duc t
should never be less than 1 in . wide . You ca n
use narrower hanger material in conjunctio n
with a sheet metal saddle that meets thi s
specification . This saddle must cover one-hal f
the circumference of the outside of th e
flexible duct and fit neatly around the lowe r
half of the duct .
The standard allows factory installed support s
that are integral to the duct, as long as th e
manufacturer's recommended installatio n
procedures are followed . However you support
the duct, make sure the supports ar e
adequately attached to the structure .
To avoid tearing the duct's vapor barrier, don' t
support the entire weight of the flexible duc t
on any one hanger during installation . Avoid
contacting the flexible duct with sharp edges
of the hanger material . You can repair damag e
to the vapor barrier using an approved tape .
If you penetrate the interior of the duct, yo u
should either replace that section, or trea t
the torn area as a connection .
31
The standard says, UL, NFPA, and most code s
make distinctions between these two products
in their limits of application . Connectors ar e
more restricted and are currently limited t o
14 ft . of installed length . Regulation s
governing these forms of duct should b e
checked, especially for floor penetrations ,
ceiling air plenums, and fire-rated floor-ceilin g
or roof-ceiling assemblies .
While flexible duct usually comes compresse d
in various lengths, if you repeatedly flex th e
metal version, it will probably develop fatigu e
stress cracks and leak when the system i s
started .
Finally, on the subject of compression th e
standard states, Compressing duct increases
first cost and friction losses . The minimu m
length refers to the practical route betwee n
connection points but not to the degree tha t
the material is overstressed or to the degre e
that all available stretch is removed . We
discourage the practice of providing exces s
length in case of future building modifications .
AIR DISTRIBUTION SYSTE M
INSTALLATION AND SEALIN G
SEALING MATERIAL S
BENEFITS OF INSULATING AND SEALING DUCT S
❑nlnsulated and
poorly sealed duct s
:neunldhn4' kdse M
lr its 6li[rcasp+te
Insulated an d
sealed ducts
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tuts
Any terminal devices you attach the flexibl e
duct to should have their own support .
6%
ab
Flexible air ducts have rectangular UL label s
on them every 10 ft . Flexible connectors, on
the other hand, have round labels every 1 0
ft .
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32
Ducting
BOOT AND DUCT CONNECTION HIGHLIGHT S
r, and
anaen
panvlauan
`
e
DUCT BOAR D
Joint laslerad and
sealed YNh tape that i s
crosslabbed every 12 -
Shplappedloln I In duel board
sloplod every2- and sealed —(—r--TT"
with approved lade
The two primary materials used to seal duct s
during installation are mastic and tapes ,
although other. sealants may also be used i n
special applications . Use all mastics, tapes ,
and other sealants according to manufacture r
instructions . Clean and dry joints, seams, an d
openings of oil, grease, and dirt befor e
applying sealants, especially when using tape s
and non-mastic sealants .
Duct insulation does NOT stop leakage and i s
NOT a sealing material ; in fact, dirty insulatio n
is a telltale sign of air leakage .
ISHRAE Installation Guid e
• Mastics Mastics that meet UL Standard s
181A or 181B may be used to seal duc t
joints . Use mastics labeled UL 181A- M
for fiberglass ducts, UL 181B-M mastic s
for flexible ducts, and either for rigi d
metal ducts and components . Waterbased mastics are preferable to
petroleum-based mastics because the y
have shorter curing times, easie r
cleanup, and more "forgiving "
application characteristics . Mastic mus t
not be diluted . Mastic should be applie d
liberally over the entire joint between an d
over mated surfaces . When using ove r
holes or gaps that are larger than 1/8 t o
1/4 inch, apply a thick layer of masti c
followed by at least one layer of fiberglas s
mesh tape, topped by a layer of masti c
that fills the scrim pattern completely an d
covers the mesh .
• Tapes—Heat-activated and pressure sensitive tapes that meet UL Standard s
181A or 181B and are marked for use i n
the intended application can be used t o
construct ducts and, in some cases, sea l
ducts and other distribution syste m
components . Heat-activated tape shoul d
be labeled UL 181A-H and used only o n
rigid fiberglass ducts . Use pressuresensitive tapes labeled UL 181A-P fo r
rigid fiberglass ducts, 181B-FX fo r
flexible ducts, and either for rigid meta l
ducts and components . Pressuresensitive tape used on rigid fiberglas s
ducts should be rubbed firmly until th e
pattern of the facing reinforcemen t
shows through the surface of the tape .
When taping traverse joints, wrap th e
tape three times . Pressure-sensitive
metallic tape with non-butyl adhesive i s
useful to temporarily seal air handle r
access panels that may need to be opene d
in the future . When sealing acces s
ISHRAE Installation Guide
Ductin g
panels, a card should be taped to th e
access panel that says "Please Replac e
Any Tape That is Removed" as a reminde r
to future repair personnel . Cloth-backed
rubber-adhesive (duct) tapes should no t
be used because they deteriorate wit h
time and exposure to heat . Pressuresensitive metallic tape with buty l
adhesive (not meeting UL Standard 181 )
can be used to seal metal-to-meta l
connections . Cork tape can be used t o
seal gaps where refrigerant lines
penetrate the air handler unit cabinet .
INSTALLATION MATERIALS
•
Staples and Tape—Ducts constructe d
from fiberglass duct board should b e
fastened together using clinching staple s
on approximately 2-inch centers an d
approved pressure-sensitive tape . Where
staples cannot be used, joints should b e
held together using approved pressuresensitive tapes . The tape should b e
placed over the seam and 8-inch-lon g
(minimum) crosstabs taped on each side
of the duct with a distance of 12 inche s
or less between crosstabs .
•
Drawbands—When joining flexible duct s
to each other or to other types of duct ,
the flexible duct must be fitted over a
beaded sleeve or collar and attached with
drawbands (UV-resistant nylon duct ties
or preferably metal worm-drive hos e
clamps, both with a temperature ratin g
of 165°F)—one drawband to secure th e
inner lining and a second drawband to
attach the outer insulation jacket .
_
•
Support Straps—Round sheet meta l
ducts suspended in the air should be
supported by hangers at least every 1 0
feet . Flexible ducts suspended in the ai r
should be supported at least every 4 feet
by straps that are at least 1½ to I N
inches wide, and they should not sa g
more than ½ inch for each foot o f
distance between the supports . Straps
used on flexible ducts should no t
constrict the inner diameter of the duct
or cut the outer jacket .
FASTENERS
Mechanical fasteners—screws, staples, an d
draw bands—should be used to secure all joint s
between sections of duct . Materials intende d
to seal against air leaks—such as tapes ,
mastics, and other sealants—should not b e
used to hold sections of duct together excep t
where mechanical fasteners are not feasible .
Ducts should also be well supported so tha t
joints are not pulled apart or the duc t
distorted (pinched) so that its air flow i s
reduced .
•
Screws—On transverse joints in roun d
sheet metal ducts that use sleeves o r
swedge or crimped fittings, use at leas t
three metal screws equally spaced around
the joint to ensure that the joint canno t
become separated . For vertica l
connections made on flexible duct, instal l
at least three screws below the drawban d
used to secure the inner lining to preven t
slippage .
Duct boots must be mechanically secure d
to the building using screws so that th e
boots do not rely on the ducts for
support .
DUCT LEAKAGE TESTING
Once ducts have been installed and sealed ,
the only way to really know how leaky they ar e
is to conduct a duct airtightness test . Such
34
Ducting
ISHRAE Installation Guide
•
Wraps of spirally-wrapped unface d
insulation should overlap at least 2
inches .
•
Permanently secure insulation to the duc t
with draw bands, non-corrosive wire ,
rust-resistant staples or nails, o r
pressure-sensitive tape wrapped at leas t
three times around the circumference .
Parallel-wrapped faced insulation i s
usually secured with pressure-sensitive
tape . Secure unfaced parallel-wrappe d
insulation at least every 18 inches alon g
its length using non-taping methods .
Attachments should not compress th e
insulation more than 20% along straigh t
duct lengths and no more than 50% i n
bends .
•
When flexible ducts are joined, th e
insulation jackets must overlap at leas t
2 inches . The overlap must be secure d
and sealed with a draw band or wit h
three staggered wraps of pressuresensitive tape .
•
Install a continuous vapor barrier outsid e
the insulation (e .g ., foil-faced fiberglas s
insulation sealed with pressure-sensitiv e
metallic tape) on metal ducts that are
used for space cooling, except in dr y
climates where condensation on the duct
surface will not occur . Tears in th e
insulation facing (especially the oute r
lining of flexible duct) must be avoide d
to prevent moisture accumulation in th e
insulation, which significantly reduces it s
effectiveness .
•
At duct terminations (e .g ., boots ,
collars), the insulation jackets of flexibl e
ducts should be pulled over the insulatio n
and secured and sealed to the fitting wit h
a draw band, mastic and fiberglass mes h
tape, or three wraps of pressuresensitive tape .
tests can be performed using a special fan
called a blower door or, better, with a specia l
duct blower often energy offf in intim e
programmes or building rating certificatio n
programmes require duct leakage testing t o
confirm the tightnes of the ducts to confir m
the airtightness of the ducts . A typical
requirement is that duct leakage measured
when the ducts are pressurized to 25 Pascal s
should not exceed 5% of the system air flo w
rate.
DUCT INSULATIO N
Insulate all portions of duct systems locate d
outside of the conditioned space (includin g
boots and plenums), typically using flexible
or rigid fiberglass insulation . Metal duct s
located in the conditioned space may b e
insulated to prevent condensation . Adhere to
the following guidelines when selecting an d
installing the insulation .
•
•
Select the insulation levels for the duc t
system in accordance with the 200 0
International Energy Conservation Code.
Use higher duct insulation levels in duct s
located outside the conditioned spac e
than those specified by this Code ,
especially when variable-speed ai r
handling equipment is being used . Lowe r
air flows provided by variable-spee d
heating and cooling systems to improve
operating efficiency increase th e
resident time of air within the ai r
distribution system, which in turn
increases thermal losses in the winte r
and thermal gains in the summer. Atti c
insulation placed over ducts helps wher e
it is possible .
Insulation must be continuous, especially
at plenums, boots, elbows, an d
connections (i .e., no gaps or voids in th e
insulation) .
ISHRAE Installation Guide
Ducting
A heating and air conditioning system is onl y
as efficient as its air delivery component . Th e
quantity and velocity of air movement withi n
space and the proper mixing of supply air wit h
space affect comfort levels.
Supply air should be directed to the source s
of greatest heat loss or heat gain to offse t
their effects . Registers and grilles for th e
supply and return systems shoul d
accommodate all aspects of the suppl y
distribution patterns such as throw, sprea d
and drop ; also, the outlet and return grill e
velocities must be held within reasonabl e
limits . Any noise generated at the grille is o f
equal or greater importance than duct noise .
The diagrams show recommended grille an d
register locations .
Supply air outlets
The principles of air distribution are discusse d
in the SMACNA "Hvac Systems - Duct Design "
manual and the American Society of Heating ,
Refrigerating and Air-Conditioning Engineers '
"ASHRAE Fundamentals ." In residentia l
system design, simplified methods of selectin g
outlet size and location generally are used .
Supply outlets fall into four general groups ,
defined by air discharge patterns : horizonta l
high, vertical non-spreading, vertica l
spreading ; and horizontal low.
35
"ALL PLASTIC "
Corrosion Resistan t
Fume Exhaust System s
and Duct Fitting s
Polyvinyl Chloride (PVC )
Chlorinated Polyvinyl Chloride (CPVC )
Polypropylene (PPRO )
Complete Pre-Engineered or Componen t
Systems
Designed for Durability and Cost Efficiency
Thermoplastics Reduce Weight and Increas e
Reliability
Suggested Standard Specifications For PVC
Ductin g
Welding for Round and Rectangular Duc t
Basic Guide to Specifying and Orderin g
Duct Fittings and Pipe
Specifications/Properties for CPVC an d
Polypropylene
Exhaust Hoods and Transitions
36
Ducting
PVC Ducting
Suggested Standard Specification s
Applicability of ASTM standards as it pertain s
to PVC Ductin g
A)
ASTM-D1784 Compounds utilized in th e
manufacture of base components, whic h
covers Type I and/or Type II materia l
B)
ASTM-D-635 Flammability UL94V-9 (Self
Extinguishing )
C)
ASTM-E-84 Flame Spread (10-25) Fue l
Contribution (0 )
EXHAUST DUC T
All ventilation duct components to b e
fabricated of PVC Type I, Grade I (dark gray )
and/or PVC Type II, Grade I (light gray )
material . The PVC Type II, Grade I materia l
can be rolled without heating, resulting in a
lower cost for the finished product . Selectio n
of materials of construction shall be at th e
purview, unless otherwise specified by th e
Buyer.
ROUND DUCT
Round PVC duct above 24" should be cold rolle d
from Type II Grade I extruded PVC sheet
ISHRAE Installation Guid e
material . The seam should be thermal fuse d
utilizing a computerized welding machine . Th e
sheet edges are heated and pressed togethe r
pneumatically achieving 100% weld strengt h
using no filler rod . Wall thickness should b e
3/16" for sizes up to 32" diameter. Above 32 "
diameter. . .1/4" material should be used ,
unless otherwise specified .
Elbows should have an approximate centerlin e
radius of 1-1/2" times duct diameter, 90 °
elbows can be either 3-piece or 5-piece mitre ,
45° elbows, 2 or 3 piece mitre . Specific jo b
requirements should determine which type i s
used . If no preference is given, 3-piece 90 °
elbows and 2-piece 45° elbows shall b e
provided .
Transitions should be tapered, cone-type only .
The cone should be the same materia l
thickness as the duct material . Transition s
should .
Branches should enter or leave the mai n
ducting at a 45° angle.
Couplings for sizes up to 24" can be eithe r
sleeve type (no stop) or standard with a stop .
Only sleeve couplings are available in size s
above 24" . Socket depth for both to be 3" .
Flanges for size 6" through 20" should be hea t
formed from PVC duct or cut from flat shee t
stock. Flanges for 24" and above should b e
formed from PVC Type I extruded angle . Le g
size should either 1-1/2" x 3/16" for diameter s
up to 30" or 2" x 1/4" for sizes above 30" .
Bolt holes should be 5/16" diameter o n
approximate 4" centers . Suggested bolting ca n
be either galvanized or 304 SS . Both shoul d
be 1/4"-20 x 1-1/4" long with a nut and two
washers provided for each bolt .
ISHRAE Installation Guide
Ducting
Suggested gaskets should be 1/8" thick ,
closed cell neoprene for duct sizes up to 24" ;
above 247, 3/16" thick neoprene should b e
used .
Suggested flexible connections should be 3 /
16" neoprene, 6" wide, with two SS dra w
bands .
Quadrant dampers or blastgates should b e
provided with a locking device for permanentl y
setting after balancing .
End caps can be either permanently welded i n
place or fabricated to allow removal .
Access panels and/or view ports can b e
provided with clear PVC material or Plexiglas
and should be held in place with SS self-tappin g
screws .
Reinforcements, if required, should be pe r
SMACNA, Second Edition, January 1995, o r
greater, for the particular water gaug e
specified .
Installation (joining) can be accomplishe d
with the bell and spigot (cementing) method ,
flanging or thermal welding .
RECTANGULAR DUC T
Rectangular duct should be formed from Typ e
I Grade I PVC extruded sheet material . Corner s
should be heat bent and seams thermal fuse d
where applicable . Where heat bending an d
thermal fusion is not possible, corner weldin g
with PVC filler rod should be utilized .
Where the developed length is 120" or less ,
3/16" material should be used. Above 120" ,
1/4 sheet should be used .
Both 45° and 90° elbows should be 2 pieces ,
square throat . The 90° elbows should hav e
turning vanes made from PVC extruded duc t
material .
37
Transitions should be tapered and should b e
the same material thickness as the duct . They
should be concentric unless otherwise noted .
Branches should-enter or leave main run at
45° angle only unless otherwise specified .
Couplings should be sleeve type only. Overal l
length is 6" and should be the same thicknes s
as the duct .
Flanges for 3/16" wall duct should be 1-1/2" x
3/16" PVC Type I angle . Flanges for 1/4" wal l
duct, 2" x 1/4" Type I PVC angle should be
used . Bolt holes should be 5/16" diameter o n
approximate 4" centers .
Bolting, gaskets and flexible connection s
should be the same as the round duct
standards .
End caps and access panels should be the sam e
as the round duct standards .
Reinforcement, if required, should be pe r
SMACNA Second Edition, January 1995, for the particular water gauge specified .
Joining can also be accomplished with the bel l
(coupling) and spigot method, flanging or fiel d
welding .
WELDING FOR ROUND AN D
RECTANGULAR DUCT
Welding should be accomplished by usin g
either the hot gas fusion method using fill rod
or thermal fusion . The rod should be 5/32" or
3/16" thick .
38
Ducting
ISHRAE Installation Guide
efficiency. There are wide range of corrosio n
resistant plastics including : PVC, CPVC and
Polypropylene .
PVC & CPVC (Belled End) Duct Fittings shoul d
conform to ASTM-D-1784 Material Standar d
Polyvinyl Chloride (PVC) Flange s
Van Stone Style Flange Socket (Two-Piece )
Sizes 10" through 24" Diameter Drillin g
Pattern Class 15 0
AU joints should have a minimum of one wel d
bead to a maximum of three . This include s
elbows, transitions, branches, couplings ,
flanges and end caps .
Unique back-up rings are computer designe d
The foregoing information is based on our 3 0
years experience as a plastic fabricator .
Particular engineering requirements may alte r
any of the above .
MATERIAL S
with a configuration engineered for maximum
performance. The combination of hubs an d
back-up flange rings represent the mos t
Thermoplastics is the answer to most difficult
design problem adding lightweight, versatility ,
durability, corrosion resistance and cost
5
Size
12
14
16
PSI at 73°
O. D. ; -
Bolt _ No of
Circl e
Bolt
Die .
Holes
S
!
*
I
.►%* 5
I
j
i
1 11
1/4
--*—–—*
Lengths
Approx Wt.
(Lbs.)
5
.5-1/2
6-1/2
12 .36
171 2
26-80
37 .50
Mm Bolt
Bolt Sae
-
18.
75
25
22-3/4
l6
1-1/4
6-1/2
60
20
50
27-1/2
25
20
1-1/4
6-1 . 2
83
50; . ;
32
29-1/2
20
. 1-3/8 .
-,
7
_
98
ISHRAE Installation Guide
Ducting
innovative two piece (Van Stone) style flang e
• available today.
Sizes 10' ;92, 14 and 16" flanges are Va n
Stone style which means they have a freefloating ring that enables the bolt holes to b e
aligned after the flange has been assembled
to the pipe, greatly simplifying installation .
These flanges are designed and manufacture d
to Class 150 Specifications, per ANSI-816 . 5
requirements . Th e
sealing surface•is of
a modified flat fac e
design, in whic h
raised ribs uniformly
grip the gaske t
material
durin g
compression ,
ensuring a leak proo f
seal .
INSTALLATION of FLANGE S
1 Alignment is critical, as these flanges ar e
not designed to pull together under stres s
or pull the weight of the piping syste m
together.
2
Recommended 1/8" thick Neopren e
gasket .
3 The faces of flanges are raise d
phonographic grooved finished so tha t
when the bolts are tightened, the face s
will be pulled together creating a positiv e
seal on the gasket .
INSTALLATION TIP S
Once a flange is joined to pipe, the metho d
for joining two flanges together is as follows :
i)
Make sure that all the bolt holes of th e
matching flanges match up . It is no t
necessary to twist the flange and pipe
to achieve this .
ii)
Insert all bolts with full size flat washers
tinder heads and nuts .
iii)
Make sure that the faces of the mating
flanges are not separated prior to bolti ng
down the flanges .
iv)
The bolts on the plastic flanges shoul c
be tightened by hand until snug then b y
pulling down the nut diametricall y
opposite each other using a torqu e
wrench . Complete tightening should b e
accomplished in stages and the fina l
torque values in the following table shoulc
be followed for the various sizes o f
flanges . Uniform stress across the flang e
will eliminate leaky gaskets .
v)
CAUTION, THESE ARE PLASTIC FLANGES ,
NOT STEEL, hence alignment must b e
achieved prior to tightening bolting .
It is recommended to use of a full face, 1/8 "
thick, flat Neoprene gasket .
10" and 12" flanges are also available in Spigo t
ends, and are also available in CPVC .
39
40
Ducting
Attempting to draw together or fi x
misalignment by tightening bolting ma y
result in cracking of the flange hub .
Unnecessary over tightening will damag e
the flange .
GOOD INSTALLATION PRACTICE S
DAMPERS
1.
Splitter type dampers offer little or no
control of air volume in ducts . The y
s hould. b e regarded as air diverters only ,
with maximum effectiveness whe n
present on duct systems exhibiting low
resistance to air flow . Valid applicatio n
of splitter dampers generally occurs a t
the ends of the branch ducts where nee d
to reduce or restrict air flow is no t
required .
2.
The application of single blade quadran t
volume dampers immediately behin d
diffusers and grilles may tend to throw
air to one side of the outlet, preventin g
uniform air flow across the outlet fac e
or cones . Hence should not be use d
there .
3.
Manually operated opposed blade o r
quadrant type volume control damper s
should be installed in each branch duc t
take off after leaving the main duct t o
control the amount of air into thes e
branch ducts .
4.
Turning vane leading and trailing edge s
should be always be parallel with th e
entering and leaving air stream t o
minimize air flow turbulence .
5.
Manual volume control dampers shoul d
be provided in the duct drop or takeoff s
to diffusers and registers to limit th e
total air to the face damper of th e
register or neck damper of the diffuser .
Sidewall and diffuser dampers cannot b e
used for air balancing .
6.
Double thickness or extended edg e
turning vanes should be utilised in al l
elbows, return as well as supply ai r
TORQUE TABLE
Flange Size
Maximu m
(inches) Recommended Torque (FT. LBS) '
3N
10"
64-75 FT/LB S
12"
95 FT/LB S
14-24"
110 FT/LBS
a9 3
fl 3
4 lB
* These recommendations are based on th e
use of flat flanges, two standard flat washers ,
standard nut and a 1/8" thick, full fac e
neoprene gasket . Lubricate hardware well ,
tighten in the proper pattern and apply torqu e
in small increments .
If the flange is mated to a rigid and stationary
flanged object, or a metal flange, particularl y
in a buried situation where settling could occu r
with the plastic pipe, the plastic flange an d
the fitting or valve must be supported t o
eliminate potential stressing
ISHRAE Installation Guid e
ducts .
ISHRAE Installation Guide
Ducting
7.
Furnish extractors where the main ai r
stream in the main duct is a distanc e
away from the branch duct take off (whe n
located on the inside radius duct wal l
following an elbow, etc .).
8.
Vertical duct risers or main return ducts
require manual balancing dampers to be
installed at each branch duct outlet /
inlet .
9.
Provide extension - ceiling mounte d
damper hardware wherever possible .
10.
Require adequate size access doors t o
be installed within working distance o f
volume control dampers, fire dampers ,
pressure reducing valves, reheat coils ,
mixing boxes, blenders, constant volum e
regulators etc . to permit require d
adjustments .
11. Avoid placing a return air opening directl y
in or adjacent to the return air plenum .
Sound lining of the duct opening in th e
plenum will not reduce the transmitte d
noise to accepted levels .
12. A slight space or opening between blade
sofanpedbllvumaperwi
generate a relatively higher noise leve l
as the air passes through the opening s
under system pressure . Damper blades
should be sealed with foam rubber or fel t
to form an effective seal with the blade s
in the closed position .
13. Duct leakages may vary from 15 to 45 %
depending upon workmanship, type o f
duct construction and fittings, syste m
design, etc . To minimize this variable ,
all duct seams, casing and plenu m
connections, etc ., should be taped, thu s
generally assuring a maximum of 5% duc t
seam leakage factor.
41
14. Avoid the use of masonry or compositio n
wall vertical air shafts for supply o r
exhaust systems on multi-storey
building . Where the use of such shaft s
is unavoidable, extreme care must b e
taken to seal not only the connection s
into the shaft, but the entire masonry
or concrete surface itself . The sealin g
of this type of shaft after it has bee n
closed is extremely expensive .
15.
Indicate volume control damper location s
at accessible points and whereve r
possible at a distance from a duc t
transition or fitting . Care should b e
taken during installation to make certai n
that sheet metal fasteners (screws) d o
not protrude into the duct and interfer e
with damper operation .
16. Do not use extractors at branch or mai n
duct takeoffs to provide volume control .
17. Proportion the sizes of the duct split _
fittings or branches based on the CF M
requirements of each resulting duct . If
higher or lower duct pressur e
requirements in the branches and outlet s
are present, adjustment of th e
proportion of the split should be made .
18.
Splitter dampers should be provided a t
all duct split fittings to permit balancin g
without raising noise levels . Sai d
dampers do not eliminate the necessity
for volume dampers in the resultin g
branch ducts .
TERMINAL DEVICES (GRILLES &
DIFFUSERS )
1.
No outlet type is best for heating an d
cooling .
2.
The best outlet types for heating are
located near the floor along outside walls
42
Ducting
ISHRAE Installation Guid e
PLASTIC DIFFUSERS AND GRILLES
SWIVEL JET DIFFUSER - INSTALLATIO N
INSTRUCTION S
1. Select the required position for the grille . Ensure
there are no obstructions above the ceiling in the
selected Iocation .Using the template provided, mar k
hole for the grille as follows :
5 .Carefully pass the grille up into the opening ensurin g
all clips are triggered down .
150 diameter grille : hole sizes 225mm dia .
200 diameter grille : holes size 275mm dia .
2. Carefully cut opening in ceiling .
6 .Adjust the air quantity using the center dampe r
controller.
Clockwise to
close ,
anticlockwis e
to open .
3 . Pull the duct through the opening in the ceiling an d
attach the grille to the duct using duct tape .
7 .Adjust the direction of throw to suit the occupant o r
furniture layout . If grille is to be used as 90 0 down je t
it will lock into position with a subtle click .
4 . Load the the clips in the upright position . TAK E
CARE you do not accidentally (rigger a clip and
catch your finger.
6 .To clean grille wipe down with warm soapy water .
9 .Please recycle all packaging .
ISHRAE Installation Guide
Ducting
43
and provide a vertical-spreading air flow,
preferably under windows, to blanket col d
areas and counteract cold drafts .
diffusers will necessitate extensive
throttling at the registers and generat e
air noise.
High sidewall outlets should deliver th e
air horizontally or slightly upward durin g
cooling . The throw of a high sidewal l
outlet should be equal to or not over 30%
more than the distance between th e
outlet and the opposite wall (or effectiv e
obstruction to a free air stream) of the
room .
10. Avoid placing diffusers or registers s o
that air patterns will be discharged int o
ceiling mounted light fixtures, or i n
having pattern follow the ceiling to o
closely.
11.
It is recommended to provide adjustabl e
extractors at each duct take off to a
register.
4.
The best outlet types for cooling ar e
located in the ceiling and have a
horizontal air discharge pattern .
12.
Return air registers should be located o n
or near exterior walls, preferably at o r
near floor level .
5.
If cooling is the primary application an d
heating is of secondary importance du e
to mild winters, ceiling diffusers wil l
perform most satisfactorily .
13.
Do not use an outlet with a low inductio n
characteristic where the air volume bein g
distributed is high and the distance o f
throw is short .
6.
Return air grilles should be located i n
hallways, near entrance doors, or o n
inside walls to ensure a low resistance
return air path between every room an d
the return side of the blower cabinet .
Return air systems use either central o r
multiple grille locations .
7.
Return air grilles should not be located
in bathrooms, kitchens, garages, utilit y
spaces, a space used for storage of fue l
or flammable materials, or a confine d
space in which a draft diverter or draft
regulator is located or to whic h
combustion air is supplied .
14. Select air outlets which have dampe r
mechanisms readily accessible fo r
adjustments . Diffusers with removabl e
cores which expose the dampenin g
devices are satisfactory ; the principa l
difficulty lies with registers whos e
dampening mechanism Opposed Blad e
Damper (OBD) are recessed too fa r
behind the register face or do not hav e
alignment of the grille face openings with
the damper mechanisms operating key,
preventing damper adjustments .
3.
8.
9.
Avoid installing diffusers or grille s
directly into the bottom or sides of a mai n
air duct . No amount of adjustment wil l
decrease the noise level generated .
Avoid installing supply registers an d
diffusers on the same duct section . Th e
greater pressure requirement of the
15. When fabricating duct drops to diffusers ,
provide a minimum length of 2 times th e
duct diameter (or square dimension) i n
length to assure even distribution fro m
the outlet .
16. Return air grilles and duct connection s
which open into common return plenum s
without return air fans should b e
oversized when possible .
44
Ducting
17. Avoid the use of built-in door louvers fo r
passage of return air when the supply ai r
system operates at low pressure (ceilin g
plenum supply etc .) .
18. Avoid the use of combination supplyreturn outlets. Air quantities handled b y
supply and return section of outlet ca n
be accurately measured and adjusted b y
means of supply air to return cannot b e
determined .
MIXING BOXE S
1.
Require that direct access be provide d
to each mixing box with sufficien t
clearance for adjustment and i f
necessary, removal of the volume contro l
element etc .
2.
Pressure testing of high pressure duc t
runs is an absolute necessity ; Spiral duc t
can be sprung in shipment or durin g
installation, with the resulting leaks alon g
the casing walls rather than at the duc t
joints . Test should be made in th e
presence of the design engineer o r
performed by an independent testin g
agency.
3.
Avoid short discharge duct connection s
from the mixing box unit to the suppl y
register or grille due to the extremel y
large variation in the discharge ai r
velocities across the box outlet opening .
It is possible .to simultaneousl y
experience induced air flow an d
excessive discharge
velocities
accompanied by air noise at the face o f
the register under the abov e
arrangement.
4.
To prevent stratification of warm an d
cool air in supply duct work ,
supplementary mixing baffles (perforated
ISHRAEInstallation Guid e
plate etc .) should be installed at th e
outlet of all mixing boxes . Temperature
differences of 20 deg . to 25 deg . F ca n
be experienced in branch supply duct s
due to this stratification .
5.
Require installation of internal duct linin g
of the discharge duct after leavin g
mixing box, said installation to follow
mixing box manufacturer' s
recommendations .
6.
Avoid short, abrupt connections fro m
unit outlet to duct split fittings o r
branches .
7.
Specify mixing box dampers shall no t
leak more than 3% of the design CFM
when functioning at the design stati c
pressure conditions .
8.
On low velocity, double duct systems ,
install round volume control dampers i n
each hot and cold duct takeoff to al l
mixing boxes . Care should be taken tha t
sufficient takeoff duct is provided to
house the damper mechanisms so tha t
the damper blade does not protrude int o
the main branch duct, or strike th e
flexible duct connection when open .
9.
Differential pressure across an orific e
offers the best method of assurin g
constant volume . The reliance upon poin t
static pressure (Duct or Box) should b e
avoided as it is not reliable .
10. Pressure will vary from one side of a duc t
to the other when a unit is on heating o r
cooling, and can give a false pressur e
signal to the controller. Pilot type stati c
pressure tips located in the center of th e
duct are recommended for consisten t
readings .
11. The same should be kept in mind whil e
installing pressure sensors for controllin g
VFDs of supply air fans or AHUs .
ISHRAE Installation Guide
Ducting
45
DUCT TESTING
SMACNA Duct Performance Test
Standards
W=25' (635mm) to 84"
(2134mm)
1 .0
W= 85" (2159mm) to 120 "
(3048mm)
1" (25.4mm )
Purpose :
The purpose of this standard is to provide a
uniform reliable laboratory test procedur e
for evaluating various performance attribute s
of HVAC air ducts .
2 .0
Scope :
The Scope of the standards covers the tes t
methods and evaluations criteria for th e
following:
a)
Burst pressure capacity or resistanc e
b) Collapse pressure capacity or resistance
c) Wall deflection measuremen t
d) Leakag e
Tolerance of + 10 %
Joints and Reinforcements Limit s
W= 48" (1219mm) or less
IA" (6 .35mm)
W. 49". (1245mm) to 120 '
(3048mm)
W/20 0
Tolerance of +7 .5%
3 .3 Oval Duct deflection Limit s
DUCE WALL
LIMITS
At Rated pressure
3/4" (19 .1mm )
At Atmospheric Pressure
1 /4" (6.35mm)
e) Suspension (optional test)
Major Dimension W= 36 "
(914mm) or les s
3 .0
W over 36" (914mm)
Performance Requirements
3 .1 Burst and Collapse tests :
This shall determine that a minimu m
safety factor of 2 on round and oval duc t
and 1 .5 on rectangular duct exist for th e
designed duct constructions and pressur e
classifications .
3 .2 Rectangular Duct deflection limits
DUCT WALL
LIMIT S
W. 12" (305 mm) or less
3/8" (9.5mm )
W= 13" (330mm) to 18"
(457mm)
½" (12 .7mm )
W= 19" (483mm) to 24"
(610mm)
N" (19 .1mm )
½" (12 .7mm )
Tolerance of + 7 .5%
3 .4 Round Duct Deflection Limit s
Duct Wall
''/a" (6 .35mm)
Positive Pressure
N .A. if shape i s
round at rated pressure .
Negative Pressure
_D/20 0
3 .5 Leakage Evaluatio n
Only applicable for determination o f
leakage class within SMACNA HVAC Ai r
Duct Leakage Manual for experimenta l
purposes.
3 .6 Suspension Effects :
5/8" (15 .9mm)
Using supports at the maximum specifie d
interval a weight equal to the dead
46
Ducting
weight of the duct is suspended at th e
midpoint between the hangers . Leakag e
or Sag are measured before and afte r
one hour. Leakage classes is reported .
4 .0 TEST SET U P
4 .1 Ducts shall be assembled in accordanc e
with the test sponsor's instructions .
4 .2 The support frames of the dial gauges
shall not rest on the ducts except at en d
caps .
4.3 Top measurements for rectangular and
oval. ducts for we pressure and botto m
measurements for -ve pressure i s
required . The greater duct dimension
should be on the top . A rigid cros s
member for determining the Zer o
pressure deflection for the flat span s
should be provided .
4.4 For round ducts the displacemen t
indicators should be taken at 12,3,6, 9
'0' clock locations .
5 .0 INSTRUMENTATIO N
5 .1 Temperature Measurement - Dry and We t
Bulb temperature measurements shoul d
be done by thermometers or transducer s
and it should have an accuracy of ±1° C
and precision of ± 0 .5°C .
5 .2 Pressure Measurement - Duct pressure s
should be measured with a manomete r
or other instrument with an accuracy of
± 1% or less and precision of ± 0 .5 % o r
less.
5 .3 Dial Indicators - Should have a range o f
0 .001 "
5 .4 Laminar Flow Meter - Precision should b e
1% .
ISHRAE Installation Guide
5.5 Piping - Manifold should be at leas t
150mm dia . Piping between manifold an d
test duct end cap should be at least 2"
dia.
5 .6 Prime Mover - The blower shall maintai n
positive and negative pressures and ca n
be operated at full or reduced spee d
using VFD or Voltage control . A blee d
valve can be installed to provide for fine .
flow adjustments.
6 .0 TEST SEQUENC E
Step1 . Set up the dial indicator(s) over th e
test point(s) . Record the dial indicato r
reading (Dl) at zero gage pressure .
Determine the sag for top and bottom
flat surfaces as required for Sectio n
4 .3 even though the DAVE calculation
might apply for only one surface .
Record sag bow at P1, P2, JI, RI an d
R2 (for both top and bottom panels) .
Step2 . Pressurize the duct to the targe t
classification . After pressure is stabl e
for one minute, record the dia l
indicator reading (D2) . Examine the
duct.
Step3 . Relieve pressure and record the dia l
indicator reading (D3) .
Step4 . Pressurize rectangular duct 50 percen t
above the step 2 level for a minimu m
of five minutes . Pressurize round an d
oval ducts 100 percent above the ste p
2 level for five minutes minimum .
Examine the duct . A dial i n d i c a t o r
record is optional .
Steps . Relieve the pressure . Examine th e
duct . Re cord the dial indicator readin g
(D4) .
ISHRAE Installation Guide
Ducting
itc . Include any observed imperfectio n
or irregularity which might influence th e
results ; if sealants are used, stat e
whether they were applied before ,
during, or after assembly of parts .
Calculate the average deflection DAVE .
DAVE = (D2 - Dl)±(D2 - D3)
2
Where:
D1 = Dial indicator reading per Step 1 .
D2 = Dial indicator reading per Step 2 .
D3 = Dial indicator reading per Step 3 .
This relates to the performance requirement s
in Sec E 3 of this test standard . The DAV E
calculation not require that the performanc e
limits for Sec 3 .2 and 3 .3 apply to theoretica l
flat zero referenc e
DATA TO BE INCLUDED IN REPORTS
OF TESTS
3.
The test setup including apparatus, leas t
scale division ai estimated accuracy of
measurement instruments, support
points and support method for specimen ,
measurement points on specimen, etc .
4 The sequence of observing and recordin g
of data, the increments of pressure, th e
zero pressure level deflections, etc.
5.
Any corrective adjustments made in th e
condition of the specimen after the star t
of testing . The location and nature o f
any failure points or conditions .
6.
(Optional) . Pressurize the duct in I in .
wg (250 Pa) increments above th e
qualifying pressure until failure occurs .
Record the observations and the failure
pressure . Use pre cautions to avoi d
injury from parts dislocated at failure
pressure .
1. Diagram of the test specimen .
2. Complete description of the specimen :
sheet thickness; galvanized coatin g
weight ; if any ; longitudinal sea m
locations ; seam size ; model of machine s
on which seams, joint members, an d
intermediate members are roll- formed ,
(or if brake-formed, so state) ;
approximate inside radius of bends i n
formed stiffener and joint members ;
type, size, and spacing for fastener,
(e.g., bolt, weld, or self- tapping screw) ;
type of sealants; gasket dimensions,
47
The laboratory may just report its findings o r
may certify that compliance with a particular
standard or requirement has been met .
TEST SET UP in next page
ISHRAE Installation Guid e
Ducting
48
TEST SET U P
,VARIABL E
/ INLET VANE S
VIBRATIO N
ELIM, BAS E
AMERICAN STANDARD SIZE 36 5
SERIES 110 AIRFOIL BLADED FAN -'`-,.,
CLASS III, CLOCKWISE ROTATION .
TOP HORIZONTAL DISCHARGE ,
DIRECT CONNECTED TO A
. 56 KW., 1766 RPM MOTOR
FAN OUTLE T
699 m m
OUTSIDE
E
r= m
WIDTH
x 1035 m m
OUTSIDE HT.o ^
MANUALLY
OPERATED BY-PAS S
GUILLOTIN E
DAMPER
0 .61 m x 0 .91 m
038 m LONG
STRAIGHTENIN G
VANES OF
127 mm CIA
TUBE S
E
OPPOSED BLADE PRESSUR E
REGULATING DAMPER I629 mm WIDE x 1219 mm HIGH
8
. .*_1m62
PLAN OF HIGH PRESSURE DUCT TEST ARRANGEMENT
SECTION -A-A'
J
ISHRAE Installation Guide
Ducting
49
As per DWI 44 Standards:
3.
This standard specifies that the testing shoul d
be according to pressure classification of th e
ducts, namely :
Class C High Pressure for maximum o f
2000Pa +ve Et 750Pa - ve pressures .
System Leakage Testing ft Loss specified :
1.
2.
1.
Class A - Low pressure for operatin g
pressures of upto 500Pa both +ve a -ve .
Class A - Low Pressure - No Testing leakage 6%
2.
Class B - Medium pressure for 1000Pa+ve
pressure and 75OPa - ve pressure .
Class B - Medium Pressure - 10% of th e
ducts randomly tested - Leakage 3 %
3.
Class C - High Pressure - All ducts teste d
- Leakage 2 %
Air Leakage Tabl e
Static
Pre ss ure
Differential
Maximum Leakage of Ductwor k
Low
Pressure
Medium
Pressure
Ctass A
Class B
High
Pressure
Class C
Stati c
Pressure
Differential
Hig h
Pressu r
e
Class C
Pa
L/s Per Sq M of Surface area
100
0 .54
0 .18
•rr
200
0 .84
0 .28
rr
300
1,10
0 .37
rr
400
1 .32
0 .44
500
1 .53
0 .51
-
-r
r
r
s
150 0
600
0 .58
0 .19
1600
0 .3 6
700
0 .64
0 .21
1700
0 .3 8
800
0 .69
0 .23
1800
0 .3 9
900
0 .75
0 .25
1900
0 .4 0
1000
0 .80
0 .27
2000
0 .42
NOTE : (Graph in next Page )
1.
Recommended 'meao' test pressures are highlighted in bold type with actual section bein g
left to the test operato r
2.
In special cases the designer can specify a higher standard of air tightness, however h e
should not specify a Class 'C' test for Class 'C' pressures for Class 'B' ducts .
3.
The practice of specifying construction standards for whole duct system based on the f n
discharge pressure may incur unnecessary costs on the project .
4.
Large system can be broken into following classification : Plant room risers - Class C, Mai n
Floor Distribution - Class B, and Branches and Outlets - Class A .
50
Ducting
em'y2 1:n o.7007:1r EC7•" • lC:
51 4 'e@***e9ee92°EEc
lily?,dl9IEa.*
e
:Eeee9
ISHRAE Installation Guid e
'e
1 "a o 060'*e a C •'•7.*3 .
S1 e°E°°1 Ei ti81 c* !Rin'
Pressure difference in pascal s
INDIAN STANDARDS - IS 65 5
Testing is not specified, however in case the entire ducting is fabricated and erected as per th e
standards, then it is expected that it shall be of desired quality and hence one can even imprint
on the ducts the ISI mark and standard no .
Section 2
PIPING
PIPIN G
Chilled water, condenser water, drain piping, refrigerant piping all are part of pipin g
works. Piping needs to be supported from the either the top or the floor . All support s
should be on load bearing portions of the structural works .
Design of pipe thickness is dependant on the fluid expected to flow in it, flow velocity,
pressure, structural support etc . This should not be compromised and site inspectio n
of pipe thicknesses should be taken up sincerely.
For butt welding of two pipes, the edge beveling and ensuring that the "V" grove i s
properly made before the tack welding is done for alignment is very important par t
of pipe welding/ fabrication works . No compromise on this should be allowed . Prope r
penetration of the weld material into the mother pipe is a must and inspector s
should look at samples properly to have the longevity of the piping system .
For piping expected to carry hotwater, steam or chilled brine solutions, where th e
difference in operating & non operating temperatures are high, then provision fo r
pipe expansion and contraction should be made . For pipes carrying steam immediat e
and safe condensate removal & recovery provision should be made .
Proper "U" loops, bends, shoe pieces should be used in respective locations . Small
compromises can become very costly in the long run .
Installation of Pressure gauges, Temperature gauges with proper insertion of probes ,
counter flow directions, final location and facing of the dial are as important as th e
system design and accuracy of the instruments .
Painting of piping should be taken up seriously. Proper colour codes, arrows showin g
flow direction, anti corrosive coatings, immediate painting of the anti corrosiv e
after removal of flux from the weld joints are as important as the piping itself .
Safety measures can never be overemphasized . Safety for the people operating ,
handling and erecting the equipment is more important than anything else . Follow al l
safety codes and more than that follow all logics to eliminate possible cause o f
accidents .
ISHRAE Installation Guide
Piping
53
1 Genera l
recommended to be done in a separate area .
Work is recommended to be carded out i n
accordance with given specification and good
engineering practice by qualified trade s
persons . The work is recommended to b e
properly documented and records prepared an d
continuously updated as necessary, for th e
proper execution and control of fabricatio n
and installation, in accordance with thi s
specification .
An area is recommended to be provided fo r
non-destructive testing . The area i s
recommended to be located at a safe distanc e
from the piping spool fabrication area t o
conduct radiographic inspection withou t
interrupting the piping spool fabricatio n
whenever required . The area shall comply with
all statutory and safety requirements .
All materials are recommended to be i n
accordance with piping class specified . The
linear dimensional tolerances for pip e
fabricated spools are recommended to be a s
follows:
DESCRIPTION
LINEAR TOLERANC E
Length Less Length 1 .5m
than 1 .5m
and longe r
End to En d
Centre to En d
Centre to
Flange Fac e
Flange Face t o
Flange Face
±1 .5mm
±3 .Omm
These tolerances apply to each stated drawin g
dimension and are not cumulative .
2 Shop Fabrication s
2 .1 Workshop Requirement s
Adequate under cover workshop facilities i s
recommended to be provided . Ample storage ,
handling, machining and testing facilities i s
recommended to be provided to ensure a safe ,
efficient and continuous piping spoo l
fabrication of high quality under all weathe r
conditions for the preparation for welding ,
assembly and testing . The surface preparatio n
and painting of the piping spools is
2 .2 Stainless Stee l
Direct contact between carbon steel an d
stainless steel is not permitted . Tools
containing carbon steel and grinding disc s
containing carbon steel particles shall not b e
used on stainless steel .
Tools used for fabrication of stainless stee l
are recommended to be clearly identified .
Tools to be used only for fabrication of
stainless steel piping and piping component s
is recommended to be stored separately t o
avoid accidental switching with tool s
previously used on carbon steel fabricatio n
work.
2 .3 Progress Control
Progress control and planning documentatio n
is recommended to be maintained to plan ,
control and report all facets of the piping spoo l
fabrication and shall include but not be limite d
to the following :
❑ Preparation of piping spool drawing s
❑ Material availability per spoo l
❑ Surplus and/or shortages per spoo l
❑ Shop fabrication progress per spoo l
❑ Lining of spools, if require d
❑ Inspectio n
❑ Testing of spools, if require d
❑ Non-destructive examinatio n
❑ Weld repair and rewor k
54
Piping
❑
Revisions to isometric drawing s
❑
Hot dipped galvanizin g
❑
Surface preparation and coatin g
❑
Shipping record s
Procedures and documentation for the control ,
reporting and recording of spool fabricatio n
is recommended to be maintained .
2 .4 Spool Sizes
Length, height and width of the complete d
spools are recommended to be within th e
limits of road transport unless specificall y
requested otherwise by the Projec t
specification .
2 .5 Galvanized Pipin g
Galvanized piping and fittings DN 80 and large r
is recommended to be fabricated as flange d
spools then hot dipped galvanized i n
accordance with AS1650 . Pipe spools are
recommended to be pressure tested prior t o
galvanizing . Pipe fittings is recommended t o
be abrasive blasted internally prior t o
fabrication and galvanizing . Piping spools i s
recommended to be easily identifiable b y
drawing and spool number.
2 .6 Painting the Spool s
Shop fabricated spools, except galvanized an d
stainless steel spools are recommended to b e
shop painted in accordance with
specifications . Prior to welding, remove
supplier applied coating for a margin of 50m m
from each shop weld joint . Paint all uncoate d
surfaces of the spool immediately after all non destructive testing of the welds has bee n
completed . Stainless steel shall not b e
painted . Flange gasket faces ar e
recommended to be protected agains t
damage and paint deposits during blasting ,
cleaning, surface preparation and painting .
ISHRAE Installation Guid e
Pipe spools shall remain identifiable at al l
times during blasting, cleaning, surfac e
preparation and painting.
3 Preparations for Weldin g
3 .1 General Requirement s
Welding is recommended to be in accordanc e
with given specification . Cutting of pipe ma y
be done either by mechanical means or b y
flame cutting, depending on the type o f
material to be cut . For carbon steel, flame or
arc cutting and beveling is acceptable only i f
the cut is reasonably smooth and true, and al l
oxides are removed from the flame cu t
surfaces by grinding . After flame cutting, th e
bevel end preparation is recommended to be
ground back to bright and sound metal .
For stainless steel pipe, plasma cutting an d
grinding back to bright sound metal is require d
if the pipe ends cannot be machined . Flame
cutting is not allowed . All welding areas ar e
recommended to be adequately protecte d
against inclement weather conditions such a s
rain, wind, dust and the like . All weld en d
preparations and adjacent areas 50mm either
side of the weld is recommended to b e
thoroughly cleaned and degreased prior t o
welding .
Welding procedures and qualification tests i s
recommended to be carried out . Use o f
permanent backing rings is prohibited .
Consumable inserts shall not be used En d
preparation for butt welding is recommende d
to be in accordance with given specification .
A straight run of pipe shall contain th e
minimum number of welds .
Defective or damaged weld ends (bevels) i s
recommended to be examined and repaired .
Use of hot or cold hammering as a means fo r
repair is prohibited . The root pass of all groove
ISHRAE Installation Guide
Piping
welds, of compressor suction and tube oi l
piping which is accessible from one side only ,
is recommended to be welded using GTAW .
3 .2 Misalignment Toleranc e
All piping fit-ups are recommended to b e
subjected to the following bore misalignmen t
tolerance .
Components with Equal an d
Unequal inside Diameter s
(More than 1mm difference )
Nominal Pipe Size Misalignmen t
DN 150 and smaller
1mm
DN 200-300
2mm
DN 350 and larger
2 .5m m
NOTE : Misalignment should be minimise d
wherever possible by rotating the pipe/fittin g
for best fit and/or by grinding the bore a s
required .
3 .3 Slip on Flange s
Slip on flanges is . recommended to b e
positioned so that the end of the pipe i s
recessed from the flange, a distance equal to
the pipe wall thickness plus 1 .5mm, or 6 .4mm ,
whichever is the lesser. Seal welding for slip
on flange is recommended to be carefully
applied in order to avoid re-facing the flange .
Pipes for insertion in slip-on flanges are
recommended to be cut square, withi n
0.5mm .
3 .4 Socket 'Wel d
Pipe for insertion in a socket weld joint i s
recommended to be cut square within 0 .5mm .
A minimum gap of 1 .6mm is recommended to
be maintained between the end of the pip e
and the bottom of the socket .
55
3 .5 Valves
Because of the possibility of seat distortio n
due to welding heat, valve stems i s
recommended to be in the open position prio r
to commencement of welding . This i s
applicable to all valve types and sizes excep t
large swing check valves .
4 Threaded Connections
Inside ends of threaded pipes is recommende d
to be deburred by reaming . All threaded
connections is recommended to be gaugechecked or chased after galvanizing . Threaded
connections shall not be seal welded .
Threaded joints in piping system ar e
recommended to be made up using PTFE pip e
tape or thread seal compound installed on th e
male thread .
5 Flanged Connection s
Unless otherwise indicated on the drawings ,
the bolt holes of all flanges is recommende d
to be offset to vertical and horizontal centre lines . The maximum angular deviation of bolt
holes shall not exceed 1 .5mm measured acros s
the bolt pitch circle .
The flange faces is recommended to be squar e
to the pipeline in which they are fitted .
Maximum deviation of flange face alignmen t
measured at flange outside diameter from th e
design plane shall not exceed the following ,
when measured in any radial direction .
Pipe
Diameter
Nominal Maximu m
Deviatio n
DN up to 100mm
1 .0m m
DN 150mm to 500mm
1 .5m m
DN 600mm to 900mm
2.5m m
DN 950mm and over
3 .0mm
56
Piping
ISHRAE Installation Guid e
Flanged connections to equipment supplie d
with raised face flanges shall have raise d
faced mating flanges and flat-faced flange s
shall have flat faced mating flanges .
reinforcing pads, the minimum distanc e
measured between the heat affected zone s
of the weld in the pipe and fillet weld of th e
pad is recommended to be 25mm .
Shop fabrication of flanged spool pieces fo r
connection to existing pipe work o r
equipment, shall have the mating flange tac k
welded to the spool and an additional allowance
of 100mm of pipe shall also be povided fo r
the correct field fitment .
7 Cold Bendin g
6 Branch Connections
Branch connection requirements ar e
recommended to be in accordance with give n
specification . Branch reinforcement i s
recommended to be as indicated on th e
drawings . Reinforcement material i s
recommended to be made from the same pip e
material as specified by the relevant pipin g
class and subject to the same specificatio n
requirements as are piping to which it i s
attached . All cuts are recommended to b e
carefully beveled and accurately matched t o
form a suitable preparation for welding an d
to permit full penetration of welds betwee n
the branch and the run pipe at all points . Al l
reinforcement pads for pressure openings, o r
each segment of built-up type reinforcemen t
pads for pressure openings, are recommende d
to be provided with 6mm NPT threaded hol e
for testing and venting . The vent hole i s
recommended to be sealed after completio n
of the pressure test with grease or silico n
sealant to prevent ingress of moisture .
Branch connections, vent nozzles, true union s
and other attachments including reinforcing
pads shall not be welded over or nea r
longitudinal or circumferential welds in th e
piping . The minimum distance from a
longitudinal or circumferential weld to the nex t
weld is recommended to be 50mm measured
between the heat affected zones . For
'Pipe DN 40 and smaller is recommended to b e
bent only where cold bending is indicated o n
the piping drawings . In alt other cases, but t
weld, socket weld or strewed elbows is
recommended to be used depending on th e
piping class . Cold bending is recommende d
to be carried out using pipe bending machines ,
or presses provided that dies are employe d
to prevent flattening .
Unless otherwise noted, the centre line radiu s
of bends is recommended to be five (5 )
nominal pipe diameters . Butt welds in the arcs
of bends or for the addition of pulling leg s
shalt not be permitted .
Bending shall not reduce the pipe wall thicknes s
below the minimum watt thickness require d
for the design temperature and pressure plu s
any corrosion allowance . Alt bends i s
recommended to be smooth, free from cracks
and surface defects, without buckles and the y
are recommended to be within tolerance limit s
allowed by given specification .
8 Mitre Bends
Segmented bends is recommended to b e
manufactured by butt welding togethe r
segments of pipe, shaped to produce th e
required bend . Wherever possible, th e
segments are recommended to be taken fro m
the same length of pipe . However, the use o f
segmented bends is recommended to b e
limited to applications detailed on the pipin g
drawings .
The change of centerline at butt welds i n
segmented bends shall not exceed 30° .
ISHRAE Installation Guide
Piping
9 Preheat and Heat Treatmen t
Preheat and inter-pass temperature contro l
and heat treatment is recommended to be i n
accordance with given specification .
10 Pipe Supports
Install all pipe supports, anchors, guides an d
other support attachments in accordance with
the details on the drawings . Pipe supports shall
also be fabricated in accordance with th e
drawings whenever required .
Welding preparations for the pipe to pip e
supports is recommended to be in accordanc e
with given specification . Structural stee l
welding for pipe supports is recommended t o
be in accordance with AS1554 .
All pipe supports is recommended to b e
individually identified by number and thi s
number is recommended to be marked on th e
piping layout plans .
All pipe supports and attachment welds to th e
pipe is recommended to be welded i n
accordance with the same welding procedur e
as used for the piping class . Temporar y
supports are recommended to be used durin g
pipework installation to prevent overstressin g
the pipe work . These temporary supports are
to be removed from site after completion o f
installation .
11 Material and Pipe Spoo l
Identificatio n
All pipes and fabricated fittings i s
recommended to be marked on their outsid e
with letters and numbers defining thei r
respective locations and duties . Markings by
welding shall not be allowed . Markings are
57
recommended to be done by permanent in k
markers that are not health hazardous .
Chloride free markers are recommended t o
be used for stainless steel .
Piping spools is recommended to be marked /
stamped after fabrication and prior t o
corrosion protection .
Drawing number and spool number i s
recommended to be hard stamped on the ri m
of the flange of a flanged fabricated spool .
For non-flanged fabricated spools, marking s
is recommended to be hard stamped on th e
bevel edge of the fitting for thick walle d
fittings and at leased 50mm away from the
bevel edge for thin walled fittings . All markings
are recommended to be hard stamped usin g
a low stress die.
In addition, metal tags stamped with drawin g
number and spool number is recommended t o
be securely tied to each spool .
Stampings on the spools is recommended t o
be suitably masked prior to blasting .
After painting, the drawing number and spoo l
number is recommended to be stenciled o n
the outside surface of the spool with a
permanent ink marker that is compatible wit h
the paint on the spool and is not a healt h
hazard . For stainless steel spools, markers are
recommended to be chloride free .
For pipework where traceability is to b e
maintained, piping materials is recommended
to be marked and identified by heat numbe r
and material specification throughou t
fabrication and installation . Identifications are
recommended to be maintained both on th e
pipe sections used for fabrication as well as
58
Piping
on pipe off-cuts . Identifications for spoo l
components and spools are recommended t o
be as described earlier.
Material identification is recommended to be
maintained throughout the fabrication ,
installation and up to and including fina l
inspection .
12 Storage and Handling of Pipin g
Materials and Piping Spool s
12 .1 General Storag e
Requirements
All piping components is recommended to b e
stored in a clean area away from th e
fabrication and construction activities an d
handled such that neither damage nor mixin g
of materials occurs .
Materials are recommended to be stored o n
pallets and not on the ground . End caps are
recommended to be kept on all components .
Threaded ends are recommended to b e
protected by end caps .
Surfaces of piping components ar e
recommended to be kept free of foreig n
materials such as grease, paint, oil and th e
like .
Hooks or chains shall not be used for lifting .
Pipes shall not be rolled off transport vehicles ,
dropped onto the ground, or dragged over th e
ground. Valves arerecommended to be store d
with spindles in vertical positions . Relief valve s
are recommended to be stored upright in a
clean area .
Flange facings are recommended to b e
protected from damage . Covers ar e
recommended to be securely fastened t o
flange facings during handling, transportatio n
and storage at site .
ISHRAE Installation Guid e
Partly installed piping components and spool s
are recommended to be protected at all times ,
from ingress of moisture or foreign matter,
by covering and taping .
12 .2 Stainless Steel Material s
Storage and handling of stainless steel pipin g
components is recommended to be as follows :
Stainless steel
materials
are recommended to be stored on nonmetallic pallets .
End caps is recommended to be kept o n
piping components .
All flanges and flanged connections ar e
recommended to be sealed with blind s
to prevent ingress of water, moisture an d
foreign matter . Threaded ends i s
recommended to be capped with plasti c
cap and sealed .
Stainless steel piping and components i s
recommended to be stored in separat e
areas away from storage areas for carbo n,._
steel and other materials to avoid direct
contact between carbon steel an d
stainless steel.
_ Steel wire slings shall not be used fo r
handling and transportation of stainles s
steel pipes . Canvas or nylon slings ar e
recommended to be used .
The surfaces of components i s
recommended to be cleaned wit h
'acetone' andthen rinsed with demineralised water to remove deposits o f
foreign materials .
12.3 Lined Steel Pipe s
Storage and handling of lined steel pipe s
requires special arrangements and i s
recommended to be as follows :
Y
ISHRAE Installation Guide
Piping
Pipes and piping components i s
recommended to be handled in such a
way that the lining and other material s
are not damaged .
Lined pipe is recommended to be store d
under cover to protect it from hig h
atmospheric temperatures (40°C an d
over) .
_ Provide 20mm bolted plywood flang e
covers.
FACTORY ACCEPTANCE ,
INSPECTION AND TESTING
1 Inspectio n
All fabrication is recommended to be inspecte d
in accordance with given specification and thi s
specification . Inspection and Test Plan (ITP)
is recommended to be submitted for writte n
approval of the Project specification .
Inspection shall include 100% visua l
examination and any other additiona l
examination necessary to ensure complianc e
with this specification . NDT and pressure tes t
records is recommended to be submitted as
per the Project specification for approval .
Inspection and testing is recommended to b e
carried out before any painting or coating i s
applied .
Non-destructive test of welds is recommended
to be carried out after any final heat treatmen t
is completed .
Tolerances specified for Fabrication and fo r
Installation work is recommended to b e
complied with .
2 Repair of Defect s
Repairs to welded joints, defective o r
damaged pipe and fittings or any other
59
pressure part shall be carried out with du e
recordings .
Repair procedures are recommended to b e
approved by the Project specification prior to
commencement of work .
If repairs or modifications are carried out afte r
heat treatment has been completed, the area s
affected by the repair or modification ar e
recommended to be heat treated again .
3 Shop Testin g
Pressure testing in the shop is recommende d
to be carried out in accordance wit h
specifications or at least 1 .5times the rate o f
pressure .
INSTALLATION, ERECTION,
CONSTRUCTION
1 . General Requirement s
All piping is recommended to be installed i n
accordance with the drawings . Flanges o r
unions are recommended to be installed to
allow installation, removal or maintenance of
equipment or valves .
Modifications to pipe routing may be necessary
at site to avoid interference . Thes e
modifications is recommended to be carrie d
out in accordance wit h ,given specification i n
a neat and workmanlike manner and i s
recommended to be reflected on "as-built "
drawings .
Straight run pipe shall not be pulled throug h
the pipe racks, unless supported on rollers .
Extreme care is recommended to be take n
during handling and erection of expansio n
joints . Shipping rods shall remain in place unti l
erection is complete but must be remove d
immediately after the expansion bellow i s
installed .
60
Pipin
ISHRAEInstallation Guid e
Proper care is recommended to be taken t o
prevent ingress of moisture or dirt into th e
expansion joint during erection .
flange is recommended to be welded to th e
floor plate/mesh to prevent chaffing an d
promote safety.
A straight run of pipe shall contain th e
minimum number of welds . The use of offcuts in straight piping runs is recommende d
to be avoided . Piping butt welds i s
recommended to be spaced a minimum of
50mm or four times the thinnest wal l
thickness measuring between the hea t
affected zones, whichever is greater .
Erection of pipework using Victaulic coupling s
or similar is recommended to be in accordanc e
with the Supplier's recommendations .
Cold springing or forcing of piping for th e
purpose of joint make up is no t
recommended .
2 Installation of Valve s
Misalignment beyond acceptable tolerances i n
straight pipe runs is not recommended . Sea m
orientation of welded straight pipe and pip e
to fittings is recommended to be such that a t
circumferential welds, the longitudinal weld s
is recommended to be staggered over the to p
of the centre line, preferable 30° left and 30 °
right of the Centre line . The minimu m
distance between the staggered joints i s
recommended to be 50mm or six times th e
thinnest pipe wall thickness measured betwee n
heat affected zones, whichever is greater.
Care is recommended to be taken to ensure
that longitudinal welds clear branc h
connections .
Pipes passing through concrete walls or floors
shall not be cast in . Pipe is recommended to
be passed through cast in sleeves or standar d
weight pipe having an internal diameter larg e
enough to give 12mm radial clearance to th e
passing flange, including its lagging, where
applicable, and shall have a light infill if air
passage is to be restricted .
Where pipework passes through floor plate
floors and grid mesh, a 75mm high colla r
having an internal diameter large enough t o
give minimum 25mm clearance to passing
A methodology statement is recommended t o
be provided for site fabrication an d
installation of piping to the Projec t
specification for approval .
Valves are recommended to be installed wit h
stems orientated properly a to be indicate d
on piping drawings . Hand wheels and lever s
are recommended to be easily accessible fo r
operation from grade or platform . Valves shal l
not be installed with their stems projectin g
into walkways . All valves located undergroun d
or in trenches are recommended to b e
provided with valve boxes and extension stem s
& to be shown on drawings .
Relief valves are recommended to be installe d
in an upright position and accessible from a
platform or grade . Relief valves or scour valve s
discharging hazardous liquids or gases, i s
recommended to be piped to a safe an d
environmentally acceptable location .
Chain wheel operators are recommended t o
be provided for valves with hand wheels mor e
than 2,050mm above the operating level .
Chains shall clear operating floors by 900m m
and shall not hang in access areas .
3 Piping for Rotating Equipment
Pump and compressor piping is recommende d
to be installed up to a break point betwee n
the nearest pipe support and the equipment .
The remainder of the piping is recommende d
to be site measured, fabricated and properl y
fitted between the equipment nozzle and its
T
ISHRAE Installation Guide
Piping
break point . It is essential that this is don e
accurately in order to avoid any external
loadings on the equipment connections .
61
RECOMMENDED BOLTING TORQUE S
BOLT SIZE inch
BOLT SIZE mm
N m
1/2
M12
55
5/8
M16
109
3/4
M20
19 0
7/8
M24
300
Carbon steel compressor suction lines i s
recommended to be pickled to ensure th e
internal surfaces of the pipework are fre e
1
M27
450
1 1 /8
M30
640
from rust .
1 1 /4
M33
91 0
The following procedure is recommended t o
be applied for the alignment of flanges t o
rotating equipment :
13/8
M36
1180
1 1/2
M39
1560
15/8
M42
1900
1 3/4
M45
244 0
1 7/8
M48
2850
2
M52
3660
Piping is recommended to be disconnected
from the equipment after installation t o
demonstrate that no stress has bee n
transferred from piping to equipment, an d
then reinstalled .
Install, bolt down on shims and grou t
rotating equipment level on th e
foundation . Driver to equipmen t
alignment
to be set withi n
manufacturer's tolerances.
Align pipework to equipment flanges t o
within the Supplier's tolerance and i n
accordance with this specification .
Stud bolts of diameter 40mm and larger i s
recommended to be tightened by torqu e
wrenches or other tightening methods whic h
result in uniform tightening of the flanges .
Recheck the coupling alignment during th e
bolting and tensioning of the pipe flanges t o
the equipment flanges . The bolting up an d
tensioning of the flanges shalt not affect th e
Bolt torques for valves and lined piping i s
recommended to be in accordance with th e
Suppliers recommendations .
coupling alignment between the driver an d
driven equipment .
Flanged connections are recommended to b e
tightened sequentially diagonally opposite i n
a clockwise or anticlockwise order so that a n
even gasket seating results .
4 Flanged Joint Bolt Torqu e
When bolting gasketed flanged connections ,
the gasket is recommended to be uniforml y
compressed to the minimum torques as pe r
table below :
Flanged spools mating with equipment flange s
is recommended to be site fitted for correc t
alignments to ensure that no stress or load i s
placed on the equipment and the spool flange
shall then be fully welded in accordance wit h
the requisite welding procedure .
62
Piping
Before flanged pipe spools are connected t o
pressure vessels, heat exchangers and flange d
equipment, inspections is recommended to b e
carried out by loosening up to 10% of flange d
or union joints to the equipment to ascertai n
that no stress is placed on equipment due t o
misalignment .
The finish of gasket faces is recommende d
to be in accordance with given specification .
The surface of flange gasket face i s
recommended to be free from rust, wel d
spatter, scars, paint, dents, arc strikes, an d
corrosion pitting and other imperfections .
All flange connections is recommended to b e
made using fully threaded stud bolts and nuts .
A minimum of one and a maximum of three
complete threads shall protrude form the nu t
after completion of tightening .
Insulating gaskets is recommended to b e
installed when shown on the piping drawings .
Care is recommended to be taken not t o
damage the bolt sleeve and gaskets whe n
installing insulation gaskets . Bolts and nut s
is recommended to . be protected by an ant i
seize compound .
5 Pipe Supports
Piping is recommended to be supported ,
guided and anchored, as per the piping an d
support detail drawings. Temporary supports
are permitted to facilitate piping installatio n
provided they are recommended . to be
completely removed upon completion .
Attaching temporary supports to pipes b y
welding is not recommended .
Piping shoes and sliding pipe suppor t
attachments is recommended to be centere d
over the concrete or steel support beam s
before any field welding or bolting to the pip e
is carried out .
ISHRAE Installation Guide
6 Insulated Pipin g
For pre-insulated piping or piping with sho p
applied insulation every precaution i s
recommended to be taken that insulated parts
remain weatherproofed at all times durin g
storage, handling and erection to preven t
moisture from entering behind or into th e
insulation materials.
7 Stainless Steel Pipin g
Special precautions are recommended to b e
taken during stainless steel piping erectio n
in close vicinity of carbon steel piping. N o
direct contact between stainless steel an d
carbon steel should be permitted . Carbon stee l
blinds, spades and caps shall not be used fo r
stainless steel pipe and components .
Stainless steel clamps and U-bolts ar e
recommended to be used for supportin g
stainless steel piping . Stainless steel or PTFE
spacer strips of adequate size is recommende d
to be installed in areas where stainless stee l
piping rests on carbon steel supports .
8 Plastic Piping
The installation and testing is recommended
to be in accordance with the following : Polyethylene Pipe (PE) for pressur e
applications to AS2033, AS413 0
_
UPVC piping to AS203 2
FRP/GRP piping to AS2634
The installation and testing of all other plasti c
piping is recommended to be in accordanc e
with this specification .
Polyethylene pipe connections ar e
recommended to be made using compressio n
fittings or butt weld fittings or usin g
mechanical joint fittings . Backing rings i s
recommended to be installed when plastic (PE)
ISHRAE Installation Guide
Piping
pipe flanges are connected to valves . P E
spacers are recommended to be used whe n
wafer type butterfly valves are used, to ensur e
free movement of the disc .
PE piping is recommended to be laid so that
it is capable of operating between th e
maximum and minimum servic e
temperatures . There is recommended to b e
sufficient excess length between anchors t o
allow for expansion and contraction .
Adequate allowances shall ensure that n o
excessive residual stresses remain in th e
piping prior to :or after start up of plan t
operations . Where excessive expansion i s
expected, adequate flexibility is recommende d
to be allowed .
Piping is recommended to be suitably anchore d
in accordance with the standard drawings .
Anchoring plastic pipes by clamping wit h
saddles or U-bolts is not right .
U-bolt guides with two lock nuts ar e
recommended to be loosely clamped to allo w
free movement of the pipe during expansio n
and contraction .
UPVC pipe connections of the socket cemen t
current type is recommended to be made usin g
solvent cement- as recommended by th e
Supplier. Threaded joints shall use Teflon tap e
or thread seal compound on male threads only .
In slurry service,;.pipes are recommended t o
be flanged at least every twenty (20) meters .
In solution service, pipes are recommende d
to be flanged at least every forty (40) meters ,
unless specified otherwise . Spools may b e
prefabricated in convenient lengths fo r
installation .
All fittings in the slurry service ar e
recommended to he flanged . Spools in solutio n
service may be prefabricated in convenient
63
lengths . Piping is recommended to b e
protected against chafing .
9 Lined Piping (Rubber,
Polyurethane and PTFE Lining )
Flanged spools are recommended to b e
fabricated and lined in accordance with th e
relevant Codes and Supplier' s
recommendations . The lining shall cover th e
face of the flange . Rubber lining shall cover
full face of flange and polyurethane lining shal l
extend up to the inside of bolt holes . Bend s
and elbows shall have flanged ends . Flanged
spools is recommended to be transported to
the work site and erected in accordance with
the Supplier's recommendations and relevan t
codes . Refer to drawings for rubber,
polyurethane and PTFE lined pipes an d
fittings .
Make up pieces is recommended to be sit e
measured, fabricated, lined and then erecte d
at site ensuring that no external loadings are
exerted on the equipment or mating flanges .
For rubber lined flanged joints, gaskets should
not be used . However, for frequentl y
dismantled joints l mm PTFE full-face gaskets
is recommended to be used to prevent bondin g
of rubber. For polyurethane and PTFE lined
flanged joints, gaskets shall not be used . Bolt
torque for flanged joints is recommended to be in accordance with the Supplier' s
recommendations .
Repairs to damaged lining is recommende d
to be done by cutting the affected area to th e
base metal and relining the affected area i n
accordance with the procedure employed fo r
the original lining . Repair procedure i s
recommended to be a hold point of the IT P
and is recommended to be submitted to th e
Project specification for approval prior to
commencing work .
64
Piping
10 Underground Pipin g
All exterior surfaces of underground stee l
piping, fittings and valves is recommende d
to be coated and wrapped .
The external surfaces of steel pipe and fittings
to be coated and wrapped, is recommende d
to be clean, dry and free of any oil and grease .
Wrapping material is recommended to b e
polyvinyl chloride pressure sensitive tape o r
approved equivalent 0 .5mm thick . Widths is
recommended to be 50mm for pipe diamete r
up to 50mm ; 100mm for pipe diameter 8m m
to 200mm and 150mm for pipe diamete r
250mm and larger.
Tape is recommended to be spirally wrappe d
on the steel pipe and fittings starting on th e
mill coating 80mm from the edge using 12m m
overlap and extending 80mm over th e
adjacent mill coating .
Underground pipework is recommended to b e
laid in trenches . Trenches is recommended t o
be of suitable width and generally 300mm dee p
except at vehicle traffic locations where th e
trench is recommended to be 600mm deep .
Pipe is recommended to be laid on a sand be d
and backfilled with suitable back fillin g
material as recommended in the projec t
specifications .
Piping and fittings is recommended to b e
inspected for defects prior to lowering int o
the trench .
Coated and wrapped steel pipes i s
recommended to be laid directly on the trenc h
bottom by lowering the pipe carefully into th e
trench using canvas or leather slings to ensur e
protective coating is not damaged.
Any damage to the coating during installatio n
is recommended to be repaired immediately .
When repairing damaged coatings th e
wrapping in the defective area shall first b e
removed and the pipe re-wrapped in
ISHRAE Installation Guide
accordance with the coating and wrappin g
procedure .
After inspection (visual and electronic) an d
all testing is complete, the trench i s
recommended to be back filled and compacted
in accordance with the project specifications .
Recommended voltage for the detector i s
recommended to be approximately 400 volts
for each 100 microns thickness . Cathodi c
protection, if required, is recommended t o
be provided in accordance with AS2832 .1 .
11 Galvanized Pipin g
Pipe and fittings DN 50 and below i s
recommended to be supplied galvanized wit h
screwed ends and is recommended to be sit e
run.
Pipe DN 80 and larger is recommended to b e
shop fabricated and hot dipped galvanized i n
accordance with AS1650 . If any modification s
are required to galvanized spool DN 80 an d
over during installation, the spool i s
recommended to be modified and hot dippe d
galvanized again . For minor modifications an d
repairs, the spool may be cold galvanized .
Procedure for cold galvanizing is recommende d
to be submitted as per the projec t
specifications for approval and i s
recommended to be a hold point .
12 Mining Hos e
The hoses are recommended to be stored in a
cool dry location away from direct sun ligh t
and high temperatures . Mine hoses i s
recommended to be handled carefully . Nylo n
slings are recommended to be used an d
properly placed while handling mining hose s
in order to support the hose properly . The hos e
shall not be kinked while handling an d
erecting . A minimum bend of 10 D i s
recommended to be used . The hose shall not
be dragged over sharp or abrasive surfaces .
ISHRAE Installation Guide
Piping
65
Piping Connection s
AI .1 IN 'TOO
rrrrrrrrrrr r ..
. 2 - 3 rrrrrrrrr .. T O ...T
rrrrr Gee rrrrrr r‘./
.0c•
4
THE .,.e-nu o
.. .v. 0 .2 IN Is, .00.
e .0 I N
P+c3SVnf GAUGE,
Inc ..or[ ACQYC I
i . W . TM 3TO .
`
" * — COCK
1 .5TAua 0
CT COnT ACTO P
9•C .fu .c
(T .. .OTTLI G)
roe 3crr .w0 rve,
ve . . 0
0 E10
PLMM+WCNT MOVMTCO GAUC C
PCK .•0C .T Moa•TCO
.n TH STOP COCK
o .,, .Ti
/
7-
AND 3TOP COC K
Prtvoec G .ac C
66
Piping
ISHRAE Installation Guid e
Service Requirement s
NOTES :
I . Though not shown . control valves (automatic o r
manual) may be requited to control flow thru eac h
uni L
2. A , shut-off valve may be installed in the ;supply and
return brands headers when headers motel to 5
units .
3. Supply and return runouts to thtcoil should hiv e
Band connections if the runouli"+j re raft copper.
Otheritise .6nioos or Hang* ire instilled to-facilitat e
servicing units .
-
COOLING TOWER IMAUtH s
THREE -WA Y
DIVERTING VALVE
NOTES :
I . A three .way diverting valve is used when the condenser is at the same level as or above the coolin g
tower. See Fig. 43 for piping layout when condense r
is below the cooling tower .
2 . A three-way mixing valve is not recommended at thi s
point as it imposes additional head at the pum p
suction .
NOTES :
I . A two-way automatic control. valve is usedrLLm'The
condenser is below the cooling tower. Scet. Fsigi .df3or
piping layout when the condenses is at- Ifific%mEe
level as or above the cooling tower .
2. The friction loss from "A" to "B" includes the loi n
thru that section of the pipe and'the lop thru the .
two-way automatic control valve . This friction los s
should be designed for the unbalanced bead'of th e
coaling tower.
3. Locate the automatic control valve close to the cool .
ing tower to prevent pump motor oyerloadand towe r
spill-over when valve is in full openposition :_"
FIG . 42 — COOLING TOWER PIPING FOR CONSTAN T
LEAVING WATER TEMPERATUR E
(CONDENSER AND TOWER AT SAME LEVEL)
FIG. 43 — COOLING TOWER PIPING FOR CONSTAN T
LEAVING WATER TEMPERATUR E
(CONDENSER BELOW TOWER )
ISHRAE Installation Guide
Piping
NOTES ;
I . Thermometer wells arc inserted in um . Remove well s
to blow out mils.
2 . A single water regulating valve must be used a
shown .If under opacity . irulalt two valve in paralle l
and connect pressure tube in liquid header .
S . Water supply in or return o u t can he at any poin t in
the headers .
Gauge Location s
Vic. . 53 — CrAGl '. LO( :ATION AT A Ptlhl p
67
Civil Penetration
NSULATED O R
UNINSULAIED PIP E
INSULATED O R
UNINSULATED PIP E
STRAP 20 GA .
SPLIT-RING CUP 20 G A
FIRE PROOF SEALAN T
FIRE PROO F
SEALANT
am ■ moo
IF EXPOSSED 10
VIEW BELOW
PPOVIDE ESCUTCHEON
f
I
-ASBESTOS PACKIN G
Pno ,
no
GAL . PIPE 5L VE WIT H
PUDDLE FLANG E
ASBESTOS PACKIN G
ROP E
FLOOR PENETRATIO N
MECH.ROOMS /WET AREAS
FLOOR PE ETRATION
DRY LOCATION
15 GA. SLEEV E
ESCUTCHEON NO T
RE UIRED I N
CONCEALED SPACES
STD . ESCUTCHEO N
IN FINISHED O R
EXPOSSED AREA S
INSULATED OR
UNINSULAT EPIPE
EXTERNAL PIPE
PROTECTIV E
COVERING SE E
SPECIFICATIO N
ASBESTO S
PACKING ROPE
IT H
SEALANT ALL AROUN D
PIP E
LEAD CAUL K
WALL PENETRATION
GAL . PIPE SLEEVE
PADDLE FLANG E
INSULATIO N
REQUIRED
Ent? NSAEL W I I $
R
IF
ISHRAE Installation Guide
Piping
TYPICAL CHILLER CONNECTION DETAIL (HEADER BELOW )
TYPICAL CHILLER CONNECTION (HEADER ABOVE)
69
70
Piping
ISHRAE Installation Guid e
TYPICAL COIL CONNECTION DETAILS
ISHRAE Installation Guide
Piping
TYPICAL CONDENSER WATER PIPING CONNECTION DETAI L
TYPICAL CONDENSER CONNECTION DETAIL
71
72
Piping
ISHRAE Installation Guid e
TYPICAL AHU CONNECTIO N
WITH 3 WAY DIVERTING VALVE
TYPICAL AH U
CONNECTIO N
WITH 2 WAY VALVE
ISHRAE Installation Guide
Piping
73
Recommended Piping Procedures
CONDENSER PIPIN G
COOLING TOWE R
1. Union Connection s
2. Plugged Tees
3. Water Strainer
4. Thermometers
5. Shutoff Valves
6. Drain Line and Valve
CONDENSER PIPIN G
CITY WATE R
1. Unit Connection s
2. Plugged Tees
3. Water Regulating Valv e
4. Pressure Reducing Valve
6 . Water Strainer
6. Thermometers
7. Shutoff Valve s
Valve d
Pressure
Gaug e
Vents
I
fttl(e1
re-1**Ie 1' .,
Union /
Vibratio n
Eliminator
!•tort
.!
/
Flow
1t
Gate Valv e
Switcn
IOplional Balancin g
Valve
attar
74
Piping
ISHRAE Installation Guid e
AVOID AIR TRAP S
////// S/////
RECOUVENCEO
/
*j/
/
MULTIPLE PUMP PIPING .
ACCEPTABLE
AIR V C
I UNI
UNIT
OFFAL, TO Avon, OwnuEUom
I
I
UNIT
THEADR
/
i¢u%R AT S xuP \\*
msGuE D .E . once.
LC.f
.O(R
Ala WASHER RETURN CONNECTIONS Ar fN F
SAME LEVEL
AVOID AIR LOCKS
SLOPE GRAVITY RETUR N
LINES TQWARO RISER
O
'LUG <W p
vu
xnwG VALVE I
Ee/
t
Sj
k,'10
/ lam
TO .ILVE O
ENTER RISER AT
SHARP ANGLE IN
DIRECTION OF RCM
/LARG E
ELEVATIO N
AIR WASHER RETURN CONNECTIONS A T
DIFFERENT ELEVATIONS
ff
oM sII .xl
lGolCmll IU
R
L
p4/I/Ol
\V/{{
*
` UPS FOR B.OSW T
Urs\*y
NOTE: Flange or union is located so coil may L c
removed.
CHILLED WATER PIPING FOR COILS
(. ).UTOMATIC CONTROL )
ISHRAE Installation Guide
Piping
75
AVOID BULLHEADIN G
N0. 1
-BULLHEADIHG--DO NOT USE
NO. 3
PERMISSIBL E
M0 . s
NO. 4
PREFERABLE TO NQ 3
PREFERABLE TO NO.1
AVOID EROSIO N
TABLE 13—RECOMMENDED WATER VELOCIT Y
,
SERVICE
Pump discharg e
Pump suction
Drain line
Header
Riser
General service
City water
VELOCITY RANGE (fps )
8
12
4- 7
4-15 .
3-1 0
5 .1 0
3- 7
TABLE 14—MAXIMUM WATER VELOCIT Y
TO MINIMIZE EROSIO N
NORMAL OPERATION
(hr/yr)
WATER VELOCIT Y
(fps l
1500
2000
3000
4000
6000
8000
12
11 3
11
10
9
76
Piping
ISHRAE Installation Guide
C.I . POT STRAINE R
SERIES : 1001/C1/40-30M M
NOMINAL SIZE (Doom 050 0651 08010100 012sIo1 s0 0200 02sio30 c
1
1
A
mm 1110 ry6 5 JI88 J206 225 250 J10 350 11 0
H
mm
L
F
318
1375
400
165
190
288
330
3b
419
465 5 15
150
160
180
210
250
575
275
650
603
1
330
E
725
B25
71 0
80 8
400
450
MATERIA L
1. Body/Bonnet — Cl 250 (GG 25 )
2. Body/ Bonnet GASKET — CA F
3. Body/Bonnet BOLTS — A307 Gr. El .
4. Basket — Brass Wvemess 24G x 14 mesh .
C.I . POT STRAINER
SERIES : 1006/C1/40-30MM
NoµNALsaE
(DN)MM) 050) 065) 080)01001012 0150 0200 025 103001
L
mm
235
280 . 310
360
435
505 , WO
130
015
D
mm
150
185
200
260
325
360
115
560
615
Lt
nm
150
150
1W
WO
250
275
330
400
45 0
T
mm
16
16
18
20
. 22
22
24
24
28
MATERIA L
1. Body/Bonnet — Cl 260 (GG 25)
2. Body/Bonnet GASKET — CAF
3. Body/Bonnet BOLTS — A307 Gr . B .
4. Basket — Perorated sheet 24G x 3mm perforation .
Note : EACH STRAINER IS HYDROSTATICALLY TESTED TO 150 PSI
1
ISHRAE Installation Guide
Piping
COMMISSIONING (INCLUDE S
INSPECTION AND TESTING )
1 Pressure Testin g
77
Limit of test as illustrated on the PEt ID' s
Location and thickness of test spade s
Test medium
1 .1 Test Requirement s
Test pressure
Pressure testing is recommended to be carried
out in accordance with the requirements of
given specification, AS4130 and thi s
specification . Pressure piping includes al l
piping designed to convey or contain proces s
or utility fluids at either a positive or negativ e
internal pressure and is recommended to b e
tested as follows :
Shop hydrostatic testing of piping spool s
shall not be required, unless specified o n
the drawings .
Shop hydrostatic testing is required fo r
galvanised piping spools . The spools are
recommended to be hydrostaticall y
tested priorto galvanising . Pressure
piping is recommended to be eithe r
hydrostatically or pneumatically tested i n
accordance with this specifications .
The test pressures is recommended to be 1 . 5
times the normal working pressures which ar e
designated for the class of piping .
Open-ended vent, drain and similar pipin g
systems operating at atmospheric pressur e
are not considered as pressure piping and shal l
not be pressure tested but is recommende d
to be leak tested by filling the lines with water.
Piping systems to be tested is recommende d
to be divided into sections referred to as 'tes t
sections' .
'Test sections' documentation shall contai n
isometrics or relevant sections of pipewor k
related to the section of piping system that i s
being tested and shall include the followin g
information:
Location of vents and drain s
Requirements for isolation or removal o f
in-line equipment and instruments .
Testing procedure is recommended to b e
submitted as per the Project specification fo r
approval . Reinforcing pads is recommende d
to be tested with air at 34 kPa gauge (5 psig) .
All weld surfaces on the inside and outside i s
recommended to be swabbed with a lea k
testing solution . After testing is complete, th e
vent hole is recommended to be plugged wit h
grease or silicon sealant . A record of al l
reinforcing pad tests is recommended to b e
maintained .
Short pieces of pressure piping which must be removed to permit installation of test blind s
are recommended to be tested separately.
Flanged connections at points where blind s
are used during pressure tests do not requir e
separate tests after test blinds have bee n
removed . Screwed and socket wel d
connections is recommended to be inspecte d
thoroughly after make-up to assure tightness .
Re-testing of any 'cut in' or repair work int o
a line already tested, shall generally be carrie d
out to the same procedure and test pressur e
as the original test .
Testing is recommended to be carried out i n
the presence of the Project specification .
Records of all pressure tests are recommende d
to be maintained .
78
Piping
Ensure that the insides of all pipes, valves ,
fittings and other associated equipment ar e
clean and free from loose foreign matter prio r
to commencement of the pressure test .
Normally, equipment is recommended to b e
isolated from the test section . However, where
equipment which could be damaged by foreig n
debris is included in a test section, temporary
in-line strainers is recommended to b e
installed .
The bench testing of pressure relief valves i s
not covered by this specification .
1 .2 Test Medi a
For hydrostatic testing of carbon steel piping
systems, test medium is recommended to be
potable water at ambient temperature with
pH value between 6 and 7 .
For hydrostatic testing piping systems o f
austenitic stainless steel test medium i s
recommended to be demineralised water wit h
a chloride content of maximum 1ppm and p H
between 6 and 7 . Water is recommended t o
be drained immediately after completion o f
hydrostatic testing and the system dried ou t
to avoid concentration of chlorides . Fo r
hydrostatic testing of piping systems with
high nickel content, the water used i s
recommended to be checked for possibility o f
generation of hydrogen sulphide (H2S) durin g
the test .
A report on water analysis including th e
chloride content and pH value of the water i s
recommended to be attached to the test repor t
at-all times when austenitic stainless stee l
systems are hydrotested .
Saline water can be used for testing of PE o r
UPVC pipework .
ISHRAE Installation Guid e
1 .3 Pneumatic Testin g
Pneumatic testing of a piping system i s
generally not recommended unless specifical y
required for the Project . Pneumatic test i s
recommended to be performed in accordanc e
with given specification and the additiona l
requirements of this specification .
Test medium : Dry nitrogen or clean an d
dry oil free air.
_
Area of test to be roped off and access
into the area to be limited .
The minimum metal temperature durin g
a pneumatic test of piping shall not b e
less than the temperature required b y
the engineering design .
_ Piping system to be tested i s
recommended to be protected by a relie f
valve . Set pressure of relief valve : Tes t
pressure plus the lesser of 70 kPa or 7 %
of the test pressure .
_ Weak soapy water is recommended to b e
used for testing leaks in the joints .
1 .4 Test Duratio n
Unless otherwise specifi ed, test pressure i s
recommended to be held for a minimum perio d
of one (1) hour to enable thorough inspectio n
of the piping system of piping component s
for leaks .
1 .5 Preparation for Testin g
All joints in a test section is recommended to
be accessible during tests and shalt not be
painted, insulated, backfilled or otherwis e
covered until satisfactory completion o f
testing in accordance with this specification .
All vents and other connections which ca n
serve as vents are recommended to be ope n
during filling so that all . air is vented prior to
ISHRAE Installation Guide
Piping
79
applying test pressure to the system . Tes t
vents are recommended to be installed at hig h
points .
Holding pins should not be removed fro m
spring supports until testing is completed an d
the system is drained .
Equipment which is not to be subjected t o
pressure test is recommended to be eithe r
disconnected from the piping or blocked of f
during the test . Safety valves and contro l
valves shall not be included in site pressur e
testing .
Pressure in the system is recommended to b e
introduced gradually until the pressure is th e
lesser of one-half of the test pressure or 170
kPa gauge . Maintain pressure for 10 minute s
and then gradually increase pressure in step s
of one tenth of the test pressure until the tes t
pressure is attained .
Temporary spades and blanks installed fo r
testing purposes-is recommended to b e
designed to withstand the test pressur e
without distortion . Presence of spades is
recommended to be clearly visible durin g
testing .
All control valves is recommended to b e
removed or replaced with temporary spool s
or blinded off during pressure testing .
Check valves shall have the flap or pisto n
removed for testing, where pressure can no t
be located on the upstream side of the valve .
The locking device of the flap pivot pin i s
recommended to be reinstated together wit h
the flap and a new cover gasket i s
recommended to be .installed after completio n
of the test .
Spring supports is recommended to b e
restrained or removed and expansion bellow s
removed during hydrostatic testing .
Drain points for fluid disposal after testing ,
is recommended to be provided .
Care is recommended to be taken to avoi d
overloading any parts of the supportin g
structures during hydrostatic testing .
Piping which is spring or counterweigh t
supported is recommended to be blocked u p
temporarily to a degree sufficient to sustai n
the weight of the test medium .
1 .6 Test Equipmen t
Equipment to be used during testing shalt hav e
suitable capacity for the range of tes t
pressures required . All pressure gauges an d
chart recorders shall have been calibrate d
within 60 days prior to testing and shall hav e
current calibration certificates . The gauge s
is recommended to be of a minimum face siz e
of 150mm in diameter and ranged t o
approximately twice the test pressure .
A minimum of two gauges is recommended to be provided for each test system . One gaug e
is recommended to be located at the highes t
point and the other at the pump or at grade .
1 .7 Completion of Testin g
Pressure test is recommended to be considere d
complete when :
All defective welds, defective materials ,
flange leaks, valve gland leaks or othe r
such defects have been corrected an d
accepted as per the Project specification .
All documentation and 'test section '
information is complete and accepted as
per the Project specification .
All temporary test blinds or spades an d
strainers have been removed, ne w
gaskets installed and the piping syste m
reinstated .
80
Piping
Sealing materials shall not be used to correc t
leaks at joints . Valve glands shall not b e
tightened to the extent that the valve canno t
be operated . If necessary, valves ar e
recommended to be repacked .
After hydrostatic testing of the system i s
complete and approved as per the Projec t
specification, all lines and equipment i s
recommended to be completely drained of the
test fluid . Piping systems vents i s
recommended to be opened while draining t o
avoid a vacuum . Care is recommended to b e
taken when draining the test fluid to avoi d
damage to other items of equipment . Specia l
attention is recommended to be given t o
points where water may be trapped, such a s
in valve bodies or low points .
Records for piping which require that pressur e
be held for a specified period of time shal l
include any corrections of test pressure du e
to temperature variations between the start
and finish of the test .
Records of all tests carried out and approve d
as per the Project specification i s
recommended to be retained in the job
records .
1
2 .1 Cleaning
Completed systems are recommended to b e
internally cleaned to remove all remainin g
foreign matter by water flushing or blowin g
with air.
Flushing is recommended to be done with clea n
water using hydrostatic test water. Water use d
for flushing and cleaning austenitic stainles s
steel shall contain less than 1ppm chlorides .
Instruments shall not be flushed through .
Where special conditions exist such as cleanin g
compressor suction and tube oil piping, a
separate cleaning procedure is recommende d
to be prepared and submitted for approval .
2 .2 Re-instatement
After successful completion of pressur e
testing, the system is recommended to b e
returned to a state of commissionin g
readiness .
Hard brazing
Soft brazin g
Brazing by soldering material s
whose fusing points are over 450 C .
Brazing by use of solder whose fusing points are
under 450 C .
Good strength and therma l
resistance
Weak in adhering (shearing) strength compared t o
hard brazing. Consequently, brazed parts easil y
falloff by impact of vibration during operation o f
a/c unit. This evokes gas leakage .
Silver solder - alloy of mainly
silver, copper and zinc . Brass
solder - alloy of mainly copper an d
zinc, but sometimes nickel, tin an d
antimony are added .
Solder used : White solder -:alloy of lead and tin .
2
3
2 Cleaning and Re-instatemen t
Piping and equipment is recommended to b e
dried if required .
1 .8 Test Record s
S.No
ISHRAE Installation Guide
j
ide
ISHRAE Installation Guide
Piping
81
Steel Pipes Dimensions - ANSI Schedule 4 0
be
ling
ing
?an
red
ess
es .
ing
a
ed
Internal and external diameters, areas, weights, volumes and number of threads for schedule 4 0
steel pipes
transverse areas
I length of pipe
Numbe
weight
fvlum r
Isq. Inches)
(per sq. foot on
nominal
o
(rube
thickness
—
thread s
—pot- nd-s
externa l Internal
feet presiz . ' (
screw
linchesl external Internal (Inches) external Internal steel surface surface
foot)
pe r er foot . (kg/m) Perin
°
o of screw
(feet)
(feet)
Ib / ft)
./8
0 .41
0 .0]
0 13 1
06 F0 W
9 .4 3
14 .20 I
00007
0 .24
0 63
.2 7
18
..
1'/
9
1
1
.0]
'
18
0 .54
0 0 .36
0 .0
0 .23
23 - 0 0 0 0 7
3
49.— 0000 ] 1 0 .42
0 .63
_.
3/8
0 .68
0 .49
0 .09
0 56
0 .19 -0.1 ]
5 .66
] .]5
0 .0013
0 .5]
0.04
I1 B8
0.11
0.55
4 .55 - 1 —6 .14
1 .26
0 .84
0 .62
0 .30
u.25
0 .0021 i 0 .05
18
0.11
0.87
3 .64
4 .64
1 .68
1 .05
0 .82
0 .53
0.33
0 .0037
1 .13
14
1 .12
1 .05
0.13
1 .36
0 .86
0.49
2 .90
3 .64
00060
2 .50
14
1 .68
'i _ .
_.14
1
2
.30
1&
1 .66
1 .38
0
2 .16
.50 1 0.67
2 .]]
0 .010 4 04
2 .27
3 .38
II
½
1 .90
1 .61
0 .15
2 .84
2 .04 10.80
2 .01
2 .37
0 .0141
2 .72
4 .04
11 Ih
.
.5 . _
2
2 .10
2 .07
0 .15
4 .41
1 .16
1 .08 ', -- 1 .61
1 .85
00
.0233 1
3 .65
5 .43
11 ½
1 .33
2½
2 .08
2 .47
0 .20
6 .49
4 .79
1 .90
1 .55
0 .0333
5 .79
8 .62
11 N
3
3 .50
3 .07
0 .22
9.62
7 .39 12 .23 1 1 .09
115
0 .0513
7 .50
11 .27
8
3q
4 .0D
1 .55
0 .23
12 .56
9 .89
2 .68
0 .95
LOB
0 .0687
9 .1 t
13 .56
8
4
4 .50
0.24
15 .90
0 .85
0 .95
0 .0884
8
4,03
12 .73 3 .17
10 .79 1 16 .06
5
5 .56
5 .05
0 .26
24 .10 i 20 .00 4 .30
0 .69
0 .76
0.1389
14 .61
21 .74 , 8
6
1 6.63
6 .07
018
14 .47
28 .09 5 .50 i 0 .58
0.63
0.2006
18 .97
24
.2) f 8
8
8 .63 ; 2 .98
0.32 1 58 .42
50 .02 8 .40
0 .44
0.48 1 0.3552
.55
42
.49 -8
28
10
10 .75
10 .02
0 .37
90 .76
78 .85 111 .901 0 .36
0 .3 8
40 .48 60 .24
8
[ 0 .5476
_ .
12 1 12 .] 5 1 11 .94
0 .41
127 .64 1111 .90 115]41 0 .30
0 .3 2
0 .]]63
53 .60 1 79 .77 18
1
14 Ir 14 .00 ' 13 .13
0 .44
153 .94 li 135 .30 118 .64 1 0 .27
0 .28
0 .935 4 1 63 .00 9
8
16
16 .00
15 .00
0 .50
201 .05 1]fi .]J 124
.35 [ 0 .24
0 .25
1 .2230
8
78 .00 1116 .08
10 i 18 .00 1 16.88 . 0.56
254.85 1224
.00 5b .85 0 .21
0.23
1 .5550
105.00 1156 .261 8
20
20 .00 118 .81
0.59
314 .15 12]8.00 x6 .151 0 .19
0.20
1 .9260 1 123.00 1183 .051 8
24
24 .00 22 .63 1 0.69 .452 .40 1402.10 1 5010 0 .16 0.17
1-2 .7930 1 171 .00 254 .481 8
pipe
diameter
linchesl
r
1
1
1
be
*.1
1
1
1
1
1
re
le
lg
1
r
1
1
1
1
Flanges - API vs . ASME/ANS I
Comparing API and ASME/ANSI flange s
The difference between ASME/ANSI and API flanges is the fabrication material and the high e
rated API operating pressure .
ASME/ANSI flanges are common in industrial process systems handling water, steam, air and ga s
API flanges are manufactured for high strength operating refinery systems with products such a :
oil and explosive gases .
The flange standards API 6A and ASME/ANSI 816 .5 are similar dimensionally - but the API 6 /
flanges are rated for higher pressures as shown in the table below :
82
Piping
ISHRA E Installation Guide
API vs . ASME/ANSI Flanges
Nominal Size Rang e
(inches )
Pressure Class Rating (psi)
Flange
Wcldneck
._ .
Blind an d
d
Threade
detl
ASME/ANSI 816 .5
API 6 A
600
200 0
900
300 0
500
500 0
600
200 0
900
300 0
1500
500 0
ASME/ANSI 616 .5
API 6A "
1 'Oi
11
1/2-29
20
aa
1 13/14 ' _ 1 1
" In the old API standard, flanges ranged from 1 13 to 10(20) inches .
Threaded Et Socket Welded Fittings - Pressure Classes and Schedule s
Pressure classes, schedules and weights of pipes for threaded & socket welded fitting s
Pipe Designation Schedule/MF R
Pressure Class
2000
3000
6000
Threaded Fittings
80/XS
160
%% S
80/XS
160
Socket Fittings
900 0
XX S
Standard (STD), Extra Strong (XS) and Double Extra Strong (XXS )
Schedule - Numbers assigned to different wall thicknesses of pipe (i .e. schedule 80 )
ISHRAE Installation Guide
Piping
Pipe Spacing Chart (Welded Piping )
Dimension "A"
Dim
2" 3" 4" 6" 8" 10" 12" 14" 16"I 18" 20"24" "8"
130 130 150 180 200 230 250 280 305 330 360 400 10 0
3"
130 150 150 200 230 250 280 280 305 330 360400 10 0
150 150 180 200 230 250 280 305 330 360 380 430 13 0
6"
180 200 200 230 250 280 305 330 360 380 405460 16 0
8"
200 230 230 250 280 305 330 360 380 405 430480 18 0
10"
230 250 250 280 305 330 360 350 405 430 460500 200
12"
250 280 280 305 330 360 380 405 430 460 480530 230
14"
280 280 305 330 360 380 380 405 430 460 480530 230
16"
305 305 330 360 380 405 430 430 460 480 500 560 250
18"
330 330 360 380 405 430 460 460 480 500 30590 280
20"
360 360 380 405 430 460 480 480 500 530 560 610 305
24"
405 405 430 460 480 500 530 530 560 590 610660 360
1. Add insulation thickness when required to dimension "A "
2. Pipe size shown in inches ; spacing in mm .
Pipe Size
1
83
84
Piping
ISHRAE Installation Guide
PIPING SUPPORT SYSTEM S
The type of support selected is equall y
important to the design of the piping system .
The stresses and movements transmitted t o
the pipe factor in this selection . Pipe supports
should not damage the pipe material or impar t
other stresses on the pipe system . The basi c
type of support is dictated by the expected
movement at each support location .
Initial support design must address the loa d
impact on each support . Typically, a moment stress calculation is used for a 2 dimensiona l
piping and a beam analysis is done for straigh t
pipe run .
If a pipe needs to have freedom of axia l
movement due to thermal contraction an d
expansion, or other axial movement, a rolle r
type support is selected .
If minor axial and transverse (and minima l
vertical) movements are expected, a hange r
allowing the pipe to 'swing' is selected . If
vertical movement is required, supports with
springs or hydraulic dampers are required .
Other structural requirements and condition s
that have the potential to affect piping system s
and piping support systems are analyzed . Pipe s
that connect to heavy tanks or pass unde r
footings are protected from differentia l
settlement by flexible couplings . Similarly
piping attached to vibrating and rotatin g
equipment is also attached to flexibl e
couplings.
Selection of Support types:
The selection of support types is dependen t
upon four criteria : the temperature rating o f
the system, the mechanism by which the pip e
attaches to the support, protective saddle s
that may be included with the support, an d
the attachment of the support to the buildin g
or other structures . Support types are shown
in the figure below and selected as per the
table hereunder :
Support Type Selection for Horizontal Attachments : Temperatur e
Criteria
Process
Typical Support Type/
Applicatio n
Temperature, EC
Number from above
(FP)
figure
Ail . Hot Systems
49 to 232?C
(120 to 450?F)
2, 3, 24,
1, 5, 7, 9, 10,
35 through 38, 59,
41, 43 through 46 ,
39, 40
Clamp s
hanger s
slidin g
rollers
insulation
protectio n
B . Ambient Systems
16 to 48?C
(60 to 119?F)
3, 4, 24, 26,
1, 5, 7, 9, 10,
35 through 38, 59,
41, 43 through 46 ,
39, 40
clamp s
hangers
slidin g
roller s
insulatio n
protection
C-1 . Cold Systems
1 to 15?C
133 to 59?F)
3, 4, 26,
1, 5, 7, 9, 10,
36 through 38, 59,
41, 43 through 46 ,
40
clamp s
hanger s
slidin g
roller s
insulatio n
protection
_
ADJ . STEELICLEEVIS-TYPE I
ADJ .STEELBANqHANGER - TYPE 7
EM . SPLIT PIPE LAMP - TYPE 1 2
INGED OR TWO BOLL
II i
PIPE SLIDE k PIPE PLATE - TYPE 3 5
STEEL DOUBLE BOLT CLAMP - TYPE 3
PIPE SADDLE SUPPORT - TYPE 3 6
STEEL PIPE CLAMP - TYPE 4
AOJ . BAND
GER - TYPE 9
U-COLT 1 - TYPE 24
PIPE STANCHION SADDLE - TYPE 37
PIPE HANGER - TYPE 5
SWIVEL PIPE HINC - TYPE 6
SPLIT OR SOLID
ADJ . SWIVE L RINK BAN D - TYP E 1 D
en .
SPLIT RING W/WD T RNBUCKLE - TYPEI1
CLIP
ITYPE 2 6
PIPE ROLL COMPLETE - TYPE 4 4
ADJ .PIPESADDLESUPPORT - TYPE3 8
SPRING CUSHION- TYPE 48
86
Piping
ISHRAE Installation Guide
Table
Support Spacing for Steel Pip e
Nominal
Pipe Size, m m
(in)
15 (0 .5)
Maximum Support Spacing, m (ft )
SS, Sch 105
CS, Sch 40
SS Sch 405
SS, Sch 55
2 .9 (9 .4)
CS Sch 8 0
2 .9 (9 .6)
2 .1 (7 .0) .
2 .9 (9 .6)
2 .5 (8 .3 )
3 .3 (10 .7)
2 .9 (9 .4 )
20 (0 .75)
3 .2 (10 .3)
3 .2 (10 .6)
2 .1 (7 .0) .
25 (1)
3 .4 (11 .2)
3 .6 (11 .9)
2 .1 (7 .0) .
3 .6 (12 .0)
3 .2 (10 .5 )
40 (1 .5)
3 .8 (12 .6)
4 .2 (13 .8)
2 .7 (9 .0p
4 .3 (14 .2)
3 .9 (12 .7 )
50 (2)
4 .1 (13 .4)
4 .5 (14 .9)
3 .0 (10 .0) -
4 .8 (15 .6)
4 .3 (14 .1 )
80 (3)
4 .8 (15 .7)
5 .2 (17 .1)
3 .7 (12 .0) .
5 .8 (18 .9)
5 .2 (17 .1 )
100 (4)
5 .0 (16 .5)
5 .6 (18 .3)
4 .3 (14 .0) -
6 .4 (21 .0)
5 .8 (19 .2 )
150 (6)
5 .9 (19 .4)
6 .3 (20 .6)
5 .2 (17 .01
7 .5 (24 .6)
7 .0 (23 .0 )
8 .3 (27 .4)
7 .9 (25 .8 )
8 .7 (28 .7 )
200 (8)
6 .2 (20 .2)
6 .8 (22 .4)
5 .8 (19 .0) -
250 (10)
7 .1 (23 .3)
7 .4 (24 .1)
6 .1 (22 .0) .
9 .1 (30 .0)
300 (12)
7 .4 (24 .3)
7 .8 (25 .6)
7 .0 (23 .0) -
9 .8 (32 .2)
.
9 .5 (31 .1 )
Notes :
CS - electric resistance welded carbon steel ASTM A 53, grade A .
SS - seamless stainless steel ASTM A 312, TP316L .
Tabl e
Support Spacing for Copper Pip e
Maximum Support Spacing, m (ft )
Nominal Pipe S i ze, mm
(in)
__
15(0 .5)
Cu Ligh t Wall
1 .5(5 .0):_
20 (0 .75)
Cu X-Stron g Wal l
Cu Regular Wall
_ .-1 .5(5 .0),
-1 .5(5 .0) .
1 .5 (5 .0) .
1 .5 (5.0)•
1 .5 (5 .0) .
25 (1)
1 .8 (6 .0) .
1 .8 (6 .0).
1 .8 (6 .0) .
40 (1 .5)
2 .2 (7 .3)
2 .4 (8 .0).
2 .4 (8 .0) .
50 (2)
2 .4 (7 .8)
2 .4 (8 .0).
2 .4 (8 .0) -
80 (3)
2 .8 (9 .2)
3 .0 (10 .0) .
3 .0 (17 .0) •
100 (4)
3 .2 (10 .4)
3 .7 (12 .0) .
3 .7 (12 .0) .
150 (6)
3 .8 (12 .6)
4 .2 (13 .9)
4 .3 (14 .0) -
200 (8)
4 .5 (14 .6)
4 .8 (15 .8)
4 .9 (16 .0) -
250 (10)
4 .9 (16 .1)
5 .3 (17 .4)
5 .5 (18 .0) .
300 (12)
5 .4 (17 .6)
5 .9 (19 .4)
--
Notes :
Cu = seamless copper ASTM 8 42, allow C 12200, drawn with brazed fittings .
Span lengths are based on a piping system that is a simple single span pipe run, is not insulated, has a
full
flow condition that is essentially water and is subject to a maximum operating condition of 93 ?C (20 0
? F) .
Maximum horizontal spacing based on MSS SP-69 (copper tube, water service) .
Piping
ISHRAE Installation Guide
REFRIGERANT PIPIN G
Items to be attended to before / durin g
brazing :
1.
Confirm that there is no explosive o r
flammable object around the work place .
2.
Wear regulated work clothes an d
equipment before starting brazing work .
3.
Remove scales and solder from brazin g
part.
4.
5.
6.
If objects such as dust, oil, scales, etc
are attached to a part to be brazed, wip e
them off with cloth and polish it with san d
paper. If a gap is too small to be brazed ,
file it.
During the work, open both ends of a pip e
and supply nitrogen gas in such a degre e
that its flow is noticed by hand. (Nitroge n
gas prevents oxidation film from bein g
created inside pipe due to brazing . )
If other parts, (such as valves, flexibl e
tubes, etc), except brazing part i s
heated, wrap them with cloth wette d
with water.
87
The operating pressure of an AC Ft
R system depends on :
a)
Ambient temperature - DBT with ai r
cooled systems, WBT with water coole d
systems for establishing the condensin g
temperature . Also ambient D B
temperature decides the standin g
pressure of the system which is th e
pressure inside the idle system .
b)
Condensing pressure
c)
Suction pressur e
d)
Lubricating oil pressure which is i n
between the condensing and suctio n
pressures.
The operating pressure of a system also varie s
with the REFRIGERANT used inside .
High and low side of the system :
High side - the area which has high pressure from compressor discharge shut off valve to
the inlet of expansion valve . High side has to
be tested to the high test pressure which i s
1 .5 times the maximum ambient temperatur e
/ condensing temperature, whichever i s
higher.
Fig Soldering and brazing
n
L .
(
I
1
Leak Testing:
Test pressures:
Generally the system is tested to 1 .5 time s
the operating pressure .
Low side - the area which has low pressure from the outlet of expansion valve to th e
suction service shut off valve on compressor.
Low side has to be tested to the lower pressur e
which is 1 .5 times the maximum suctio n
pressure / standing pressure correspondin g
to the maximum ambient temperature .
Procedures adopted in pressur e
testing:
a) First test the entire system to the lo w
pressure and make sure that there ar e
no leaks . Keep all the valves in th e
system open .
88
Piping
ISHRAE Installation Guide
b)
Shut off the discharge service shut of f
valve/s and liquid line service valve/s .
b)
Go over each and every joint / sea m
with the open end of the feeler tube .
c)
Apply high pressure to the high side only
and test the system for leaks .
c)
Observe for change in colour of the flame
and thus locate the leak .
Methods adopted for pressure
testing:
d)
Stop the leaks without pressure insid e
preferably.
I . Use soap solution to detect leak s
e)
Pressure test again till you are sure tha t
there are no more leaks .
Principle - Air leaking from a joint turns th e
soap solution film to visible bubble and thu s
the leaky spot is identified .
III. Use Electronic leak detector -
a)
Apply into the system the desired tes t
pressure using Nitrogen . Avoid usin g
Carbon - Dioxide if Nitrogen is no t
available, as much as possible .
Principle - Electronic instruments ar e
available to detect presence of halogen gase s
in the vicinity of the instrument . You will ge t
either visible or audible indication as soon a s
the instrument is taken near the atmospher e
charged with halogen gas .
b)
Smear soap solution of prope r
concentration over EVERY JOINT and ove r
the pipe seams totally.
The instrument can be adjusted to monito r
leaks of different magnitudes, leaks such a s
one ounce per year per leaky joint .
c)
Observe formation of bubbles if any.
IV. Vacuum standing test :
d)
Stop the leaks without pressure insid e
preferably.
a)
Using a good quality vacuum pump, draw
the desired vacuum within the entir e
system .
e)
Pressure test again till you are sure tha t
there are no more leaks .
b)
Note down the date, time, temperatur e
of surrounding air and the quantum o f
vacuum reached .
c)
Close the valves leading to the vacuu m
pump.
d)
On the next day at the same time (i .e .
after 24 hours), observe the vacuum i n
the system and the temperature of ai r
surrounding the system .
e)
Subject to slight variation in ambien t
temperature, the vacuum in the syste m
should remain the same . If not, the n
there is / are leaks to be detected an d
stopped .
II . Use Halide leak detector Principle - A burning flame which is generall y
blue in colour will turn green when any of th e
Halogen gases (fluorine, chlorine, bromine o r
iodine) come near the flame .
Note - This method is not suitable for AMMONI A
systems or for any system using a fluid othe r
than a halogen gas .
a) Apply a pressure upto 5 lbs into th e
system using R12 / R 22 / R11 . Increas e
the test pressure to the desired leve l
using Nitrogen or Carbon-di-oxide .
ISHRAE Installation Guide
Piping
Vacuum holding test is very essential wit h
systems having absorption machines ,
centrifugal machines using R-11/ R-123 ,
systems working with vacuum as suction .
b)
remain as a non condensable insid e
condenser and reduce condenser capacity
and thus reduces the cooling effect .
c)
Educate the user the need to have prope r
pressure testing and pit falls of hurryin g
through improper pressure testing .
increase condensing temperature ,
temperature of parts inside th e
compressor.
d)
reduce the effective use of electri c
power consumed - lower efficiency .
Have total patience while doing pressur e
testing . There should be no hurr y
whatsoever in executing the job .
Moisture inside the system will
result i n
DOs :
a)
b)
c)
a)
formation of acids inside the compresso r
due to heat, oil gas and moisture .
b)
acids acting on the motor winding if it is
a hermetic / semi-hermetic compressor .
c)
acids acting on the parts of compressor,
resulting on corrosion .
d)
breakdown of compressor eithe r
electrical or mechanical or both .
e)
blocking of expansion valve at the needl e
valve by formation of ice .
f)
poor operation of the system .
Do a thorough job of stopping leaks .
DON'Ts :
a)
Do not be in a hurry.
b)
Do not rely on the work of new comer a s
he has no experience .
c)
Do not use oxygen for pressure testing .
You are bound to end up in accident of a
big magnitude .
d)
89
Do not test the system for a pressure
higher than desired .
e)
Do not use gas cylinders without prope r
pressure regulating valves .
f)
Do not start the system while pressur e
testing even by chance.
Extent of vacuum required :
a)
The limit specified should be acceptabl e
and practicable . To remove moisture t o
the maximum extent in the field, we ca n
examine the boiling point of water bein g
32 deg F at 0 .18 inch of mercury i .e. ,
4 .5 mm i .e ., a vacuum of 29 .74 inche s
(755 mm of mercury) or 4500 microns .
This limit is very practical in the field .
b)
We aim at 29 .917 inches (759 .9 mm) in .
order to have a better system fo r
hermetic / semi-hermetic compresso r
systems . This too is possible .
Vacuumisin g
Ensuring that the AC a R system is withou t
moisture and air.. at the time of charging oi l
and refrigerant is vacuumising . The need fo r
vacuumised system :
Air inside the system wil l
a) prevent us from charging refrigeran t
fully.
90
Piping
Procedures adopted whil e
vacuumising :
a)
We need a good vacuum pump which ca n
draw the required vacuum within a
reasonable time .
b)
In a rotary pump, there is no clearanc e
volume and hence deep vacuum i s
possible . A two stage pump is mor e
desirable to make sure that th e
discharged air is at a pressure highe r
than atmospheric pressure . Air ballas t
facility with the vacuum pump i s
beneficial too to make the operatio n
faster. The air ballast is a manually
operated valve which allows a certai n
amount of atmospheric air into th e
compression side of the rotor and thi s
air becomes hot while passing throug h
the body of the vacuum pump and carrie s
away the moisture to the atmosphere .
c)
Do not . use the system compressor fo r
drawing vacuum as the compressor ca n
not draw the required vacuum ; the
compression ratio will become very hig h
and will heat up the parts badly.
d)
System should not have any leaks as tha t
will prevent us from drawing a goo d
desired vacuum .
e)
Vacuum pump should have oil of prope r
quality'and changing the oil is desired
as the oil will be absorbing moisture
continuously while in operation.
f)
Connection between vacuum pump an d
the ACR system should be minimum wit h
two pipes ; one leading to the high sid e
and another to the low side ; the pipe s
should be of at least'/ "dia .
g)
A non return valve between pump an d
system is desirable to avoid suction of
ISHRAE Installation Guide
oil into the compressor in the event of
power failure .
h)
One vacuum gauge has to be located a t
the farthest point from the pump and a t
the top most point on the system an d
this can establish the vacuum inside th e
system .
i)
Gauge on the vacuum pump is not to b e
relied upon as the reading from thi s
gauge reads the condition within th e
pump almost and not the situation insid e
the system .
Instruments used for measuring
vacuum :
a)
Compound gaug e
b)
Vacuum gaug e
c)
McLloyd manomete r
d)
Electronic vacuum gaug e
Methods to improve vacuumisin g
process :
a) Heating the system This can be used for small systems only.
The size of the oven decides the size o f
the system it can handle . Sometimes
cooling coils and condensers are flam e
heated to drive the moisture quickly.
b) Triple evacuation After vacuumising fully, charge th e
system with R 22 to 0 .14 kg/sgcm (g) ,
let the gas and revacuumise . Do this
operation thrice ..The gas let out drives
the moisture quickly .
ISHRAE Installation Guide
Piping
c) Use cold trap -
Cold trap is an intercooler place d
between the vacuum pump and th e
system. The intercooler provides a col d
surface in the air stream from the syste m
and the moisture in the air get s
condensed on the cold surface . The air
going beyond the cold trap is with les s
moisture and the pump will have to tak e
out mostly dry air with less moisture .
91
movement. See Figure below for methods o f
constructing proper suction line P-traps . Sized
for Minimum Load Sized for Full Load Size d
for Minimum Load Sized for Full Loa d
slopevr
pet Lo h
twa b
REFRIGERANT . PIPING - GOOD
PRACTISE S
'INCORRECT'
`°"'"`°'CORRECT '
Suction Line s
t
Horizontal suction lines should slope away
from the evaporator toward the compresso r
at the rate of 1 /4 inch per 10 feet for good oi l
return . When multiple evaporators ar e
connected in series using a common suctio n
line, the branch suction lines must enter th e
top of the common suction line . For dual o r
multiple evaporator systems, the branch line s
to each evaporator should be sized for th e
evaporator capacity. The main common lin e
should be sized for the total system capacity .
Suction lines that are outside of refrigerate d
space must be insulated .
Suction Line Riser s
Prefabricated wrought copper traps ar e
available, or a trap can be made by using two
street ells and one regular ell . The suction tra p
must be the same size as the suction line .
For long vertical risers, additional traps ma y
be necessary. Generally, one trap i s
recommended for each length of pip e
(approximately 20 feet) to insure proper oil
"
'&711E .
Full
ELI
L
itt
—
'ENO Oa
NOTE: Asuction line trap must be installed at _
the point where piping changes the directio n
of refrigerant flow from any horizontal run t o
an upward vertical run .
Liquid Lines
Liquid lines should be sized for a minimu m
pressure drop to prevent "flashing" . Flashin g
in the liquid lines would create additiona l
pressure drop and poor expansion valv e
operation . If a system requires long liquid lines
from the receiver to the evaporator or if th e
liquid has to rise vertically upward an y
distance, the losses should be calculated to
determine whether or not a heat exchange r
is required . The use of a suction to liquid heat
exchanger may be used to sub cool the liquid
to prevent flashing . This method of su b
cooling will normally provide no more tha n
200F sub cooling on high pressure systems .
92
Piping
ISHRAE Installation Guide
Condenser al Some or lower Level Than the compressor .
Condenser Wore Than 8 reel Above Compre s o
u
..
:Q.
Condenser Less Than 8 p eel Above Compressor .
Double Riser Syslern for Nel Cos Discharge lines .
ill
Lamm .
Single Olsehaepe Riser with Oil Seperalor .
X
i_
IVINN IIJftld* I
— N[BN 90VdBu *
Piping System for two or More Evaporators In tlalic d
Below the Compressor .
I0
Piping Anangemml for Tow or Wor t Faporalon Inalallee Abov e
M . Compuner In o Sylem Wlhoul Pump Down Cycle .
Arrangement Used to Bimini Refrigerant and CB Dorn Collidin g
In Evaporators Not Being Used . When Each Evaporator is Cenlmlled by
a Separate' Solenoid Valve and Connate lo the Comm . Suction we .
ISHRAE Installation
Guide
Piping Anongemenl Whe n
Common Condenser Is
Belo, the Compressors .
Piping
9 3
NpsO Amo.mnl Wilh
Ca mp.a.w OW1. Cad. lu.r
Is 10 IWO of Y O.1r . Abm
he Cmp. .0 .
Pkh Or.
name m en n1 WIl .n
Condon
. n.nrs.
Piping Anangemenl Whe n
Common Condenser i s
Above IEe Compressors .
Plpinp Arrongemml Whe n
Condenser I. Abor .
Compressor .
Piping Arrdngemenl Whe n
Compressors in Parallel Ar e
used wn
Singl e
Evaporative Condenser.
Cl Eanln
Compnwl^r
\ C
Shut—oh
Discharge Una rOp . Hurl Be
U .S II Condenser Is m Foal o r
U . Aber. the Compmreu .
parallel With Double Pipe Equalizers .
img
94
Piping
ISHRAE Installation Guid e
Piply Mnpam.nl Wn. n
Suction Lies . Co m. . I n
rrom 9allam.
Piping Amnpam .nl Whe n
Pamllal Compn . .or
n Sap , 1m
Imp Condon .
.ra .
Pipinp Nor{.m.nl When•Common Satllen Un .
m., . . In r:am lo p .
Compressor Ganu[o .. Connm.a AI oil 1 ..n m cor
n
9r Evaon'or Un. .
OIL AND GAS EQUALIZER
ISHRAE Installation Guide
Piping
95
on loose foundations, ensure that ever y
20mters flexible connections are mad e
with proper flanges, to allow for tectonic
movements .
GOOD ENGINEERING PRACTISE S
1.
Follow guidelines and simple logic .
2.
Select the proper supports and materia l
3.
Ensure that adequate space is availabl e
for servicing at a later date at al l
locations.
4.
Thermomete rs are inserted into thermowells which are properly inserted in th e
pipe line . Insertions should be minimu m
of 50% of the pipe dia and the length o f
insertion should not be less than 75% o f
the pipe dia . The angel of inclination o f
the thermowell should be 45° against th e
direction of flow of the liquid .
5.
6.
7.
Drain plugs and cocks are given wit h
proper lengths of nipple for attaching
hose while draining .
The drain slope should be minimum a s
recommended and should be teste d
properly before handing over to th e
commissioning team .
All underground piping should be o n
concrete pedestals with proper bas e
foundation . In case such a precaution i s
not practical, and pipelines have to be
8.
When pipelines are buried, and covered
ensure that every 40meters a vertica l
pipe is extended above ground level wit h
provision for gauge connections . Thi s
will help in reading the pressure drops ,
thus helping in locating any leaks /
damage.
9.
Use proper supports with insulation such
that the pipe body is isolated from th e
metal and concrete of the building . Thi s
not only prevents vibratio n
transmissions, but also heat loss .
10. Ensure that branch tappings are take n
after at least "5d" from the bends ,
valves .
11. Supports are clamped / anchore d
properly.
12. Provision for testing at a later date i s
made before and after every hidden /
non accessible runs, equipment .
13. Installation of air vents manual o r
automatic is a must and should be take n
as a law.
96
Piping
NOTES
ISHRA E Installatio n Guide
Section 3
INSULATION -
Proper insulation laying, removal of air traps from insulation is a s
important as selection of the insulation material and thicknesses . Any
slackness in implementation of this can lead to huge loss of insulatio n
property.
The insulation thickness selection is done with some surface velocity
as an assumption . Ensuring that that much minimum air velocity i s
available at the insulation location is as important as proper laying o f
insulation. Condensation form insulation surface can be menace tha t
one can face for the life of the insulation material . Hence proper sealin g
of the joints, provision for collection of the condensate formed on th e
surface of the insulation at critical locations should be considered an d
precautions taken .
Safety measures can never be overemphasized . Safety for the peopl e
operating, handling and erecting the equipment is more important than
anything else. Follow all safety codes and more than that follow all logic s
to eliminate possible cause of accidents .
ISHRAE Installation Guide
Insulation
99
•
On below-freezing applications and i n
high-abuse areas, the jacket shall b e
protected with a PVC vapor retardin g
outer jacket . In addition, exposed end s
of insulation shall be sealed with vapor
barrier mastic installed per the masti c
manufacturer's instructions . Vapor seals
at butt joints shall be applied at every
fourth pipe section joint and at eac h
fitting to isolate any water incursion .
•
On chilled water systems operating i n
high humidity conditions, it i s
recommended that the same guideline s
be followed as listed for below-freezin g
applications .
•
Exterior hanger supports ar e
recommended .
Glass Wool Pipe
Thermal Insulatio n
Precaution s
Hot Pip e
•
May be installed white the system is i n
operation, at all temperatures up t o
1000°F (538°C) .
For insulation thicknesses greater tha n
6' (152 mm) the temperature must b e
increased from 500°F (260°C) t o
maximum temperature at a rate no t
exceeding 100°F (56°C) per hour .
•
•
•
•
During initial heat-up to operatin g
temperatures above 350°F (177°C), a
slight odor and some smoke may be give n
off as a portion of the bonding materia l
used in the insulation begins to underg o
a controlled decomposition .
If natural convection is not adequate i n
confined areas, forced ventilation shoul d
be provided in order to protect agains t
any harmful fumes and vapors that migh t
be generated .
Care must also be taken when usin g
sealants, solvents or flammable adhesiv e
during installation .
Outside Application
•
Do not expose glass wool insulation t o
weather. It must be covered with appropriate jacketing, mastic or vapo r
retardant adhesives .
•
All exposed surfaces must be protected .
Indoor/Outdoor PVC Jacketing i s
recommended . Check specifications fo r
recommended PVC jacketing applicatio n
guidelines .
•
Apply jacketing, mastics or vapo r
retardant adhesives per manufacturer' s
instructions . For metallic jackets ,
factory-applied and condensate retarders
are recommended .
A maximum of 6" (152 mm) wal l
thickness is recommended .
Cold Pipe
•
•
Use a continuous vapor retarder o n
piping operating below ambien t
temperatures .
Seal all joints, surfaces, seams an d
fittings to prevent condensation .
Pipe Sections
•
Keep adhesive and contact surfaces fre e
from dirt and water, and seal immediately
once adhesive is exposed .
1 00
Insulation
ISHRAE Installation Guid e
•
Apply when ambient and insulatio n
temperatures are between 0° F and 130" F
(-18°C and 54°C) .
for nuisance type dusts should be used wher e
sensitivity to dust and airborne particles ma y
cause irritation to the nose or throat .
•
If stored below 0° F or above 130°F, allo w
insulation cartons to stand withi n
recommended temperature range for 24
hours prior to application .
Application Guideline s
•
Do not store product below -20°F (-29"C )
or above 150°F (66°C) .
•
When using closure system, make sur e
the longitudinal and circumferential
joints are properly sealed by rubbing th e
closure firmly with a squeegee . Use o f
staples is not recommended .
•
When using Pipe Insulation, the surfac e
temperature of the insulation should b e
between -20°F and 150°F (-29°C an d
66°C) during the life of the insulation .
Fittings and Hanger s
•
•
Storag e
•
Protect insulation from water damage o r
other abuse, welding sparks and open
flame .
•
Fiber Glass Cartons are not designed fo r
outside storage.
Preparatio n
•
Apply only on clean, dry surfaces .
•
Pipe or vessel should be tested an d
released before insulation is applied .
General Guideline s
•
All sections should be firmly butted .
•
Seal circumferential joint with a
minimum 3" (76 mm) wide butt strip .
•
Jackets, coating and adhesives shoul d
have a comparable F.H .C . rating.
•
Factory-applied jacket can be painte d
with latex or water-based paint . Solventbased paints should not be used .
•
Do not expose factory-applied jacket to
chemicals or liquid water.
•
All piping should have continuou s
insulation.
•
Position longitudinal lap downward to
avoid dirt and moisture infiltration .
•
Do not expose pipe insulation t o
excessive vibration or physical abuse .
e
Faced insulation should not have a facin g
temperature above 150°F (66°C) .
Use 25/50 Rated (ASTM E 84) PVC Fittin g
Covers, applying PVC fittings .
Fittings should be insulated to sam e
thickness as the adjoining insulation .
•
Apply fittings as per manufacturer' s
instructions .
•
When required by specification, a har d
insert of sufficient length should be use d
to avoid compression of the insulation .
Cautio n
Fiber glass may cause temporary ski n
irritation . Wear long-sleeved, loose-fittin g
clothing, head covering, gloves and ey e
protection when handling and applyin g
material . Wash with soap and warm wate r
after handling . Wash work clothes separatel y
and rinse washer . A disposable mask designed
ISHRAE Installation Guide
Insulation
101
1E : IF RULER PR,PJOLS HYDR O
I .an nx, uµ1, TO xu1H[RCm(i
WEATHERPROOF JACKETING
(CIRC ffERENML SPLIC E
Al SHOE)
SHO E
WELDED SHO E
SPLIT RING HANGE R
Recommended Thicknesse s
The minimum thicknesses are generally base d
on ASHRAE 0 .1-1989 standards and do not
necessarily represent the Economic Thicknes s
of Insulation or the thickness required fo r
proper condensation control . Rather, they
serve as minimum recommendations fo r
commercial applications .
For recommended Economic Thickness, instal l
according to Manufacturer or NAIMA ET I
programs or as specified .
Fiber Glass and Mol d
Fiber glass insulation will not sustain mold
growth . However, mold can grow on almos t
any material when it becomes wet an d
contaminated with organic materials .
Carefully inspect any insulation that has bee n
exposed to water. If it shows any sign of mol d
it must be discarded . If the material is we t
but shows no evidence of mold, it should be
dried rapidly and thoroughly.
If it shows signs of facing degradation fro m
wetting, it should be replaced.
Notes
The chemical and physical properties of Pipe
Insulation represent typical average value s
determined in accordance with accepted tes t
methods .
For piping which requires Pipe Insulation ove r
1 1/2" (38 mm) wall thickness, an extra
fiberglass insert shall be applied or eac h
additional inch of pipe insulation wall
thickness . It is recommended that the surfac e
temperature of the Pipe Insulation and PVC t o
be no higher than 125°F (52°C) . To complet e
application of PVC Fittings on hot piping, th e
throat seam shall be tack fastened or taped .
Seal all laps outdoors and in wash down areas .
HEAVY INDUSTRIAL APPLICATION S
OUTDOOR S
Use .030" or higher PVC Jacketing . Use "heavy
duty" two piece fitting covers made fro m
minimum .030" thick to .050" thick PVC shee t
depending on size of fitting cover . Jacketing
to be cut and oven precurled .
Pipe Insulation End Caps : Use on all outdoor,
indoor washdown areas, and all vapor seale d
systems . End caps will be PVC, metal, o r
gasket materials appropriate for the meta l
pipe temperatures . Silicone rubber (500°F )
can be applied (min . 1/16" thick) as an en d
cap outdoors . Indoor hot piping need not b e
sealed to the end cap . Cap will be sealed o r
taped to the jacket .
Paintin g
Painting must be done only after priming the
PVC surface with a suitable primer.
102
Insulation
REMEMBER Manufacturer's data are subjec t
to normal manufacturing variations . The dat a
are supplied as a technical service and i s
subject to change without notice . HENCE us e
the latest data as supplied by the manufacture r
for any material .
ISHRAE Installation Guid e
adhesive . AU damaged areas of the air strea m
surface shall be repaired with an adhesive tha t
conforms to ASTM C 916 .
Liner should be adhered to the duct with 90 %
minimum area coverage by an adhesive tha t
conforms to ASTM C 916 .
References to numerical flame spread rating s
are not intended to reflect hazards presente d
by these or any other materials under actua l
fire conditions . Always check wit h
Manufacturer's Insulation sates representativ e
to assure information is current .
Mechanical fasteners shall be located wit h
respect to the interior duct dimensions ,
regardless of air flow direction .
Mechanical fasteners should not compress th e
insulation more than 1/8" (3 mm), and shall
be installed perpendicular to the duct surface .
All fasteners should compiy with the guideline s
of NAIMA's Fibrous Glass Duct Liner Standard .
GLASS WOOL DUCT ACOUSTI C
INSULATION
Application and Specification Guideline s
Metal nosings shall be securely installed ove r
transversely oriented liner edges facing th e
air stream at fan discharge, at access doors ,
and at any interval of lined duct preceded b y
unlined duct . In addition, where velocitie s
exceed 4000 fpm (1219 mpm), metal nosin g
shall be used on upstream edges of liner a t
every transverse joint .
Storage
Inside storage is recommended .
Fabrication and Applicatio n
Fabricate in compliance with the latest editio n
of NAIMA's Fibrous Glass Duct Liner Standard .
Liner shall be folded and compressed in th e
corners of rectangular duct sections or shal l
be cut and fit to assure lapped, compresse d
joints . Longitudinal joints in duct liner shoul d
not occur except at the corners of the duct .
Longitudinal joints in liner shall be coated with
Limitation s
Duct Liner should not be used in system s
operating at velocities exceeding 6000 fp m
(1829 mpm) or at temperatures above 250° F
(121°C) .
TYPICAL PERFORMANCE CHART
SOUND ABSORPTION COEFFICIENTS, 1/3 OCTAVE BANDS (ASTM C 423, TYPE A MOUNTING )
7hidmess+ .
_1257 . . -1250
500
1000
2000
. .4000 :'
1 .5 PCF (24 kg/m3)
1' (25 mm)
.18
.36
.59
.86
.95
.90
.70
1 .5 PCF (24 kg/m3)
1 .5' (38 mm)
.35
.51
.83
.93
.97
.96
.8 0
1 .5 PCF (24 kg/m3)
2" (51 mm)
.34
.64
.96
1 .03
1 .00
1 .03
.90
. 0enslty„, . - ; ;
NRC
2 .0 PCF (32 kg/m3)
.5' (13 mm)
.09
.14
.40
.60
.73
.82
.4 5
2 .0 PCF (32 kg/m3)
V (25 mm)
.25
.35
.69
.89
.96
1 .01
.70
2 .0 PCF (32 kg/m3)
1 .5' (38 mm)
.27
.55
.87
.99
1 .00 •.
.98
.85
ISHRAE Installation Guide
Insulation
1 03
FRICTION LOSS (INCHES OF WATER PER 100 FT. )
AP,)_
R
_iF*
500
600
700
800
900
1000
2000
3000
4000
5000
10'HD
16 HD_
24 H D
._
054
.077
.104
.534
.569
.207
.806
11797
3.179
4.952
..
030
.042
.057
.074
.093
.114
.443
.988
1 .748
2.724
018
.025
.034
.044
.056
.068
.266
.594
1 .050
1 .636
32 HD
'ulCrJ"<
.012
.018
.024
.031
.039
.048
.186
.415
.734
1 .143
THERMAL CONDUCTANCE, C AND RESISTANCE, R (ASTM C
`'Density !-,.: ` 1 .5 PCF(24 kg/m3) i 1 .5 PCF (24 kg/m3)*
1 .5 PCF (24 kg/m3)i
2.0 PCF (32 kg/m3)
2.0 PCF (32 kg/m3)
2.0 PCF (32 kg/m3)
-
Thickness
1"(25 mm)
1 .5" (38 mm)
2" (51 mm)
.5' (13 mm)
1" (25 mm)
1 .5" (38 mm)
- _G 61(10
.24
.17
.13
.48
.24
.16
6 t
-
40.I HD ".
*W-. .*
.009
.013
.018
.023
.029
.036
.141
.315
.557
.867
7
H0, *
r4is
.005
.007
.009
.011
.014
.018
.069
.153
.271
.422
100 I
.5,tr
003
.004
.006
.008
.01 0
.01 2
.046
.103
.18 1
.283
177 )
-:C-Vatue .(51)
1 .36
.97
.74
2.73
1 .36
.91
,-__; RVaWe " .• RNalo
4.2
W .74
6.0
1 .06
8.0
1 .41
2.1
.3 7
4.2
.74
1 .1 1
6.3
50' -
_
STANDARD SIZES AVAILABLE IN MARKE T
_' Density
__
,,,,_ Thickness ___
1 .5 PCF (24 kg/m3)
1" (25 mm)
1 .5 PCF (24, .kg/m3)
1' R5 mm)
1 .5 PCF (24 kg/m3 )
- "'
1 .5 PCF (24 kg/m3)
1 .5" (38 mm)
2.0 PCF (32 kg/m3)
0 .5' (13 mm)
2 .0 PCF (32 kg/m3)
1' (25 mm)
2" (51 mm)
_Width(34' to 36`,, no edge-coating)L.'
35.5-, 46.25", 4T', 47 .5', 48', 56' ,
56 .25", 56.5', 5T, 59 .5', 60'
(902, 1175, 1194, 1207, 1219, 1422 ,
1428, 1435, 1499, 1511, 1524 mm)
47'
(1194 mm)
4T, 48"
(1194,1219mm)
4T, 48"
(1194, 1219 mm)
35.5', 4T, 47 .5', 48', 59", 59 .5'
(902, 1194, 1207, 1219, 1499, 1511 mm)
47.5', 48'
(1207, 1219 mm)
.' .Length, .100' (30 .48 m )
S0 (15 .24 m )
50' (15 .24 m )
50' (15.24 m)
100 (30 .48 m)
50' (15 .24 m )
1 04
Insulation
ISHRAE Installation Guide
•
Pressure-sensitive tapes should be a
minimum 3" (76 mm) wide and shoul d
be applied with moving pressure usin g
an appropriate sealing tool. Staple s
should be outward cinch and placed 6 "
(152 mm) on center.
•
Closure systems should have a 25 Flam e
Spread and 50 Smoke Developed per U L
723 .
•
For rectangular ducts over 24" (610 mm )
wide, secure the insulation to the botto m
side of the duct with mechnical fastener s
spaced on 18" (457 mm) centers to reduc e
sag . Care should be taken to avoi d
overcompressing the insulation with th e
retaining washer:
•
Unfaced Duct Wrap should be overlappe d
a minimum of 2" (51 mm) and fastene d
with 4" (102 mm) to 6" (152 mm) nail s
or skewers placed 4" (102 mm) apart, o r
secured with a wire or banding system .
Care must be taken to avoid damagin g
the duct wrap .
DUCT THERMAL INSULATIO N
Application and Specificatio n
Guideline s
Storage
Protect stored insulation from water damage ,
construction damage, and other abuse .
If stored outside, proper protection fro m
weather conditions should be provided .
Preparatio n
Install over clean, dry sheet metal ducts . Al l
sheet metal joints and seams must be seale d
to prevent air leakage from the duct .
Applicatio n
•
Install with facing to the outside t o
obtain specified R-value using a
maximum of 25% compression .
•
Butt all insulation joints firmly together.
Longitudinal seam of the vapor retarde r
must be overlapped a minimum of 2" (5 1
mm) . Sometimes manufacturer provides
a 2" (51 mm) tab for the circumferential
seam, and it must be overlapped .
Installation Procedure s
•
•
Where vapor retarder performance i s
necessary, all penetrations, joints ,
seams, and damage to the facing should
be enclosed/sealed with an foil tape, o r
staples, tape or mastic prior to syste m
startup .
Use the table below to determine stretchouts required for the nominal insulatio n
thickness to limit average compressio n
of the insulation to 25% or less . Use
staple flange to speed measurement o f
duct wrap .
All Seams & Joints stapled 6" (150mm) in center before sealing with tape or mastic
ISHRAE Installation Guide
Insulation
1 05
INSERTION LOSS (DB/LF), 1/3 OCTAVE BAND S
(SOUND AND VIBRATION DESIGN AND ANALYSIS, NEBB '94 )
Nominal .;..
Nominal
TMckness.mm)
-0egsify (kg/m')
12"x12"(305x305)
24 GA
1 .5"(38)
0 .75 PCF (12)
.6
24"x12"(610x305)
24 GA
1 .5" (38)
0 .75 PCF (12)
48"x12"(1219x305)
212 GA
1 .5" (38)
24"x24"(610x6]0)
22 GA
24"x12"(610x305)
24"x8"(610x203)
Duct
khee t
DimensioriSimm) - Metal
f63 r *
5
y-* ;HzH( 2
Hz
250 500 5700lg+2000 x4000; 1
Hz , U
MHz
tIt- a tl ''114
.6
.6
.7
7 .4
14 .2
20 . 9
.6
.6
.6
.7
7 .4
14 .2
20 . 9
0 .75 PCF (12)
.5
.5
.5
.6
7 .4
14 .1
20 . 9
1 .5"(38)
0 .75 PCF (12)
.5
.5
.5
.6
7 .4
14 .1
20 . 9
26 GA
1 .5"(38)
0 .75 PCF (12)
.8
.8
.8
.8
7 .5
14 .2
21 . 0
26 GA
2" (51 )
0 .75 PCF (12)
1 .0
1 .0
1 .0
3 .6
10 .4
17 .1
23 .9
R-VALUES (ASTM C518) @ 75°F MEAN TEMPERATUR E
Out-of-Package --_ - :R Value _
Density
- -
'Thickness
.75 PCF
11/2"
5 .1
4. 2
.75 PCF
!2"
6 .8
5. 6
.75 PCF
'23/16"
7 .4
6. 0
.75 PCF
21/2"
8 .5
7.0
.75 PCF
3"
10 .2
8.4
1 .0 PCF
11/2"
5 .6
4. 5
1 .0 PCF
2"
7 .4
6.0
1 .5 PCF
11/2"
6 .1
4 .8
8 .2
6.4
1 .5 PCF
2"
"--Installed R}Yal'ue'r, ,
-*{(@25%'Comffession')'I ` ';
.
THERMAL EFFICIENCY (ASTM C 177 )
Mean ___
Temperature
Mea n
75 PC F
k
i75 PC F
Temperature (SI)
1 0 eCF
k-:`
1 :0" PCF
1 S,PCF (1 5'PCF,,
k (SI) `
* k _;,, .'-' k (SI) ,, ,
50°F
10°C
.28
.040
.26
.037
.23
.03 3
75°F
24°C
.29
.042
.27
.039
.24
.03 5
100°F
38°C
.31
.045
.29
.042
.26
.037
125°F^' - 52°C
.33
.048
.31
.045
.28
.04 0
150°F
66°C
.36
.052
.34
.049
.31
.04 5
175°F
80°C
.39
.056
.37
.053
.33
.04 8
200°F
93°C
.43
.063
.40
.058
.36
.052
(SI)
1 06
Insulation
ISHRAE Installation Guide
FORMS AVAILABL E
Density . :: :
Thickness (mm)
Width (mm)
Length (m)
Facin g
.75 PCF (12 kg/m3)
11/2' (38)
48" (1219)
100' (30 .48)
FSK, Unfaced, PS K
.75 PCF (12 kg/m3)
2" (51 )
48" (1219)
75' (22 .86)
FSK, Unfaced, PS K
.75 PCF (12 kg/m3)
23/16" (56)
48" (1219)
75' (22 .86)
FSK, P5 K
.75 PCF (12 kg/m3)
21/2" (64)
48" (1219)
75' (22 .86)
FSK, PS K
.75 PCF (12 kg/m3)
3" (76)
48" (1219)
50' (15 .24)
FSK, P5 K
1 .0 PCP (16 kg/m3)
11/2" (38)
48" (1219)
100' (30 .48)
PSK, Unfaced, P5 K
1 .0 PCF (16 kg/m3)
2' (51 )
48" (1219)
75' (22 .86)
PSK, Unfaced, P5 K
1 .5 PCF (24 kg/m3)
11/2' (38)
48" (1219)
40' (12 .19)
FSK, P5 K
1 .5 PCF (24 kg/m3)
2- (51 )
48" (1219)
40' (12 .19)
FSK, P5K
STRETCH-OUTS
Round .
Square
11/8' (29 mm)
P+91/2" (241 mm)
P+8" (203 mm)
P .7- (178 mm )
2" (51 mm)
11 /2" (38 mm)
P+12" (305 mm)
P+10" (254 mm)
P+8" (203 mm )
23/16 (56 mm)
15/8- (42 mm)
P+13" (330 mm)
P+11" (279 mm)
P+81 /2" (216 mm )
P+91/2"(241 mm )
P+111 /2" (292 mm )
Laheled , „
Thickness
Installed .'.
'._!'ic,y(25%Compression)
11/2” (38 mm)
-- e
21/2" (64 mm)
17/8°(48 mm)
P+141/2(368 mm)
P+121/2"(318 mm)
3 (76 mm)
21 /4- (57 mm)
P+17" (432 mm)
P+141 /2" (368 mm)
Here are a few things to thin k
about before you install :
1.
Leave fiber glass insulation in its
packaging until you're ready to use it .
Packaged insulation is highly compresse d
and expands greatly when the packag e
is opened .
2.
Use continuous rolls in floors because o f
longer joist spans .
3.
4.
To cut insulation, lay it on a board wit h
the kraft or foil facing down, if
applicable . Lay a yardstick (or 2 x 4) ove r
the area of insulation to be cut . Pres s
your straight edge down hard and cut wit h
a utility knife, using the straight edg e
as a guide .
Remember that only the bottom portio n
gets stuck t the surface . Rest of th e
insulation material is only bonded by the
Rectangular
_
resin in the glass wool, and henc e
susceptible to shear, displacement etc .
5.
To ensure that the material stays i n
place, it is recommended to wrap wit h
chicken wire mesh, tie straps at regula r
intervals, stick dowel pins in random an d
phased manner. The higher the thicknes s
more important to carry out the above .
6.
Do not compress the product when you
install it . The insulation should be in ful l
contact with the studs or drywall on al l
sides and the front and back .
7.
Avoid leaving any gaps around the edge s
or around pipes; or wiring .
8.
Look for specific guidance whe n
installing insulation around pipes an d
wiring .
9.
Do your homework to see if you need a
vapor retarder '
ISHRAE Installation Guide
Insulation
UNDERDECK INSULATION CONCRETE SLA B
INSTALLATION Et DESIG N
CONSIDERATION S
•
Foam or Fiberglas insulation board can
be installed on the underside of concrete
decks with mechanical fasteners ,
impaling pins or compatible adhesives .
•
Use, large head mechanical fasteners o r
minimum 1," washers to prevent fastene r
head from pulling through insulation .
•
The need for a vapor retarder should be
determined by the designer based o n
local conditions .
•
In cold climates vapor retarders shoul d
be as continuous as possible . Use per m
rating less than 1 .0. Available ratings are
less than 0 .02.
•
•
Use Tape to seal joints between Foa m
panels . Preferable use proper an d
approved duct closure tape to seal th e
vapor retarder facing joints .
Air circulating or vented from the ceiling
plenum to an occupied space must be
separated from the polystyrene insulatio n
with a code approved thermal barrier .
•
Polystyrene insulation must be separate d
from the building interior with a cod e
approved thermal barrier.
•
Compliance with !oval code requirement s
must be verified .
1 07
Synthetic Insulation for Pipin g
The following should be taken care of while
using the material for low temperature piping :
1.
The selection of the material is done wit h
proper parameters of temperatur e
extremes, relative humidity extreme s
and lowest surrounding air velocity on th e
surface of the insulation .
2.
Where stagnant air is anticipate d
(shafts, poorly ventilated basements ,
above the false ceilings, minimall y
ventilated service floors, etc) avoid using
this method for chilled water/ brine
insulation .
3.
Use proper/ good quality/ manufacture r
recommended adhesive only .
4.
Carry a simple flame test at site .
5.
Do not expose the material to UV rays,
open solar rays . Cover and seal all th e
avenues for tight hitting the surface .
6.
Do not press/ stretch the sheets on th e
base surface .
7.
Do not leave air gaps/ pockets trappe d
between the surface and the insulation .
8.
Seal all butt joints with proper sealin g
tape . (same material self adhesiv e
tapes) . Do not use PVC / electri c
insulation tapes .
9.
Keep the butt joint of the insulation a t
the bottom to keep the same visible fo r
ease of inspection and rectification . I t
will also help the condensate to fall of f
from the surface, rather than trave l
inside the crack and further increase the
problem .
10. Use proper tools for cutting, spreadin g
of adhesive, and rolling the material on
1 08
Insulation
the pipe surface to remove air traps .
Simple wooden rollers (with cylindrica l
and concave curved profiles) can be used
for proper pressing of the insulation an d
uniform adhesion to the mother surface .
ISHRAE Installation Guid e
Weld pins should be spaced 50mm fro m
all edges and spaced 200-300mm apar t
in all directions.
DUCTIN G
General Information .
Closed Cell Foam Material insulation can b e
installed either with conventional mechanica l
fastening method (weld pins), or wit h
pressure sensitive adhesive (applied in house )
The Insulation Material can be easily cut wit h
a sharp knife .
All joints should be butted firmly together a
sealed with high grade aluminium foil such a s
PPC 493 or equivalent.
50 .7:
9-AO .,io
■
Material should be pulled firmly aroun d
corners to ensure a tight fit .
■
All joints should be butted firmly togethe r
& sealed with high grade aluminium foi l
such as PPC 493 or equivalent .
■
Where supporting hangers are in place ,
slit Closed Cell Foam Material as require d
and pass slit sections around the hanger.
Seal slit with aluminium tape
Closed Cell Foam Material can be supplied wit h
Flange Strips of 100 mm, 120 mm, and 15 0
mm widths for insulation of flanges .
Installation Method s
Flange Insulatio n
Mechanical Fixing (Weld pins) .
■
Closed Cell Foam Material should b e
butted against flange joints tightly.
■
For flange insulation use same materia l
Flange strips (150-200 mm wide )
supplied separately.
■
Fix one side first with aluminium foi l
tape, then fold material over flange and
fix with aluminium foil tape . Asmall ga p
in the corner is normal and does no t
affect the performance of the insulation .
■
Closed Cell Foam Material's flexibilit y
allows it to either be wrapped aroun d
duct or, for large thicknesses, it can b e
sheeted for easier application .
I CUT 5E071050
WR P-AROUNDI
-► AREAS TO BE SEALED W01175 mm ALIJWNlW FOIL TAPE
ISHRAE Installation Guide
Insulation
1 09
Application of Insulation Materia l
o
,r
..
Area to be soled with 75mm aluminium foil tap e
Fixing with transfer adhesive .
WRAP - AROUND SYSTE M
o
Cut Closed Cell Foam Material to th e
required length . Always allow excess 20
mm for final adjustment . Do not peel the
backing paper off at this stage .
o
Lay duct section on the floor. To avoi d
damage to the insulation, use cardboar d
sheets on the floor .
o
Peel off only a small section to start of f
with (150 mm) . Align with duct edge wit h
the insulation sheet edge, and gentl y
lower to the duct . Pad firmly. Startin g
from the fixed edge, move to the othe r
edge by lowering the insulation to th e
duct progressively whilst paddin g
insulation at the same time . Peel off
enough paper to cover one side at a tim e
only. Ensure air is expelled .
Adhesive basics .
o
The adhesive used is a pressur e
sensitive acrylic system . It relies o n
pressure to properly pond to the duct .
Once fixed, adhesive should be padde d
firmly to ensure contact with the duc t
metal shee t
o
The adhesive can be re-positioned fo r
better alignment, provided no pressur e
is applied and it is done immediately .
However, once the adhesive cures, it will
be impossible to re-position or peel off
the duct .
o
No weld pins are required .
Surface preparatio n
o
o
All ductwork should be clean of duct an d
grease & oil To clean the duct, first wip e
down with a clean cloth to remove exces s
dust. To remove grease & oil, a suitabl e
solvent should be used such a s
methylated spirits or acetone . Wipe
ducts clean and allow solvent t o
evaporate .
Work in a reasonably clean area an d
avoid dusty places .
Firstly cut the required length of Close d
Cell Foam Material required . This will
depend whether a wrap-around syste m
(usually less than 20 mm thickness) i s
used or whether four cut sections ar e
used (usually above 20mm thicknesses )
DO NOT TRY TO LOWER ENTIRE SHEET T O
ONE SIDE OF THE DUCT AT ONCE . THIS WIL L
LEAD TO TRAPPED AIR POCKETS . (see Fig 1 )
Closed Cell Foam Material is a closed cel l
material and will not allow trapped air t o
escape .
o
Once one side is fixed, turn duct to expose
new bare side.
o
Slowly peel off enough backing paper t o
cover the edge and side of duct . Slowly
pad the adhesive to the edge ; DO NO T
PULL THE INSULATION ON THE DUCT
110
Insulation
CORNERS . Guide the insulation over th e
corner by pressing lightly (Fig 2) . The
insulation on the corners should be th e
same thickness as on the flat sections .
o
Repeat until completely covered . On th e
final side, ensure the insulation lengt h
reaches the same level as the startin g
edge . Trim off excess length with shar p
knife until it is level with adjacent side .
(Fig 3) .
CUT SECTION INSTALLATIO N
For thicknesses above 15 mm it is advisabl e
to use four cut sections to insulate the duct .
Observe cleaning requirements of the duct a s
outlined in the previous section .
o
Observe application techniques a s
explained in the previous section relatin g
to application of sheets . Apply sheet s
slowly starting from one edge and then
slowly moving to the opposite edge ,
whilst applying pressure at the sam e
time. NEVER LAY THE WHOLE SHEET AT
ONCE AS THIS WILL LEAD TO AI R
POCKETS .
o
Ensure width of sheets is adequate t o
cover the duct and the extra width fro m
the adjacent sheets of insulation . (Se e
Fig 3) .
Use aluminium foil tape to seal the join t
o
ISHRAE Installation Guide
,M.Y
.01
DrMnl MS !ADM ONE ELM ,
DUCT INSTALLATION
HANGERS
o
al
DO NOT PULL ON
FDG
DORNESS.
SIOULD S_AamD .
F2
Conventional hangers are suitable for th e
installation of Closed Cell Foa m
Material . if the duct is insulated before
it is installed, the hanger base must b e
lined with foam of the same thicknes s
of Closed Cell Foam Material to protec t
against compression . (Fig 4) . Closed Cel l
Foam Material can also be used in plac e
of plain PE foam .
i1I
UM= TOT E
we me, ..T
mans
VEAL JOINTS WDH 35 MM ALLRL FOE TAPE
Fig3
Fe 4
ISHRAE Installation Guide
Insulation
111
Closed Cell Foam Material can be easily drilled
or cut to accommodate installation of othe r
services after insulation is fixed .
UNDERSLA B
General Information .
Closed Cell Foam Material insulation shoul d
be mechanically fixed with a pin/clip fastenin g
system suited to the structure of the unde r
slab.
All joints should bebutted firmly together S
sealed with high grade aluminium foil tap e
such as PPC 493 or equivalent .
Installation Method
SLAB
Thermobreak
Fasteners spaced at 300mm centres
Seal all butt joints with reinforced aluminium foil tap e
ROOF INSULATION
Closed Cell Foam Material can be installed bot h
under and above puffins . Under - Puffin metho d
is recommended due to higher insulatio n
performance attained with such a method .
All joins should be sealed with 75 m m
aluminium foil tape such as PPC 493 o r
equivalent . Closed Cell Foam Material can b e
supplied in customised roll lengths to reduc e
joints and eliminate waste .
20 -- fa ' s :
I SL
ABOVE PURLIN INSTALLATIO N
The insulation material is bought in roll fro m
On custom lengths if required) .
Reflective foil surface should face downwards .
Apply a 200 mm self adhesive foil stri p
between roll joints . The joint of the two
adjacent rolls should rest in the middle of th e
foil strip. (see below)
.
75 mm fai: 7x
1 12
Insulation
ISHRAE Installation Guid e
insulation . This is to avoid excessive
pressure against the insulation .
BELOW-PURLIN INSTALLATIO N
This method gives superior insulatio n
performance than above-purli n
installation . Closed Cell Foam Material Foil both sides is required to achieve this
higher performance .
For 1200 mm width material, bore tw o
holes 600mm apart . ( 2 per puffin) (see
diagram) Attach insulation with sel f
tapping screws .
Installatio n
Once a complete length is completed ,
repeat procedure . ,
Installation is performed under the purlins an d
at right angles to the purlins .
Butt adjacent sections as tightly a s
possible . Seal joint with 75 m m
aluminium foil tape .
Start at one end of the roof and procee d
to the other end, whilst fastening Close d
Cell Foam Material rolls on the purlins .
Ensure adequate pressure is applied t o
the aluminium foil tape .
Fasten with self tapping screws . As a n
option, an aluminium flat bar ( 25mm )
can be used between the screw and th e
&ELOIN PURWN :RbOR INSULATION
't
AItl1.411111N11T W . TAVIi I i nml
ISHRAE Installation Guide
Insulation
113
REFRIGERANT PIPE INSULATIO N
paint within seven days of installing th e
insulation . Allow proper drying time s
between coats.
POINTS TO REMEMBER FO R
INSTALLATION OF SYNTHETI C
MATERIAL INSULATION :
1.
Use good quality tools and, in particular,
fresh adhesive and good adhesiv e
brushes
sharp non-serrated edge knives
9.
In double layer work, apply insulation
with the side and end joints staggered .
10. Use Insulation Pipe Hangers to prevent
thickness compression and condensatio n
gaps .
2.
Insulation must be dry and clean prior t o
application
3.
Apply Insulations only when the pipes ar e
dean, dry and unheated or uncooled .
Surface to be insulated must be free o f
rust or debris .
4.
Never stretch insulation when sealing the
joints . It is better to compress it slightly.
Use pieces of insulation that are slightly
longer than the section of pipe to be
insulated .
Insulation New Refrigeration Piping : The Slip On Metho d
5.
Always use the proper size insulation fo r
a particular sized pipe . Do not stretch i t
over the pipe .
The Slip-On Method is used when you ca n
insulate new piping before it goes up or as i t
is being connecte d
6.
Do not crowd insulation covered pipes .
Space pipes to allow for the fre e
circulation of air. Air movement is a n
extra safeguard against surfac e
condensation of cold pipes, especially
under hot, humid conditions .
All you do is slip the pipe insulation over th e
7.
Use Proper sealing of all pipe insulatio n
is important to minimize heat loss an d
control condensation . On cold lines, ope n
pipe insulation joints may allow th e
formation of condensation, increasin g
the potential for or contributing t o
possible pipe or tubing corrosion . All
insulation joints must be sealed .
pipe or copper tubing . The inside of th e
Insulation is coated with a powdered lubricant ,
making it easy to slip the insulation over th e
pipe.
When using insulation outdoors, alway s
paint with two coats of UV protective
(NOTE: Small amounts of powdered lubricant
may enter open ends of pipe or tubing . This
8.
11. Do not compress Insulation at joists ,
studs, columns, ducts, hangers, etc . This
is important because the insulation wil l
lose thermal efficiency where it i s
compressed . On cold systems, surfac e
condensation may occur where insulatio n
is compressed .
INSTALLATION
1 14
Insulation
ISHRAE Installation Guid e
dust must be kept out of refrigeratio n
systems . Plug open ends of pipe before slippin g
on Insulation Pipe Insulatio n
Allow the adhesive to set until tacky to th e
touch when joining surfaces ; apply sligh t
pressure to both ends .
Since Insulation tubing is flexible, it will follo w
bends in tubing and can be slipped right ove r
bent tubing, 45° sweat "Ls", 90° sweat "Ls "
and couplings . We would recommend wal l
thicknesses above ½" installed usin g
fabricated mitered fittings .
At the beginning, at every 12 to 18 feet an d
ends of piping runs, the insulation shall h e
adhered directly to the copper using a 2" stri p
of adhesive . Insulation should not be adhered
to the pipe at the extreme low points in an y
piping run .
Fabricating Fitting Covers fro m
Mother Tube s
The insulation carton may have a convenien t
miter guide with all angles necessary fo r
normal installations .
When using 314 and 1-inch wall insulation, i t
is recommended to fabricate a miter-cu t
fitting cover . To do this, fabricate a miter cut
using the carton template . See the section o n
Fabricating Fitting Covers .
Cut through the Insulation tube at a 45° angl e
with the help of the miter template in th e
carton .
Reverse the position of one of the sections i n
Use a length of Insulation as long or slightly
longer than the section of piping to be covered .
NEVER STRETCH THE INSULATION MATERIAL .
relation to the other so that an elbow i s
formed, and join the two sections usin g
adhesive .
Since this is a contact-type adhesive, apply a
brush coating of the same to both butt end s
to be joined.
Insulatio n
ISHRAE Installation Guide
Slit open on the inside, taking care not to
damage the opposite wall of the tube .
Apply adhesive to the seam (not to the but t
ends), allow to tack dry, and fit over th e
fitting . Press the seams together working fro m
the ends toward the center of the elbow.
11
5
After fabrication, the 180° cover can be sli t
along the inside radius so that it may be shape d
around the trap and then sealed with adhesive .
segments are mood by
making Iwo 0PPOSbg
2250 mas and rola0ng
segment ls0°
Refrigeration
sucbbn 1n P-tz
Adhere Insulallon lo
PIPe using 520 or 52 0
BIN Adhensiv e
coa l
[s ADprmknatey
to ore o0 of
Al miters and wts
moor be artashe d
using 520 Amrss,e
Finally, wet seal the butt ends to the incomin g
lengths of Insulation tube . Cut the incomin g
lengths so that the butt joints are in sligh t
compression .
P-Trap Fittings
hsuallo n
The Insulation must be adhered to the pip e
on both sides of the P-trap using Adhesive .
Insulation on Existing Refrigeratio n
Piping :
The Snap-On Metho d
The Snap-On Method is used when pipe o r
copper tubing is insulated after it has bee n
installed and connected .
When using 3/4 and 1-inch watt insulation, i t
is normatty necessary to fabricate miter-cu t
fitting covers . This can he accomplished b y
using either a 45° miter layout or a 22 .6 °
miter layout -
With unslit tubular Insulation, use a shar p
knife to slit the Insulation lengthwise on on e
side . Snap the insulation over the pipe .
Adhere Insulation to pipe usin g
ReIAgerallon suction 520 or 520 UV Adhensive
lino P-hap
Apprmimatey
s2 the gists=
beW een return
bend anti 90.
elbow
5
Oulslae measurement or
return be0a plus two
WAI Nlramess
Brush-coat both slit surfaces with adhesive .
Push the insulation down over the pipe to hol d
the adhesive-coated surfaces apart while the
adhesive dries .
1 16
Insulation
ISHRAE Installation Guid e
Double-Layer Insulation : apply insulation wit h
the side and the end joint staggered wher e
possible .
Adhesive should be dry to the touch but tack y
under slight pressure before joining sr Tes t
with back of fingernails.
Insulation at Pipe Hange r
ILM
Location s
At pipe hanger locations where the insulatio n
must resist compression, supporting device s
must he used in combination with meta l
hanger shields.
Insulation Pipe Hangers
If the insulation should become stuck to the
IPH (Insulation Pins Hangers) and NP H
pipe after applying adhesive, break the
(Nonhalogen Insulation Pipe Hangers) provid e
insulation loose by running a finger down the
fast, reliable support for insulated pipes, a n
pipe . innovative alternative to traditional block an d
dowel methods . The pre-insulated hangers
ensure optimum load bearing, protect agains t
thickness compression, and preven t
condensation gaps that could otherwis e
compromise system integrity.
When the adhesive has air-dried, apply
moderate pressure to the entire joint to
assure a vapor-tight bond .
This features a self-adhesive closure and a n
exclusive foam-to-foam bond . The insulate d
pipe hanger is adhered to insulations usin g
adhesive .
If the application is for clevis or saddle typ e
of pipe hangers it is recommended tha t
Insulation Tape be wrapped around the support
prior to placing in the clevis or saddle hanger.
To minimize the movement of support, it i s
recommended that a pair of non-skid pads b e
adhered to the clamps . In addition to preven t
loosening of the clamps, use of an antivibratory fastener, such as a nylon locking nu t
or spring washers .
ISHRAE Installation Guide
Insulation
1 17
Easy Application on Clevis (Saddle )
Application with insulation
Clamp (friction fit)
Traditional metho d
Although timesaving ready made supports ar e
easier to install and use, we can use traditiona l
supporting devices such as short lengths o f
wood dowels For wood blocks, which are th e
same thickness as the insulation . These
supporting devices rest on the metal shiel d
that is installed between the insulation surfac e
and the pipe hanger.
Wood inserts
Short wood dowels, used singly or in multiples ,
may be used to support small-size pipes (se c
Figure 1) . Larger-size pipes will require woo d .
blocks approximately 1" x " or 1-1/2 x 4 b *
the insulation thickness, singly or in multiples .
It is always best to curve the woodbloc M
surfaces to match the curve of the pipe an c
the curve of the metal shield .
1 18
Insulation
The holes cut into the insulation to receiv e
the supporting devices are to be undersize d
so the supporting devices fit tightly. Coat th e
supporting device with adhesive, and insert
into the hole in the insulation while th e
adhesive is still wet . Then coat the oute r
surface with adhesive as a vapor seal To eliminate the possibility of large or heav y
pipes from teetering on the woodblocks, it i s
recommended that /a" or 1" diameter woo d
dowels be placed at 4 o'clock and 8 o'cloc k
positions with each woodblock .
ISHRAE Installation Guid e
surface and the joint feels tacky, the join t
maybe closed . The maximum adhesive force
will be obtained when two tack-dry surfaces
are brought together.
Press the surfaces being joined together firml y
for a short time only. If the surfaces are lef t
to dry for too long a period, they will no t
adhere when pressed together. In this case ,
reactivate by applying a further filth of
adhesive .
NOTE : Some adhesives may not adhere t o
asphalt, bitumen, red-lead or cemen t
surfaces . '
To clean tools, contaminated metal surfaces
or surfaces which have talc applied, wipe wit h
a cloth dampened with alcohol or acetone .
In general, the application of adhesive shoul d
not be carried out when the ambien t
temperature is below 40°F. If working
outdoors at temperatures between 40°F an d
50°F, keep the can of adhesive indoors at 65° F
until needed .
CORRECT USE OF SYNTHETIC FOA M
INSULATION ADHESIVE
Before use, shake or stir the adhesiv e
thoroughly. Use small cans for actual insulatio n
work to prevent it from drying too rapidly . Keep
the can covered to prevent drying. Use a brus h
with short, stiff bristles .
Apply adhesive in a thin, uniform layer to bot h
surfaces, it becomes tacky between 2 to 5
minutes after application . This time will vary
according to ambient temperatures an d
relative humidity. Avoid "open times" i n
excess of 10 minutes.
Allow the adhesive to "tack dry' . The correc t
initial drying period is checked by th e
"fingernail test" : touch the surface with a
fingernail ; if the fingernail adheres to the
Wet sealing : At times, two insulation surfaces
or joints may require "wet sealing" fo r
condensation control . This method will requir e
compressed joints and overlapping surfaces .
This is accomplished by applying wet adhesiv e
between the surfaces and immediately dosin g
in the desired position without any "ope n
time" for the adhesive . ,
The "open lime" is defined as the perio d
between first applying the adhesive and finally
closing together the joint seam or surf ace .
IMPORTANT INSTALLATIO N
CONSIDERATIONS :
1 . All seams and joints of elastomeri c
insulation must be properly seated wit h
manufacturer recommended adhesive,
ISHRAE Installation Guide
Insulation
thereby preventing condensatio n
between the insulation and the coppe r
tubing .
2.
Installers of copper should avoi d
introducing applied stress to the copper.
Applied stress can be a result of an y
manipulation, direct or indirect, resultin g
in stresses to the copper tubing .
3.
Under no circumstances shoul d
chlorinated solvents such as 1 .1 .1 trichtoroethane be used to clean a coppe r
refrigeration system . Such solvents have
been linked to rapid system failure .
4.
No acidic materials such as citric acid o r
acetic acid (vinegar) should be used o n
copper systems Such acids are found i n
many cleaners .
5.
Self -evaporating lubricating oil, and eve n
refrigerants themselves, can react wit h
moisture to produce corrosive acidi c
materials such as acetic acid . Therefore ,
all soldered connections must be ga s
tight, as a leak could result in failure t o
a section at of insulated copper tubing .
6.
Insulation, when installed in accordanc e
with manufacturer's specifications, wil l
not cause stress corrosion cracking o f
copper tubing .
2 Extraneous chemicals or chemicalbearing materials, such as corrosiv e
cleansers containing ammonia and/o r
amine salts, wood smoke, nitrates and
ground or trench water, should not com e
into contact with the insulation .
3 Where the layout of the system is suc h
that condensation may form and ru n
along uninsulated copper by gravitationa l
force, a beginning run of insulation mus t
be adhered completely to the copper
tubing with adhesive . This will preven t
the entrance of water between, th e
insulation and the copper .
4 Copper used on refrigeration system s
should comply with ASTM B 250 and should
be from a reputable manufacturer .
System Testing:
1.
When pressure testing copper tub e
systems, care must be taken not t o
exceed the specific yield point of th e
copper tube used .
2.
When testing copper tubing for leaks ,
use only a detector solution specificall y
designed for that purpose .
3.
It must be assumed that all commerciall y
available soap and detergent product s
contain ammoniacal or amine material s
which do contribute to the formation o f
stress cracks .
4.
Any insulation that has become wette d
or saturated with refrigeratio n
lubricating oils should be completel y
replaced . Such oils can react wit h
moisture to form corrosive materials .
Engineering Considerations :
1 Appropriate wall thicknesses at insulatio n
suitable for the environment and th e
operating conditions must be used t o
avoid condensation of the copper tubing
1 19
1 20
Insulation
NOTES
1SHRAE Installation Guid e
Section 4
EQUIPMENT 4.1 Chiller Package
Chiller Package
Skid mounted chiller packages are the order of the day . All large chille r
packages are factory built and standalone systems, normally pre-charged
from the factory with oil and Refrigerant .
Installation of such systems, are generally, very simple and wel l
instructed . Care should be taken while unloading and positioning of th e
units. A proper load bearing structural works needs to be done whic h
can takethe static as well as dynamic loads of the units . It should b e
remembered that the load bearing beams do also have its elasticity an d
are prone to bending moments . Hence even very small amplitude
vibrations which are not isolated can lead to an ear drum knockin g
feeling in the occupants for the entire occupation and the operatio n
period .
Any damages taken place during transit or installation process shoul d
be brought to the notice of the factory and proper guidance of refrigeran t
and oil charge as well as disposal should be taken before undertakin g
such activities at site .
Safety measures can never be overemphasized . Safety for the peopl e
operating, handling and erecting the equipment is more important tha n
anything else . Follow all safety codes and more than that follow all logics
to eliminate possible cause of accidents .
ISHRAE Installation Guide
Equipment
1 23
Unit Identification - Nameplates
When the unit arrives, compare all nameplate data with order, submittal and shipping information .
A typical unit nameplate is shown in Figure 1
MODEL :
MODEL NO :
SERIAL NO :
ELECTRICAL CHARACTERISTICS :
V
RATED VOLTAGE :
NAMEPLATE NMKW :
kW
VOLTAGE UTILIZATION RANGE :
MINIMUM CIRCUIT 'AMPACITY:
MAXIMUM CIRCUIT BREAKER
COMPRESSOR MOTOR
OIL PUMP MOTOR
OIL TANK HEATER
CONTROL CIRCUIT
V,
VAC
AMPS, MAXIMUM FUSE :
AMPS, MAXIMUM 0/L TRIP:
Hz,
Hz,
V
V,
Hz
Hz
V,
GENERAL CHARACTERISTICS :
REFRIGERANT SYSTEM
TO BE FIELD CHARGED
WITH
KG OF R-
(A),
Phase,
LRAY,
Phase,
(A), FLA
WATTS TOTA L
VA MAX
ACTUALLY CHARGE D
WITH
KG OF R-
MAXIMUM REFRIGERANT WORKING PRESSUR E
HI SIDE
BAR
LOW SIDE
BAR
FACTORY TEST PRESSUR E
HI SIDE
BAR
FIELD LEAK TEST PRESSURE
AMP S
AMP S
LOW SIDE
BAR MAX .
BAR
LRAD.
1 24
Equipment
Unit Inspectio n
When the unit is delivered, verify that i t
is the correct unit and that it is properly
equipped . Inspect all exterior components
for visible damage . Report any apparen t
damage or materialshortage to the carrie r
and make a "unit damage" notation o n
the carrier's delivery receipt . Specify th e
extent and type of damage found an d
notify the appropriate Sales Office . Do not
proceed with installation of a damage d
unit without sales
offic e
approval . Inspectio n
ISHRAE Installation Guid e
location . Take photos of the damage, i f
possible . The owner must provid e
reasonable evidence that the damage di d
not occur after delivery.
•
Notify the Manufacturer's sale s
representative and arrange for repair . Do
not repair the unit,however, until damage
is inspected by the transportation _
representative .
Loose Parts Inventory
Check for the loose parts items shippe d
along with the equipment . Normally it i s
kept in the motor junction box for unit s
without a unit-mounted starter, or in th e
starter panel for units equipped with a
unit-mounted starter. This generall y
includes the isolation pads, extra oil fitter,
and any optional factory-shipped items .
Checklist
To protect against loss due to damage
incurred in transit, complete the precommissioning checklist, which can be
obtained from your Factor y
representative .
Installation Overview
•
•
•
Inspect the individual pieces of th e
shipment before accepting the unit .
Check for obviousdamage to the unit o r
packing material.
Inspect the unit for concealed damag e
as soon as possible after delivery an d
before it isstored . Concealed damag e
must be reported within 10 days afte r
receipt .
If concealed damage is discovered, stop
unpacking the shipment. Do not remov e
damaged material from the receiving
For convenience, Table 1 summarize s
responsibilities that are typicall y
associated with the Skid Mounted chille r
installation process .
•
Locate and maintain the loose parts suc h
as, isolators, bulb wells, temperature _
sensors, flow sensors or other factoryordered field-installed options, as
required . Loose parts are located in th e
starter panel if equipped with a unitmounted starter. If not equipped with a
. unit-mounted starter, loose parts ar e
shipped in the motor junction box .
ti
ISHRAE Installation Guide
Equipment
1 25
Table 1 . Installation responsibility chart for Typical Skid Mounted Chiller unit s
Requiremen t
supplied,
Manufacturer-supplied ,
-Manufacturer-installed
Manufacture r
Field-installed
Rigging
Field-supplied ,
Field-installe d
Safety chain s
Clevis connectors
Lifting beam equipment, skates .
rollers, and other lifting operation s
Isolation
Electrical
Circuit breakers or non-fuse d
disconnects (optional )
Unit-mounted starte r
(optional)
Isolation pad s
Spring isolators
Spring isolators
Remote-mounted
starte r
(optional )
Circuit breakers or fusibl e
Temperature senso r
(optional outdoo r
air)
Terminal lugs Ground connection(s )
disconnects (optional )
Jumper bars
BAS wiring (optional )
IPC wirin g
Control voltage wirin g
Chilled-water-pump contactor and wirin g
Condenser-water-pump contacto r
and wirin g
Optional relays and wirin g
Water piping
Flow switches (ma y
be field.suppliedl
Thermometers
Water flow pressure gauge s
Isolation and balancing valve s
water pipin g
Vent and drain valves
Pressure relief valves (for wate r
boxes as required )
Pressure
Relief
Insulation
Relief valves
Vent line and flexible connecto r
Insulation (optional)
Insulation
1 26
Equipment
Storage
•
If the chiller is to be stored for at least on e
month prior to installation, observe th e
following precautions :
•
Do not remove the protective covering s
from the electrical panel .
▪
•
Store the chiller in a dry, vibration-free ,
secure area .
•
At least every three months, attach a
gauge to the service valve and manually
check the pressure of dry nitrogen in th e
refrigerant circuit . If the pressure i s
below 5 psig (34 kPa) at 70°F (20°C) ,
call a qualified service organization an d
the appropriate Manufacturer's sale s
office .
ISHRAE Installation Guide
Where specified, supply and instal l
valves in the water piping, upstream an d
downstream of the evaporator an d
condenser water boxes, in order to
isolate the shells for maintenance an d
to balance and trim the system .
Supply and install flow switches o r
equivalent devices in both the chilledwater piping and the condenser-wate r
piping . Interlock each switch with the
proper pump starter, to ensure that th e
unit can only operate when water flow i s
established .
•
Supply and install taps for thermometer s
and a pressure gauge manifold in th e
water piping, adjacent to the inlet an d
outlet connections of both the evaporato r
and the condenser.
▪
Supply and install drain valves on eac h
water box .
▪
Supply and install vent cocks on eac h
water box .
Installation
Install the unit on a foundation with fla t
support surfaces, level within 1/4" ( 6
mm) and of sufficient strength and mas s
to support the chiller operating weight .
Place the manufacturer supplie d
isolation-pad assemblies under the unit .
Install the unit per the instruction s
outlined in the Mechanical Installatio n
section .
•
Complete all water piping and electrica l
connections .
Note : Field piping must be arranged an d
supported to avoid stress on the equipment .
It is strongly recommended that the pipin g
contractor provide at least 3 feet (914 mm )
of clearance between the preinstallatio n
piping and the planned location of the unit .
This will allow for the proper fit upon arriva l
of the unit at the installation site . All
necessary piping adjustments can be mad e
at that time .
•
Where specified, supply and instal l
strainers ahead of all pumps an d
automatic modulating valves .
Supply and install refrigerant pressure relief piping from the pressure-relie f
valve to the atmosphere .
Use rubber boot-type isolators for al l
water piping at the unit .
Use flexible electrical conduit for fina l
connection to the UPC .
Isolate all pipe hangers and be sure they
are not supported by main structura l
beams that could introduce vibration int o
occupied spaces .
ISHRAE Installation Guide
•
Equipment
1 27
Make sure that the piping does not pu t
additional stress on the unit .
3S {B4 mm )
Recommende d
clearance
Note : Do not use 'metal braided typ e
eliminators on the water piping . Metal braided
eliminators are not effective at th e
frequencies at which the unit will operate .
Foundatio n
Provide rigid, non-warping mounting pads o r
a concrete foundation of sufficient strength
and mass to support the chiller operatin g
weight (including completed piping and ful l
operating charges of refrigerant, oil and
water) .
Clearance s
Provide enough space around the unit to allow
the installation and maintenance personne l
unrestricted access to all service points . Refe r
to submittal drawings for the unit dimensions .
Allow adequate clearance for condenser an d
compressor servicing . A minimum of 36" (914
mm) is recommended for compressor servic e
and to provide sufficient clearance for th e
opening of control panel doors . Refer t o
Figures 4 and 5, Tables 7 and 8 for minimu m
clearances required for condenser tub e
service . In all cases, local codes will tak e
precedence over these recommendations .
Notes : Required vertical clearance above th e
unit is 36" (914 mm) . There should be n o
piping or conduit located over the compresso r
motor. If the room configuration requires a
variance to the clearance dimensions, contact
your manufacturer's sates
offic e
representative .
..
.L _
CL1 - Length of chille r
CL2-3'11"
1 28
Equipment
ISHRAE Installation Guide
Single Pit (See Note 2 )
anima
MDL
// //// / / / / / / // / / / / / / / % / // / / / / ////
/ / / / /
Double Pit (See Note 2)
aa •
[24I N.
d
1ua•
[3658m]
MX
-ter,!'
7fSQ
2erm. 4
ss
iiiio**// / t/A
Multi Pit
/////////////////////////////////////////////////////////////////////////////////%i
Corner Wall
96'[24 nnI
MM
%'12430'n3
MN.
Notes:
1.) NI dimensbrm are minimal, unless
othenVse noted.
2.) Pit InsfaIa&r are not re=mended. Re-circulation of hot
h
condenser air In combination wit
surface air turbulence cannot b e
predded. Hot air re-clrciiaUon vril l
severely affect unit efficiency (EER)
and can corms high pressure or fa n
motor temperature tips.
ISHRAE Installation Guide
Equipment
12 9
REMEMBER:
Ventilation
•
Follow the procedures and diagrams i n
this manual and in the submittal .
The unit produces heat even though th e
compressors (water cooled or air cooled) ar e
cooled by the refrigerant . Make provisions to
remove heat generated by unit operation fro m
the equipment room . Ventilation must be
adequate to maintain an ambient temperatur e
lower than 122°F (50°C) .
•
Always use lifting equipment with a
capacity exceeding the unit lifting weigh t
by an adequate safety factor. (+10%) .
Isolation Pads
Vent the unit pressure relief valves i n
accordance with all local and national codes .
When the unit is ready for final placement ,
position isolation pads end-to-end under th e
full length of the chiller leg . The pads measur e
6" x 18" (152 x 457 mm) . See Figure 6 . No
gaps should be present between pads.
Make provisions in the equipment room to
keep the chiller from being exposed to freezing
temperatures of'32°F (0°C) .
Remember that the chiller must be level withi n
1/4" (6 mm) over its length and width after i t
is lowered onto the isolation pads .
Water Drainag e
In addition, all piping connected to the chille r
must be properly isolated and supported s o
that it does not place any stress on the unit .
Locate the unit near a large capacity drai n
for water vessel drain-down during shutdown
or repair. Condensers and evaporators are
provided with drain connections . All local and
national codes apply.
Moving and Riggin g
The Model CVGF chiller should be moved by
lifting at designated lift points only. Refer to
the rigging diagram that ships with each uni t
for specific per unit weight data .
Heavy Objects !
Do not use cables (chains or slings) except as
shown . Each of the cables (chains or slings )
used to lift the unit must be capable o f
supporting the entire weight of the unit .
Lifting cables (chains or slings) may not be o f
the same length . Adjust as necessary for eve n
unit lift.
Other lifting arrangements may caus e
equipment or property only damage . Failur e
to properly lift unit may result in death o r
serious injury. See details below:
Spring Isolators
Spring isolators should be consideredwhenever chiller installation is planned for a n
upper-story location . Spring isolator selectio n
and placement information is presented i n
Figure 7 and Figure 8 .
Note: Three types of spring isolators, show n
in Tables 11-13 are used . Each type has its
own maximum loading characteristics . Sprin g
isolators are typically shipped assembled an d
ready for installation . To install and adjust th e
isolators properly, follow the instruction s
given .
Note : Do not adjust the isolators until th e
chiller is piped and charged with refrigeran t
and water.
1 . Position the spring isolators under th e
chiller as shown in Figure 7 and Figur e
9 . Make sure that each isolator i s
centered in relation to the tube sheet .
1 30
2.
3.
Set isolators on the sub-base ; shim or
grout them as necessary to provide a flat ,
level surface as the same elevation for
all mountings . Be sure to support the ful l
underside of the isolator base plate ; no
not straddle gaps or small shims .
If required, bolt the isolators to the floo r
through the slots provided, or cemen t
the pads .
Note: fastening the isolators to the floor i s
not necessary unless specified .
4.
ISHRAE Installation Guid e
Equipment
If the chiller must be fastened to th e
isolators, insert cap screws through th e
chiller base and into the holes tapped i n
the upper housing of each isolator . Do
not allow the screws to protrude belo w
the underside of the isolator uppe r
housing . An alternative method o f
fastening the chiller to the isolators i s
to cement the neoprene pads .
adjusting bolt one complete revolutio n
upward . Repeat this operation until a 1 /
4" (6 mm) clearance is obtained at al l
isolators .
7.
After the minimum required clearance i s
obtained on each of the isolators, leve l
the chiller by turning the adjusting bol t
on each of the isolators on the low sid e
of the unit . Be sure to work from on e
isolator to the next : Remember that th e
chiller must be level to within 1/4" ( 6
mm) over its length and width and tha t
clearance of each isolator must be 1/4 "
(6 mm) .
yr
6 .)mm l
d
r6 d
nm .6
Sr
5.
6.
Set the chiller on the isolators ; refer to
the "Rigging" section for liftin g
instructions . The weight of the chiller wil l
force the upper housing of each isolato r
down, perhaps causing it to rest on th e
isolator's lower housing . Figure 9
illustrates spring isolator construction .
Check the clearance on each isolator . If
this dimension is less than 1/4" (6 mm )
on any isolator, use a wrench to turn the
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ISHRAE Installation Guide
Equipment
Figure 10 . Rigging diagram with anchor hol e
and bolt detail
detai l
Optional unitmounte d
starte r
Figure 11 . Rigging diagram withsafety chain placement
13 1
132
Equipment
ISHRAE Installation Guid e
Connecting Groove Pipe s
•
Air vents (to bleed air from system )
PRECAUTIO N
•
Water pressure gauges manifolded wit h
shutoff valve s
•
Pipe union s
•
Vibration eliminators (rubber boots )
Piping damage !
To prevent damage to water piping, do no t
overtighten the connections .
Note : Make sure that all piping is flushed an d
cleaned prior to starting the unit .
Equipment damage!
Shutoff (isolation) valve s
•
Thermometers
•
Cleanout tee s
To prevent equipment damage, bypass the uni t
if using an acidic flushing agent .
•
Pipe straine r
Vents and Drain s
In addition at the leaving chilled water sid e
the following should be installed : -
Install pipe plugs or ball valves, with Nationa l
Pipe Thread (NPT) to water hose thread
connections, in evaporator and condenser
water box drain and vent connections befor e
filling the water systems .
To drain water, remove the vent and drai n
plugs or open the ball valves . Install an NP T
connectors in the drain connection, an d
connect a hose to it.
Evaporator Pipin g
Component s
Note : Ensure that all piping components ar e
between the shutoff valves, so that both th e
condenser and the evaporator can be isolated .
Piping components include all devices and
controls used to provide proper water-syste m
operation and unit operating safety. Thes e
components and their general locations ar e
described below.
Entering & Leaving - Chilled & Condenser Water Piping
•
Balancing valve
•
Pressure relief valve
Flow switc h
Equipment damage !
To prevent evaporator damage, do not excee d
150 psig (1035 kPa) evaporator water pressur e
for standard water boxes . The maximu m
pressure for highpressure water boxes is 30 0
psig (2100 kPa) . To prevent tube damage b y
erosion, install a strainer in the evaporato r
water inlet piping .
To prevent tube corrosion, ensure that th e
initial water fill has a balanced pH .
Water Treatmen t
Water Treatment !
Do not use untreated or improperly treate d
water. Use of untreated or improperly treate d
water may result in equipment damage .
Using untreated or improperly treated wate r
in these units may result in inefficien t
operation and possible tube damage .
ISHRAE Installation Guide
Equipment
Consult a qualified water treatment specialis t
to determine whether treatment is needed .
The following disclamatory label should b e
pasted in unit:
The use of improperly treated or untreate d
water in this equipment may result in scaling ,
erosion, corrosion, algae, or slime . The
services of a qualified water-treatmen t
specialist should be engaged to determin e
what treatment, if any, is advisable . The
Manufacturer warranty specifically exclude s
liability for corrosion, erosion, or deterioratio n
of the equipment . The manufacturer shal l
assume no responsibility for the results of th e
use of untreated, improperly treated, saline ,
or brackish water.
Flow-Sensing Devices
Use field provided flow switches or differentia l
pressure switches with pump interlocks t o
sense system water'flow . To provide chiller
protection, install and wire flow switches i n
series with the water pump interlocks, for bot h
chilled-water and condenser-water circuit s
(refer to the Installation Electrical section) .
Specific connections and schematic wirin g
diagrams are shipped with the unit .
Flow switches must stop or prevent compresso r
operation if either system water flow drop s
below the required minimum that is shown o n
the pressure drop curves . Follow th e
manufacturer's recommendations for
13 3
selection and installation procedures . General
guidelines for flow switch installation ar e
outlined below.
•
Mount the switch upright, with a
minimum of 5 pipe diameters o f
straight, horizontal run on each side .
•
Do not install close to elbows, orifices ,
or valves .
Note: The arrow on the switch must point i n
the direction of the water flow.
To prevent switch fluttering, remove al l
air from the water syste m
Note : The generally flow switched provides a
six second time delay on the flow switch inpu t
before shutting down the unit on a loss-offlow diagnostic . If machine shutdowns persist,
contact your local manufacturer' s
representative .
Adjust the switch to open when wate r
flow falls below nominal . Refer to th e
General Data tables for minimum flo w
recommendations for specific water-pas s
arrangements . Flow switch contacts ar e
dosed when there is proof of water flow .
134
Equipment
NOTES
ISHRAE Installation Guide
Section 4
EQUIPMENT 4 .2 Pumps
PUMPS
Pumps are simple equipment which if once installed properly gives year s
and years of service with minimal service requirements . However i f
not installed properly, it may require hours and hours of service ever y
few weeks .
The main requirement for pumps in our industry is to recirculate wate r
(either chilled or brine or condenser water) within a very smal l
temperature difference (3-8°C) . Hence the change in viscosity an d
specific gravity does not arise in its operational range . Moreover th e
media used in our industry is also normally pH neutral, thus furthe r
simplifying the operational matter. All we need to ensure that the pump s
are installed properly for years of smooth operation and,required usag e
and service .
The rotodynamic action also results in the pump having vibrations i n
more than one axis and hence the isolation of this vibration from th e
pipe lines and the base floor/slab is very important. The dry mass o f
the foundation should be at least twice the mass of the pump and motor
assembly.
For neat installation and operation, the collection water from the glan d
or seal leakage and proper drain line makes the area look more efficient .
ISHRAE Installation Guide
Equipment
Use of proper support and foundations are a
must .
•
13 7
Don't install on thin concrete pads o r
unsupported wooden floors .
Base Plat e
Install level and flat to within 0 .005' per foo t
in all directions . May need shims between
pad and base .
Rough check s
Before grouting the pump base :
-
Check for "soft foot" at pump and moto r
Check rough alignmen t
Use a dial indicator.
•
Grout
Concrete foundatio n
•
▪
•
Rigid and heavy enough to resist th e
forces that will act on it in norma l
operation.
Non-shrinking cement or epox y
compound .
NOR '
TO MEEP SMIMS M
ALLOW! FORSMIME . PLACEALLON CRO W
PEACAO% NOINSItCS TOMW APIOYMO ro , OWL! T O
OF ANCHOR SOOM Ntt0DOWMLUO£
rf•SI NI L
2 .5 to 3.0• times the weight of the pump .
9AMERRIL
PWPYAP C
*
.:
LEYEUNC OF PUMP SAS E
ONCONOIETE FCUSOAOON
•
•
Marna
•
Pour into the pump base to insure that i t
flows evenly and fills the entire bas e
volume .
▪
Allow cement grout to cure for 48 hours .
•
Follow directions for epoxy grout .
Firmly attached to the floor system .
If installed on a metal structure, insur e
that it's stiff and strong enough to dam p
out any vibrations .
• taxi '
. . . ,a
1 38
Equipment
Grouting the base (2)
ISHRAE Installation Guid e
For closed coupled pumps -
•
Don't use the submittal drawing to locat e
base studs .
•
Ask for a "certified drawing" .
Base Plate
Formed in Grou t
l Shim s
Plate
Pipin g
:_
Anchor Bolt
,
v
Anchoring fo r
Long Coupled Pumps
PIPE
SLEEVE
FOUNDATIO N
BOLT
‘BUILT-U
*
P
CONCRETE FOUNDATION
•
Always run pipe from the pump to som e
point where system connections can be
made.
Minimize pipe stress on the pump .
•
Before the arrival of the pump and it s
installation leave at least 3' space fo r
piping. Once the pumps are installed,
this gives sufficient space for alignin g
the pipes .
Incorrect
di d
Incorrect
Correc t
ISHRAE Installation Guide
Equipment
Suction piping
Supply an "evenly distributed flow "
•
- No "swirl", or"pre-rotation "
Good Practices:
1.
Keep the suction line short and straight .
2.
Suction line should be minimum one siz e
higher than the pump inlet . Follow the
recommended maximum inlet velocit y
from the manufacturer's instructions .
3.
Use eccentric reducers to minimise the
air pockets possibility. .
4.
Do not install horizontal elbow at th e
inlet.
5.
Avoid lifting of pump header, of tappin g
above the main header.
6.
For cooling tower ensure that the suctio n
is by gravity from the sump .
7.
Keep minimum 1D gap between th e
bottom of the sump to the pump suction .
- No strong local currents
•
Sufficient NPSHA to prevent cavitatio n
•
Avoid excessite entrained ai r
•
Ideal is straight pipe, no fitting s
•
Poor suction piping can lead to :
Nois e
- Cavitatio n
- Early failure of seals and bearing s
13 9
Right
1.
2.
Pipe supporte d
Length of suction piping allows eve n
impeller loadin g
c cEC (
II SA(P
CO••E :T
Wrong
1. Pipe weight hangs on pump flange .
2. Short suction pipe results in uneve n
impeller loading
tCOen(C (
CO' 'C C
CC•,E : i
CWE :1
1 40
Equipment
ISHRAE Installation Guid e
In-line pump s
BEST
Ca.
Shorter run* OK
50
Needs longer run then a t
least 5D required.
Suction Defuse r
Where very short space is required, a suctio n
diffuser is recommended .
•
Transition between suction pipe size an d
pump suction nozzle .
•
Eliminates pre-rotation .
•
Provides fully developed flow .
•
Reduces bearing loads .
•
Provides support for suction piping .
Wherever strainers are installed it i s
recommended to commission the system wit h
fine mesh strainer along with a coarse strainer .
This will help eliminate the particles in th e
water line and after thorough flushing, th e
fine mesh can be removed to minimiz e
pressure drops .
Section 4
EQUIPMENT 4.3 Cooling Towers
142
Equipment
ISHRAE Installation Guid e
COOLING TOWERS
The entire heat load and the heat of compression is removed to th e
atmosphere through the cooling tower. Hence the efficient operation of
this is as important as the chiller efficiency . For efficient operation th e
air entering the cooling tower should be fresh air and not recirculate d
air. Likewise the air leaving the cooling tower should not be allowed t o
enter the building via the outside/ fresh air suction .
Since the cooling tower without the water is a very light weight item a s
compared to its bulk, the support structure should be designed to tak e
the vibration of the entire bulk without the stability offered by th e
water at its basin .
The space and stability of the arrangement for the servicing and remova l
of fans and motors from the cooling tower should also be given du e
importance .
The pipes connected to the cooling tower should be supported properl y
and independent of the cooling tower body or structure .
ISHRAE Installation Guide
Equipment
14 3
Safety
•
Proper earthing and grounding .of th e
cooling tower .
The following safety issues should be
considered by those responsible for designin g
the tower installation .
•
Proper motor enclosure of the terminals .
•
Bird cages to prevent birds entering into
the cooling tower from any side .
•
access to and from maintenance acces s
doors, top of tower access platform wit h
handrail system around the perimeter o f
the platform with a ladder for access to
the platform .
• the possible need for ladders (eithe r
portable or permanent) to gain acces s
to the discharge level or maintenance
access doors
•
the possible need for external acces s
platforms .
•
potential access problems due t o
obstructions surrounding the towe r
•
lockout of mechanical equipmen t
•
the possible need for safety cages aroun d
ladders
the need to avoid exposing maintenance
personnel to the potentially unsafe
environment inside the tower.
Tower Location
Space available around the tower should b e
as generous as possible to promote ease o f
maintenance—and to permit freedom of
airflow into and through the tower. Follow th e
guidelines from the manufacturer fo r
adequacy of the available space and th e
intended configuration of the tower .
Prepare a stable, level support foundation fo r
the tower, utilizing weight, wind load, an d
dimensional information appearing o n
appropriate submittal drawings . Supports
must be level to insure proper operation o f
the tower.
The cooling tower must be located at suc h
distance and direction to avoid the possibilit y
of contaminated tower discharge air bein g
drawn into building fresh air intake ducts .
1 44
Equipment
Receiving the cooling tower a t
site
Receive and then cross check the shipmen t
advise and the no . of cartons . Follow th e
instructions given to lift/ hoist the material .
Do not preassemble modules prior to hoisting .
2.
Ensure that the hot water inlet header i s
at an elevation lower than the coolin g
water inlet level of the cooling tower.
3.
In case the pipe line design size is smaller
than the connection of the cooling tower,
ensure that the water connections are
taken in correct alignment and then have
a reducer to make the line connection .
Do not connect the reducer directly o n
to the Cooling tower inlet/ outlet
connection .
4.
Change the flow to downward directio n
always after the cooling tower outlet and
like wise raise the inlet connection to
connect to the cooling tower and never
reverse.
5.
Connect quick fill, make up water an d
bleed line and drain line connections t o
the cooling tower with the recommende d
size of pipes and ensure that the size s
are not reversed, e.g. the bleed off lin e
bigger than the make up water line etc .
Foundation Leve l
1.
Ensure that the cooling tower foundatio n
is leveled prior to start of installation .
2.
In case more than one cooling tower i s
being installed and connected to same
header, having the same foundation leve l
becomes more important .
3.
4.
A water equalizing line should be installe d
in cases where more than one coolin g
tower is to be installed .
Use synthetic vibration isolation pad s
instead of standard rubber pads .
Erection of Cooling Towe r
1 . All the openings are properly covere d
with bird cages.
Air and water leakages are sealed . All
joints are properly bolted with gaskets .
Pump Connections :
1.
3 . Sump is properly tested for leakages at
minimum level as well as maximum wate r
level .
Water Connection s
1 . The cooling water piping should b e
connected to the cooling tower pipes with
adequate support . The body of th e
cooling tower will not be able to support
the water pipe tine and its vibration i n
any circumstance .
ISHRAE Installation Guid e
The cooling water pump should have it s
top of the volute casing lower than th e
base of the sump level of the coolin g
tower. This will ensure that even in cases
where the sump level has reduced by a
little amount, we prevent the pump fro m
aeration and vortexing by preventing ai r
to enter the pump .
2.
Ensure that the pump vibrations are no t
passed on to the cooling tower bod y
through the pipes . Hence pum p
vibrations should be properly isolate d
using bellows .
Section 4
EQUIPMENT 4 .4 Fans
1 46
Equipment
ISHRAE Installation Guid e
FAN S
Fans are used to either evacuate or distribute the air . In the process i t
requires to overcome the friction offered by the distribution syste m
and for doing so has to be operated at the required speed (RPM) t o
generate that head or static pressure . This results in generation o f
vibration and noise which has to be minimized by having a stable an d
leveled installation, isolation of vibration at the inlet and outle t
connections etc.
A clear and smooth inlet of air to the fan impeller makes the fan silen t
and efficient, which is the aim of a good installation practise .
The outlet of the fan should have smooth and gradual change of directio n
or divergence if required, thus minimising the loss and the nois e
associated with it .
ISHRAE Installation Guide
Equipment
Two Components of System Desig n
Remember - Manufacturer is no t
responsible for system resistance o r
system effect, hence please cross chec k
the fan static requirements befor e
releasing the same to fan manufacture r
for production .
Calculate flow resistance losses for eac h
component in the syste m
Select and' position fan to avoid syste m
effect loss .
-
If loss cannot be avoided, estimate los s
and select fan for higher pressur e
System Effect ?
•
A factor used to correct for syste m
induced installation effects whil e
estimating the static pressure losses i s
called system effect .
•
The difference in performance betwee n
a fan tested in the laboratory and on e
tested in a real installation is due to th e
system effect .
Causes of Non-Performing System s
•
System resistance has bee n
miscalculate d
•
Fan not properly selecte d
•
Defective fan (or fan rating )
•
There is a system effect los s
Fan Manufacturer's Responsibilit y
•
Provide accurate fan performanc e
ratings
•
Provide a fan built within tolerance s o
that it is capable of meeting its rating
1 47
The extra static pressure losses due to th e
installation issues, site constraints on the fa n
system as a whole is given hereunder. Carryin g
out the installations with the below give n
recommendations will minimize the losses and _
reduce the unaccounted for "system effect"
X
WRONG
RIGHT
WRONG
RIGH T
WRONG
RIGHT
WRONG!?
RIGHT
1 48
Equipment
RIGHT
WRONG
ISHRAE Installation Guide
WRONG
RIGHT
RIGH T
WRONG
RIGH T
o
Improper fan blade attack angl e
o
Turbulence which disrupts the flo w
Definition of System Effec t
•
•
•
Fan rating are established using AMC A
210 test codes that are close to idea l
condition s
Fans in actual systems are often les s
than ideal, because of the constraint s
and the connections .
The difference in performance for th e
same fan tested in both conditions is th e
"System Effect"
•
o
Inlet losses are caused by :
o Unequal loading of the fan blade s
(eccentric flow)
Loss of conversion of local hig h
velocity into pressure
Inlet vs . Outlet Losses
•
Inlet induced losses tend to be higher tha n
outlet losses
•
Losses induced cn the inlet can ofte n
exceed 20%
•
Losses as high as 50% have bee n
reported
Causes of Losses
•
Outlet losses are caused by :
1 49
Equipment
ISHRAE Installation Guide
Outlet System Effect s
Inlet Flow Conditions for a Fan
•
Straight uniform flow directed only in the • In addition to the flow velocity, we ma y
need to know :
axial direction—on the fan inlet
•
For Ducted fans - a straight length of o effective duct lengt h
outlet ductwork
o blast are a
For Axial Fan s
100% EFFECTVE DUCT LENGT H
TO CALCULATE 100% EFFECTIVE DUCT LENGTH. ASSUME A MINIMUM O F
2 1 /2 DUCT DIAMETERS FOR 2500 FPM OR LESS . ADD 1 DUCT DIAMETE R
FOR EACH ADDITIONAL 1000 FPM .
NO
DUCT
12 %
EFFECTIVE
DUCT
25 %
EFFECTIVE
DUCT
50 %
EFFECTIV E
DUCT
100 %
EFFECTIV E
DUCT
Tubeaxlal Fan
-
-
-
-
-
Vaneaxlal Fan
U
V
W
-
-
For Centref used Fan s
1 50
Equipment
ISHRAE Installation Guid e
System Effect Curves for Outlet Ducts
BLAST AREA
OUTLET AREA
OUTLET
ELBOW
POSITION
NO
OUTLET
DUCT
N
HI M
L- M
L-M
O
N
M
M
P- 0
0-P
N
N
S
R-S
O
0
0- P
14-0
M- N
M-N
PM
0-P
N
N
R
0
0- P
0-P
T
S-T
BS
p5
O
P
N. 0
N-O
0- B
O
0
0
S
R
0
0
U
T
S
S
R-S
0- R
P
P
S
BS
O
D
T
5-T
P- S
B-S
V
U. V
T
T
S
R- S
OM
O-N
S T
S
R
R
T- U
T
S
S
W
WV
U-V
T
S
P
P
T-U
UN
W
B
C
D
S-T
5
S
T. 0
S-T
ST
W
V
V
A
B
C
D
T
S-T
HS
B-S
T-U
T
S
S
UN
U
T
T
W
W
V
V
A
B
L
D
0.4
A
0.5
B
C
O
A
B
C
D
O.B
A
B
C
D
0 .7
A
B
C
D
0 .0
A
OS
0
12 %
25 %
50%
100%
EFFECTIVE EFFECTIV E EFFECTIVE EFFECTIVE
DUCT
DUCT
DUCT
DUC T
V
o
L
jl
2
rh
a
0
IIXM EFFECTIVE DUCT LENGTH .
Hence outlet duct elbows should b e
placed after the effective duct lengt h
DUCT
PRESSURE
RECOVERY
0%
12%
EFFECTIV E
5%
EFFECTWE
O%
ERMINE
ITO %
EREOIIVE
DUCT
DUCT
DUCT
DUCT
50%
Bl%
ROY.
1M %
BUSTARD%
OUTLET AREA
SYSTEM EFFECTCURVE
OA
P
05
P
RS
RS
U
U
0
W
-
OS
R- S
ST '
UW
W-A
-
0.7
5
W
V.W
U
V-W
W.%
WY
X
-
-
-
OS
OS
1D
-
'*ov D
Equipment
ISHRAE Installation Guide
15 1
System Duct Effect for Inlet of Axial now Fan s
FIUBEAX
:*±
:
WLFANSHOW N
ii"
VANE;oam_ FAN SHOWN
DUCT LENGTH
H?
Tubeaxial Fan
Tubeaxial Fan
Tubeaxtal Fan
VaneaxlalFan
Vaneaxial Fan
90°
NO
ELBOW
DUCT
2 Pc
4 Pc
2 Pc
2 Pc
4 Pc
U
X
V
Q-R
W
0.25
0.25
0.35
OBI
0.61
0 .5 D
[1] [2]
V
W
O-R
W-X
to o
&0 0
[1] [2]
W
X
S-T
-
T-U
-
System Duct Effect for Outlet of Axial Flow Fan s
`U1
l' !I
TUBEAxIAL FAN SHOWN
OWN
VANFNML FAN
WN
.
..
`
* _ .- EFFECRV
DUCT LE N
..
90 4
ELBOW
Tubeaxia l
NO
DUCT
284
Fan
Pc
Vaneaxia l
Fan
2
Pc
Vaneaxla l
Fan
4
Pc
25 %
50%
100 %
12 %
EFFECTIVE EFFECTIV E EFFECTIV E EFFECTIVE
DUCT
DUCT
DUCT
DUCT
_
U
U-V
V
W
For Fans and Plenum s
W
_
15 2
Equipment
ISHRAE Installation Guide
2L
*° EQUAL
1
L
4
*n EQUAL
I*
Right Angle Turns At Fan Inlet
Inlet with 3-piec e
elbow
inlet with rectangular
inlet duct connection
Remember System Effect Factor s
are Rea l
•
When designing your fan/system, d o
everything possible to avoid a "syste m
effect" for efficient use of energ y
•
When conditions leading to system effec t
cannot be avoided, add the calculate d
loss to the fan pressure requirement at
the system . design stage
Fan Sound Specification s
•
•
Sound spectrum : the human ear i s
sensitive to frequencies between 20 an d
20,000 H z
For fans, frequencies between 45 and
11,000 Hz are of interest
inlet with speciall y
designed inle t
connection box
•
Reasons the frequency characteristic o f
sound rating ratings is used :
•
Sound at different frequencies behave s
differently
•
Human ear responds differently t o
different frequencies of soun d
•
Audible sound is divided into 8 octav e
bands
•
Starting at 63 Hz, each succeeding octav e
band has a center frequency twice th e
previous band
•
Sound Level is defined for every fa n
operating poirt by a spectrum o f
frequencies as below:
ISHRAE Installation Guide
Equipment
Octave Bands
1
2
3
4
5
6
7
8
Frequency Rang e
(Hz)
45
to
90
90
to
180
18 0
to
355
355
to
700
71 0
to
1400
1400
Jo
2800
280 0
to
4600
560 0
to
11200
Center Frequency (Hz)
63
125
250
500
1000
2000
4000
8000
•
Sound power leve l
o
The acoustical power radiating from a
sourc e
o
Describes the total amount of acoustica l
energy the fan emit s
o
This value is independent of location ,
distance and environmen t
o
Sound power cannot be measured directl y
o
Sound power is usually expressed i n
decibels with a reference level to 10- 12
watts (or 1 Picowatt) . It is the log rati o
of 2 'power like' quantities :
•
1 53
Lw (dB) = 101og 10 (W / Wrer) : Where ,
Wre1 = 1 pW = 10-12 Watts
•
Sound pressurelevel -
o
The amplitude of pressure oscillations a t
some locatio n
o
Describes the loudness level of the sound ,
like the brightness level (lumens) of a
light bulb at some location
Row
1
2
3
Octave Band
Lw at Inlet
Aweighting
LwA weighted
1
99
-26 .2
72.8
2
98
-16 .1
81 .9
3
94
•8.6
85.4
o
This value varies with the distance fro m
the sound source and is affected by th e
environment surrounding the sourc e
o
Easily measured directly with a mete r
o
Sound pressure is usually expressed i n
decibels with a reference level of 20 m
Pa
•
Lp (dB) = 10log 10 (P z / Pferz ) = 201og 10 (P
/ P rer )
•
Where, Pm, = 20 mP a
o
What is LwA?
•
The 8 octave band sound power level s
can be reduced to one number (LwA) .
•
The LwA value represents the logarithmi c
summation of all 8 octave band values ,
'A weighted' to account for the respons e
of the human ear.
o
Log summation: Lw = 10 log (10Lw1/1 0
+ . . 10Lw8/10 )
4
91
•3.2
87.8
5
88
0
88
6
84
1.2
85.2
7
79
1
80
8
73
-1 .1
71.9
LwA
93
Note: Although Lw (row 1) in bands 1-3 are significantly higher than Lw A weighted (row 3) th e
human ear will always perceive the sound as LwA = 93 . Thus it does not make too much sense i n
saying band 1 is 26 dB 'lower' or 'quieter' when 2 fans are compared .
1 54
•
•
Equipment
Fan sound specifications are normally
based on sound pre ,611re level s
o
Relocate the fan to where the nois e
is not a proble m
o
o
Add vibration isolators and/or flexibl e
connector s
o
Insulate or acoustically enclose th e
fa n
o
Add silencers or duct lining to the inle t
and/ordischarge -
This value varies with the distance
from the sound source and the
environment surrounding the sourc e
Sound specifications are intended to :
o
Limit annoyance s
o
Prevent health damage
o
E .G . - OSHA limit of 85 dBA - 8 hou r
exposure is a pressure leve l
•
Sound Pressure is NOT Guaranteed
•
•
•
•
Sound pressure levels (dBA) are NOT
guaranteed due to several uncertaintie s
The surface reflectivity, the number of
such surfaces, etc plays a role and othe r
than in a testing lab, the reflectivity o f
the surface cannot be ascertained .
The actual sound pressure will depend o n
many factors of the installe d
environment which cannot be predicted .
Even acousticians cannot guarantee th e
Sound Pressure predicted from Soun d
Power
Noise Problems
•
ISHRAE Installation Guid e
Two types of noise problems :
o
Those that we anticipate from ou r
sound ratings
o
Those emanating from som e
abnormal condition
Common sources of abnormal o r
unanticipated noise :
o
Fan wheel unbalance
o
Resonance of fan or attache d
components
o
Rotating components rubbing o n
stationary part s
o
Failing, misaligned, or contaminate d
bearings (on fan or motor )
o
Air leakage - can allow sound leakag e
and also generate a 'whistle '
o
Belts slipping
o
Coupling misalignment
o
Motor noise, especially with imprope r
power supply and inverter drive s
o
Air turbulenc e
o
Operation in surge
o
Loose component s
o
High velocity air blowing over fixe d
components which are not part of th e
fan
Balance & Vibratio n
•
Cures for noise anticipated from sound
ratings :
o
Select a different fan (tip : select lowe r
tip speed fans)
•
Balance
o
This is a property of the fan and stay s
the same at any location
ISHRAE Installation Guide
Equipment
o
Imbalance is present even if the fan i s
not runnin g
o
The process ofadding or removing weigh t
on a rotor in order to move the center o f
gravity towards the axis of rotatio n
o
The purpose of balancing is to reduce the
unbalance force s
.
Vibratio n
o
Strongly influenced by the fan s
environment and operating speed
1 55
Vibration Terminology
•
NOTE : Do not mix these two concepts !
Amplitud e
o
The measure of cyclic energy o r
movement in a vibrating objec t
o
Three common ways of expressing :
STATIC UNBALANC E
•
•
Static unbalance can be corrected b y
adding a single weigh t
Heavy spot will "bottom out" when rotor
is placed in bearing s
.
Displacement in mils peak to pea k
.
Velocity in inches/second pea k
▪ Acceleration in g's rm s
o
•
Amplitude measurements can b e
converted between the different unit s
if the frequency is known
Frequency
o
The number of times that a vibratin g
object repeats its motion per unit o f
time
o
The fan rotational frequency in Hertz
equals the RPM / 6 0
DYNAMIC UNBALANC E
•
Dynamic (couple) unbalance requires
correction in two or more plane s
o
The rotational frequency is ofte n
called 1 X
•
Heavy spot will not "bottom out" whe n
rotor is placed in bearings
o
Other frequencies are ofte n
identified as multiples of 1X o r
harmonics, such as 2X, 3X, 4X, etc .
1 56
Equipment
ISHRAE Installation Guid e
Vibration Spectrum: (a display of frequency vs . amplitude)
VIINffrmN SPEGIR U
02 '
m.
002
r30
.pI(Y ap w
Vibration Measuremen t
Rigidly Mounted
o Generally applies to a fan mounted to a
concrete slab
•
Vibration can be measured at any locatio n
•
Normally, only the vibration on the fa n
or motor bearings are of concern
•
Normally, horizontal, vertical, and axia l
readings are taken on each bearin g
•
Overall (filter-out) amplitude is a .
measure of the maximum vibration leve l
over a wide frequency rang e
•
Filtered (filter-in) amplitude usuall y
refers to the vibration at 1X (th e
operating speed frequency )
o A very rigid steel structure may qualif y
Flexibly Mounte d
o Fan is mounted on springs or a sprin g
isolation base
o An inertia base (filled with concrete )
performs best for vibration
Overall
.3 - .8
.8 - 1 .2 " .
3.5
3 .5- 2Khz
Balance
RP M
In/Sec Peak In/Sec Peak In/Sec Peak hi/Sec Peak In/Sec Pea k In]Sec Pea k RPM
DBH 10.151
10.047
0038
11385.14 4
10.043
10.065
10.118
OBH 10.11 1 .
10.049
0.063
0.037 ---- 0.064` 0.058 -- 11385.144
1DBA10 .185
x385.144
- 10.046
10.089 - 10 .124
10 .089
. 0.086
OBA 1-0.139.,
0 .048 _
10060
1385.144
10.065
;0.092
10.061
DBV 10.117
0 .047
0.044
10.062
10.040
11385.14 4
10 .071
10BV 10.124
0 .052
;1385.144
;0 .048
0.084
10.053
10.043
ISHRAE Installation Guide
1 57
Equipment
•
where :
Filter-in = Balance at 1 X running speed (RPM )
or frequency (Hz )
o Bearing flaws and non-symmetrie s
o Bearing contaminatio n
Filter-out = Overall across all frequencies (Hz )
o Distorted bearings (pinched )
Spectrum (DBH, OBH, DBA, OBA, DBV, OBV )
o Bearings which do not freely self-alig n
DBH : Drive Bearing - Horizonta l
o Distortions caused by set-screw s
OBH : Opposite Drive Bearing - Horizonta l
DBA : Drive Bearing - Axia l
Bearing induce d
o Grease or oil churnin g
•
OBA : Opposite Drive Bearing - Axia l
Fan construction induce d
DBV: Drive Bearing - Vertica l
o Imperfect fan wheel component s
(run-out )
OBV: Opposite Drive Bearing - Vertica l
o Rubbin g
o Misalignment (bearing and coupling )
Causes of Vibratio n
•
o Fan impeller, sheaves, coupling, o r
moto r
•
o Resonance
Unbalance (the most common cause)
•
o Turbulent and eccentric flow throug h
the fa n
V-belt drive induced vibratio n
o Fan in stal l
o Sheaves not concentric
o Belts which are not uniform in length ,
worn or that have hard spot s
•
Installation and environmenta l
o Inadequate support (resonance )
o Loose or missing anchor bolt s
o Misaligned- sheave s
o Loose access doors, rattling panels ,
etc .
o Adjustable pitch sheaves often hav e
unequal groove spacin g
•
Aerodynami c
o Solids which impact the fan whee l
Shaft induce d
o Fans with stacks vibrate due t o
vortex sheddin g
o Shafts notstraigh t
o Keyways create local weak spot s
(center hung rotors )
•
Motor eccentricities (electrical an d
mechanical )
o Out-of-round shaft
•
AMCA 204-96-Vibration Measuremen t
o Undersize shafting
•
The standard says where to tak e
vibration readings
1 58
Equipment
ISHRAE Installation Guide
Vertica l
SAMPLE MEASUREMENT OF VIBRATION AT SIT E
Condition
Start-up
Alarm
Sh u tdown
Application
Rigidl y
Mounted
Flexibl y
Mounted
BV-3
BV-4
BV-5
BV-3
BV-4
BV-5
BV-3
BV-4
BV-5
0.25
0 .16
0.10
0.40
0.25
0.20
0.50
0.40
0.30
0.35
0.25
0.1 6
0.65
0.40
0.30
0.70
0.60
0.40
_
_
_
_
All dimensions readings are in inch/se c
RIGID AND FLEXIBLE OPERATIO N
•
Fundamental frequency: Coincidin g
forced and natural frequencie s
•
Rigid mounting operates below the firs t
fundamental frequency of the syste m
•
Flexible mounting operates above th e
first fundamental frequency of th e
system
NOTE: Do not operate on fundamenta l
frequency
Flexible Foundation Desig n
•
Includes isolators to reduce fundamenta l
frequency to 30% or less of operatin g
frequency
•
Isolators selected to have close to equa l
deflection
•
Steel vibration bases must hav e
sufficient rigidity to prevent resonanc e
•
Inertia bases (filled with concrete) ad d
stiffness and mass, and are preferre d
Equipment
ISHRAE Installation Guide
•
Building structure supporting spring s
must have high rigidit y
•
Fan Foundation - Vibration Isolator s
•
Used to prevent fan vibrations fro m
being transmitted to the suppor t
structure
1 59
o Rubber in shear isolators are use d
for small fans with speeds of 1,00 0
rpm or highe r
o Spring isolators are used for large
fans, with lower operating speeds .
VIRRATION ISO! ATOR S
VIRRATION IROLATOR$
RUBBER—IN—SHEA R
SPRING TYPE
MENG vs..0
•
Achieving Lower Vibration Level s
•
Do not specify ultra-low vibration limit s
unless absolutely necessary
•
Adds cost with minimal extension of fa n
life
•
Involves better precision of man y
component s
o Better balance of all rotatin g
component s
. Fan wheel (balance with fan shaft )
. Sheaves
. Couplings
. Moto r
o Straighter shafts with precisio n
diameter tolerance and roundnes s
o Less hop and wobble in fan whee l
o Better fits in attached components
o Reduced internal clearance i n
bearings
o Bearing mounting surfaces machine d
flat
o Adapter mounted bearing s
o Premium quality v-belt drive s
o Precision alignment of v-belt drive s
or coupling s
o Precise tensioning of belt s
•
Involves other special desig n
consideration s
o Heavier an more rigid components :
Use Class III instead of Class I I
o Aluminum fan wheel (reduced roto r
weight)
o Use inertia base for flexibly mounte d
fan
o No variable pitched v-belt drive s
o Select lower speed fan s
o On Arrangement 3 — Avoid operation
at'/ first critical speed
1 60
Equipment
ISHRAE Installation Guid e
Drive Arrangements Fo r
Centrifugal Fan s
Arrangement 3 SWS I
o
For belt drive (or direct) connectio n
Arrangement 1 SWS I
o
One bearing on each side and supporte d
by fan housin g
o
Motor mounted beside fan, typically o n
a common bas e
o
For belt drive (or direct) connectio n
o
Impeller overhun g
o
Two bearings on base
o
Motor mounted beside fan, typically o n
a common bas e
Arrangement 3 DWD I
Arrangement 2 SWS I
o
For belt drive or direct drive connectio n
o
Impeller overhun g
o
Bearings in bracket supported by fa n
housing
o
Rarely used today
o
For belt drive (or direct) connectio n
o
One bearing on each side and supporte d
by fan housin g
o
Motor mounted beside fan, typically o n
a common bas e
Arrangement 4 SWS I
o
For direct drive connectio n
o
Impeller overhung on prime mover shaf t
o
No bearings on fan
ISHRAE Installation Guide
o
Equipment
1 61
Motor base mounted or integrally directl y
connecte d
Arrangement 9 SWS I
Arrangement 7 SWS I
o
For direct drive connection
o
Arrangement 3 plus base for moto r
o
Motor coupled to fan shaf t
o
For belt driv e
o
Impeller overhun g
o
Two bearings with motor mounte d
outside base
Arrangement 10 SWS I
o
For direct drive connection
o
Arrangement 3 plus base for moto r
o
Motor coupled to fan shaft
o
For belt driv e
o
Impeller overhun g
o
Two bearings with motor mounted insid e
base
Arrangement 8 SWS I
o
For direct drive connection
o
Arrangement 1 plus extended base fo r
motor
o
Motor coupled to fan shaft
M
r
Equipment
1 62
ISHRAE Installation Guid e
Arrangement 9 belt drive motor positions - for inline fans .
•
Rotation of fans is determined by viewing the fan outlet en d
•
Specify horizontal or vertical mountin g
•
Fans can be supplied with support legs for horizontal floor mounting or horizontal clips fo r
ceiling mounting. Vertical mounting clips are also available .
—\360)- ' % /
1315'
** 45
en.
270
901 -
=--
'225j
135
Motor Shown in Position 360
j
View Facing Outlet
MOTOR POSITIONS :
Location of motor is determined by facing the drive side of fan and designating the moto r
positions by letters W, X, Y, or Z as the case may be .
ISHRAE Installation Guide
Equipment
1 63
Fan Rotation Et Discharge Position s
Up Blast
Top Angular Up
Top Horizontal
Top Angular Dow n
Down Blasi.
Botto m
Angular Down
Botto m
Horizontal
Botto m
Angular U p
Up Blas t
Top Angular Up
Top Horizontal
Top Angular Dow n
Dawn Blast
Botto m
Angular Down
Botto m
Horizontal
Botto m
Angular Up
1 64
Equipment
ISHRAE Installation Guide
5.
Fans before installation should b e
checked for the availability of drai n
points, cleaning man holes, lubricatio n
points, space for person to stand an d
drive in and out the keys in the shaft .
6.
Adequate pace for suction of air shoul d
be available . Recommended is "1D" ..
Hence in case of DIDW fans "Yz D" shoul d
be available on both sides .
7.
In-Line fans installed wherever should b e
isolated from the rigid ducts usin g
flexible connections on both sides .
However the alignment of the centerlin e
to the main duct should be taken car e
of.
Good Installation Practices :
1.
The fans are rotating equipment whic h
in most cases operate 24/7 . Special care
should be taken to install and conside r
space for maintenance .
2.
Shims wherever inserted should b e
highlighted in the installation /
commissioning report and the service
technician should be advised to inspect
the same every visit .
3.
The path from the unloading space to th e
installation space should have adequat e
space for taking in and taking out th e
fan at any given time . Hence th e
staircase/ service lifts, doors, should o f
adequate width .
4.
For very large fans the provision fo r
removing and servicing the impelle r
should also be made .
Section 4
EQUIPMENT 4 .5 Air Handling Units
AIR HANDLING UNI T
This equipment is responsible to treat and handle air and hence can be delicat e
in construction . Any damage to the structure and the panels can be a costl y
affair. Hence the equipment is to be handled with care . Wrong installation ca n
result in the air and water being wasted and carried to unwanted places ,
resulting in damage to property as well as loss in energy .
Any ceiling suspended unit should be taken care of in terms of proper loadin g
of the structure and measures used in isolation of the vibrations . Any transfe r
of vibration to the ducts, supports, structures will result in noise in loss o f
property, not to speak of the accidents that it may cause .
The DX or chilled water coils which reduce the temperature of the air belo w
the dew point temperature results in moisture condensation and hence wate r
drain . Proper drain collection points and slope of the drain pan is very importan t
for the condensate removal from the unit as soon as possible . Stagnation of
condensate in the unit can lead to algae/ fungus formation inside the AHU .
Improper slope within the unit can result in condensate water overflow an d
then flooding of the area where the units are located .
Care should be taken to ensure that the motor is safeguarded from the wate r
carried over by the air as well as settling of the condensate on its surface a s
well as on its terminal box .
Care should also be taken to ensure that no surface of the unit which is cold i s
exposed to direct ambient air. This results in condensation on the surface an d
with no facility to collect this condensate the area can have costly damages t o
property as well as can lead to accidents .
Safety measures can never be overemphasized . Safety for the people operating ,
handling and erecting the equipment is more important than anything else .
Follow all safety codes and more than that follow all logics to eliminate possibl e
cause of accidents.
ISHRAE Installation Guide
Equipment
16 7
The following is to be taken care of for AH U
installation .
■
Filter differential pressure measurin g
device functional.
•
Documentation - should be i n
hand .
•
Coil and piping installation should be as below -
♦
Manufacturer's performance data (fa n
curves, coil, etc .) .
Installation and startup manual .
Sequences and control strategies .
❑
Pipe fittings complete and pipes properl y
supported .
❑
❑
Manufacturer's manuals .
Successful deflection test.
Successful leakage test.
❑
❑
❑
Cabinet installation - Shoul d
be done to ensur e
❑
Pipes properly labeled and painted .
Pipes and fittings properly insulated .
Pipe strainers in place and clean .
Pipe systems properly flushed .
Pipes leak tested and have no leaking ,
dripping, or seeping .
Coifs connected correctly.
♦
♦
♦
♦
♦
•
■
■
■
■
■
■
■
■
■
■
■
■
Permanent labels affixed (includin g
fans) .
Exterior casing in good condition (no
dents, scratches, etc . )
Interior casing in good condition (n o
dents, rust, etc . )
Access door gaskets installed and door s
close tightly.
Access doors swing fully open with n o
obstruction .
Boot between duct and AHU tight and i n
good condition .
Vibration isolation equipment installe d
and functional .
Maintenance access acceptable for uni t
and components .
Instrumentation installed according to
specification (thermometers, pressur e
gauges, flow meters, etc . )
Equipment is dean and debris removed .
Clean filters installed and filte r
replacement type, efficiency, and siz e
permanently affixed to housing .
Fitters tight fitting .
❑
Coils are clean and fins are in goo d
condition .
❑
❑
Coil headers of specified material .
Condensate drain pans properly piped ,
trapped, and sloped .
Valves properly labeled.
❑
❑
❑
❑
❑
❑
•
Valves installed in proper direction .
Valves stroke fully and easily and spannin g
is calibrated .
Valves not leaking when closed at norma l
operating pressure .
Isolation valves installed per drawings .
P/T plugs installed per drawings .
Sheet metal installation
❑
Ducts visibly sound, clean, seated and i n
good condition .
❑
❑
Ducts have no apparent flow restrictions .
Ducts have sound attenuators installe d
if required .
Ducts have turning vanes in squar e
elbows.
❑
❑
Duct balancing dampers installed pe r
drawings and site visit .
1 68
Equipment
❑
Duct balancing and control dampers
operable .
❑
Dampers stroke fully and close tightl y
without binding .
❑
❑
❑
•
♦
Damper linkages have minimum play.
Damper spans calibrated and verified .
Smoke , and fire dampers installe d
properly and accessible .
Controls installatio n
Thermometers and gauges visible from
floor.
♦
Control system interlocks hooked up an d
functionaL
♦
♦
Smoke detectors in place .
Low limit freeze stat sensor locate d
properly.
All control devices, pneumatic tubing an d
wiring complete .
♦
♦
♦
♦
♦
♦
♦
Static pressure or other controllin g
sensors properly located .
Static pressure or other controllin g
sensors calibrated .
Installation of system and balancin g
devices allowed balancing to be
completed following specified procedures
and contract documents .
The HOA switch properly activates an d
deactivates the unit .
OAT, MAT, SAT, RAT, chilled water supply
sensors properly located and secure
(related OAT sensor shielded . )
Inlet vanes aligned in housing, actuato r
spanned, modulate smoothly an d
proportional to input signal and EMS
readout .
•
ISHRAE Installation Guid e
Fan installatio n
❑
Supply fan and motor alignment correct .
❑
Supply fan belt tension and conditio n
good .
❑
Supply fan protective shrouds for belt s
in place and secure .
❑
Supply fan and motor properly lubricated .
❑
Supply fan rotation correct .
❑
Supply fan has no unusual noise or o
Return/exhaust fan and belt protectiv e
shrouds in place and secure .
❑
Return/exhaust fan and motor tube line s
installed and tubed .
❑
Return/exhaust fan rotation correct .
❑
Return /exhaust fan has no unusual nois e
or vibration .
❑
Vibration isolators leveled and shippin g
blocks removed .
•
Electrical installatio n
❑
Pilot lights are functioning.
❑
Power disconnects in place and labeled .
❑
All electric connections tight .
❑
Proper grounding installed fo r
components and unit .
•
Final installatio n
❑
Smoke and fire dampers are open .
❑
Startup report completed with thi s
checklist attached .
❑
If unit was running during constructio n
are the ducts and coils clean .
ISHRAE Installation Guide
Equipment
169
❑
Pressure variations between rooms matc h
those indicated in contract documents .
•
Sensor and actuato r
calibration verificatio n
❑
Pressure difference between building an d
OA match those indicated in contract
documents .
❑
❑
Specified sequences of operation an d
operating 'schedules have bee n
implemented with all variation s
documented .
All field-installed temperature, relative
humidity, CO, CO2 and pressure sensors
and gages, and all actuators (dampers
and valves) on this piece of equipmen t
shall have the calibration accurac y
verified using a calibrated reference .
❑
Specified point-to-point checks have
been completed and documentatio n
record submitted for this system .
Sensors installed in the unit at th e
factory with calibration certificatio n
provided need not be field verified .
❑
Have all test instruments had a certified
calibration within the last 12 months .
❑
1 70
Equipment
ISHRAE Installation Guid e
Ceiling Suspended Air Handling Uni t
Shown is a photo of a ceiling suspende d
horizontal flow air handling unit installed above
false ceiling. The Secondary drain pan unde r
the air handling unit has to be installed t o
catch condensation if the primary pan wer e
to overflow . This is the secondary
condensation pan which is installed under th e
air handler to save a ceiling .
Also a float switch can be installed which offer s
triple protection against flooding above fals e
ceiling if the primary drain were to plug up .
The primary and secondary drains coming fro m
the air handler also drain into condensatio n
pumps .
Such pumps should have floats inside the m
and a reservoir. When the reservoir reaches
a certain height the float switch rises and turn s
on the motor and the pump which pumps th e
condensation out of the attic and usuall y
outside. In cases where these drains have t o
terminate in a sanitary drain, in case any othe r
drain is not possible and the condensation
drain is piped directly to the sanitary drain i t
is important that proper pipe method s
including traps be used to prevent sewer gase s
from back feeding into the condensatio n
drains and eventually into the air handler an d
air stream which provides air to the structure .
The height of the "U" trap in such cases should
be minimum 150% of static pressure of th e
AHU fan in "mm of WC "
The important part of tha ceiling suspende d
AHU installation is that the air handler ha s
plenty of drains and a safety cutoff to ensur e
that the air handler turn off before th e
secondary drain pan overflows into the . .lse
ceiling .
Supports required for such installations ar e
varied in nature . In places where vibratio n
and cleanliness and sound levels are to b e
restricted, the supports should be with sprin g
isolation for prevention of the unit vibratio n
to be transmitted to the roof structure .
ISHRAE Installation Guide
Equipment
171
HEPA FILTE R
HEPA Filters are fabricated under exactin g
conditions to meet the rigid specifications o f
international Test Standards as per U .S .
Federal STD . 209D . (DOP Test) or BS - 392 8
(Sodium Flame Test) . Every filter is certifie d
to have a minimum collection Efficiency of
99 .997% in removing particles of 0 .3 micron s
and above .
Temperature / Humidity Parameters : HEPA
Filters with metal sides can operate a t
temperature upto 350E. At temperatures ove r
175F special high temperature gaskets on th e
holding frames are required .
Humidity of 55 5% is generally specified . The
media is water resistant and can withstan d
inter mitten exposure to water .
FGI has testing facilities for Humidity an d
Temperature and they are recorded thru . The
electronic counter.
Special Feature s
1.
Butt joined edges are sealed an d
fastened to ensure a strong corner joint .
2.
Standard foam sealant expands into th e
media and secures separator end s
eliminating voids and possible leakage .
3.
Special inter locking dovetail gaskets ar e
provided on al HEPA Filters for increase d
protection against leakage.
4.
Sufficient pleats to provide a "Soli d
Pack" which eliminates shifting of medi a
and assures more surface area, lowe r
media velocity and longer life .
5.
HEPA Filters can be supplied i n
Aluminium, GI painted, Stainless stee l
and fire retardant plywood casings .
6.
Each HEPA Filter is individually package d
in a heavy duty carton consisting of o n
outer shell and inner liner, fabricate d
from multiple corrugated board . Each
carton is marked with filter style, code ,
size Et part no.
Dioctylphthalate Gas (DOP Gas) Fo r
HEPA a filter testing
The DOP test method employing homogeneou s
particles with a mass size of 0 .3 microns i s
the best standards or specifications when suc h
filters are to be tested .
DOP in aerosolized form has been extremel y
useful in the field of high efficiency filteration for determining filter efficiencies, for locating
filter defects and for evaluating the intergrit y
of installed filter including clean room ceilings .
Dioctylphthalate (DOP) and several of it s
family members including Di-2 (ethylhexys )
plthalate (DEHP) have been used for over 3 5
years to measure the efficiencies of HEPA
Filters and to test Alternatively where the plan t
noise is going to be high, it may be best t o
locate silencer where the ducts leave the plan t
room, thus eliminating any possibility o f
flanking .
ISHRAE Installation Guid e
Equipment
1 72
Applications
:anal°irj
)
Isolation Room (Cusl/dralt free.
temperature controlled modules )
Microscopy. clinical chemistry.
forensic chemistry, spectroscop y
and chromatography .
Em4pnmantal Room (Temperatur
e
and humidity controlled environments)
Computer applications, pathology ,
microbiology . malarial storage. ASTM
testing .
III1116d!IIII:'dllll 6
Horizontal Laminar Flow Room
(Tunnel design enables Mr to mov e
through the work area and exhaust a t
opposite end .) Advantageous for smal l
Work areas and where callin g
Clearance is a factor.
Clean Room (HEPA filtered positive
pmsaure work area) Pharmaceutica l
and cosmetic analysis . biomedica l
procedures . particle technology.
analytic recording .
Illlil!Illllllllf IIIlilillilllllllll'IIIIIIIilllllll
UNILAR (Totally contained laboralory
work area) Hazardous waste analysis .
toxicology, chemical end acid fum e
ventilation . aalely stations, explosio n
proof and flammable storage .
Micro-Electronic Aaaambly (Cominuoua clean room syslems) Qualit y
control and testing . electronic
packaging, robotics . and slsti c
protection .
b
Section 4
EQUIPMENT 4.6 Package & Split Refrigeration Ai r
Conditioning Unit
Package Et Split Refrigeration Air Conditioning Uni t
This equipment is responsible to treat and handle air and hence can b e
delicate in construction . Any damage to the structure and the panel s
can be a costly affair. Hence the equipment is to be handled with care .
Wrong installation can result in the air and water being wasted an d
carried to unwanted places, resulting in damage to property as well a s
loss in energy.
Any ceiling suspended unit should be taken care of in terms of prope r
loading of the structure and measures used in isolation of the vibrations .
Any transfer of vibration to the ducts, supports, structures will result i n
noise in loss of property, not to speak of the accidents that it ma y
cause .
The DX or chilled water coils which reduce the temperature of the ai r
below the dew point temperature results in moisture condensation an d
hence water drain . Proper drain collection points and slope of th e.drain
pan is very important for the condensate removal from the unit as soo n
as possible . Stagnation of condensate in the unit can lead to algae /
fungus formation inside the AHU . Improper slope within the unit can
result in condensate water overflow and then flooding of the area wher e
the units are located .
Care should be taken to ensure that the motor is safeguarded from th e
water carried over by the air as well as settling of the condensate on its
surface as well as on its terminal box .
Care should also be taken to ensure that no surface of the unit which i s
cold is exposed to direct ambient air. This results in condensation o n
the surface and with no facility to collect this condensate the area ca n
have costly damages to property as well as can lead to accidents .
Safety measures can never be overemphasized . Safety for the people
operating, handling and erecting the equipment is more important than
anything else . Follow all safety codes and more than that follow all logics
to eliminate possible cause of accidents .
176
Equipment
General Safety Informatio n
1.
2.
3.
Installation and maintenance to b e
performed only by qualified personne l
who are familiar with this type o f
equipment.
Some units are pressurized with dry air
or inert gas . All units must be evacuate d
before charging the system wit h
refrigerant.
Make sure that all field wiring conforms
to the requirements of the equipmen t
and all applicable national and loca l
codes .
4.
Avoid contact with sharp edges .and coi l
surfaces . They are a potential injury
hazard .
5.
Make sure all power sources are
disconnected before any service work i s
done on units .
I . Delivery Inspection
Responsibility should be assigned to a
dependable individual at the job site t o
receive material. Inspect alt cartons an d
crates for damage as soon as they arriv e
against the bill of lading . If damage is noted
to shipping crates, or cartons, or if a shortag e
is found, note this on the bill of Lading (al l
copies) prior to signing . Call the deliverin g
truck line and follow up the call with a writte n
report indicating concealed damage to your
shipment.
Check the serial tag information with invoice .
Report any discrepancies
Ask for an immediate inspection of you r
concealed damage item . Crating material
MUST be retained to show the inspector fro m
the truck line .
ISHRAE Installation Guid e
Heavy equipment should be left on its shippin g
base until it has been moved to the fina l
location.
INSTALLATION INSTRUCTION S
I . Handling and Placement o f
Condensing Uni t
To minimize damage to the unit housing, it i s
recommended that the crate not be remove d
until the unit is moved to its final location .
The following should be considered whe n
placing the unit :
A.
The condenser coil (air inlet) should no t
be located so as to restrict air flow int o
the coil . A minimum of 12' is require d
(18" is preferred) between the face o f
the coil and a wall or other vertica l
obstruction .
B.
A minimum of 6" is required on the side s
to allow access to the housing clamps .
C.
A minimum of 24" is required on th e
louvered end (air outlet) for clearanc e
when opening housing and for ease o f
maintenance .
D.
Do not position multiple units so that th e
air discharge of one is into the condense r
air intake of another.
Holes should be provided in the base support s
for mounting bolts and for bridle lift rods .
For indoor mounting, motor rooms should b e
provided with fans designed to move 1000 cf m
of air per ton of refrigeration .
II . Space and Locatio n
Requirements :
The most important consideration which mus t
be taken into account when deciding upon the
ISHRAE Installation Guide
Equipment
Location of air-cooled equipment is th e
provision for a supply of ambient air to th e
condenser, and removal of heated air fro m
the condensing unit or remote condenser area .
Where this essential requirement is no t
adhered to, it will result in higher hea d
pressures, which cause poor operation an d
potential failure of equipment . Units must no t
be located in the vicinity of steam, hot air o r
fume exhausts . Corrosive atmosphere s
require custom designed condensers .
Another consideration which must be take n
is that the unit should be mounted away fro m
noise sensitive spaces and must hav e
adequate support to avoid vibration and nois e
transmission into the building .
Units should be mounted over corridors, utility
- areas, rest rooms and other auxiliary area s
where high levels of sound are not a n
important factor. Sound and structura l
consultants should be retained fo r
recommendations .
Space and Location Requirement s
for Condensing Units and Remot e
Condensers
Walls or Obstruction s
The unit should be located so that air may
circulate freely and not be recirculated . Fo r
proper air flow and access all sides of the uni t
should be a minimum of "W" away from an y
wall or obstruction . It is preferred that thi s
distance be increased whenever possible . Care
should be taken to see that ample room I s
left for maintenance work through acces s
doors and panels . Overhead obstructions ar e
not permitted . When the unit is in an are a
where it is enclosed by three walls the uni t
must be installed as indicated for units in a
pit.
177
AIRFLOW
Multiple Units
For units placed side by side, the minimu m
distance between units is the width of th e
largest unit . If units are placed end to end ,
the minimum distance between units is 4 feet .
AIR FLOW
AIR FLOW
Units in Pits
The top of the unit should be level with th e
top of the pit, and side distance increased to
"2W" . If the top of the unit is not level wit h
the top of pit, discharge cones or stacks mus t
be used to raise discharge air to the top o f
the pit. This is a minimum requirement .
Decorative Fences
Fences must have 50% free area, with 1 foot
undercut, a "W" minimum clearance, and mus t
not exceed the top of unit . If thes e
requirements are not met, unit must b e
installed as indicated for "Units in pits" .
1 78
Equipment
I
MIN . B
f) 1
I W AIR'ioLyr 1
1
MIN .
MIN .
i NI
I
41-n
ISHRAE Installation Guid e
Ill . Requirements for
Remote and Water Coole d
Condensing Units
General Installation
Walls or Obstructions fo r
Horizontal Air Flow
Multiple Units with Horizontal Ai r
Flow
AIR FLO W
The indoor compressor units are designed t o
be used with a remote condenser . The wate r
cooled units are similar, except that they hav e
an integral water cooled condenser . Inlet an d
outlet water connections are to be made i n
the field . On units having a compressor wate r
jacket, incoming water shall be routed throug h
the jacket prior to entering the condenser .
For cleaning purposes, condenser end plate s
can be removed to give access to the wate r
tubes . Cleaning is accomplished by a simpl e
spiral tool powered by an ordinary electric drill .
During installation, allow space for cleanin g
the condenser. Commercial equipment of thi s
type is intended for installation by qualifie d
refrigeration mechanics .
Typical Arrangements
W MW.
WAIN
aW%\' * W* N. U t t o.N.,N * oWAL t \Xh** MM%X
"W" = Total width of the condensing unit o r
condenser.
Diagram 1 illustrates a typical pipin g
arrangement involving a remote condense r
located at a higher elevation, as commonl y
encountered when the condenser is on a roo f
and the compressor and receiver are on grad e
level or in a basement equipment room . In
this case, the design of the discharge line i s
very critical . If properly sized for full loa d
condition, the gas velocity might be too lo w
at reduced loads to carry oil up through th e
discharge line and condenser coil . Reducin g
the discharge line size would increase the ga s
velocity sufficiently at reduced loa d
conditions ; however, when operating at ful l
load, the Line would be greatly undersized, an d
thereby creating an excessive refrigeran t
pressure drop. This condition can be overcom e
in one of two of the following ways :
ISHRAE Installation Guide
Equipment
1.
The dischargeRine may be properly size d
for the desired pressure drop at full load
conditions and an oil separator installed
at the bottom pf the trap in the discharge
Line from the Compressor.
2.
A double riser discharge line maybe use d
as shown in Diagram 2 . Line "A" shoul d
be sized to carry the oil at minimum load
conditions and the line "B" should b e
sized so that at the full load condition s
both lines wduld have sufficient flo w
velocity to carry the oil to the condenser.
179
Diagram 1
Water Regulating Valve
Using this control on the water coole d
condensing units, the head pressure can b e
maintained by adjfisting the flow of wate r
through the condenser section . This typ e
control is most often located on the wate r
entering side of the 'condenser and is regulate d
by the refrigerant condensing pressure .
Subcooler
Diagrams 1 and 2 below show typical subcoole r
piping . Diagram 1 is the preferred connectio n
with receiver as it provides maximu m
subcooling . Diagram 2 may be used if th e
receiver is located far from the condenser.
Notes:
1.
All oil traps are to be as short in radiu s
as possible . Common practice is t o
fabricate the trap using three 90 degre e
ells.
2.
Pressure relief valves are recommende d
at the condenser for protection of th e
coil .
3.
A pressure valve at the high point in the
discharge line is recommended to aid i n
removing non-condensables .
Diagram 2
4.
The placement of a subcooler should b e
that it does not interfere with norma l
airflow of the condenser. Increased stati c
of the unit could cause a decrease in
system capacity and fan motor damage .
IV. Condensing Unit Rigging an d
Mounting
Rigging holes are provided on all units . Caution
should be exercised when moving these units .
To prevent damage to the unit housing during
rigging, cables or chains used must be hel d
apart by spacer bars . The mounting platfor m
or base should be level and located so as t o
permit free access of supply air.
Ground Mountin g
Concrete slab raised six inches above groun d
level provides a suitable base . Raising the bas e
above ground level provides some protectio n
from ground water and wind blown matter.
Before tightening mounting bolts, recheck
1 80
Equipment
level of unit . The unit should in all cases b e
located with a clear space in all directions tha t
is at a minimum, equal to the height of th e
unit above the mounting surface . A condensin g
unit mounted in a corner formed by two walls ,
may result in discharge air recirculation wit h
resulting loss of capacity.
ISHRAE Installation Guid e
Figure 11 . Spring Mount
Roof Mountin g
Due to the weight of the units, a structura l
analysis by a qualified engineer may b e
required before mounting . Roof mounted units
should be installed level on steel channels o r
an I-beam frame capable of supporting th e
weight of the unit . Vibration absorbing pads
or springs should be installed between th e
condensing unit legs or frame and the roo f
mounting assembly.
Acces s
FIgv.9 . Spring Moun t
Mount Is shown In popedy adjusted position
space on the connection side to permit servic e
of components .
V. Recommended Indoor Uni t
Placement
Some general rules for evaporator placemen t
which must be followed are :
1 . The unit location should be such that i t
has a smoothest path for air distributio n
to cover the entire space desired fro m
that unit .
NEVER locate evaporators over doors .
Location of aisles, racks, etc . must be
known .
Location relative to compressors fo r
minimum pipe runs .
Location of condensate drains fo r
minimum run .
Provide adequate space at the compressor en d
of the unit for servicing . Provide adequate
he size and shape of the room, and th e
)poication will generally determine the typ e
td number of evaporators to be used an d
Ieir location . The following are some typica l
samples:
ISHRAE Installati6n Guide
Equipment
Minimum Unit Clearance s
Figurel . Medium 'Profile and Large Uni t
Coolers
'
r//////nrfl//////
PLAN VIEW
1
F 12 w
0
1
W
PLAN VIEW
AIR FLOW .I2W *
10
18 1
Indoor Unit Mounting
Most evaporators can be mounted with ro d
hangers, fag screws, or bolts . Use 5/16" (8mm )
bolt and washers or rod for up to 250 Lb s
(110Kgs), 3/8" (10mm) for up to 600 Lb s
(275Kgs) and 5/8" (16mm) for above that.
Care should be taken to mount the units leve l
so that condensate drains properly.
Note that some unit cooler designs achiev e
drain pan slope by using different heigh t
mounting brackets . In this situation ,, the top
of the mounting brackets should be level .
Adequate support must be provided to hol d
the weight of the unit .
e
112W e W
w
H
Ir2 W
Two evaporators
Figure2. Low Profile Unit Cooler s
i//////////////////'
/
j1VH
PLANVIEW
0?
PLAN VIEW
AIRFLOW
=
When using rod hangers, allow adequate spac e
between the top of the unit and the ceilin g
for cleaning . To comply with NSF Standard 7 ,
the area above the unit cooler must be seale d
or exposed in such a way to facilitate hand
cleaning without the use of tools . When
lagging or bolting the unit flush to the ceiling ,
seal the joint between the top and the ceilin g
with an NSF listed sealant and ends of open
hanger channels must be sealed to preven t
accumulation of foreign matter.
r
Figure 3 . Bulb and Contact Location
&
%
////////////////
4
1 112H
y
a. 1112H
4
1 1121-I
y
13Hr
H 1112H
incorrect locatio n
Two evaporators
NOTE: Leave space equal to unit heigh t
between bottom of unit and area to be coole d
(false ceiling/ racks) .
correct location
1 82
Equipment
Figure 4 . Multiple Evaporators
Above and Below Main Suction Line
Ironic een uaoae w
— no kW m[ut
ISHRAE Installation Guid e
Suction lines should slope down 1 /2 inch fo r
each 10 feet of horizontal run towards th e
compressor. If any portion of the suction lin e
rises above the exit elevation of th e
evaporator, P-type oil traps should be locate d
at the base of each suction riser for prope r
oil return to the compressor.
While brazing, dry nitrogen MUST be passed ,
through the lines at low pressure, to prevent
scaling and oxidation inside the tubing'an d
fittings . All flux must be removed from th e
joints after brazing .
MINIMIZE the amount of flux used to preven t
internal contamination of the refrigeration
system.
V. Refrigerant Piping (for detail s
refer the refrigerant piping chapter )
The condensing unit must remain sealed an d
pressurized from the manufacturer until pipin g
is complete and final connections are read y
to be made .
System piping must be done in accordance wit h
good refrigeration practices .
Use only refrigeration grade copper tubing ,
(ACR), type "L", bright annealed, dehydrated ,
and properly sealed against contamination.
Soft temper tubing may not be used for fiel d
interconnection of refrigeration component s
(condensing unit to evaporator assembly) .
Take extreme care to keep refrigeratio n
tubing clean and dry prior to installation . Use
an appropriate size tube cutter (DO NOT CU T
TUBING WITH A SAW) .
Refrigerant lines must be sized as dictated b y
the charts/ design drawings .
Silver brazing wire is to be utilized (hig h
temperature alloy of 15% silver content on al l
copper to copper connections, and hig h
temperature alloy of 45% silver content on al l
dissimilar metal connections) .
All equipment should be installed in accordanc e
with the recommended of the manufacturer ,
but generally in line with the followin g
minimum specified clearances.
Leak Chec k
When all refrigeration line connections hav e
been made, the complete system, includin g
factory connections, should be leak checked .
Add the proper refrigerant to 60 psig, the n
boost to 175 psig with dry nitrogen . Leakcheck all joints with an electronic leak detecto r
or a halide torch . If leaks are found, reliev e
the pressure and make repairs as necessary
and recheck.
Condensate Drain Line s
Either copper or steel drain lines should b e
used and properly protected from freezing . In
ISHRAE Installation Guide
18 3
Equipment
running drain lines, provide a minimum 1/ 4
inch per foot pitc hjfor proper drainage . Drai n
lines should be at least as Large as th e
evaporator drain connection . AIL plumbin g
connections should be made in accordance wit h
local plumbing codes . All condensate drai n
lines must be trapped, and run to an ope n
drain . They must never be connected directl y
to the sewer system . Traps in the drain lin e
must be located in a warm ambient . We
recommend a trapon each evaporator drai n
line prior to anytee connections .
Inspect drain pan periodically to insure fre e
drainage of condensate . If drain pan contain s
standing water, check for proper installation .
The drain pan should be cleaned regularly wit h
warm soapy water. ,
Evacuation, Dehydration and StartUp
A vacuum of 500 microns or less must be pulled
to properly dehydrate the system . Thi s
requires a two-stage vacuum pump with an
electronic vacuum indicator.
DO NOT USE THE SYSTEM COMPRESSOR AS A
VACUUM PUMP.
DO NOT OPERATE COMPRESSOR WHIL E
SYSTEM IS IN A VACUUM .
Evacuation Procedure
A.
Open all condensing unit service valve s
and relieve system pressure . Also, ope n
any line valves installed in the syste m
and energize all solenoid valves t o
facilitate evacuation .
B.
Connect the vacuum pump to the hig h
and low sides of the system using 1/4 "
or larger cop per lines or 1/4" ID hose s
with high vacuum designation .
C.
Leaks or moisture will be indicated if th e
system pressure rises when the vacuu m
Line is closed off .
D.
Pull a vacuum of 1500 microns, clos e
vacuum line and "break" vacuum to 5
psig, maximum, with refrigerant to b e
used in the system .
E.
Repeat step D .
F.
A final vacuum of 250 microns should b e
pulled before charging . When 25 0
microns is achieved, dose vacuum lin e
and charge through high side, with prope r
refrigerant to the level of 2-1 /2 lbs . per
ton of refrigeration .
Figure 5 . Condensate Drain Line s
DRAIN LINE MIN .
PITCH -1/4"/ FT.
1 84
Equipment
Finish Charging Procedures
A. Preliminary
1.
Be sure all service valves are "open" .
2.
Loosen the compressor hold-down bolt s
and remove shipping clips to allo w
compressor to float freely on the springs .
3.
Check evaporator fan motors after startup . Medium temperature, air defros t
fans run continuously. Low temperature
fans and coolers provided with electri c
defrost will be delayed by the fan control .
4.
Start the system by "flipping on" th e
circuit breaker in the unit electric box .
5.
Start charging.
CAUTION : Never add liquid refrigerant to th e
suction side of the compressor.
6.
Check operating pressures while chargin g
and on initial pull-down to preven t
damage if a problem occurs . If syste m
"floods" back to the compressor, adjus t
the thermostatic expansion valve a s
required for proper operation . There
should be at least +30°F superhea t
entering the compressor.
7.
Observe compressor amperage draw and .
compare to compressor nameplate t o
prevent damage due to high amperage .
The oil sight glass should be between 1 /
2 and 3/4 full during normal operation .
Built-Up Remote Condensing Unit s
In case the units are equipped with a hea d
pressure control valve for low ambien t
operation, the valve will flood the condense r
when ambient temperatures are low, requirin g
additional refrigerant to provide correc t
operation under various ambient conditions .
ISHRAE Installation Guid e
Check for the manufacturer's recommendatio n
for the exact charge .
DANGER
Charging of the refrigeration system must b e
performed only by a certified refrigeratio n
mechanic. Improper or faulty hook-up o f
refrigeration electrical components can result
in injury or death .
Pre-Charged Remote Refrigeratio n
Systems
• Place a steel or treated-wood spreader o n
the top of the walk-in to distribute the loa d
of the coil . The spreader must be at least
twice the width of the coil . The coil must b e
mounted away from the edge of the roof a
distance equal to the height of the coil (Se e
Figure)
6S,,sing Un d
• Uncrate the coil and through-bolt it to th e
ceiling of the conditioned space with suitabl e
fasteners.
• Uncrate the condensing unit and locate near
coil. Be sure air movement around the unit i s
not restricted so the condensing unit will hav e
a sufficient supply of air to function properly.
NOTE : Install evaporator coil in accordanc e
with the manufacturer's recommendations
ISHRAE Installation Guide
Equipment
from inside wall or obstructions to rear of
evaporator.
Drill holes through the wall large enoug h
to pass refrigeration lines, electrical lin e
and drain line .
•
After routing condensate line from drai n
pan of evaporator coil, seal around al l
refrigeration, electrical and drain line s
with silicone or butyl caulking.
•
Start compressor and allow to run at leas t
24 hours before using the conditione d
place .
Connect liquid and suction lines to th e
coil and the condensing unit .
Lubricate rubber seal in male half o f
coupling with refrigeration oil .
Thread coupling halves together by han d
to ensure proper mating of threads .
Tighten with Wrenches until coupling
bodies "bottom" or a definite resistanc e
is felt . (See Figure)
1 85
During the testing period yo u
should :
•
Check the temperature holding rang e
against the control setting .
•
On low temperature units, check the
defrost control system, whereve r
applicable, to see that all ice is remove d
from the coil during each defrost cycle .
•
Perform checks of door operation and al l
other component operations .
These particular systems are pre-charged a t
the factory with proper refrigerant, but shoul d
be operationally checked as pe r
manufacturer's recommendations .
•
•
•
Using a scribe or ink pen, mark a line
lengthwise from the coupling hex to th e
bulkhead . Then tighten an additional 1 /
6 to 1 /4 turn . The misalignment of the
mark will show the degree of tightenin g
for future reference . This final turn i s
necessary to ensure that the knife edge
metal seat bites into the brass seat o f
the coupling halves, forming a teak-proo f
joint .
Final Check List
A . Check high-low pressure control settings .
B. Check setting of defrost timer (whereve r
applicable) :
1.
Medium temperature 2 to 4 defrost/2 4
hours, with 35 minutes fail safe .
2.
Low temperature 3 to 4 defrost/24
hours, with 44 minutes fail safe .
When routing refrigeration lines, specia l
care should be taken not to "kink" the
lines and restrict the flow of refrigerant .
C . Check operating pressure .
Connect correctly rated over-curren t
protection device in the service tine t o
the service line on the condensing unit .
E. Set temperature control for desire d
temperature range .
D . Check electrical requirements of unit t o
power supply voltage .
1 86
Equipment
F.
Check setting of thermostatic expansio n
valve for proper operation .
G.
Check sight glass for proper refrigeran t
charge.
H.
Check compressor oil level .
I.
Check system for proper defrost
settings, wherever applicable, an d
operation .
J.
Check condensing unit for vibrating o r
rubbing tubing . Dampen or clamp a s
required.
K.
Open all valves completely counte r
clockwise .
L.
Check packing nuts on all service valves .
M.
Replace all service valve caps and latc h
unit covers.
VI . GENERAL :
1.
Suction lines should be pitched down i n
direction of flow, 1/2" per 10 feet of line .
2.
Refrigerant lines should be supporte d
and fastened properly to prevent leak s
and for professional looking installation .
Supports should be every 5 feet for line s
to 7/8" OD, 7 feet for 1-1/8" to 1-3/8 "
OD lines, and 10 fegt for 1-5/8" and 21/8" OD lines .
3.
Where condensation dripping would b e
objectionable, insulate suction lines, an d
where the sun could adversely affect
performance, insulate both the liqui d
and suction lines . Insulation thickness of
1/2" will usually be adequate .
4.
A "P" trap must be installed at the botto m
of the riser in all vertical suction line s
rising 4" or more . To insure proper oil
ISHRAE Installation Guid e
return to the condensing unit, the tra p
should be the same size as the horizonta l
line and the riser should be sized per th e
line sizing charts as per design criteria .
In installations where condensate ca n
accumulate on the "vibrasorber", a coverin g
of heat shrink PVC tubing or waterproof tap e
may be used to prevent freezing under the '
ferrule, causing a rupture .
NOTE :
If you sell or give away your refrigeratio n
system and you evacuate the refrigeran t
charge before shipment, you must evacuat e
the refrigerant into an approved recovery an d
reclaim system in order to satisfy all applicable
local and national regulations regarding releas e
of refrigerant compounds into th e
atmosphere .
The release of refrigerant compounds into th e
atmosphere is a source of ozone depletion an d
regulated by the law.
It is also recommended that a laminate d
sheet with the following data is stuck to th e
panel of the unit for future use .
Equipment
ISHRAE Installation Guide
187
INSTALLATION DATA
Date System Installed :
Installer (contractor/ service engineer) Name and Address:
Phone :
Condensing Uni t
Model
Serial
Volts
Electrical
Phase
Evaporator(s )
Quantity
Model
Serial
Thermostat Setting
°F
Defrost Setting
/24 hrs .
Electrical
Volts
Operating Pressures
Design Ambient and indoor conditions
Min. Fail Safe
Amp s
Suction
Discharge
1 88
Equipment
ISHRAE Installation Guid e
Recommended Installation Clearance s
Tr/cfm
A
B
C
D
E
5/2000
50
600
450
150
450
7 .5/3000
50
600
450
150
450
10/4000
50
600
450
150
600
15/6000
50
700
450
150
650
_
• For piping Connections .
PAIR OF 100x100x12 SERRATED
RUBBER PAD S
1220
EQ
EQ
ISHRAE Installation Guide
Equipment
1 89
4x10 m m
atkeast
with hooks or anchorin g
x 200 x 200 H
Concrete Blocks
t >C
For
Piping
600
Fo r
r Ai r
Discharg e
1 90
Equipment
NOTES
ISHRAE Installation Guid e
Section 4
EQUIPMENT 4.7 Motor
Moto r
The motors convert electrical energy into mechanical energy.
A typical AC motor consists of two parts :
1.
An outside stationary stator having coils supplied with AC curren t
to produce a rotating magnetic field, and ;
2.
An inside rotor attached to the output shaft that is given a torqu e
by the rotating field .
When a current is passed heat is also generated, which has to be release d
or removed . hence motors should be installed with proper ventilation .
Proper care should be taken to ensure that it is not liable to exposue o f
dirt, duct corrosive liquid, oil, vapours, copper dust etc . For hazardou s
zones always remember to doubly cross check the ratings and safet y
class of the motors .
ISHRAE Installation Guide
Equipment
Receiving and Storin g
Unpacking and Inspectio n
A packing case which shows external signs o f
damage should be opened in the presence of
an Insurance Surveyor. Similarly, if damag e
to the contents is observed on opening th e
case, the matter should be reporte d
immediately to the Insurance Surveyor and th e
goods unpacked in his presence .
19 3
is commonly called "Stationery vibration" o r
"false brinelling" A roller bearing machin e
should not be stored on a vibrating floor, but ,
if it is unavoidable, the machine should b e
placed on thick blocks of rubber, cork or felt,
and the armature turned approximately a
quarter of revolution every week . Standb y
sets subjected to vibration should also b e
turned once in a week .
Handling
Every machine should be inspected to see tha t
all parts are intact . While reporting th e
damages or missing parts to the carriers ,
always quote the Motor Name place details '
including its machine number .
Always use lifting hook to lift the motor excep t
in very small frame where no lifting hook i s
provided . Do not roll or drag the motor o n
floor.
Storag e
Do not keep totally enclosed fan cooled moto r
in vertical position with external cover a s
base .
Prior to installation the machine should b e
stored in a clean, dry place . The machine d
parts have a protective coat of anti-rus t
preservative which should not be taken of f
during normal storage period . In case of lon g
storage, periodic examination should b e
carried out and fresh preservative applied i f
removed . During the storage period (an d
during installation as well as their working life )
machine should be protected from moisture ,
acid, alkali, oils, gas, dust, dirt and other
injurious substances, except of course, in th e
case of a machine specially designed to wit h
stand such conditions .
Special precautions should be taken when a
machine is idle for considerable period t o
avoid corrosion of the bearings and loss o f
grease . It is advisable to rotate the shaft
periodically as the grease tends to settle a t
the bottom of the housings .
Damage to rollers and races maybe caused by
fretting corrosion if a machine fitted with rolle r
bearings is subjected to continued vibratio n
for long periods whilst stationery, such damage
Avoid jerks and jolts to motors to increas e
life of the bearings .
The insulation resistance will be found to dro p
considerably as the motor warms-up, whic h
should not be less than 1 megaohms by 50 0
volts .megger.
During the drying out period, readings o f
temperature and insulation resistance shall b e
taken at least once an hour in order to se e
how the drying out is progressing . Th e
temperature of the motors shall be kept a s
constant as possible, otherwise, the insulatio n
resistance readings may be misleading .
After drying out, air drying varnish should b e
applied by brush on the winding surfaces onl y
and this be applied when winding is no t
condition to prevent absorption of moisture .
The length of drying time depends on th e
amount of dampness but in any case it shoul d
be atleast six hours .
194
Equipment
ISHRAE Installation Guide
Installatio n
Drives-Belt s
Electric machines and apparatus should alway s
be installed where they can obtain adequat e
ventilation and clean dry air. They should b e
accessible for full inspection and repairs . If
the air contains dust, moisture or corrosiv e
gases the equipment should be appropriatel y
protected or else supplied with pure ai r
through special pipes or ducting .
Arrange the drive so that the slack side o f
the belt is uppermost . Do not overtighte n
the belt and avoid a belt fastener which knock s
the pulley as this may damage the bearings .
Avoid vertical drives . Fast and loose pulle y
drives should be arranged so that the drive i s
on the fast pulley when the belt is nearest t o
the motor.
The machines should .be erected on solid and
vibration free foundation studs . On totally
enclosed machines drain holes are provide d
at the bottom of the stator for condensation .
Couplings : Use flexible type couplings whic h
will accommodate small inaccuracies i n
alignment between motor and driven member.
Ensure that the shaft does not project beyond
the face to the coupling and that there is a
small amount of axial clearance between th e
faces of the two halves of the couplings s o
that the motor bearings are not subjected t o
end thrust .
Pulley driven machines should be mounted o n
slide rails . The slide rails should have th e
screw in opposite directions so that the scre w
which is nearest the belt is between the motor
and the driven machine : The machines shoul d
always be carefully aligned, this being o f
special importance when it is direct couple d
drive .
Fitting of pulleys or coupling s
Clean both shaft extension and coupling bor e
and smear lightly with oil .
Antirust preservative applied on the machine d
parts, wherever necessary can be easily take n
off with white spirit, petrol (gasonline) o f
Kerosene (paraffin) . Clean keyway and make
sure key is fitting properly on the sides onl y
of the keyway both shaft and coupling or pulley.
The key should have clearance at the top an d
should not fit tightly on top and bottom faces .
Should force be applied to fit pulley or couplin g
on shaft, it is desirable that the non drive
end bearing bracket is removed and shaft i s
supported so that the pressure or hamme r
blows are not borne by the bearings .
Terminal Markings
The terminal markings are as specified in IS325 . Special instructions, if any, will be give n
separately. To reverse the direction o f
rotation, interchange any two of the line leads .
Wiring
Connect the motor in accordance with th e
diagram supplied, using cables of adequate
size to carry the full load current marked o n
the motor name place and also large enough
to carry the starting current without excessiv e
voltage drop . The starting current for direc t
on tine starting will be 6 to 7 times full loa d
current at rated voltage in the case of squirre l
cage motors .
The motor body should be effectively earthe d
using the earthing provision on the motor Body .
Section 4
EQUIPMENT - 4 .8 Thermal Energy Storage Tanks
THERMAL ENERGY STORAGE TANKS (TES )
Special equipments are not special in terms of qualities . It is only use d
in some installations wherever applicable and designed . Hence care
should be taken to ensure that at least one member of the installatio n
team is technically exposed to the said equipment in prior installation s
and is aware of the design criteria of such equipment . Read all instruction
given by the manufacturers .
Safety measures can never be overemphasized . Safety for the people
operating, handling and erecting the equipment is more important tha n
anything else . Follow all safety codes and more than that follow all logic s
to eliminate possible cause of accidents .
ISHRAE Installation Guide
Equipment
All Thermal energy storage systems requir e
tanks which are the single largest part of th e
system . These tanks can be installed over th e
ground, under the ground . They can be single
or can be multiple ; They can be horizontal o r
vertical . All needs to be insulated as per th e
manufacturer's recommendations . Som e
manufacturers supply pre insulated-tanks ,
while others require site insulation . In both
the cases however the insulation plays as muc h
a role as the capacity of the tank as loss i n
insulation is direct loss in storage .
19 7
Following precautions needs to be taken : 1.
Ensure that the manufacturer' s
recommendations are followed .
2.
On receipt of the material at site, ensure
that the bill of lading/ transporters copy
is truly matched with the crates which
are received .
3 . Report any damages or shortages
immediately, and ensure that the sam e
is mentioned in the transporter s
receipts .
198
Equipment
I
4.
5.
6.
I
Care should be taken while unloading an d
placing the tanks at safe locations . Since
the space occupied by them is fairly large ,
prior site planning of location of receip t
and storage before installation is alway s
recommended .
In case of single large horizontal tank s
ensure that the ground is fairly levele d
to minimize undue stresses in the tan k
joints .
Before installation ensure that the tank s
are installed with a firm structural base.
In case of synthetic tanks, ensure that
the entire base is flat and leveled to hav e
full contact with the tank base.
7.
In case of multiple tanks ensure that al l
tanks are leveled properly.
8.
If multiple vertical tanks ensure that th e
top 25% of the tank remains abov e
ground . Space the tanks properly fo r
proper load distribution .
9.
ISHRAE Installation Guid e
Connect the piping as recommended b y
the manufacturer . ensure that inlet an d
outlet along with the control valves
locations are exactly as per the desig n
and manufacturer's requirements .
Improper pressure balancing may diver t
the water n reverse directions tha n
desired, which may lead to ineffective
storage tanks.
10. Ensure that the pressure an d
temperature gauges are installed in th e
piping network with proper angle o f
inclination and reverse to the directio n
of flow. Ensure that the operating range s
of the thermometers are also as per th e
expected temperatures .
11. Once the tanks are insulated an d
installed, piping connected, pressur e
testing of the system can be done . Hold
and release the pressure a s
recommended by the manufacturer fro m
one side to the other in sequence .
12. Ensure that at least 900mm of space i s
minimum clear above the tanks fo r
inspection . In case at a later date the
tanks need to be removed and replaced ,
this height will be required to install an y
pulley block hooking arrangements .
Section 4
EQUIPMENT 4 .9 Variable Air Volume Boxes & Systems
Variable Air Volume Boxes et Systems
ISHRAE Installation Guide
equipment that might disrup t
communications and away from hig h
vibration equipment .
BEFORE INSTALLIN G
1 .'
2.
3.
20 1
Equipment
Check contents for any sign of damage .
If the VAV assembly is damaged in an y
way, contact the dealer or selle r
immediately.
The VAV Actuator comes ready to moun t
directly onto the damper shaft using th e
attached .V-Clamp . The VAV electronic s
board is housed within the clamshell typ e
enclosure and the entire assembly i s
attached to the duct with one sheet meta l
screw.
Please be sure and verify th e
compatibility and power requirements o f
the unit being installed and power source s
available .
4.
The VAV controller assembly is designe d
for use on new construction projects o r
retrofit of existing variable air volum e
terminals where actuators are replaced ,
i .e . pneumatic conversion, etc . Th e
controller is generally a self-containe d
unit which generally consists of a plasti c
enclosure and 3-wire floating dampe r
actuator.
5.
The retrofit controller is used on existin g
variable air volume terminals wher e
existing 3-wire floating actuators may b e
reused .
3.
Do not mount the unit near any sources
of electromagnetic interference (EMI) o r
flammable vapors .
Install the VAV controller on the VAV termina l
by placing the opening of the actuator ove r
the damper shaft extended from the box a s
shown in Figure below . Make sure that th e
terminal end of the enclosure is over a fla t
area of the box, or a mounting bracket mus t
be used.
NEW INSTALLATION CW or CC W
OPEN DAMPER
A standard actuator normally rotates Clockwis e
v.
MOUNTING THE UNI T
VAV NEW CONSTRUCTIO N
INSTALLATIO N
1.
The VAV must be mounted in a relativel y
clean environment, free from majo r
airborne dust and contaminant s
(moisture, oil, etc .) .
2.
Keep the VAV away from high voltage
tubin g
five pair cab
to open the VAV damper . To connect th e
actuator to the damper shaft :
1.
Turn the damper to the closed position .
2.
Press the black triangular shaped clutc h
on the right edge of the actuator an d
rotate the actuator fully counterclockwise .
Equipment
202
3.
Place the assembly over the damper shaf t
and hand-tighten the nuts on the actuato r
V-damp .
4.
Attach the assembly to the box o r
mounting plate by driving a sheet meta l
screw through the eyelet on the termina l
strip end of the assembly.
5.
Lock the actuator to the shaft b y
tightening the nuts on the V-clamp .
6.
Remove the VAV cover and set th e
address DIP switch as required .
7.
Connect the low voltage power to th e
unit .
8.
Connect temperature sensors .
9.
Connect fan or heating stages i f
required .
10. Connect modulating reheat valves i f
required .
In case the VAV needs to operate such tha t
the actuator needs to rotate counter clockwis e
to open the damper, then the action for seria l
no . 2 will need to change to clockwise .
ISHRAE Installation Guid e
NOTE : For 24 VAC power, use only powe r
supplies with a Class 2 transforme r
rating.
2.
Do not power with any voltage other tha n
the 24VAC low voltage listed . Connec t
power to the VAV by connecting wire s
from the transformer to the 24VA C
terminals LI and 1.2. The terminals are
normally labeled on the edge of the VAV .
3.
A Light indicator LED under the boar d
clam shell cover will illuminate when th e
power is properly connected .
4 For connections to the VAV/WR, strip th e
wire back approximately 3/16" and insert
into the terminal block . Back out th e
screw on the terminal block until the bar e
wire inserts fully, and turn the screw bac k
down until there is firm tension on th e
wire .
5. Make sure that the clamp secures th e
stripped portion of the wire, and that n o
insulation is under the clamp .
NOTE : In case the power source desire d
as per the manufacturer is 230V AC ,
please ensure that similar power sourc e
is available for connection .
Further the connection on the actuator need s
to be reversed to ensure that the actuato r
rotates in the opposite direction for the same /
similar command to open .
Verify and cross check the box and the rating s
before any connections .
All other steps shall remain the same .
COMMUNICATIONS BUS WIRIN G
CONNECTING THE POWE R
The VAV can be used in a stand alon e
configuration with a wall mounted sensor, wit h
a simple controller in smaller applications, o r
in an array utilizing hundreds of units . Whe n
used in an application smaller than 32 tota l
units, a minimum of one (1) PSC must b e
installed .
1 . The VAV must be powered by 24VAC Clas s
2 low voltage transformers . To connec t
the power wiring to the VAV, locate th e
terminals on the outside edge of the VAV
terminal strip and connect to the 24VA C
power source .
ISHRAE Installation Guide
Equipment
If used in a large array they must be used in
conjunction with the BAS or some Supervisory
System an d
must not exceed 4000 feet . (check wit h
each manufacturer/ supplier )
•
The drain wire of the communicatio n
cable must NOT be connected to the VAV /
WR controller, twist shield wires togethe r
to create single shield for the entire dais y
chain and connect to ground at one en d
only (suggest at the UBE location) .
•
Connection of the REF terminal on th e
VAV/WR controller is NOT required .
•
Each VAV/VVR in the daisy chain mus t
have a unique address and refer to th e
manufacturer's instructions for settin g
the Device Address (ADDR) dip switch ,
etc.
•
Connect the communications wiring t o
the terminal blocks on the edge of th e
VAV/VVR assembly marked +, -, and RE F
as shown in Figure below .
NOTE : All manufacturers/ suppliers have thei r
minimum and maximum numbers of VAV s
that can be ' controlled by th e
models of the controllers . Ensure that th e
right one selected is delivered an d
then connected .
All communication wiring should be shielded ,
plenum rated cable . Use 22AWG, twisted pair,
stranded, shielded, plenum rated cable for al l
communications wiring . In lieu of the 6500FE
cable, a stranded 2 pair cable with individuall y
paired shields may be used . When connecting
a channel of controllers, connec t
communications in a daisy chai n
configuration .
In case the communication is via EIA RS-48 5
protocol, then it would require that the syste m
be wired according to the following method s
and rules :
•
Communications cable must be 1 twisted
pair (Belden 6500FE), 22 AWG, plenu m
rated .
•
The total distance from the UBE expande r
to the last VAV/VVR in the daisy chai n
VAV : Variable Air Value s
VVR : Variable Volume Register
20 3
CAUTION : All communication wiring must be
connected such that the plus (+) terminal i s
wired to a plus terminal and the minus termina l
(-) is wired to a minus terminal. Do not instal l
communications cables near power cables o r
in power conduits . Isolate all communication s
wiring from large motors, fluorescent lightin g
fixtures or other sources of high intensity
electromagnetic interference (EMI) .
2 04
Equipment
ISHRAE Installation Guid e
COMPI FX COMMUNICATIONS AIIS WITH FXPANDFR MODUI E S
BAS SCM SUPERVISOR
BAS UBE EXPANDER S
. VAV/WR CONTROLLERS
VAV1 .1
VVRZ-1
L VAV3-1
VAVI-2
WR2•2
VVR2 2
VVR24
VAVJ J
The room sensor monitors the space ambien t
temperature, as well as optional setpoin t
adjustment and system override function . In
addition, the sensor can be provided with a n
RJ11 jack, which allows connection to th e
individual controller with a laptop through th e
room sensor.
Typical Room Sensor Connection
VVR4 .1
II
VAVS .2
Mount the room sensor according to th e
manufacturer's instructions . Make sure that
the sensor is not mounted so that diffuser ai r
is directly hitting the sensor, and that no heat
producing equipment is nearby (coffee pots ,
etc.) .
ISHRAE Installation Guide
Equipment
205
CONNECTING THE DUCT SENSO R
The duct sensor monitors the incoming supply air temperature, and allows the reverse operatio n
of the damper upon a high entering duct temperature . This is typically used on air handlin g
equipment with morning warmup function .
The reversing function will reverse the operation of the damper i .e. open on a call for heat .
Mount the sensor upstream from the VAV box in the branch duct according to the manufacturer' s
installation instructions .
Make sure that the sensor is in a straight section of duct, and install at least 5 duct diameter s
ahead of box and away from elbows.
RED
-OW1 -
tia,n,,=, —
a
a
DUCT SENSOR
Typical Duct Sensor Installation .
206
Equipment
ISHRAE Installation Guid e
CONNECTING THE VELOCITY SENSO R
The VAV/VVR uses an on-board differential pressure sensor for monitoring of air flow and velocit y
of the box discharge to the conditioned space . On the VAV, the sensor is connected with flexibl e
tubing to external taps on the lower edge of the enclosure marked "HIGH" and "LOW" . On th e
WR, the tubing is connected directly to the velocity sensor at the top of the WR controller board .
IMPORTANT: When connecting tubing directly to the on-board velocity sensor, the lower (closes t
to the board) connection is the "LOW" pressure, and the upper connection is the "HIGH" .
NOTE :On the VAV assembly, the external taps accept a 1/4" OD tubing . On the VVR retrofit
board, the sensor taps are 3/8" OD .
VELOCITY SENSORI TUBING CONNECTION S
Lo.
oon
1
!11', A
2
4--w wmnu w
.4 ...an In,
•„av,obw
,m..sax, P 1 n .,.
0
Section 4
EQUIPMENT - 4 .10 Heat Recovery Wheel
HEAT RECOVERY WHEEL
ISHRAE Installation Guide
Equipment
passes over it a distance of 5-8 mm . The
rotation monitor can be ordere d
separately.
Installation Instructions fo r
General Equipmen t
READ INSTRUCTIONS CAREFULLY BEFOR E
ATTEMPTING TO ASSEMBLE, SERVICE O R
OPERATE THE HEAT RECOVERY WHEEL .
FAILURE TO COMPLY WITH INSTRUCTION S
COULD RESULT IN PERSONAL INJURY AND /
OR PROPERTY DAMAGE !
Maintenance Instructions fo r
Equipmen t
GENERAL
■
The heat recovery unit is made to recove r
heat from the exhaust air and put it int o
the supply air. This will reduce energ y
demand and annual energy consumption .
Improper operation will cause les s
efficiency, higher energy consumption ,
and a lower supply air temperature .
■
Some reasons for tow efficiency can b e
low rotation speed and/or contaminatio n
of dust in the channels of the rotor.
SPECIAL WARNING: No untrained perso n
should attempt to install, maintain, o r
service the units.
MOUNTIN G
■
The drive unit (motor plus reductio n
gear) is mounted on the bracket locate d
in the heat exchanger, and the contro l
unit is mounted in a suitable positio n
either inside the heat exchanger' s
housing, or in the control room . Th e
motor can be procected against bracket
vibrations by, for example, rubber anti vibration mountings. The direction o f
rotation cannot be changed . In the even t
of incorrect direction of rotation, th e
drive unit can be turned 180 degrees o r
exchanged for another model . A n
installation ki€-for the motor can b e
ordered separately.
MOUNTING THE ROTATIO N
MONITO R
■
The magnet for the pulse generator - th e
rotation monitor - is screwed tightly t o
the periphery of the heat exchanger. If
the housing around the rotor is itsel f
magnetic, then the magnet must b e
isolated from the housing . The pulse
generator is mounted so that the magnet
20 9
PROCEDURES
IMPORTANT! Before doing anything ,
disconnect electrical power to unit. Also ,
avoid touching the rotor surface with hand s
or tools .
■
Controls
o
Make sure the rotor rotates easily. If it
doesn't, check that the brush seals hav e
correct clearance and coat the brushe s
with silicone oil.
o
Check the drive belt for proper tension .
You should not be able to spin the drive
sheave inside the belt . Tighten V-belt a s
required . If tension adjustment is a t
maximum range, the V-belt must b e
shortened and re-spliced .
o
Protect the drive belt against damag e
and keep it as clean as possible . Keep
210
Equipment
the rotor surface free from obstruction s
and protect from damage .
o
The maximum allowable pressure fro m
a spray nozzle is 85 psi . The nozzle mus t
be kept at least 3/16" from the roto r
surface .
o
After cleaning the rotor, recoat the brus h
seals with silicone oil .
■
Greasing
o
All wheel ball-bearings are permanentl y
lubricated and need no further greasing
a Cleanin g
o Clean rotor surface by vacuuming with a
soft brush attachment . Grease or dir t
can be removed from the rotor b y
spraying water or a mild detergent whic h
is compatible with aluminum .
Compressed air and low pressure stea m
can also be used for cleaning .
ISHRAE Installation Guid e
Section 4
EQUIPMENT 4 .1 1 Air Sepatator
ISHRAE Installation Guide
Equipment
21 3
AIR SEPARATO R
3" THROUGH I V
R AND RL MODELS
Note : When Installed an th e
support skirt proper drain piping
should be provided prior t o
Installing the unit In the syste m
piping.
Fig . 1 Air Contro l
Pressure Reducing Valv e
y
High Capacit
Mr Vent
re--Service Valve
•.
tl
From Boller,
Chiller, or -0.
Converto r
Rolalrtrol
Air Separato r
k Cold Water
Flu
—►
Pressurize d
Expansion Tank
Fig . 2 Air Eliminatio n
21 4
1.
2.
Equipment
The air separator is designed for close d
loop system only. Domestic, potable or
fresh water can cause serious corrosio n
and leakage in the tanks and system .
The separators should be properl y
supported for the operating weight ,
using structural supports .
4.
Use proper mating flanges, connectors ,
bolts and nuts with gaskets fo r
prevention of loss of chilled or hot wate r
and thereby saving energy and accidents .
5.
on a diameter as close to the outsid e
diameter of separator as possible o r
factory installed support brackets .
Note : Welding to the pressure vesse l
boundary will void the ASME stamp .
Use lifting lugs given by factory only t o
lift, shift and . position the tank in th e
required position . Units should be empt y
and disconnected before shifting o r
moving .
3.
ISHRAE Installation Guid e
The Separators can be supported in th e
piping system as long as pipe hanger s
are attached to the tangential nozzles a s
close to the separator shell as possible .
Sizes larger than an 8" connection wil l
need to have additional supports, suc h
as a cradle under the Separator acting
6.
Air Separators have strainers which mus t
be removed and cleaned after 24 hours
of operation, 30 days of operation an d
as required to maintain proper syste m
air separation . Before installing the
separator refer to the Table below fo r
minimum distances to be maintaine d
between the blowdown connection or en d
of the pipe plug and the floor or othe r
equipment for strainer removal .
7.
A manual blowdown valve can be adde d
to the blowdown connection . Th e
function of the MBV is to facilitate th e
purging of sediment from the vessel .
8.
A manual blowdown valve can be adde d
to the 3" through 12" tanks, by removin g
the 3" pipe plug and replacing with th e
proper sized reducer.
Minimum distance required to remove straine r
Stu
(Inches)
Distance
(Inches)
2
2 .5
3
4
5
6
a
10
12
14
16
16
20
22
24
L5
0 .5
12
14
17
20
2]
29
34
37
42
52
56
60
64
Section 4
EQUIPMENT 4 .12 Pressurised Expansion Tank
ISHRAE Installation Guide
Equipment
21 7
Pressurised Expansion Tan k
Horizontal and Vertica l
Location of Expansion Tank s
DO NOT LOCATE THIS PRODUCT WHER E
LEAKING OR FLOODING COULD CAUS E
DAMAGE TO THE SURROUNDING PROPERTY .
The expansion tank may be placed in an y
convenient position within the mechanical
room (or building) . It will work equally well in
either vertical or horizontal position . I f
multiple tanks are installed, they should all
be on the same level .
Point of Connectio n
1. Unlike a conventional tank, the seale d
air cushion does not requir e
replenishment so DO NOT connect to a n
air separator or othe r
2. Air collection device .
3. As with any expansion tank, it i s
recommended that the pressurised tan k
also be connected to the suction side o f
the pump . This will prevent the pum p
head from becoming subtractive which
21 8
Equipment
ISHRAE Installation Guid e
may result in entry of air and vapo r
formation at high points in the system .
6.
The tank may now be piped to th e
system.
4.
By connecting the expansion tank on th e
boiler or chiller return, displacement o f
coolest/ warmest system water into tan k
is ensured reducing energy waste .
7.
5.
Low pressure drop components such a s
air separators and boilers may be place d
between point of connection and pum p
suction if desired .
Connection to each tank must have a loc k
shield gate valve and union to allo w
isolation and removal if required . Make
up and fill valves, whether manual o r
automatic, should be tied into th e
connecting line . This will ensure tha t
pump operation will not affect valv e
operation
6.
System design will dictate the feasibilit y
of this .
.
7.
Natural convection losses and the entr y
of air into tanks are eliminated b y
connection to the side or underside o f
main pipe . The piping should be pitched
up and away from the expansion tank t o
eliminate any potential air traps .
In addition.8 to the lock-shield valve abov e
TPV or a drain valve, automatic air ven t
and a pressure gauge must be installe d
in the piping . The drain valve is used
for flushing (item 2 above) and to drai n
the water out of the tank for proper ai r
charging.
Installatio n
1.
2.
3.
4.
5.
Pump cavitation and unbalanced circuit s
can result from improper tank location .
Connect tank as close to suction side o f
system circulating pump as possible .
Failure to follow this instruction could
result in property damage and/o r
moderate personal injury.
Note location of system connection, ai r
charge valve and drain connection o n
tank.
Remove the plug or pipe cap from th e
system connection.
Remove the plug covering the air charg e
valve .
Before making any connection to th e
tank, check the tank and air charge (use
an accurate pressure gauge) . The ai r
pressure must be equal to or lower tha n
the minimum system pressure at the tan k
location .
After making sure the air charge i s
correct, replace the plug over the ai r
valve.
9.
Tank sizing calculations are based o n
minimum temperature rise of the air i n
the tank . For this reason, an antithermosyphon loop must be formed i n
the tank-to-system piping to minimize
the effects of gravity (thermal )
circulation into the tank . A drop leg fro m
12" to 20" long is usually sufficient . It is
also suggested that this piping and tan k
not be insulated (heating systems only) .
10. Allow an overhead clearance of at leas t
36" to remove the bladder through th e
flanged opening in case replacement i s
required .
11. For bladder replacement, the tank mus t
be removed from the system .
12. The branch piping to the tank must b e
attached to the main to minimize th e
possibility of air and debris entering th e
tank piping . If connected to th e
horizontal main, do not use top (1 2
o'clock) and bottom (6 o'clock )
positions . Side connections are th e
proper positions . If connection must b e
made at the bottom, a dirt trap leg wit h
a flushing drain valve, should be installed.
ISHRAE Installation Guide
219
Equipment
Pressurized Tani (Series 0 1
Tanks May be Floor Mounte d
with BLZ Leg Assemblie s
See Fig. I for Seres B Tank Mountin g
Pre-Charging Ai r
Connection
Se
— See Table A rorPlpe Size
Tiple Duly Valv e
Horizontal Tank Installation with Rolairtrol Air Separato r
Vertical Tank Installation with Rolairtrol Air Separati
2 20
Equipment
NOTES
ISHRAE Installation Guid e
Section 4
4.13 VIBRATION - ISOLATION
ISHRAE Installation Guide
Equipment
223
Vibration Isolation and Contro l
The other problem involving secondar y
transmission of fan noise, is mechanica l
vibration . Most rotating machines have som e
degree of residual out-of-balance force . I f
this vibration is allowed to transmit itself to
the building structure or to connected
ductwork, it may set in motion large surface
areas which are efficient radiators of sound .
In this way the vibration originating in th e
fan may cause objectionable noise at a
considerable distance from the fan itself .
Vibration Isolators - Materials &
Types
Steel springs are the most popular an d
versatile isolators for HVAC application s
because they are available for almost an y
desired deflection and have virtually unlimited life. All spring mountings shoul d
include an acoustical barrier, such as a rubbe r
pad at bottom to prevent transmission of ver y
high frequency vibration and noise and provid e
corrosion protection .
Rubber Isolator s
Rubber isolators are available in mound and
ribbed or waffle pad configurations, the pad s
being used in single or multiple layers . Rubbe r
isolators can be designed for 12 .5 mm (9 .5in. )
or generator deflections, but due to cost . and
practical considerations they are generally used
where deflections of 8mm (om3 in .) or les s
are required .
Isolation Hanger s
Isolation hangers are used for suspended pipe
and equipment and usually incorporate rubber ;
springs, or a combinati9on of spring an d
rubber elements .
Structural Base s
Structural bases are used where equipmen t
cannot be supported at individual location s
and/or where some means is necessary t o
maintain alignment of component parts suc h
as with fans. Structural base can be used wit h
spring or rubber mountings and should always
be designed with ample rigidity to resist al l
starting and operating forces with ou t
supplemental holddown devices . To
accomplish this, usual industry practice is t o
make bases in rectangular configuration s
using structural members whose debts ar e
one-tenth the longest base dimension, with a
minimum depth of 100mm (4 in .) . Maximum
depth is generally limited to 355 mm (14 in . )
Concrete Bases
Concrete bases consist of a steel pourin g
usually provided with welded-in reinforcin g
bars, provision for equipment holddowns, an d
mounting brackets . As with structural bases ,
concrete bases should be rectangular ,
wherever possible and, to provide desire d
rigidity, have a depth equal to one-twelfth o f
the longest base dimension, with a minimu m
150mm (6 in,) . Bass depth need not excee d
300 mm (12 in) unless specifically require d
for mass, rigidity, or component alignment .
It is important to understand the function o f
concrete bases before Specifying their use .
The inertia bases or mass of the system hav e
no effect on efficiency of isolators : however,
they do affect the movement of the equipmen t
itself and, as such, can effect the transmissio n
to the building structure through connecte d
piping and ducts .
224
Equipment
Choice of Isolators The choice of isolators for any give n
application primarily depends on require d
deflection, however, one must also conside r
fife, cost, and suitability for specific
ISHRAE Installation Guid e
application . In the past, charts such as the _
Efficiency chart shown in fig . 10 have been
used to facilitate the choice . However, thi s
chart has number of limitations .
ISHRAE Installation Guide
Equipment
225
RANGE OF OPEN AND ENCLOSED SPRING MOUNTINGS, HANGERS, RUBBER PAD S
& MOUNTINGS, INERTIA POURING FRAMES, FLOATING FLOOR SYSTEMS ,
RUBBER EXPANSION JOINTS & BELLOWS
FlEICON S
F1aLV Rpenae
CoiFiwe SIP 32450 NB
RmbOm MmxOnp
Loaf 5 . Y01p
Sna &sas
— +•
S
-&veb]
'
0
GENREM O■M.O
RMtV Mo &g.
Load : 250 . 20M kg
g
RP
SNORER
nun
Land , ■ BRO IMO
RP
Spam CO, P .C, (SC,
Load µb2 tOb M
Equipments
-
PUMPS . BASE MOUNTED
PUMPS . BELT DRIVEN
PUMPS - CLOSE COUPLED
PRESSURISATION UNITS
®L
CENTRIFUGAL FANS
AXIAL FLOW FANS
SUSPENDED FANS, ETC .
CHILLERS RECIPROCATING
dHI I LERS CENTRIFUGAL
COOLING TOWERS &
AIR COOLED CONDENSERS
BOIBER S
INTERNAL COMPUSTION
ENGINES & DG SET S
MISCELLANEOUS EQUIPMENTS FO R
COMPRESSED AIR, WATER SUPPLY, FIR E
FIGHTING, LAUNDRY & ELECTRICA L
PANELS, LIFTS, ESCALATORS ETC .
60
ComRh.d Spiv •
Oenn UM3
Imam-5919
BM
Ls, Mous
LM : 3W . WOA 4
SF O
V. Duma n
Fuue,Aew 1
s_
I
I
Locatio n
I
II
II I
Minimum Deflect ion (mm)
6
6
3
3
10
10
20
6
25
25
10
10
10
10
. 6
15
15
15
15
10
25
25
25
25
5
-
25
50
15
20
25+1 5
20
226
Equipment
ISHRAE Installation Guid e
Rubber Application
Anti Vibration- Mounts
These are available in two
different sizes . The smalle r
size has a stud on one sid e
while the larger one has n o
stud. Two numbers of th e
larger size are used a s
rubber springs . These ca n
be loaded in compression and withstan d
compression loads upto 1000Kg and upto 200Kg
in shear.
A time tested mount fo r
isolating vibrations fro m
diesel generators an d
compressors screens ,
blowers and other medium
and heavy machines . Thi s
can absorb a combination of shear an d
compression loads . Installation can be made fo r
most of the machines without bolting so th e
floor by using oil resistance friction pad supplie d
with the mount . Load range 500kg to 1600kg .
Low cost mountin g
arrangements which are
easy to install either i n
compression or in shear.
They come in differen t
l'
sizes with either stud on
both ends or stud on one
end and threaded insert in other or threaded
inserts at both ends . Load range 10kg to 2500kg .
These mounts have
threaded inserts at the to p
and have an elliptical bas e
with metal reinforcement .
They can be supplied i n
synthetic rubber such a s
neoprene or nitrite
depending on the servic e
conditions . It is used for generators as well a s
blowers, axial and centrifugal fans . Load range
1000kg.
r
al
, These are similar t o
cylindrical mounting s
except for the concav e
rubber profile which permits
greate r
deflection for a give n
load . These are used t o
protect sensitive electrical/ electroni c
equipment from low frequency externa l
vibrations . The bolts on either end promote eas y
installation .
These pads are used for
sound suppression an d
are laid directly under th e
machines . These provid e
`low deflection and ar e
used in conjunction wit h
other mountings . Thes e
are available with or without corks .
These mounts provid e
large deflections, hig h
load carrying capacit y
and a long service life .
They should be give n
first consideration fo r
isolating vibrations fro m
generators and most medium weight to heav y
machines and for protection of precisio n
machinery and heavy electric/ electroni c
installations from external vibrations .
These machine mount s
absorb shock and impac t
from punching machine s
and presses, also th e
horizontal forces fro m
injection mouldin g
machines and shapin g
machines . Lathes grindin g
machines and other precision machines ar e
protected from external shock loads an d
vibration .
ISHRAE Installation Guide
Equipment
22 7
Installation of Rubber Expansion Joints : Some
Important Points :
1.
Alignmen t
Measure the face to face distance of th e
location where Rubber Expansion Joints
are to be installed and chec k
misalignment of the pipe flange i .e.
Lateral & Angular . If the Rubbe r
Expansion Joints are to be installed wit h
initial misalignment, compression o r
elongation then these values will reduc e
the allowable movements of Rubbe r
Expansion Joints during system operatio n
2.
Control Unit s
Always use Control units to avoi d
excessive movements of the Bellows, Se e
enclosed drawing for fitment purpose .
4.
5.
Bolting
Always use correct size bolt to avoi d
leakages in bold holes . Tighten bolts by
Mating Flanges
Be sure that the mating flanges are clea n
before assembling with the Rubber
Expansion Joints .
6.
Retainer Ring s
Retainer Rings are to be used if en d
flanges are made out of integrate d
Rubber Flanges . Be sure that rings are
clean before assembling with the Rubbe r
Expansion Joints
Anchoring
Before assembling Rubber Expansio n
Joints, Pipe anchors and flange support s
are to be done to take care of end thrus t
etc. Pipe weight should not be allowe d
to act on the Rubber Expansion Joints.
3.
alternating around the flange and tighten
all the bolts equally. Check the bolt
tightness atleast once in a month an d
periodically thereafter.
7.
Improper Installatio n
Rubber Expansion Joints are to b e
installed properly without exceeding th e
movement capabilities . Some examples
of Improper installation are shown in th e
enclosed sketch.
Improper installations of Rubbe r
Expansion Joint reduce the normall y
expected life of Rubber Expansion Joint .
228
Equipment
ISHRAE Installation Guide
PROPER INSTALLATION (ASSEMBLED CONDITION )
RUBBER EXPANSION JOINT ASS Y
DRAWING FOR STRETCHER PLATE ORIENTATIO N
H•LE FO R
CONTROL RO
TYPE - 1
TYPE - 2
TYPE 1
FOR SIZES 25NB TO 300NB (TEST PRESSURE 10Kg/Sq cm )
FOR SIZES 25NB TO 200NB (TEST PRESSURE 15Kg/Sq cm )
TYPE 2
FOR SIZES 250NB a 300NB (TEST PRESSURE 15Kg/Sq cm )
ISHRAE Installation Guide
Equipment
229
SOME EXAMPLES OF IMPROPER INSTALLATIO N
OF RUBBER EXPANSION JOINT S
1 . OVER COMPRESSION
2. OVER EXPANSION
3 . OVER COMPRESSION IN ONE SIDE
4 . OVER EXPANSION IN ONE SIDE
5 . OVER ANGULAR MOVEMENT
6 . OVER LATERAL DEFLECTIO N
AU
. DIMENSIONS ARE IN ' UN 1 UNLESS OTHERWISE SPECIFIE D
IRa Roo © NUT & L0a NU T
0
of
t
SS-•S .*1^*
r
**4v* .+
- - -- . :
--.I
.f? .
11
11
WIHRGR P%P ANCIDN M11M ASC Y
DFSIGN DAT A
LUX WORKING PRESSURE 6.50 22/o co (9 )
ID A9/w an (9) At ROOM rrYP .
2) NSORO TEST PRESSURE
3) FLOMNB 100UN
¢1:11N6 WADY
I) TDIPERA1URE
MAX 60 C
5) SNORE HARDNESS
0595'A 'A'
O) DRRL01O STANDARD
RS 10 TARIE'D '
]) MOVEMENTS AT MAI WORINO PRESSUR E
10 no
o) ANAL EWAN901
b) RRAL COMPRESSON
15 ran
C) LATERAL 0EFlEC1 DN
IS on
RUBBER EXPANSION JOIN T
QI
TOLERANCE: AS PER ES. STANDAR D
SVo ID PCD 00 6a N
L
23 63 114 10 a
25 0
1
2 32 67 121 lB 4 25 0
3 40 00 133 16 4
250
25 0
50114152 19
250
4 S 6s 122 165 1 9 4
a 14 0 154 12
25 0
6 B
7 100 170 21 6 19
25 0
250
B 125 210 25 4 19
9 I'
D 235
19
25 0
10 200 292 Y2 I9
250
11
250 35 6 40 6 2 2
300
300
12 300 40 6 45 ] 22
1
2
5
6
7
9
10
11
1
37 0
3Io
I2
12
2
2
125
12
70
135
100
370 I50
150
390 150
150
125
150
410 150
150
200 420 125
17 3
250 5D0 200
200
350 5GO 200 ' 200
14 '
4
18
10
20
21
24
2
2
2
3]0
6(80
7
—6
9
10
II
12
C .I. MRE REINFORCEMEN T
5 OUTER COVER (NEOPRENE
7 DOLT,NUTdWASHER
Q STRETCHER PLATE
RETAINER RING
QE
3
125
1 25
w
5o
CROSS SECTION OETAIL
(SO JA1 J
1 NNER TUBE (NATURAL)
2 RAYON C0RD/N110N EABEOC
3 FILLER RUBBER
1 Nax
-N - Nx
NB
24
x1 n
25
55
133
40
60
05
00
NCO
72
92
102
11]
146
90
1 .:
127
146
,28
®
33
152
165
2
150 200 235 279
20G 260 292 3 7
250 316 350
300 1320rb5Tf452
le
19
;9
9
I9
19
4
4
4
4
I4
1
a
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19
19
B
21 I12
SNo NB I A
1
25 59
2
63
B NI
6D 16
60 1 6
6D 1 6
5o1 6 B 60 16
90 60 16
103 60 16
7
00 126 60 IB
s B2 00 20
6 1s
so 92 6 0 2 2
11 5 6 0 2 3
i on 70 1 25
12 300 a 70 22
W
16
16
16
19
19
19
19
19
19
19
22
22
R
20
20
20
2D
2D
20
20
20
20
20
25
25
20 10
20 IB
20 1 0
20 1 0
20 t o
0 10
20 ID
2 0 10
12
20 12
20 19
20 19
1
4
4
4
4
4
4
4
4
4
12 5
125
2
2
2
2
NOT IN CUR SLOPE
6
NVT & L0 NU T
SE E
IS 1367 Cl. 4 . 0
S
CONTROL ROD
TABLE
IS 136] CL 4 .6
4
STRETCHER PLATE
IS 2062 Cr - A
3 COMPAMON FLANGE
NOT IN OUR SCOP E
2 RETAINER RING
IS 2062 G - A
2
1 RUBBER EVANSON JOINT S
1 1 RUBBE R
DESCRIPT11W
SN O
I Orr I
MATERIAL '
36'i5 € WI E
ESN
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END SGN
2227
APRA 565
2W
RUBBER EXPANSION JOINT (REJ) ASS Y
SCALE 'NE S
UIpISan
DRG .NO: CEPC/DAIO/HVAC/3000/0
B
Section 5
ELECTRICAL PANEL AND CABLING
ELECTRICAL PANEL AND CABLIN G
Ensure that all instructions given are followed to the last word in lette r
and spirit . Make sure that the all access and contact points are provide d
with safety switches, isolating switches etc . Marking and labeling the
danger sign at all open / accessible locations are as important as righ t
sizing of the electrical equipment .
Insulation of the electrical power at all locations is to be kept in min d
while installation. Even a lose strand of wire can lead to safety trip s
which are very difficult to locate and eliminate . Hence importance t o
the activity of stripping and lugging of the terminations should be don e
as carefully and patiently as possible .
Safety measures can never be overemphasized . Safety for the people
operating, handling and erecting the equipment is more important tha n
anything else. Follow all safety codes and more than that follow all logic s
to eliminate possible cause of accidents .
ISHRAE Installation Guide
Equipment
Electrical accidents are generally caused b y
unsafe conditions, unsafe acts, or combinatio n
of the two . Some unsafe electric equipmen t
and installations can be identified by th e
presence of damaged insulation, imprope r
grounding, loose connections, defective parts ,
ground faults in equipment, or energized part s
left unguarded .
Environments containing flammable vapors ,
liquids, or gases ; areas containing a corrosiv e
atmosphere and wet and damp locations ar e
environments that can create electrica l
hazards .
Unsafe acts, such as the failure to de-energiz e
- electrical equipment when it is being repaire d
or inspected, the intentional removal o f
grounding pins from electrical cords, the us e
of defective and unsafe electrically powere d
tools, or the use of tools or equipment to clos e
to energized parts all contribute to electrica l
hazards .
Classified Location s
Class I Locations Those locations in which flammable gases o r
vapors are or may be present in the air i n
quantities sufficient to produce explosive o r
ignitable mixtures . Class I locations includ e
the following :
Class I, Division 1 Those locations in which hazardou s
concentrations of flammable gases or vapor s
may exist under normal operating conditions ;
or in which hazardous concentrations of suc h
gases and vapors may exist frequentl y
because of repair or maintenance operation s
or because of leakage ; or in which breakdow n
or faulty operation of equipment or processe s
might release hazardous concentrations of
233
flammable gases or vapors, and might als o
cause simultaneous failure of electri c
equipment.
Those locations in which volatile flammabl e
liquids or flammable gases are handled ,
processed, or used, but in which the hazardou s
liquids, vapors, or gases will normally b e
confined within closed containers or close d
systems from which they can escape only i n
case of accidental rupture or breakdown o f
such containers or systems, or in case o f
abnormal operation of equipment .
Class II Location s
Those locations that are hazardous becaus e
of the presence of combustible dusts . Class I I
locations include the following :
Class II, Division 1 Those locations in which combustible dust i s
or may be in suspension in the air unde r
normal operating conditions in quantitie s
sufficient to produce explosive or ignitable
mixtures; or where mechanical failure o r
abnormal operation of machinery or equipmen t
might cause such explosive or ignitabl e
mixtures to be produced, and might als o
provide a source of ignition throug h
simultaneous failure of electric equipment ,
operation of protection devices, or from othe r
causes ; or in which combustible dusts of a n
electrically conductive nature may be present .
Class II, Division 2Those locations in which combustible dust wil l
not normally be in suspension in the air i n
quantities sufficient to produce explosive o r
ignitable mixtures, and dust accumulations ar e
normally insufficient to interfere with th e
normal operation of electrical equipment o r
other apparatus .
234
Equipment
Class III Location s
ISHRAE Installation Guide
Exposed live parts on one side and no live o r
grounded parts on the other sid e
Locations that are hazardous because of the
presence of easily ignitable fibers or flying s
but where such fibers or flyings are not likel y
to be in suspension in the air in quantitie s
sufficient to produce ignitable mixtures. Class
III locations include the following :
ondition 1
Class III, Division 1
Those locations in which easily ignitable fiber s
or materials producing combustible flyings are
handled, manufactured, or used .
Class III, Division 2
Those locations in which easily ignitable fiber s
are stored or handled, except in th e
manufacture process .
900mm in front of the panel enclosur e
measuring from the enclosure door, from sid e
to side needs to be 750mm with the hinge d
door swing to no less than 90 °
Minimum headroom of 6ri f t
Approach Distances for Qualified
Employees - Alternating Current
Voltage Range
Inhase to phase)
Minimum Approach
Distanc e
300V and less
Avoid Contact
Over 300V, but
less than 750V
1 ft. 0 in . (30.5 cm )
Over 750V, but less
than 2kV
1 ft. 6 in . (46 cm)
Space required i n
front of the panel
ISHRAE Installation Guide
Equipment
then the same should be immediately
brought to the attention of concerne d
authorities . Proper drain slope with ,
bunds etc should be provided to ensur e
clean and dry place for panel operations .
REMEMBER :
1.
Never dismantle the panel board t o
reduce its weight for lifting, shifting o r
positioning .
2.
When assembling various section of th e
panel board, the bus bar should b e
connected and tightened using a torqu e
wrench and fixed torque for all bolts .
3.
Unevenness in the tightening results in
temporary or permanent warping of th e
bus bars resulting in unsteady voltage s
and spikes, uneven heating of bus bars
etc.
4.
5.
6.
Spacing between the bus bars and th e
switchgears are normally with minimu m
required standards and hence n o
additional item/ tapping should be take n
from them, or introduced in between a t
site . In case additional power sources /
feeders are required, use the outgoin g
and then connect another panel wit h
additional feeder tapping from that .
Ensure that the minimum spacin g
between panels, in front of the panel s
and the behind, the panels ar e
maintained .
All operating points of the panel shoul d
be accessible from a permanent and rigi d
platform . In case certain switches /
handles are to accessed which are highe r
than the human reach, then a permanen t
insulates structural framework should b e
installed .
7.
Use properly rated (1100V for M V
switchgear) rubber mats all around th e
panel for accessing the same .
8.
In case the panel location has potentia l
sources of water leakages/ drippings,
1
23 5
9.
Ensure that fairly good numbers (20% o f
the feeders) of sign boards are kept in
the operating place for hanging on to th e
switches before start of any repair /
maintenance works .
CABLING :
1.
The cables should be neatly dressed t o
have a uniform look . This helps i n
making the cables traceable at any time .
2.
The cables should have tag numbers a t
regular intervals for ease of tracing an d
serviceability.
3.
There should be no slack and bends fro m
support to support . This will ensure th e
space and gap that needs to b e
maintained between the conductors a s
per the design . In case of reduction i n
spacing the potential drops .
4 Maintain at least 1 cable diamete r
between the ends of clamps and henc e
more than 1 cable diameter between th e
cables .
5.
Earth flats should be properly welded .
6.
In case of cables being laid in trays on e
above the other try and keep the sam e
in as much open space as possible fo r
free movement of air.
7.
Bunching of cables are allowed, but th e
correct deration factors should b e
estimated . The current carrying capacit y
derates by a factor of 0 .88 for 2 cable s
and can go upto 0 .71 for upto 6 cables i n
a bunch .
236
Equipment
ISHRAE Installation Guid e
Earthing
Typical Plate Earth Electrode
50 mm thick PCC slab
Brickln tineor cement
Cement Concrert e
BOO x 800 x 6 .3 mm GI Plat e
or 500 x 500x 13 .5 mm GI Plat e
or 500 .500x 5 .1h mmeopper Plat e
Typical G . I . Pipe Earth Electrode
Salt Layer
Charcoal or coal in powder
Lsommixea .4th salt
Copper Stnpo n
Cl strip
44
Detail-a
Earth Lead
ISHRAE Installation Guide
Equipment
23 7
Typical C. I . Pipe Earth Electrode
Charcoal
Sal t
Charcoal or coke powder
mixed with salt Et clay
Typical M. V. Installation and
Switchboard Earthing Arrangement
Earth pit
(typical
)
Earth
d
M/C Moto r
(typical)
Inter Connection
(typical )
Earth
Earth Sub
‘
u
0
II
Earth Sub
Rollin g
shutte r
Factory/WC hall
Switch fus e
Single Earth Lea d
rah Su b
Medium Voltage Switchboard (Back View)
a
238
ISHRAE Installation Guid e
Equipment
Good Practices for Terminations
DVERLAP
DONS' S .
STRA14HT IM $NRON 4
/a *VIRECIb y
Do's.
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DFiopM LINES
110 COMPENSAT E
powp1
FOA OFGSCT .
:-og WEL11N4 UN1_ CAN BE
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$1,A pep
ISHRAE Installation Guide
239
Equipment
Do`6
DON' TS.
#
-e•
z
00
WI STAND CONNECTIO N S
WITHOUT LUGS
IMPROPER SIZE OF
LUG
/ MAKE CONNECTION S
WITH LUGS
r
e
'
40
USE CORRECT SIZE
OF LUGS
•
•
DERSIZED DI E
USED FOR CRIMPIN G
HENCE INCOMPLET E
CRIMP . ALSO DONOT
rTCF nvpncT7.Fn nT t
DO NOT ENLARG E
THE HOLE ON PALM OF
LUG .
.rte *
', \COMPLETE CRIM P
CORRECT DIEUSED FOR
CRIMPING .
24 0
Equipment
NOTES
ISHRAE : Installation Guid e
Section 6
SAFETY
SAFETY
• Helmet (we have some to borrow . Hare
hats are okay . Or you can purchase a t
www thefirestore .c orNStore/categary .cfm
?cID=1501 )
• Ear protection (we'll suppy these )
• E ye protection (sunglasses are okay)
• Long sleeve shirt
• Work gloves
• Long pants (army surplus stores sell
cargo/emt parts)
• Boots (preferaby steel toe )
Additional protective padding is optima l
(urees . elbows) .
ISHRAE Installation Guide
Safety
24 3
Ladders
10 . Never allow workers working at a heigh t
with loose slippers .
1 . Use step ladders . Avoid using temporary
arrangements like drums ,
boxes, etc .
Face masks
2.
While using a ladder :
a.
when handling loose fibre glas s
a.
Properly secure top and botto m
b.
while painting of equipments / material s
b.
Check rugs / steps are not spliced . . 0
c.
while working in places (like cemen t
factories) where there is lot o f
airborne dust .
11 . Use face masks
c : Provide side rails extending above to p
landing.
3 . Do not permit joining of ladders, fo r
extension purposes, by rope or othe r
unreliable means .
Scaffoldin g
4 . Use scaffolding for erection of ducting ,
piping, insulation, etc carried out at a
height .
5 . Firm platform should be provided on to p
of scaffolding (properly fixed) . Loose
wooden planks should be avoided .
Face shield s
12 . Insist on usage of welding face shield s
by workers carrying out welding /
gas cutting .
Protective goggle s
13 . Use protective goggle s
a.
while welding of pipes .
b.
when helping welders
c.
while chipping and grindin g
6 . Whenever scaffolding with wheels ar e
used, make sure the wheels are in locke d
position .
Safety belt s
7. Never move a movable scaffolding with
- people sitting on top.
a.
while working at height (with belt firml y
tied to some permanent member to
avoid free fall of workmen )
b.
while working in wells, tanks, pits ,
shafts, etc
14. Use safety belts
Safety helmet s
8.
All persons at site to use safety helmets .
Safety shoes
9.
Insist on usage of safety shoes . Neve r
allow any worker to move aroun d
barefoot in the site .
Hand glove s
15 .
Use hand gloves
a.
while welding of pipes
2 44
Safety
b.
when handling sharp edged sheets an d
other material s
c.
when handing hot materials like ho t
bitume n
Precautions before / while
welding
27.
ISHRAE Installation Guid e
Do not store gas cylinders in the ope n
space unless they are protected agains t
the adverse influence of the sun's rays .
Other general safety
consideration s
28.
Check all the ropes used in hoisting o r
lowering material .
29.
Use proper barricades for roof and floo r
cutouts, stairwells, etc
Provide fire blanket, barricade aroun d
welding location if situation demands .
30.
Do not allow smoking at site, to avoi d
any unintentional accidents .
18. When carrying out welding at height ,
take precautions to prevent sparks o r
hot metal falling on persons or flammable
material .
31.
Whenever working close to a rotatin g
machine like fan, motor, etc . ,
do not wear any loose dress / shawls /
tie / etc., which can get entangled /
sucked inside .
32 .
Do not forget to fix the guards for al l
open belt drive packages as wel l
as couplings .
33 .
Whenever hot bitumen is used, mak e
sure that the melting of bitumen i s
carried out at a safe place .
34 .
Do not run water, steam and other liqui d
carrying pipe lines (with joint s
and valves) over electrical apparatu s
unless such equipment is drip proo f
or splash proof .
16. Welding and gas cutting should not b e
carried out in the vicinity of an y
flammable or combustible material .
17.
19.
20.
Never use existing process pipe lines a s
part of earth conductor while carrying ou t
arc welding . Pipes may be carryin g
flammable gases .
Use good quality welding cables .
Fire extinguishers
21.
Keep portable fire extinguishers at site .
First aid
22.
Keep first aid box at the site .
Handling gas cylinders
23.
Keep gas cylinder upright and chained .
Electrica l
24.
Use trolleys for moving gas cylinders .
35 . Use proper sockets, etc for tapping powe r
for welding and other hand tools .
25.
Do not store charged gas cylinders i n
staircases, passages or in thei r
immediate vicinity.
26.
Store gas cylinders in a room properly
ventilated .
Use 3 pin sockets and plug tops wit h
proper earthing .
No loose wires to be inserted int o
sockets . Always use plug tops .
ISHRAE Installation Guide
Safety
live parts . Work from below rather tha n
above in this case .
36. All electrical cables to be routed to allo w
safe traffic by all concerned .
37. Avoid unsafe methods of joining /
extending power wires .
38. Do not allow any open live wire i n
dangerous position .
39. While drilling holes for erection of panel
boards, ensure that the drill does not
touch concealed live conduits or wires .
40. Avoid working on equipment or lines fro m
any position by which a shock or slip wil l
tend to bring the body towards exposed
24 5
41.
Use hand gloves before you start cuttin g
the wires or cables, to protec t
the hands .
42. While working out of sight of disconnec t
switches or valves that are set i n
a safe position, some one may rese t
them without your knowledge .
Protect yourself .
43. Always wear Shoes while doing electrica l
work.
246
ISHRAE Installation Guid e
Safety
SAFE WORKING LOADS FOR CHAIN SLING S
& WIRE ROPE SLING S
Chain slings find application in those areas where the primary requirements are ruggedness ,
abrasion resistance and high temperature resistance . Table 1 gives the rated safe working load s
for chain slings (Alloy Steel) & table 2 for wire rope slings .
Tables are provided for information only on the more commonly used types of wire rope slings .
For actual safe working loads of slings consult with the sling manufacturer. These tables ar e
based on safety factors of 5 : land assume that the slings are in excellent condition .
TABLE CHAIN SLINGS (ALLOY STEEL )
MAXIMUM SAFE WORKING LOADS - POUNDS
Rope
Single Baske t
Singl e
Single Choke r
Hitc h
Hitc h
Vertical Hitch
(Vertical Legs)
(Inches)
p
2-Leg Bridle Hitch
Diamete r
°
Single Basket lined
With th Le o of Inclined
60°
45°
5,600
11,400
19,500
28,600
39,800
49,800
67,100
77,000
99,500
116,000
138,000
173 , 000
4,600
9,300
15,900
23,300
32,500
40,600
54,800
63,000
81,000
94,500
113,000
141,000
l
/p
J
\
'/ 4
3 /6
i
5/
3 /4
r/ s
1
1'/ 6
1'/ 4
1 3/6
1'/ 6
1 3/4
3,250
6,600
11,250
16,500
23,000
28,750
38,750
44,500
57,500
67,000
80,000
100 , 000
2,440
4,950
8,400
12,400
17,200
21,500
29,000
33,400
43,000
50,000
60,000
75 , 000
6,500
13,200
22,500
33,000
46,000
57,500
77,500
89,000
115,000
134,000
160,000
200 , 000
30°
3,250
6,600
11,250
16,500
23,000
28,750
38,750
44,500
57,500
67,000
80,000
100,000
Fused with Choker Hitc h
multiply above values by 3/4
For Double Basket Hitch
multiply above values by 2
6/\d
3
(/Il
3 k)
NOTE : Table values are for slings with eyes and thimbles in both ends, Flemish Splice d
Eyes and mechanical sleeves .
Eyes formed by cable clips - reduce loads by 20% .
Safety
ISHRAE Installation Guide
247
Table 2
WIRE ROPE SLING S
6 x 19 Classification Group, Improved Plow Steel, Fibre Core
MAXIMUM SAFE WORKING LOADS - POUND S
(Safety Factor=5)
Rope
Di ame ter
(Inches)
3/ 6
'/,
S/1 6
3/6
7/1 6
'4
°/ 1 6
5/6
7/6
1
1 1 /6
1%
1 3/6
1 ' /2
. 1%
1 3/,
1%
2
2 1/2
2%
Single
V er ti ca l
Hitch
.600
1,10 0
1,650
2,400
3,20 0
4,400
5,300
6,600
9,50 0
12,80 0
16,70 0
21,20 0
26,20 0
32,40 0
38,40 0
45,200
52,00 0
60,80 0
67,600
84,000
104,000
122,000
Singl e
Ch oke r
Hitch
450
825
1,25 0
1,800
2,400
3,30 0
4,000
4,950
7,100
9,600
12,500
15,900
19,70 0
24,300
28,80 0
33,900
39,000
45,600
50,700
63,000
78,000
91,500
Single
Basket
Hitch
(Vertical
Legs )
\
2-Leg Bridle Hitch &
Sing l e Bas ket Hitch
With Legs Inclined
\
/S a
V
I
600
45°
300
1,20 0
2,20 0
3,300
4,80 0
6,40 0
8,800
10,600
13,200
19,00 0
25,600
33,400
42,40 0
52,40 0
64,80 0
76,800
90,40 0
104,000
121,600
135,200
168,000
208,000
244,000
1,050
1,900
2,850
4,150
5,550
7,600
9,20 0
11,40 0
16,50 0
22,200
28,900
36,70 0
45,40 0
56,10 0
66,500
78,300
90,000
105,300
117,100
145,500
180,100
211,300
850
1,15 0
2,350
3,400
4,500
6,200
7,500
9,350
13,40 0
18,10 0
23;600
30,00 0
37,00 0
45,80 0
54,30 0
63,900
73,500
86,000
95,60 0
118,800
147,000
172,500
600
1,100
1,65 0
2,400
3,20 0
4,400
5,300
6,60 0
9,500
12,800
16,700
21,200
26,200
32,400
38,40 0
45,200
52,000
60,800
67,600
84,000
104,000
122,000
II used with Choker Hitch multiply abov e
values by 3/,
For Double Basket Hitch multiply above
values by 2
2 48
Safety
ISHRAE Installation Guid e
•
When splicing side rails, the resultin g
side rail must be equivalent in strengt h
to a one-piece side rail made of the sam e
material .
•
Two or more separate ladders used t o
reach an elevated work area must b e
offset with a platform or landing betwee n
the ladders, except when portable ladders
are used to gain access to fixed ladders .
•
Ladder components must be surfaced t o
prevent injury from punctures o r
lacerations .
•
Wood ladders must not be coated wit h
any opaque covering, except fo r
identification or warning labels whic h
may be placed only on one face of a side
rail.
LADDER SAFETY
Several fatal and serious accidents are cause d
by fall of persons engaged in jobs, whil e
working at height if using ladder. The ladde r
accidents occur due to careless or imprope r
ladder usage .
The following general requirements apply t o
all ladders, including job-made ladders for saf e
work:
•
Ladder rungs, cleats, and steps must b e
parallel, level, and uniformly space d
when the ladder is in position for use .
•
Rungs, cleats, and steps of portable an d
fixed ladders must not be spaced les s
than 10 inches (25 cm) apart, nor mor e
than 14 inches (36 cm) apart, along th e
ladder's side rails .
•
Rungs, cleats, and steps of step stool s
must not be less than 8 inches (20 cm )
apart, nor more than 12 inches (31 cm )
apart, between center lines of the rungs ,
cleats, and steps .
•
Rungs, cleats, and steps at the bas e
section of extension trestle ladders mus t
not be less than 8 inches (20 cm) no r
more than 18 inches (46 cm) apart ,
between center lines of the rungs, cleats ,
and steps . Therung spacing on th e
extension section must not be less tha n
6 inches (15 cm) nor more than 12 inches
(31 cm )
•
Ladders must not be tied or fastene d
together to create longer sections unles s
they are specifically designed for suc h
use.
•
A metal spreader or locking device mus t
be provided on each stepladder to hol d
the front and back sections in an ope n
position when the ladder is being used .
Portable Ladder s
•
Non-self-supporting and self-supportin g
portable ladders must support at leas t
four times the maximum intended load ;
extra heavy-duty type 1A metal or plasti c
ladders must sustain 3 .3 times th e
maximum intended load . The ability o f
a self-supporting ladder to sustain load s
must be determined by applying the load
to the ladder in a downward vertica l
direction . The ability of a non-selfsupporting ladder to sustain loads mus t
be determined by applying the load in a
downward vertical direction when th e
ladder is placed at a horizontal angle o f
75.5 degrees .
•
The minimum clear distance betwee n
side rails for all portable ladders mus t
be 11 .5 inches (29 cm) .
•
The rungs and steps of portable meta l
ladders must be corrugated, coated wit h
skid-resistant material, or treated t o
minimize slipping .
ISHRAE Installation Guide
Safety
24 9
•
The step-across distance between th e
center of the steps or rungs of fixe d
ladders and the nearest edge of a landin g
area must be-no less than 7 inches (1 8
cm) and no more than 12 inches (30 cm) .
A landing platform must be provided i f
the step- across distance exceeds 1 2
inches (30 cm) .
•
Fixed ladders without cages or wells mus t
have at least a 15- inch (38 cm) clea r
width to the nearest permanent objec t
on each side of the centerline of th e
ladder.
•
Fixed ladders must be provided wit h
cages, wells, ladder safety devices, o r
self-retracting lifelines where the length
of climb is less thah 24 feet (7 .3 m) bu t
the top of the ladder is at a distance
greater than 24 feet (7 .3 m) above lowe r
levels.
•
If the total length of a climb on a fixed _
ladder equals ,or exceeds 24 feet
(7.3 m), the following requirements mus t
be met : fixed ladders must be equippe d
with either (a) ladder safety devices ; (b)
self-retracting lifelines, and res t
platforms at intervals not to exceed 15 0
feet (45 .7 m) ; or (c) a cage or well, an d
multiple ladder sections, each ladde r
section not to exceed 50 fee t
(15 .2 m) in length . These ladder section s
must be offset from adjacent sections ,
and landing platforms must be provide d
at maximum intervals of 50 fee t
(15 .2 m) .
•
Steps or rungs for through-fixed-ladde r
extensions must be omitted from th e
extension ; and the extension of side rails
must be flared to provide between 2 4
inches (61 cm) and 30 inches (76 cm )
clearance between side rails .
Fixed Ladder s
•
•
•
Individual rung/step ladders must exten d
at least 42 inches (1 .1 m) above a n
access level or landing platform eithe r
by the continuation of the rung spacin g
as horizontal :grab bars or by providin g
vertical grab bars that must have th e
same lateral spacing as the vertical leg s
of the ladder rails.
Each step or rung of a fixed ladder mus t
be capable of Supporting a load of at leas t
114 kg applied in the middle of the ste p
or rung . Fixed ladders also must suppor t
added anticipated loads caused by ,
winds, rigging, and impact load s
resulting from the use of ladder safet y
devices .
The minimum clear distance between th e
sides of individual rung/step ladders an d
between the side rails of other fixe d
ladders must be 16 inches (41 cm) .
•
The rungs of individual rung/step ladders
must be shaped to prevent slipping of f
the end of the rungs .
•
The minimum perpendicular clearanc e
between fixed ladder rungs, cleats, an d
steps, and any obstruction behind th e
ladder must be 7 inches (18 cm), excep t
that the clearance for an elevator pi t
ladder must be 43 inches (11 cm) .
•
The minimum perpendicular clearanc e
between the centerline of fixed ladde r
rungs, cleats, and steps, and an y
obstruction on the climbing side of th e
ladder must be 30 inches (76 cm) . If
obstructions are unavoidable, clearanc e
may be reduced to 24 inches (61 cm) ,
provided a deflection device is installe d
to guide workers around the obstruction .
250
•
Safety
When safety devices are provided, th e
maximum clearance between side rai l
extensions must not exceed 36 inche s
(91 cm) .
ISHRAE Installation Guid e
made for access to the platform or othe r
point of access .
Wells for Fixed Ladder s
Cages for Fixed Ladder s
•
Wells must completely encircle the [adder .
•
•
Welts must be free of projections .
•
The inside face of the well on th e
climbing side of the ladder must exten d
between 27 inches (68 cm) and 30 inche s
(76 cm) from the centerline of the ste p
or rung .
•
The inside width of the well must be a t
least 30 inches (76 cm) .
•
The bottom of the well above the poin t
of access to the bottom of the ladde r
must be between 7 feet (2 .1 m) and 8
feet (2 .4 m) .
•
•
Horizontal bands must be fastened to th e
side rails of rail ladders, or directly to
the structure, building, or equipment fo r
individual- rung ladders .
Vertical bars must be on the inside o f
the horizontal bands and must b e
fastened to them .
Cages must not extend less than 2 7
inches (68 cm), or more than 30 inche s
(76 cm) from the centerline of the ste p
or rung, and must not be less than 2 7
inches (68 cm) wide.
•
The inside of the cage must be clear o f
projections .
•
Horizontal bands must be spaced a t
intervals not more than 4 feet (1 .2 m )
apart measured from centerline t o
centerline .
•
Vertical bars must be spaced at interval s
not more than 9 .5 inches (24 cm) apar t
measured from centerline to centerline .
•
The bottom of the cage must be betwee n
7 feet (2 .1 m) and 8 feet (2 .4 m) abov e
the point of access to the bottom of th e
ladder. The bottom of the cage must b e
flared not less than 4 inches (10 cm )
between the bottom horizontal band an d
the next higher band .
•
The top of the cage must be a minimu m
of 42 inches (1 .1 m) above the top of
the platform, or the point of access a t
the top of the ladder. Provisions must be
Use of all Ladders (Including Jo b
made Ladders )
•
Ladders must be maintained free of oil ,
grease, and other slipping hazards .
•
Ladders must not be loaded beyond th e
maximum intended load for which the y
were built nor beyond thei r
manufacturer's rated capacity.
•
Ladders must be used only for th e
purpose for which they were designed .
•
Non-self-supporting ladders must b e
used at an angle where the horizonta l
distance from the top support to the foo t
of the ladder is approximately onequarter of the -working length of th e
ladder. Wood job-made ladders wit h
spliced side rails must be used at a n
angle where the horizontal distance i s
one-eighth the working length of th e
ladder.
ISHRAE Installation Guide
Safety
•
Ladders must be used only on stable an d
level surfaces unless secured to prevent
accidental movement.
•
Ladders placed in areas such as passageways, doorways, or driveways, or where
they can be displaced by workplac e
activities or traffic must be secured t o
prevent accidental movement, or a
barricade must be used to keep traffi c
or activities away from the ladder.
•
•
•
Ladders must not be moved, shifted, o r
extended while in use.
Ladders must have nonconductiv e
siderails if they are used where th e
worker or the ladder could contac t
exposed energized electrical equipment .
Cross-bracing on the rear section o f
stepladders must not be used for climbing
unless the ladders are designed an d
provided with steps for climbing on bot h
front and rear sections .
•
Single-rail ladders must not be used .
•
Do not use a ladder as a horizonta l
platform, plank, scaffold or materia l
hoist .
•
•
Always face the ladder when climbing u p
or down and use both hands and maintai n
a secure grip on the rails or rungs.
Never carry heavy or bulky loads up a
ladder. Climb up first and then pull u p
the material with a rope .
•
Climb and stand on a ladder with you r
feet in the centre of the steps or rungs .
•
Do not overreach from a ladder or lean
too far to one side .
Never climb onto a ladder from the side ,
from above the to p
NINE POINT ELECTRICAL SAFET Y
PROGRAMM E
Electricity- it is safe, don't misus e
it
•
Electricity makes life easy an d
convenient for us . We have it literally at
our fingertips- to do our bidding at th e
mere flick of a switch .
•
But it also needs careful handling . If not
treated with respect it can result i n
shocks, fires and other disasters .
•
As the standard of living improves an d
modern appliances become mor e
affordable, the misuse of electricity als o
increases .
•
One or other type of electrical equipmen t
is available in every kitchen . And all of
these can cause accidents if not operate d
or maintained with care . Most of the m
have built in safety devices but they can' t
be termed foolproof or fail-safe .
•
A normal household, invariably, use s
appliances and electrical gadgets muc h
more in number and load than what wa s
envisaged at the time wiring was initially
done for the house .
•
Domestic current in our homes can caus e
serious injury and even death .
Ladder Climbing and Standin g
•
25 1
Water + Electricity = Disaste r
•
Electricity always seeks the easiest pat h
to the ground . It tries to find a conductor,
such as metal, wet wood, water-or eve n
our body. Remember 70 percent of our
body is water.
Safety
252
•
Water and electricity do not go togethe r
so avoid wet hands at all costs while
operating any electrical appliance .
•
Do not work in a damp or moist area an d
not store all electrical appliances in a
damp area. In case your appliance give s
a shock, do not use it until the fault ha s
been rectified .
•
If you touch an energised bare wire o r
faulty appliance while you are grounded ,
electricity will instantly pass through t o
the ground causing a harmful or fata l
shock .
Fuse is for your safety-don' t
tamper with it
•
The position of the electrical cutouts an d
fuse boxes should be easily approachable
in an emergency. It should not be locked .
•
It is a good idea to have separate main s
for each room so that you don't have to
rush to the main fuse box in a n
emergency.
•
•
•
It is advisable to have all the fuses an d
circuit breakers in the main fuse bo x
labeled so that identification is easy i n
times of need .
Electrical switches, which becom e
damaged due to wear and tear, shoul d
be replaced with a switch of proper ratin g
and at the earliest .
For personal safety it is advisable t o
install Earth Leakage Circuit Breake r
(ELCB) in the domestic circuits i n
addition to MCBs and fuse cutouts .
Avoid extension cord s
•
As far as possible avoid the use o f
extension cords and in case you use one,
ISHRAE Installation Guid e
it should be of optimum capacity. Do not
use it permanently.
•
Extension cord should not be left danglin g
or trailing on the floor . It can b e
hazardous for the very young and ver y
old and those with failing eyesight .
Trailing cords can cause people to tri p
and fall .
•
Remember not to let the cord lie ove r
wet or hot surfaces or concealed unde r
carpets and mats . This can damage thei r
insulation, which in turn can lead to short
circuits and electrical shocks .
Don't be a 'Do-it-yourself' perso n
•
Use any electrical appliance with du e
care, especially if it is a newly acquired
one . Consult the instruction manual fo r
correct operation and maintenance o f
the appliance .
•
Each time you use an appliance ,
remember to switch off and remove th e
cord from the socket .
•
However, in case you do it yourself, us e
tools that have insulated handles an d
casings.
Do you know how to handle a n
electrical emergency
•
Break the contact by switching off th e
current, preferably at the mains or b y
removing the plug or pulling the cabl e
free.
If you are unable to reach th e
cable, socket or 'mains :
•
Stand on dry, insulating material (eg.
wooden box, phone book, rubber mat ,
thick pile of newspapers) .
ISHRAE Installation Guide
•
•
Safety
Use something like a broom or wooden • Place the casualty in the recovery positio n
chair (not metallic) to push the casualty's
and dial for an ambulance .
limbs away from the electricity source .
• Cool any burns with lots of cold water .
As a last resort pull at the casualty' s
Casualty is consciou s
loose, dry clothing, but do not touch their
flesh .
•
Cool any burns with lots of cold water.
Once the contact is broken and
the victim is unconscious :
•
25 3
Check breathing and pulse and carry ou t
resuscitation if necessary.
• Consult a Doctor.
25 4
Safety
ISHRAE Installation Guid e
COMPARISON BETWEEN TEMPORARY AND s PERMANENT
ELECTRICAL INSTALLATION S
Yeiii6 ary lnstallatitms
.
Permanent Installatio n
Infra structure required to house supply
equipment more of temporary nature bu t
safe enough to withstand environmenta l
conditions for the duration required .
Infrastructure required to house suppl y
equipment more of a permanent natur e
like RCC construction, and permanen t
enclosures for outdoor equipmen t
capable of withstanding environmenta l
conditions permanently.
Installation to adhere to rules o f
temporary installation .
Installations must adhere to IE Rules ,
Indian Electricity Act, Codes of practices .
Installation generally permitted for th e
temporary period after which du e
extensions must be sought and approved .
Annual inspection by the electrica l
inspectorate, after Commissioning, on a
regular basis .
Cable laying need not be on trays o r
underground . They could be clampe d
safely to existing walls or on poles
Cable laying either underground o r
structurally safe cable trays .
Distribution boards can be mounted safel y
on wooden boards or structures bu t
adopting odes for temporary installations .
Distribution is based on a properl y
planned load balance and at convenien t
and safe locations accessible to regula r
maintenance .
Need not have elaborate wiring diagram s
and cable routes marked with the positio n
of distribution boards marked etc .
Preparation of single line diagram showin g
distribution of power and layout drawin g
showing cable routes a position o f
distribution boxes Et switch boards is a
must for trouble shooting durin g
maintenance and keeping record of loa d
additions with updated drawings .
The Supply co . usuallyarranges supply at
medium or low voltage unless the powe r
requirement is very large .
Permanent installations generally receive
supply from the Supply Co . at Hig h
Voltage stepped down by the user at th e
substation .
ISHRAE Installation Guide
Safety
25 5
CHECKLIST ON PORTABLE POWER TOOLS
The checklist is meant to serve as a tool t o
improve the working Fonditions of the workers
in various industries and thereby to reduc e
the number of accident s
Points to remember whil e
selecting tools :
•
•
The right tool is used for the job ; tool s
are used within their design limitations .
Tools are used only for their intende d
purpose .
•
Tools are well-balanced .
•
Tools fit the hand comfortably.
•
Tools are not so heavy that they strai n
the arm and shoulder.
Work Practices
•
Workers use only tools with which they
have experience, or on which they have
been trained .
•
Tools are used only on secure and stabl e
work surfaces . Work is secured with a
vise or clamps if necessary.
•
While using tools stand on a clean, dry
surface to prevent slipping .
•
Air hoses and electric cables used i n
elevated locations are securely fastened
to a substantial anchorage at or near the
working level. They are fastened no more
than 15 feet from the working end .
Electrical Tools
•
Tool handles are designed to minimiz e
the grip force needed .
•
All electrical tools are grounded or doubl e
insulated .
•
Handles have soft grips that don't cut
hand .
•
Earth returns are not used for grounding .
•
Every receptacle is grounded .
•
Electrical cords are protected fro m
damage by vehicles, etc .
•
Electrical cords are regularly checked fo r
fraying .
•
Electrical tools are not used in wet areas ,
or in areas where flammable vapors ma y
be present, unless specifically designe d
for that purpose .
Chucks, collars, and other tool holdin g
parts are in good operating condition .
•
Electrical tools are not hoisted or lowere d
by their cords .
Damaged, defective, or worn tools ar e
tagged and removed from service unti l
repaired .
Pneumatic Tool s
Inspectio n
•
•
•
•
Tools are inspected daily before use an d
are kept clean and in good condition .
Blades, bits, and other cutting parts are
inspected prior to each use, are kep t
sharp, and are replaced if worn o r
cracked .
•
Air hose connections are checked t o
make sure they are secured properly .
•
Compressed air over 10 psi is never use d
to blow dirt, chips, or dust from clothin g
which it is being worn .
•
All pneumatic impact tools have safet y
dips or retainers so dies and tools won' t
be accidentally expelled from barrel .
•
Pneumatic nailers and staplers operating
at more than 100 pounds per square inc h
(psi) have a safety device to preven t
operation when the muzzle is not i n
contact with the surface .
•
•
•
•
•
ISHRAF. Installation Guid e
Safety
25 6
Pneumatic nailers and staplers are
disconnected at the tool from the air
supply when not in use .
Hoses over Y2" inside diameter hav e
safety devices at supply source, o r
branch lines to reduce pressure in case
of hose failure .
Operators using pneumatically drive n
nailers and staplers on steep roofs (1/ 3
pitch or greater) always wear a securely
fastened safety belt and lanyard .
Circular Saws
o The upper half of the saw blade i s
permanently guarded .
o
The lower half of the saw blade i s
guarded with a telescopic or hinged
guard .
•
Guards are not blocked open to preven t
functioning .
Grinders and Abrasive Wheel s
•
Excessively worn grinding disks ar e
discarded and replaced .
•
Abrasive wheels have hoods or guard s
to protect workers from flying fragment s
of a bursting wheel .
•
There are guards on spindle end and o n
nut and flange projections . They ar e
mounted to maintain proper alignmen t
with the wheel . The strength of th e
fastenings exceeds the strength of th e
guard .
•
Wheels are inspected before mounting ,
and the spindle speed is checked to mak e
sure that it doesn't exceed the ratin g
marked on the wheel .
•
Wheels fit freely on spindles under al l
grinding conditions .
•
All contact surfaces of wheels, blotters ,
and flanges are flat and free of foreig n
matter.
•
If there is a bushing in the wheel hole, i t
doesn't exceed the width of the wheel ,
and it doesn't contact the flanges
On roofs of 1/4 pitch or greater, the ai r
hose for a pneumatic nailer or stapler i s
secured at roof level to provide ample ,
but not excessive, amounts of hose.
Pneumatic tools are not hoisted o r
lowered by their hoses .
•
On portable compressors :
•
Wheels are fixed, locked, or blocked t o
prevent rolling .
•
Fans are guarded with a shroud or sid e
screens .
•
Air tanks are drained of liquid accordin g
to the manufacturer's specifications .
ISHRAE Installation Guide
Safety
257
MARK CRITERIA FOR FIRE EXTINGUISHER S
The criteria for labeling of Fire Extinguishers
as Environment friendly has been notified b y
the Ministry of Environment and Forests ,
Govt. of India vide GSR No . 237(E) dt . 1s t
April, 1999 .
1.
General Requirement s
i.
Any fire extinguisher having BIS standard
mark qualifies for consideration o f
Ecomark . Following are the BIS Standard s
for portable and mobile fire
extinguishers :
IS 940 :1989 Portable Fire Extinguisher s
Water Type (Gas Cartridge )
IS 13849 :1993 Portable Fir e
Extinguishers Dry Powder Type (Constan t
Pressure )
ii .
The product manufacturer must apply to
Bureau of Indian . Standards for th e
Ecomark .
Hi . The product manufacturer must have the
consent clearance / authorisation as pe r
provisions of Environment (Protection )
Act, 1986, the rules framed thereunde r
and other Acts related to prevention an d
control of pollution of water and air.
iv.
The product may display in brief th e
criteria based on which the product ha s
been awarded Ecomark .
v.
The product may be sold along wit h
instructions for proper use so as to
maximize product performance wit h
statutory warning, if any, to minimiz e
waste and method of safe disposal .
vi.
The material used for product packagin g
(excluding refills) shall be recyclable ,
reusable or bio-degradable .
IS 10658 :1983 Higher Capacity Dr y
Powder Fire Extinguishers (TrollyMounted )
vii.
The product must display a list of critica l
ingredients present in percent by weight .
2.
Product Specific Requirement s
IS 11833 :1986 Dry Powder Fir e
Extinguishers for Metal Fires
i.
The fire extinguishers should not contai n
any Ozone Depleting Substance (ODS )
relevent to Fire Extinguishers Industr y
as identified under the Montreal Protocol .
ii.
Gas-based extinguishing media onc e
discharged in the atmosphere should no t
have atmospheric life time of more tha n
a year.
IS 2171 :1985 Portable Fire Extinguishers
Dry Powder Type (Cartridge )
IS 2878 : 1986 Fire Extinguishers Carbo n
Dioxide Type (Portable and Trolly Mounted )
IS 6234: 1986 Portable Fire Extinguisher s
Water Type (Stored Pressure )
IS
10204 :1982
Portable
Fir e
Extinguishers Mechanical Foam Typ e
IS 13385 :1992 Specifications for Fir e
Extinguishers 50 litre Wheel-Mounte d
Water type (Gas Cartridge )
IS 13886 :1992 Specifications for Fir e
Extinguishers 50 litre Mechanical Foa m
Type
25 8
Safety
iii.
Chemical used should not have globa l
warming potential .
iv.
The metallic body and other metal part s
of the fire extinguishers shall be free o f
load or lead alloys .
v.
The coating used for the metallic par t
shall not be formulated with mercury an d
mercury compounds or be tinted wit h
pigments of lead, cadmium, chromiu m
VI and their oxides . Excluded are natura l
impurities or impurities entailed by th e
reduction process up to the amount o f
0 .1 percent by weight which ar e
contained in the raw material .
Note: CO2 extinguishers may b e
permitted till suitable substitutes ar e
available .
Frequency of fire outbreak and loss suffere d
as a result, could be considerably reduced i f
proper attention is paid to following saf e
practices : Storag e
•
Ascertain beforehand fire hazards of th e
materials you store . Assume the material
to be hazardous if complete informatio n
is not available .
•
Store the materials susceptible to wate r
damage, on skids pallets and suc h
elevated platforms of at least2O c m
above the ground . Prefer noncombustible material for such platforms .
•
Ensure that safe floor load limits give n
in IS : 875 : 1964 are not exceeded .
•
Ensure adequate ventilation wher e
flammables are stored, handled or used .
•
Don't allow even temporary storage o f
goods if it obstructs access to godow n
doors, aisles, fire exits, and fir e
equipment .
•
Store incompatible chemicals separately.
•
Keep flammable materials away fro m
ignition sources .
•
Use self-closing containers fo r
flammables/spontaneously combustibl e
materials and vent containers of volatile
flammable solvents .
FIRE SAFETY IN stores
Fire in godowns account for a major chunk of
total number of outbreaks in industria l
occupancies and almost invariably assum e
serious proportions resulting into not only
colossal but also damage to surroundin g
environment and community.
ISHRAE Installation Guid e
Principal Causes
•
Surreptitious smokin g
•
Spontaneous ignitio n
•
Use of naked flames or cooking
•
Faulty electrical installation s
Segregatio n
•
Storage of incompatible hazardous good s
•
•
Carrying out dangerous operations suc h
as welding, cutting, spray painting, etc .
in godowns or adjacent building s
Segregate the materials as hazardous ,
extra-hazardous and non-hazardous a s
per IS-1641 : 1960 and store them i n
separate areas .
e
Store the materials, which emit a large
ISHRAE Installation Guide
Safety
amount of smoke and/or noxious gases ,
in separate well- ventilated godowns .
•
•
Use detached buildings segregated fro m
all other storages by separating walls t o
store gas cylinders which are liable t o
explode when exposed to fire.
Don't store contaminating commoditie s
such as poisons, dyes, tanning extracts ,
gums and soda ash along with or on floo r
above foodstuff storage.
Stackin g
•
Give due regard to the characteristics
of the materials when you stack them .
•
Maintain safe and stable stackin g
heights.
•
Stack such that internal spread of fire i s
minimized and materials are easil y
accessible for fire fighting .
•
Ensure that stacks are not more than 4 . 5
m in height and a gap of at least 1 .0 m
is maintained between the top of th e
stack and the ceiling, beam etc ., or
sprinkler heads .
systematic removal of weeds, from th e
compound .
•
Keep storage areas dry, clean and wel l
ventilated.
•
Ensure high housekeeping standards an d
avoid spillages . Promptly eliminate oil /
gas leaks and clean spillage o f
flammables . Keep clean-up equipment fo r
spills handy.
•
Inspect thoroughly god own premise s
before it is closed .
Handlin g
•
Ensure label on every chemical container.
Don't use or handle unlabelled containe r
but report them . Follow the instruction s
on the label and in the Material Safet y
Data Sheet .
•
Follow approved procedures for materia l
handling, goods movement and loading /
unloading.
•
Ensure electrical grounding and bondin g
of the containers labelled FLAMMABL E
before pouring, dispensing o r
transferring any liquid from them .
•
Strictly follow work permit instruction s
when welding, cutting and other such hot
work are undertaken in areas where
flammables are present.
•
Don't drag containers labelle d
FLAMMABLE. Handle them with care an d
use appropriate trolleys .
•
Use rubber cradle while transportin g
unpackaged glass bottles of chemicals .
Housekeepin g
•
25 9
Equipment and appliance s
•
Use certified flameproof forklift trucks
where highly flammable goods are store d
or handled .
•
Never fill or empty fuel tanks of petrol /
diesel -powered mobile material handlin g
equipment .
•
Ensure that induction system of all petro l
motors is provided with flame arrestor.
Ensure that all godowns and compounds
are swept clean everyday. Also ensure
2 60
•
•
Safety
Ensure that fuel-operated materia l
handling equipment carry suitable types
of fire extinguishers .
ISHRAE Installation Guid e
•
Don't smoke in places other tha n
permitted zones .
•
Keep fire check doors shut when not
needed and after the end of the day' s
work.
•
Don't drain out flammable chemical ,
spillages with water. Collect them b y
using absorbent material for saf e
disposal .
•
Avoid re-use of empty chemica l
containers . Thoroughly empty, rinse ,
decontaminate, puncture and crush the m
before disposa l
Prefer non-flammable refrigerants fo r
refrigeration systems .
Electrical installation s
s
Don't overload electrical circuits . .Avoid
temporary connections .
•
Locate all switches and control equipmen t
outside the godowns storing fibrou s
goods, flammables liquids, nitrocellulose
and fireworks or explosives . Don't us e
flexible lighting pendants and portabl e
lamps but ensure use of flameproo f
fittings in such situations .
Handling Emergencie s
•
Always be prepared for emergencies .
•
See that no light fitting has a clearance
of less than 75'cm from the highes t
stacking level .
•
Know and understand precautions and
procedures in case of spillage/leakage
and fire .
•
Keep electrical fuse and switch boxe s
clean and closed .
•
Keep emergency telephone numbers
handy
•
Never carry out electrical repairs on you r
own . Call authorised electrician .
•
Know locations of fire exits and kee p
them clear.
•
Ensure that fire equipment in workin g
condition and accessible .
•
Know how to use fire extinguishers .
•
Conduct fire emergency drills at regula r
intervals
Other Measures
•
Don't allow use of naked flames, welding ,
cutting and spray painting operation s
except in detached buildings specifically
set apart for such purposes .
Section 7
CONVERSIONS AND TABLES -
p a plo.e aq of Allwaua 0
011e s,-01 = 100 000 000 000 000 000' 0
olwal
si-OI = 100 000 000 000 000 0
oald
1 , .OI = 100 000 000 000 0
oueu
6 .01 = 100 000 000' 0
on l w
9 .01 = 100 000' 0
I111W 1.0L=100' 0
Ilua°
9 .01 - 10'0
.pap
=t o
.eyap
1 01=0 1
.o1a4
601 -00 I
OIP1
601 - 000 l
w
ebaw
9 01 = 000 000 1
e515
9
601 = 000 000 000 I
sal
1
1 ,01 = 000 000 000 000 1
d
egad s101 - 000 000 000 000 000
3
exa
9 ,01 = 000 000 000 000 000 000
logwAS xllald
ape) uo p ealldPln W
sexllaid IS 4 a l g el
e
/
d
u
d
w
a
P
up
4
slaw lad I
w/1
ale. sign s
w
s/ 9w
pumasaad aalaw alenbs
s.ed
pumas-lease d
[/ w
pumas ad slaw
up4ayJalaw lad IIEM
IN•wl/ M
lalaw ad uolmo u
wIN
fi I/rw
wwfioN, aad 1asaw alg m
u!Apy .wweolly ad atrial
(N•Sxl/f
Dien! oily ad aloof
6x/ r
(N•Syl/ f
uplay-ww6opx aad alno f
aqM
uelpelass Jad Item
ps. lw)/M uelpelals-alaw-annbs ad IIeM
w/d
aalaw aad pun ;
aaaw aad Aua y
w/N
aalaw-uulma u
uFAlax . alow aad aloo f
uIAlay . alow ad vino (
Wow ad alno l
aalaw aad aaadw e
aalaw wenbsnd elapue ,
•
•
s/pw
l s/ea
i s/w
IogWAs
lagwnu ann.
wn) . A
apewaupl Alnoasi A
alweuRp'Atlsmsl n
Mini m
AIIANSn p um lewaw
uopual aaepns
0wnl'A wlpads
Adana 3upads
Mlnua 'goads
Alped os 1ea4-allpad s
Wan' sueip w
aduelp w
AllApawaa d
A1111geawa d
aan) to wawa .
Alpedea lea4Jelo w
Manua mow
A6auaJwow
41Suans pl°Uopaufiew
aauewwn l
ane l pen i
lalaw aJenbs
Item
uap
lls xnllgea y
wins' ad aloo f
Alpedm wa y
wispy lad alno l
Adonu a
mow sign ad alno l
Allsuup Asaau a
lalaw alenbs ,ad gwoln m
Allsuap xmi . ap pal a
,aaw ad 11 .A
416uane ppi) . 3paaIa
slaw 'ma lad gwolno a Alsuap abaeW-a!Pal a
nalaw algna aad wEISg0y
w 'lsu.P
,alas annbs lad wadw e
Alsuap Vienn a
Imue l sgns to
lalaw alga aad slow snow . Jo) uollenuan m
Japw ants .
tan
pumas laduelpw
ppolan aelnbue
palenbs puo,as aduelpw
uollenalaae aeln5ue
pannbs pumas aad aa l aw
uapeaalaaa¢
Nun
Alpuenb
IS )o s wop paApeQ 4OWIO9 I euo nlpp tl E amen
£9Z
pasn AlamM
pu paidaDDe avo w
Apeuopeuaalu L
we smun I s
p
fi x ?
s/ I
ew/wl
ni ps
tl/qM
lw/qm
A
A/V
V/A
An
•
•
Au
Rw e
b0 la,anbaa q
xnl
xl
w1
wnl
Auay
H
ellsal
1
lagaM
qM
suowals
S
wyo
IJ
pww
asap pa glasg e
(sapipnuopeJ p) ANIS E
aaueulwnp l
xnll sneulwn l
n I npu l
Alsuap xnl)opaufie w
xn0o0aufi¢ w
muvnnpu m
muelsIsal Jppap
aauwpvay s
aalol aglowonaala
A
11Wanwalllp lellnalod 1 p'lualod Dwai n
J gwolnm aSleya apnala •g Plapala )a Apuen b
a n ti luelpw bama d
M
11PM
levy Jo Alpuenb 'yaoM •ASaau a
alnol
r
Imsed
ssans 'aanssaa d
ea
N ummau vol
aH navy (uouawouayd alpopad e )o) Aauanba q
Alpuenb
saumN I .14ads aneH 4PI4M IS to Mull PeA p ea Z eI g m_
wnwmj
locuMs
nun
. sappaed sans to sdnoafi
pallpads no 'saplped Jaya 'suoaaala 'suol 'salmalow • wore eq Ae w
Aayl :pal/pads eq lsnw sapllua Aaeluawala ayl 'pass sl alow alp uay M
is
pea
•
•
IogwAS Hun is
alSua PIIO s
uelpwals
uewui
al6ue auel d
_eopuawlp . ao Alpuenb Aleluawalddn s
elapuea
Allsualul snoulwnl
slow
asuewgns to lunow e
un0ay aingwadwal alweuApowiay l
aaadwe lua,ana apnala
pumas
aw l)
wei5ol l y
sse w
4)Sua l
blew
uolsuawl p, ao Alpuenb aseg
Hun IS
poisuawip i Jo Milano
shun pue sappuvnb Aaeluawalddns pue aseg is 1 en vy
apinA* uopepeasul 3V1l {SI
1
264
ISHRAE Installation Guid e
Table 5 Conversion Factors : U.S. Customary and Commonly Used Units to SI Unit s
Quantity
Customary or commonl y
used unit
SI unit
Alternate
SI
unit
Corversion factor ; multiply
customary unit by factor to
obtain SI uni t
Space . U time
Length
naut mi
mi
chain
link
fathom
yd
11
in
in
mil
km
km
m
m
m
m
m
cm
mm
cm
µm
1 .852'
E + 00
1 .609344' E+0 0
2 .011 88' E+0 1
2 .011 68' E-0 1
1 .8288'
E + 00
9 .144'
E-0 1
3 .048'
E-0 1
3 .048'
E + 01
2 .54'
E + 01
2 .54
E+00
2 .54'
E + 01
Area
mi a
section
acre
ha
yd a
Itz
in 2
km 2
ha
ha
ma
ma
m2
mm 2
cm z
2 .589 988 E + 00
2 .589 988 E + 02
4 .046 856 E-0 1
1 .000 000' E+0 4
8361 274 E-0 1
9 .290 304' E-0 2
6451 6'
E + 02
6 .451 6'
E + 00
Volume
cubem
acre ll
km 3
ma
ham
m3
ma
ma
dm a
ma
dm 3
m3
dm 3
dma
dm a
dm 3
cm a
cm a
cm 3
4 .168 182
1 .233 482
1 .233 482
7 .645 549
1 .589 873
2 .831 605
2 .831 685
4 .546 092
4 .546 092
3 .785 412
3 .785412
1 .136 523
9 .463 529
4 .731 765
2 .841 307
2 .957 353
1 .638 706
yd3
bbl (42 U .S . gal)
113
U .K . gal
U .S . gal
U .K .qt
U .S .qt
U .S .pt
U .K . II oz
U .S . II oz
in 3
Plane angle
Solid angle
Time
rad
siege)
min(')
sec(')
Sr
year
week
h
min
mµs
Mass
U .K . ton
U .S . ton
U .K. owl
U .S . cwt
Ibm
oz (Troy)
oz (av)
gr
L
L
L
L
L
L
1
1 .745 329
2 .90B 882
4 .848 137
1
1
7 .0'
3 .6'
6 .0'
6 .0'
1 .666 667
1
rad
rad
rad
rad
Sr
a
d
5
min
s
h
ns
Mass amount of substance
Mg
Mg
kg
kg
kg
g
g
mg
1
I
-
1 .016 047
9 .071 847
5 .080 234
4 .535 924
4 .535 924
3 .110 348
2 .834 952
6 .479 891
E + 00
E + 03
E-0 1
E - 01
E-0 1
E - 02
E+0 1
E-0 3
E+00
E-0 3
E+00
E +00
E -0 1
E-0 1
E + 01
E + 01
E+0 1
E-0 2
E-0 4
E-0 6
E + 00
E+03
E + 01
E+0 1
E-0 2
E +0 0
E-0 1
E + 01
E+0 1
E-0 1
E+0 1
E + 01
E+01
ISHRAE Installation Guide
26 5
Table 5 Conversion Factors : U .S. Customary and Commonly Used Units to Si Units (Contd.)
Quantity
Customary or commonl y
used unit
SI unit
Alternate
SI
unit
Conversion factor ; multipl y
customary unit by factor to
- obtain SI uni t
Enthalpy, calolrific value, heat, entropy, heat capacity
Calorific value, enthalpy
(mass basis)
Calorific value, enthalpy
Clarlflc value (volume
basis - solids and liquids)
Btu/lbm
cal/g
cal/Ibm
kcal/(g•maq
Btu/(lb•mol)
Btu/U .S, gal
Btu/U .K . gal
Btu/ft 1
Calorific value (volume
basic gases)
Specific entropy
Specific-heat capacity (mass
basis)
cal/mL
(ft .lb/)/U .S, gal
cal/mL
kcal/m 1
Btu/it s
Btu (Ibm• °R
cal / (g • K)
kcal / (k g ' °C)
kWh (kg . °C)
Btu (Ibm•°F)
kcal (kg . °C)
MJ/kg
kJ/kg
kWh/kg
kJ/kg
J/kg
kJ/kmol
kJ/kmol
MJ/m s
kJ/m 1
kWh/m 1
MJ/m 1
kJ/m s
kWh/m 1
MJ/mJ
kJ/m 3
kWh/m 3
MJ/m 1
kJ/m r
kJ/m 1
kJ/m s
kJ/m 1
kWh/m
kJ/(kg • K)
kJ/(kg • K)
kJ/(kg ' K)
kJ/ (kg • K)
kJ/(kg • K)
kJ/(kg K)
J/g
J/g
kJ/dm 1
kJ/dm J
kJ/dmJ
J/dm 3
J/dm"
J/dm 1
J/(g• K)
J/(g• K)
J/(g' K)
J/(g' K)
J/( g ' K)
J/(g• K)
2 .326 000
2 .326 000
6 .461 112
4 .184•
9 .224 141
4 .184•
2 .326 000
2 .787 163
2 .787 163
7 .742 119
2 .320 800
2 .320 800
6 .446 667
3 .725 895
3 .725 895
1 .034 971
4 .184•
3 .581 692
4 .184•
4 .184•
3 .725 895
1 .034 971
4 .186 0•
4 .184•
4 .184•
4 .186 8•
4 .184•
E -0 3
E + 00
E - 04
E + 00
E + 00
E+03
E + 00
E-01
E +0 2
E-0 2
E-0 1
E + 02
E-0 2
E-02
E + 01
E-02
E+00
E - 01
E + 03
E + 00
E+0 1
E-0 2
E + 00
E + 00
E + 00
E + 03
E + 00
E + 00
Temperature, pressure, vaccu m
Temperataure (absolute)
Temperature (traditional)
Temperature (difference)
Pressure
°R
K
°F
°F
atm (760 mm Hg at
0°C or 14 .696 psi)
bar
mmHg (0°C) = torr
Vacuum, draft
pmHg (0°C)
pbar
mmHg = torr( %I
cmH r O(4°C)
Ibf/ft1 (psi)
mHg(°C)
bar
dyn/cm 1
inHg(60°F)
in H ie (39 .2°F)
in H 1O (60°F)
mm Hg (0°C) = torr
cmH tO(4°C)
K
N
°C
K,°C
MPa
kPa
bar
MPa
kPa
MPa
kPa
bar
kPa
kPa
kPa
kPa
kPa
Pa
Pa
Pa
kPa
kPa
kPa
kPa
kPa
5/ 9
1
5/9(°F-32 )
5/ 9
1 .013 250• E - 0 1
1 .013 250• E + 02
1 .013 2500 E + 00
1 .0•
E - 01
1 .0•
E + 02
6 .094 757 E - 0 3
6 .894 757 E + 0 0
6 .894 757 E - 02
3 .376 85
E + 00
E-0 1
2 .488 4
1 .333 224 E-0 1
E-0 2
9 .806 38
4 .788 026 E - 02
1 .333 224 E - 0 1
1 .0 .
E - 01
1 .0•'
E-0 1
-
3 .77685
2 .490 82
2 .488 4
1 .333 224
9 .80638
E+00 E - 01
E - 01
E - 01
E-02
266
ISHRAE Installation Guid e
Table 5 Conversion Factors : U .S. Customary and Commonly Used Units to SI Units (Contd.)
Quantity
Customary or commonl y
used unit
Liquid head
11
in
Pressure drop/length
psilll
SI unit
Alternat e
SI
unit
to
mm
cm
kPa/m
Conversion laclor ; multipl y
customary unit by [odor t o
obtain SI unit 3 .048'
2 .54'
2 .54'
2262059
E-0 1
E + 01
E + 00
E + 01
kg/m3
g/m3
kg/m3
g/cm3
kg/m s
kg/m a
g/cm o
kg/m 3
kg/ma
1 .601 846
1 .601 846
1 .198 264
1 .198264
9 .977 633
1 .601 846
1 .601 846
1 .0'
1 .601 846
E + 01
E+0 4
E+02
E-0 1
E + 01
E + 01
E-0 2
E + 03
E + 01
kg/kg
g/kg
mg/kg
1 .0'
1 .0'
1
E-0 2
E+0 1
2 .853 010
2 .641 720
2 .199 692
1 .198 264
9 .977 633
1 .711806
2 .288351
2 .853 010
2 .641 720
2 .288 351
1
1 .28B 931
1 .0'
1 .605 437
1 .336 806
2 .641 720
2 .199 692
E + 00
E-0 1
E- 0 1
E + 02
E + 01
E + 01
E+0 3
E + 00
E-0 1
E+0 1
Density, specific volume, concentration, dosag e
Density
Ibmlll 3
Ibm/U .S . gal
Ibm/U .K . gal
Ibm/It s
glan s
Ibm/IP
Concentration (mass/mass)
Concentration(mass/volume)
Concenlralion (volume/volume)
wt %
wt ppm
Ibm/bbl
g/LLS . gal
g/U .K . gal
Ibm/1000 U .S. gal
Ibm/1000 U .K . gal
gr/U .S . gal
gr/It s
Ibm/1000 bbl
mg/U .S . gal
gr/10003
113/11 3
bbl/(acre .tt)
vol%
U .K . gallll3
U.S . galll13
mUU.S . gal
mLIU.K. gal
vol ppm
U .K . gal/1000 bbl
U .S . gaV100 g bbl
U.K . pV1000 bbl
std 113 (60° F . 1 alm)/bbl
Energy, work
therm
U .S . lonl•mi
both
ch•h or CV•h
kWh
Chu
Btu
kg/m3
kg/m3
kg/mn
g/m3
glm 3
g/ms
mg/m 3
g/m3
g/ma
mg/m 3
m 3/m 3
m 3/m 3
m 3/m a
dm 3 /m3
dm3 /ma
tlm3/m 3
tlm3/m a
cm 3/m 3
dm3 /m3
cmo/m 3
cm3/m 3
cm3/m s
kmol/m 3
Energy, work, power
MJ
kJ
kWh
MJ
MJ
kJ
kWh
MJ
kJ
kWh
MJ
kJ
kJ
kWh
kJ
kWh
gldm 3
g/L
mgldm 3
mgldm 3
mg/dm 3
mg/tlm 3
mg/dm 3
Um 3
L/m 3
Lim a
Vm 3
Lima
E - 04
E-0 2
E+02
E + 02
E-0 1
E-0 1
1 .0'
E-0 3
2 .859 403 E+0 1
2 .380 952 E + 0 1
3 .574 253 E + 00
7 .518 21
E - 03
1 .055 056
1 .055056
2 .930 711
1 .401 744
2 .684 520
2 .664 520
7 .456 999
2 .647 78D
2 .647 780
7 .354 999
3 .6'
3 .6'
1 .899 101
5 .275 280
1 .055 056
2 .930 711
E + 02
E+0 5
E+0 1
E+0 1
E + 00
E + 03
E-0 1
E + 00
E + 03
E - 01
E + 00
E+0 3
E+0 0
E-04
E+0 0
E-04
1
ISHRAE Installation Guide
267
Table 5 Conversion Factors : U.S. Customary and Commonly Used Units to SI Units (Contd. )
Customary or commonl y
used unit
Quantity
SI unit
Alternate
SI
unit
Conversion factor ; multipl y
customary unit by factor t o
obtain SI uni t
kcal
cal
11•Ibl
Ibhll
J
(Ibl•II 2 )/e s
erg
kJ
kJ
kJ
kJ
kJ
kJ
J
kgl•m
IbWt
erg/cm'
J
J
mule
E+0 0
4 .184'
4 .184'
E-0 3
1 .355 818 E-03
1 .355 818 E-03
1 .0'
E-03
4 .214 011 E-05
1 .0'
E-07
9 .806 650' E + 0 0
1 .355 818 E + 0 0
1 .0'
E+0 0
million Bluth
ton of relrigeralion
Owls
kW
hydraulic horsepower-hhp
hp (electric)
hp [(550 It Ws]
ch or CV
Btu/min
(11•Ibf)/s
kcallh
Btu/h
(II•Ibf)/min
MW
kW
kW
kW
kW
kW
kW
kW
kW
kW
W
W
W
2 .930 711
3 .516 853
1 .055 056
1
7 .460 43
7 .46'
7 .456 999
7.354 999
1 .758 427
1 .355 818
1 .162 222
2 .930 711
2 .259 697
Bwl(s•II 3 )
cal/(h•cm 3 )
Blu/(hII 3)
hp/11 5
cal/(h•cm3 )
Btu/(M1 3)
Blu/(h•113 )
Blut(bhp•h)
kW/m 3
kW/m 5
kW/m 3
kW/m3
kW/m3
kWtm3
kW/m 3
W/kW
Specific fuel consumption
(mass basis)
Ibm/(hp•h)
Specific fuel consumption
(volume basis)
m3lkWh
U .S . gal/(hp•h)
U .K . pt/(hp•h)
mg/J
kg/kWh
dm3/MJ
dm3 /MJ
dm3 /MJ
0m 3/100 km
dm3/100 km
km/dm 3
km/dm 3
km/h
km/h
m/s
cm/s
m/s
mm/s
mm/s
m/d
mm/s
mm/s
Impact energy
Surface enerygy
Power
Power/area
Heat-release rare, mixing power
Cooling duly (machinery)
Fuel consumption
Velocity (linear), speed
-
U.K . gal/mi
U .S . gal/raj
ml/U .S . gal
m g U .K . gal
knot
mi/h
IUS
I gmin
ltlh
IUday
in/s
in/min
Corrosion rate
Rotational frequency
in/year (ipy)
mil/year
r/min
Acceleration (linear)
IVs'
mm/a
mm/a
r/s
rad/s
m/s3
cmts r
-
kg/MJ
mm 3/J
mm 3/J
mm 3/J
1./100 km
L/100 km
km/L
km/L
E - 01
E + 00
E + 00
E-0 1
E - 01
E-0 1
E-0 1
E-0 2
E - 03
E+0 0
E-0 1
E-0 2
1 .135 653 E+0 1
1 .162 222 E-02
3 .154 591 E-03
2 .633 414 E + 0 1
1 .162 222 E + 0 0
3 .725 895 E + 0 1
1 .034 971 E -0 2
3.930 148 E-0 1
1 .689 659 E -0 1
6 .082 774 E - 0 1
2 .777 77B E+0 2
1 .410 089 E+0 0
2 .116 806 E-0 1
2 .824 807 E + 0 2
2 .352 146 E + 0 2
4 .251 437 E -0 1
3 .540 064 E-0 1
1 .852'
E+0 0
1 .609344' E+0 0
3 .048'
E-0 1
3 .048'
E + 01
5 .08'
E-03
8 .466 667 E -02
3 .527 778 E - 03
3 .040'
E-0 1
2 .54'
E + 01
4 .233 333 E-0 1
2 .54'
2 .54'
E + 01
E-02
1 .666 667
1 .047 198
3 .048'
3 .048'
E-02
E-0 1
E-0 1
E + 01
268
ISHRAE Installation Guid e
Table 5 Conversion Factors : U.S. Customary and Commonly Used Units to SI Units (Could. )
Quantity
Customary or commonl y
used unit
SI unit
Acceleration (relational)
rpm/s
Momentum
Force
(Ibm•ll)/s
U .K . tonl
U .S . tool
kgl(kp)
Ibl
dyn
Bending moment, torque
U .S . Waft
kgl•m
Ibl•II
Ibl•in
(Ibl•ll)/in
(Ibl•in)/in
writ'
kN
kN
N
N
mN
kN•m
N•m
Mori
Non
(N•m)/m
(N-m)Im
kg•m 2
Mass/length
U .S . reran'
kgllmm 2
U .S . tool/IF
Ibl/in 2(psi)
Ibl/II2(psi)
dyn/cm2
Ibm/II
MPa
MPa
MPa
MPa
kPa
Pa
kg/m
Mass/area structural loading,
bearing capacity (mass basis)
U .S . 10 .110
bailie
Mg/m r
kg/m 2
Diffusivity
11*/s
m e/s
It°/h
Bending momenVlenglh
Moment of inertia
Stress
Thermal resistance
Heal flux
Thermal conductivity
Alternate
SI
unit
roovs°
(kg•m)/s
Blu/(h•11 1)
(cal•cm)/(s•cm1 •°C)
(Blud0f(h•It2 • F)
Volumetric heal . lransfer
coefficient
Surface tension
Blu/(s•83 •°F)
Blu/(h•11 1 •°F)
dyn/cm
Viscosity (dynamic)
(Ibbs)/in r
(IbEs)Illr
(kgosym 1
Ibm/(lt•s)
(dyn e s)/cm 2
cP
Ibm/(II•h)
Pa-s
Pa•s
Pa•s
Pa•s
Pa•s
Pa•s
Pa•s
(kcal•m)/(h•m2•°C)
(Blu•in/(h•11°•°F)
(ca1•cmpoi . cm1 •°C)
cal/(s•cm i•°C)
Blu/(s•11 2•°F)
CaV(h•cm r •°C)
Btu/(h•11 2•°F)
Btu/(h•II 2 •°R)
kcal/(h•m r •°C)
1 .047 198 E-0 1
1 .382 550 E -0 1
9 .964 016 E + 0 0
8 .896 443 E +0 0
9 .806 650 E + 0 0
4 .448 222 E+0 0
I .0
E-02
2 .711 636 E + 0 0
9.806 650' E+0 0
1 .355 818 E + 0 0
1 .129 848 E-0 1
5 .337 866 E+D l
4 .448 222 E+0 0
4 .214 011 E-0 2
1 .378 951 E+0 1
9 .606650' 5+00
9 .576 052 E- 0 2
6 .894 757 E - 0 3
•1 .788 026 E-0 2
E-0 1
1 .488 164 E + 0 0
9 .764 855 E+0 0
4 .882 428 E+0 0
Miscellaneous transport propertie s
m*/s
mm2/s
m°/s
(°C•n 2 •h)/kcal
(K•m r)/kW
( 0 F•II 2 •h)/Btu
(K•m2)/kW
kWlrn
W/(m•K)
WArmK)
(kJ•m)Ih•m2•K)
W/(m•K)
W/(m•K)
W/(m•K)
kW/(m1 •K)
kW/(m 1 •K)
kW/(m 2 •K)
kW/(m'•K)
kJ/(h•mr •K)
kW/(m2 •K)
xwnm2 •K)
kW/(mr •I()
kW/(m°•K)
mN/ m
Heal-transfer coefficient
N/mm*
Nlmm 2
N/mm 2
N/mm 2
Conversion factor ; multipl y
customary unit by factor l o
obtain SI uni t
9 .290304' 5-02
E + 06
2.58064' E-0 5
8 .604 208 E + 0 2
1761102 E + 02
3 .154 591 E-0 3
4 .184'
L730 735
6 .230 646
1 .162 222
1 .442 279
1 .162 222
4 .184'
2 .044 175
1 .162 222
5 .678 263
2 .044 175
5 .678 263
1 .162 222
6 .706 611
1 .862 947
(N•sym°
(N•s)/m r
(N•s)/m 2
(N•s)/m 2
(N . $)/m 2
(N-s)/m7
(NS)/m°
E+0 2
E + 00
E + 00
E+0 0
E-0 1
E-0 1
E+0 1
E+0 1
E-02
E-03
E+0 1
E-03
E-0 3
E + 01
E -0 2
6 .894 757 E + 0 3
4 .788 026 E + 0 1
9 .806650' 5+0 0
1 .468 164 E + 0 0
E-0 1
E-0 3
4 .133 789 E-04
ISHRAE Installation Guide
269
Table 5 Conversion Factors : U .S .-Customary and Commonly Used Units to SI Units (Con(d . )
Quantity
Customary or commonly
used unit
viscosity (kinematic)
Permeability
-Mass-transfer coefficient
SI unit
112/s
in2/s
m2/h
11 2/h
cSt
darcy
milidarcy
m2/s
mm2/s
mm 2/s
m 2/s
mm 2/s
pm t
pm t
(Ib•mog/(M1•11 2(Ib•moVll°))
(g•mol)I(s•m 2(g•moVL)j
m/s
m/s
Alternat e
SI
unit
Conversion factor ; multipl y
customary unit by factor to
obtain SI uni t
-
9 .290 304' E — 0 2
6 .451 6'
E + 02
2 .777 778 E + 02
2 .58064' E—0 5
1
9 .869 233 E — 0 1
9.869 233 E — 0 4
6 .467
1 .0
E—0 5
E + 01
' Indicates mauve conversion factor is exact ,
a Conversion factors for Ienglh, area, and volume are based on the internalional tool . The international loot Is longer by 2 parts in 1 million than the U .S .
Survey loot (land-measurement use) ,
NOTE; The following unit symbols are used in the tabl e
Unit Symbol
A
a
8q
C
cd
Ci
d
°C
0
dy n
F
Ic
G
g
gr
Name
ampere
annum (year )
'becquere l
coulom b
candel a
curi e
da y
degree Celsiu s
degre e
dyn e
fara d
lootcandle
gaus s
gra m
grain
Unit Symbol
Gy
H
h
ha
Hz
J
K
L, I
lm
Ix
m
mi n
N
nail mi
Name
gra y
henry
hou r
hectar e
hert z
joul e
-kelvi n
lite r
lume n
lu x
mete r
minut e
minut e
newto n
U .S . nautical mile
Unit Symbol
Oe
fl
Pa
rod
r
S
s
Sr
Sl
T
I
V
W
Wb
Nam e
oerste d
- oh m
pasca l
radia n
revolutio n
siemen s
secon d
secon d
sieratlia n
stoke s
testa
tonn e
vol t
wat t
webe r
ISHRAE Installation Guid e
2 70
Table 6 Alphabetical Listing of Common Conversion s
To convert from
To
Multiply b y
43,56 0
4074
Acres
Acres
Square feet
Square meters
Acres
Square miles
Acre-feet
Cubic meters
123 3
Ampere-hours (absolute)
coulombs (absolute)
360 0
0 .00156 3
Angstrom units
Inches
Angstrom units
Meters
Angstrom units
Microns
Atmospheres
Millimeters of mercury at 32 F
Atmospheres
Atmospheres
Dynes per square centimeter
Atmospheres
Feet of water at 39 .1 F
Atmospheres
Grams per square centimeter
Atmospheres
Inches of mercury at 32 F
Atmospheres
Pounds per square foot
Atmospheres
Pounds per square inch
14 .69 6
Bags (cement)
Pounds (cement)
94
Barrels (cement)
Pounds (cement)
37 6
Barrels (oil)
Cubic meters
0 .1589 9
Barrels (oil)
Gallons
42
Barrels (U .S . Liquid)
Cubic meters
0 .1192 4
Barrels (U .S . liquid)
Gallons
31 . 5
Barrels per day
Gallons per minute
0 .0291 7
Bars
Bars
Bars
Board feet
Boiler horsepower
Boiler horsepower
B .t .u .
B .t .u .
B .t .u .
B .t .u .
B .t .u .
B .t .u .
B .t .u .
B .t .u .
Atmospheres
Newtons per square meter
Pounds per square inch
Cubic feet
B .t .u . per hour
Kilowatts
Calories (gram)
Centigrade heat units (c .h .u . or p .c .u .)
Foot-pounds
Horsepower-hours
Joules
Liter-atmospheres
Pounds carbon to CO2
Pounds water evaporated from and a t
212 F
0 .986 9
1 X 10 5
14 .504
1/1 2
33,48 0
9 .80 3
25 2
0 .5555 6
777 . 9
3 .929 X 10 - 4
1055 . 1
10 .4 1
6 .88 X 10- 5
B .t .u .
B .t .u .
B .t .u . per cubic foot
B .t .u . per hour
B .t .u . per minute
B .t .u . per pound
Cubic foot-atmospheres
Kilowatt-hours
Joules per cubic meter
Watts
Horsepower
Joules per kilogram
0 .367 6
2 .930 X 10 - 4
37,26 0
0 .2930 7
0 .0235 7
2326
Newtons per square meter
3 .937 X 10 - 9
1 X 10 -1 0
1 X 10 -4
76 0
1 .0133 X 10 6
101,32 5
33 .9 0
1033 . 3
29 .92 1
2116 . 3
0 .00103 6
ISHRAE Installation Guide
To convert from
271
To
Multiply b y
B .t .u . per pound per degree
Calories per gram per degre e
Fahrenheit
Centigrade
B .t .u . per pound per degree
Fahrenhei t
Joules per gram per degree
B .t .u . per second
Watts
B .t .u . per square foot per hour
Joules per square meter per second
3 .154 6
B .t .u . per square foot per min .
Kilowatts per square foot
0 .175 8
B .t .u . per square foot per sec
Calories, gram (15 °C), per square cen -
1 .240 5
Kelvin
1
4186 . 8
1054 . 4
for temperature gradient o f
timeter per second for a temperatur e
1 F. per inc h
gradient of 1 °C per centimete r
B .t .u . (60 F) per degree Fahrenheit
Calories per degree centigrade
Bushels (U .S . dry)
Cubic feet
1 .244 4
Bushels (U .S . dry)
Cubic meters
0 .0352 4
Calories, gram
B .t .u .
3 .968 X 10 - 3
Calories, gram
Foot-pounds
3 .08 7
Calories, gram
Joules
4 .186 8
Calories, gram
Liter-atmospheres
4 .130 X 10 -2
1 .5591 X 10 - 6
453 . 6
Calories, gram
Horsepower-hours
Calories, gram, per gram per degree °C
Joules per kilogram per degree Kelvin
Calories, kilogram
Kilowatt-hours
0 .001162 6
Calories, kilogram per second
Kilowatts
4 .18 5
Candle power (spherical)
Carats (metric)
Lumens
Grams
12 .55 6
0.2
Centigrade heat units
B .t .0
1 .8
Centimeters
Angstrom units
1 .0 X 10 8
Centimeters
Feet
Centimeters
Inches
0 .0328 1
0 .393 7
Centimeters
Meters
Centimeters
Microns
Centimeters of mercury at 0 °C
Atmospheres
0 .01315 8
Centimeters of mercury at 0 °C
Feet of water at 39 .1 °F
0 .446 0
Centimeters of mercury at 0 °C
Newtons per square meter
Centimeters of mercury at 0 °C
Pounds per square foot
27 .84 5
Centimeters of mercury at 0 °C
Pounds per square inch
0 .1933 7
Centimeters per second
Feet per minute
1 .968 5
Centimeters of water at 4 °C
Newtons per square meter
98 .06 4
Centistokes
Square meters per second
1 .0 X 10 - 6
Circular mils
Square centimeters
5 .067 X 10 - 6
Circular mils
Square inches
7 .854 X 10 - 7
Circular mils
Square mils
Cords
Cubic feet
Cubic centimeters
Cubic feet
3 .532 X 10- 5
Cubic centimeters
Gallons
2 .6417 X 10 -4
4186 . 8
0 .0 1
10,00 0
1333 . 2
0 .785 4
12 8
272
To convert from
ISHRAE Installation Guid e
To
Multiply by
Cubic centimeters
Ounces (U .S . fluid)
0 .0338 1
Cubic centimeters
Quarts (U .S . fluid)
0 .001056 7
Cubic feet
Bushels (U .S .)
0 .803 6
Cubic feet
Cubic centimeters
Cubic feet
Cubic meters
0 .02831 7
Cubic feet
Cubic yards
0 .0370 4
Cubic feet
Gallons
7 .48 1
Cubic feet
Liters
28 .31 6
Cubic foot-atmospheres
Foot-pounds
Cubic foot-atmospheres
Liter-atmospheres
28 .31 6
Cubic feet of water (60 F)
Pounds
62 .3 7
Cubic feet per minute
Cubic centimeters per second
472 . 0
Cubic feet per minute
Gallons per second
Cubic feet per second
Gallons per minute
Cubic feet per second
Million gallons per day
0 .6463 2
Cubic inches
Cubic meters
1 .6387 X 10 -
28,31 7
2116 . 3
0 .124 7
448 . 8
Cubic yards
Cubic meters
0 .7645 6
Curies
Disintegrations per minute
Curies
Coulombs per minute
2 .2 X 10 1 2
1 .1 X 10 1 2
Degrees
Radians
0 .01745 3
Drams (apothecaries or troy)
Grams
3 .88 8
Drams (avoirdupois)
Grams
Dynes
Newtons
Ergs
Joules
x 10- 7
Faradays
Coulombs (abs .)
96,50 0
Fathoms
Feet
6
Feet .
Meters
0 .304 8
Feet per minute
Meters
0 .508 0
Feet per minute
Centimeters per second
0 .01136 4
Feet per (second) 2
Meters per (second) 2
0 .304 8
Feet of water at 39 .2 F
Newtons per square meter
Foot-poundals
B .t .u .
3 .995 X 10
Foot-poundals
Joules
0 .0421 4
Foot-poundals
Liter-atmospheres
4 .159 X 10' 4
Foot-pounds
B .t .u .
Foot-pounds
Calories, gram
0 .001285 6
0 .323 9
Foot-pounds
Foot-poundals
32 .174
Foot-pounds
Horsepower-hours
Foot-pounds
Kilowatt-hours
5 .051 X 10- 7
3 .766 X 10 - 7
Foot-pounds
Liter-atmospheres
0 .01338 1
Foot-pounds force
Joules
1 .355 8
Foot-pounds per second
Horsepower
0 .001818 2
Foot-pounds per second
Kilowatts
0 .0013558
1 .771 9
1 X 10' 5
298 9
-g
ISHRAE Installation Guide
To convert from
273
To
Multiply b y
Furlongs
Miles
0 .12 5
Gallons (U .S . Liquid)
Barrels (U .S .liquid)
0 .0317 5
Gallons
Cubic meters
0 .00378 5
Gallons
Cubic feet
0 .1336 8
Gallons
Gallons
Gallons
Gallons per minute
Gallons per minute
Grains
Grains
Grains per cubic foot
Grains per gallon
Grams
Grams
Grams
Grams
Grams
Grams
Grams per cubic centimeter
Grams per cubic centimeter
Grams per liter
Grams per liter
Grams per square centimeter
Grams per square centimeter
Hectares
Hectares
Horsepower (British)
Horsepower (British)
Horsepower (British)
Horsepower (British)
Horsepower (British)
Horsepower (British)
Horsepower (British)
Horsepower (British)
Horsepower (metric)
Horsepower (metric)
Hours (mean solar)
Inches
Inches of mercury at 60 F
Inches of water at 60 F
Joules (absolute)
Joules (absolute)
Joules (absolute)
Joules (absolute)
Joules (absolute)
Joules (absolute)
Kilocalories
Kilograms
Kilograms force
Kilograms per square centimeter
Kilometers
Kilowatt-hours
Kilowatt-hours
Gallons (imperial)
0 .832 7
Liters
3 .78 5
Ounces (U .S . fluid)
12 8
Cubic feet per hour
8 .02 1
Cubic feet per second
0 .00222 8
Grams
0 .0648 0
Pounds
1/700 0
Grams per cubic meter
2 .288 4
Parts per million
17 .11 8
0 .564 4
Drams (avoirdupois)
Drams (troy)
0 .257 2
Grains
15 .43 2
Kilograms
0 .00 1
Pounds (avoirdupois)
0 .002204 6
Pounds (troy)
0 .00267 9
Pounds per cubic foot
62 .4 3
Pounds per gallon
8 .34 5
Grains per gallon
58 .4 2
0 .062 4
Pounds per cubic foot
2 .048 2
Pounds per square foot
Pounds per square inch
0 .01422 3
Acres
2 .47 1
Square meters
10,00 0
B .t .u . per minute
42 .4 2
B .t .u . per hour
254 5
Foot-pounds per minute
33,00 0
Foot-pounds per second
55 0
Watts
745 . 7
Horsepower (metric)
1 .013 9
Pounds carbon to CO 2 per hour
0 .17 5
2 .64
Pounds, water evaporated'per hour at 212 F
Foot-pounds per second
542 .4 7
Kilogram-meters per second
75 . 0
Seconds
360 0
Meters
0 .025 4
Newtons per square meter
3376 . 9
Newtons per square meter
248 .8 4
B .t .u . (mean)
9 .480 X 10 - 4
Calories, gram (mean)
0 .238 9
0 .348 5
Cubic foot-atmospheres
0 .737 6
Foot-pounds
2 .7778 X 10' 7
Kilowatt-hours
Liter-atmospheres
0 .00986 9
Joules
4186 . 8
Pounds (avoirdupois)
2 .204 6
9 .80 7
Newtons
Pounds per square inch
14 .22 3
Miles
0 .621 4
B .t .u .
341 4
Foot-pounds
2 .6552 X 106
2 74
ISHRAE Installation Guid e
To convert from
To
Multiply b y
Kilowatts
Knots (international)
Knots (nautical miles per hour)
Lamberts
Liter-atmospheres
Liter-atmospheres
Liters
Liters
Liters
Lumens
Micromicrons
Microns
Microns
Miles (nautical)
Miles (nautical)
Miles
Miles
Miles per hour
Miles per hour
Milliliters
Horsepower
Meters per second
Miles per hour
Candles per square inch
Cubic foot-atmospheres
Foot-pounds
Cubic feet
Cubic . meters
Gallons
Watt
Microns
Angstrom units
Meters
Feet
Miles (U .S . statute)
Feet
Meters
Feet per second
Meters per second
Cubic centimeters
Millimeters
Meters
Millimeters of mercury at 0 C
Newtons per square meter
Millimicrons
Microns
0 .00 1
Mils
Inches
0 .00 1
Mils
Meters
2 .54 X 10 - 6
Minims (U .S .)
Cubic centimeres
0 .0616 1
Minutes (angle)
Radians
2 .909 X 10 - 4
Minutes (mean solar)
Seconds
60
Newtons
Kilograms
0 .11019 7
Ounces (avoirdupois)
Kilograms
0 .0283 5
Ounces (avoirdupois)
Ounces (troy)
0 .911 5
Ounces (U .S . fluid)
Cubic meters
2 .957 X 10- 5
Ounces (troy)
Ounces (apothecaries)
1 .00 0
Pints (U .S . liquid)
Cubic meters
4 .732 X 10' 4
Poundals
Newtons
0 .1382 6
.
1 .341 0
0 .514 4
1 .151 6
2 .05 4
0 .0353 2
74 .7 4
0 .0353 2
0 .00 1
0 .2641 8
0 .00149 6
1 .0 X 10 - 6
1 .0 X 104
1 .0 X 10 . 6
608 0
1 .151 6
528 0
1609 . 3
1 .466 7
0 .447 0
1
0 .00 1
133 .3 2
700 0
Pounds (avoirdupois)
Grains
Pounds (avoirdupois)
Kilograms
0 .4535 9
Pounds (avoirdupois)
Pounds (troy)
1 .215 3
Pounds per cubic foot
Grams per cubic centimeter
0 .01601 8
Pounds per cubic foot
Kilograms per cubic meter
16 .01 8
Pounds per square foot
Atmospheres
4 .725 X 10- 4
Pounds per square foot
Kilograms per square meter
4 .88 2
Pounds per square inch
Atmospheres
0 .0680 5
Pounds per square inch
Kilograms per square centimeter
0 .07031
ISHRAE Installation Guide
To convert from
To
Multiply b y
Pounds per square inch
Newtons per square meter
6894 . 8
Pounds force
Newtons
4 .448 2
Pounds force per square foot
Newtons per square meter
47 .8 8
Pounds water evaporated from and at 212 FHorsepower-hours
0 .37 9
Pound-centigrade uints (p .c .u .)
B .t .u .
1 .8
Quarts (U .S . liquid)
Cubic meters
9 .464 X 10 - 4
Radians
Degrees
57 .3 0
Revolutions per minute
Radians per second
0 .1047 2
Seconds (angle)
Radians
4 .848 X 10- 6
Slugs
Gee pounds
1
Slugs
Kilograms
14 .59 4
Slugs
Pounds
32 .1 7
Square centimeters
Square feet
0 .001076 4
Square feet
Square meters
0 .092 9
Square feet per hour
Square meters per second
2 .581 X 10- 5
Square inches
Square centimeters
6 .45 2
Square inches
Square meters
6 .452 X 10 - 4
Square yards
Square meters
0 .836 1
Stokes
Square meters per second
1 .0 X 10- 4
Tons (long)
Kilograms
101 6
Tons (long)
Pounds
224 0
Tons (metric)
Kilograms
100 0
Tons (metric)
Pounds
2204 . 6
Tons (metric)
Tons (short)
Tons (short)
Kilograms
907 .1 8
Tons (short)
Pounds
200 0
Tons (refrigeration)
B .t .u . per hour
Tons (British shipping)
Cubic feet
42 .0 0
Tons (U .S . shipping)
Cubic feet
40 .0 0
Torr (mm . mercury, 0 C)
Newtons per square meter
133 .3 2
Watts
B .t .u . per hour
3 .41 3
Watts
Joules per second
1
Watts
Kilogram-meters per second
0 .1019 7
Watt-hours
Joules
Yards
Meters
1 .102 3
12,00 0
360 0
0 .9144
276
ISHRAE Installation Guid e
UNITS AND CONVERSION S
Table 7 Conversion to SI Unit s
Multiply
acre
ba r
barrel (42 U.S. gal, petroleum )
Btu (inlernalianal Table)
SLO P
Blu/gal
BtudWi .it' ° F
Btu•iN(h•1t2•°F) (thermal conductivily,k)
Blu m
BIWfl 2
BIW(h•fl2)
((ov °F)
(overall heal trans . coel8cienl, U)
Bulb
Blu/gb•°F)(Specific heal, C )
bushel
calorie, grain
calorie, kilogram; kilocalori e
centipoise, dynamic viscosity, LL
centfstokes, kinematic viscosily, v
clo
dyne/cm2
EDR hot water (150 Blum)
EDR sleam (240 Blum )
EE O
II
It
IVmin, fp m
IVs, fps
It al wale r
It of water per 100 fl pip e
fl 2
fl 2 4h °F/Btu (thermal resistance . R )
ft 2/s, kinematic viscosily, v
fl s
0'
Pm, clh
IP/min, clm
Its/s, ci s
II'Ib 1 (torque or moment)
h•Ib 1 (work)
fl•Ibr/lb(specilic energy )
It•Ib,Imin (power )
faomandle
gallon (U .S ., '231 ins )
gph
gpm
Drift'
g m/Ion refrigeralio n
grain (1(7000 Ib )
gr/ga l
gru b
horsepower (boiler )
horsepower (550 Ib-Ib/s )
inch
in. of mercury (60°F)
in . of water (60P )
in/10011, thermal expansion
e
To obtain
By
0 .4047
'100
159
0 .159
1 .055
37 .3
0 .279
1 .731
0 .1442
0 .2931
11 .36
3 .155
To obtain Multiply
ha
kP a
L
ms
kJ
kJ/m r ;JI
L
kJ/ L
W/(m•K)
W/(m•k)
W
kJIm2
W/m2
5 .678
WW/(rrr•K )
2 .326
kJ/k g
4 .184
kJ/(kg'K)
0 .03624
m3
4 .187
J
4 .187
kJ
'1 .00
mPa• 5
1 .00
mm 2/s
0 .155
rn' KM'
'0 .100
Pa
44 .0
W
70 .3
W
0.293
cap
'0 .3048
m
304 .8
mm
0 .00508 Ms
'0 .3048
Ms
2.99
kP a
0.0981
kPal m
0 .09290
n
i
0 .176
m?KNJ
92900
mas
28 .32
L
m3
0 .02832
7 .866
mus
0.4719
Us
28 .32
Us
1 .36
N•m
1 .36
J
2 .99
Jlk g
0 .0226
W
1 .076
Ix
3 .7854
L
1 .05
mUs
0 .0631
Us
0 .6791
U(s•mr)
0 .0179
mUJ
0 .0648
g
17.1
mg4
0 .143
glkg
9 .81
kW
0 .746
kW
25 .4
mm
3 .377
kP a
248 .8
Pa
0.833
mm/m
By
Divide
By
To obtai n
113
645
16.4
0 .273
16400
416200
0 .278
'3 .60
2 .12
9 .81
4 .45
6 .695
'0.001
'56 .15 .
133
1 .61
1 .85
1 .61
0 .447
'0.100
0 .133
9 .80
28 .35
0 .278
29 .6
7.06
7 .49
5] .45
146
173
Mon
mm2
mL
mL/s
mina
mm'
mis
MJ
J4
N
kN
MP a
m3
W/m 2
mP a
km
km
kmlb
Ms
kP a
kP a
Pa
g
N
mL
mN• m
gIL
ng/(s•rMPa
ng(s•m•Pa)
mL
kg
9
N
kglm
mPa s
mPa• s
Pa m
91s
kg/s
kW
Pa
kg/m 2
kg/ms
kg/m 3
mglk g
kP a
EJ
L
m2
mL
mL
MJ
Mg
Mg
kW
Pa
W/m2
m
yd 2 0.83 6
yd s 0 .7646
0.4536
153 .6
1 .45
49
I) .413
1490
•17 .88
26
11 .00756
0 .284
47.9
4 .88
16 .0
120
'1 .00
6 .895
1 .055
0946
9 .29
15
5
105 .5
1 .016
0 .90]
3 .52
33
10 .8
'0.9144
m2
m3
To obtain
By
Divid e
In .lb (torque or moment )
in3
ins (volume)
in3lmin(SCIM)
in' (section modules)
in' (section moment )
k h
kW
Wh
kW/1000 cIm
kilopond (Kglorce )
kip (1004 Ib)
kiprn7 lksi)
litre
me t
micron(m) of mercury (60°F )
mil e
mile, nautica l
mp h
mph
milliba r
mm ol mercury (G0'F)
mm of water (60°F )
ounce (mass, avoirdupois )
ounce (force or thrust )
ounce (liquid, U.S . )
ounce inch (torque, moment)
ounce (avoirdupois) per gallo n
perm (permeance )
perm inch (permeability )
pint (liquid, U.S . )
pound
lb (mass )
b (mass )
Ib, (force or thrust)
Iblll (unilarm load)
1b n/01•h) (dynamic viscosity, p )
Ibrg1I•s) (dynamic viscosity, p )
Ibrs/II 2 (dynamic viscosily, p)
Ib/h
lb/min
bth [steam at 212°F (100°C) I
Ib,/11 2
Ibll1 2
Ib/Its (density, p )
b/gallon
ppm (by mass )
psi
quad
quart (liquid U.S.)
square (100112 )
tablespoon (approximately)
tablespoon (approximately)
therm (U .S . )
ton, long (2240 lb )
ton, short (2000 lb)
Ion, refrigeration (12 000 Bluth )
tort (1 mm Hg at 0°C)
wall per square foo t
yd
Note: Units are U .S. values unless noted otherwise ,
'Conversion lamor is exact .
ISHRAE Installation Guide
277
Table 8 Conversion Factors
Pressure
in . of wate r
in . H g
mm Hg
psi
(60°F)
(32°F)
atmosphere
1
= 27 .70 8
= 2 .036 0
= 0.068046
0 .036091
1
0 .073483
2.4559 x 10' 3
0.491154
13.609
I
0.03342 1
14 .6960
407 .19 '
29.92 1
I
0.0193368
0.53570
0 .03937
0.0013157 9
14 .5038
401 .86
29.53 0
0.9869 2
14 .223
394 . 1
28.95 9
0.9678 4
I A50213 x 10''
4 .0186x ID ' 3
2 .953
9.8692
Mass
lb (mix.)
grain
= 7000'
I
1 .4286x1 0 ''
f
0 .06250
437.5'
2 .20462
15432
Volume
cubic inch
cubic loot
gallon
mm H g
(32°F)
= 51 .71 5
1 .866 5
25.40 0
760. 0
1
750 .062
735 .559
0 .00750
ounce (volt .)
bar
= 0 .06894 8
2.4884 x 10 ' 3
0.03386 4 1 .01325 '
0.001333 2
1
0.98066
10' 5
kgl/cm2
= 0.07030696
2 .537 x 10' 3
0 .03453 2
1 .03323
0 .001359 5
1 .01972
1
IA192x 10' S
kg
0 .45359
6 .4800 x ID' S
0 .02835 0
1
- cubic metre (m )
= 16'
2 .2857x10' 3
I
35.274
hire
=
I
1728'
231 .0'
61 .02374
61,023.74
= 5 .787x 10'
I
0 .13368
0.03531 5
35.315
= 4.329x10' 3
7.08455
1
0.264173
264 .173
D .0163W1
28 .317
3]054
1
1000
= 1 .63871x10' 5
0.02831 7
0.003785 4
0.001 '
1
11•Ib
= 778.17
I
3 .08803
0 .73756
calorie (cal)
= 251 .9957
0.32383
1
0.23885
Density
Btu
I
1 .2851 X 10 ' 3
3 .9663%10 ' 3
9 .4782%10 '
lb/11 3
joule (J)
= 1055 .056
1 .355818
4 .1868'
1
AICm 3
wallsecoM 1w• s )
= 1055 .05 6
1 .35581 8
4 .1868 '
1
kg/m3 (g!L )
Specific Volume
1
7 .48055
62 .4280
0 .0624280
11 3/lb
= 0.133680
1
0.34538
0.008345
gal/lb
= 0 .016018
0 .119827
1
0 .001
cm3/g
` 16.01846 3
119 .827
100 0
I
m'lkg(IJg )
I
0 .133660
0.016018
16,010463
Specific Heat or Entropy
7 .48055
1
0 .119827
119 .827
= 62 .4280
0 .34538
1
1000
= 0.052428 0
0 .008345
0 .00 1
1
Energy
Enthalpy
Thermal Conduclivily
lb/gal
Blullb• °F
1 .0
0 .21805
Blullb
1 .8
0 .42992
Blulh•fl• °F
kJ(kg•K)
call(g'K)
= I
I
0.23885
cal/g
= 4 .1868'
4 .1868'
1
Ji g
= 2 .326 '
4 .1868'
1
= 0.55556
1
0,23095
call(s•cm•°C)
4 .1338x10 ' 3
1
2 .3805x 10 ' a
WI(m•K )
241 .91
0.57779
I poise =1 dyneJsecicm 2 = 0.1 Pa 's = I g/(cm's)
Ib i 5111 2
Ibi h/11 2
kgl(m•s )
= 2 .0885x10 ' 3 = 5 .8014x10' 3
= 0 .1
1
2 .7778x10'
47 .88026
3600
1
172,369
0 .020885
5 .8014 x 10' S
I
3 .1081x10 - 2
8 .6336x10' 5
1 .4882
Viscosity (absolute)
poise
1
478 .8026
1,723,689
10
14 .8819
Coefficient of Heat Transfer
Bwlh'I1 2' °F
call(s•cm 2•°C)
1
= 1 .3562 x 10''
7373 .5
I
0 .2048
2.7778 x 10' 5
0 .1761
2 .3885 x 10' 5
Ole: Tho Bw, calorie, antl Mloculorie are based on the Inlernarional Table .
` 1 .7307
418 .6 8
1
N•slm 2
= 0 .1
47 .88026
172,369
1
1 .4802
lbm/(fl•s )
= 6 .71955x10' 2
32 .1740 5
115,827
0 .0671955
I
kcalllh•m2 •°C)
W/(m 2•K )
= 4 .8824
36,000
I
0.8598
= 5 .678 3
41,868 '
1 .1630 '
1
pasca l
= 6894 .8
248.8 4
3386. 4
101,325'
133 .3 2
10 5'
90,06617 '
278
ISHRA E Installatio n Guide
NOTES
Section 8
IS CODES & STANDARDS
IS CODES AND STANDARD S
AIRCONDITIONING EQUIPMEN T
IS 7896 : 1975 (reaffirmed 1991)
Data for outside design conditions fo r
airconditioning for summer months .
G2
IS 8148 : 1976 (reaffirmed 1991)
Packaged airconditioners . (Amendment 1 )
G7
IS 659 : 1964 (reaffirmed 1991)
Safety code for airconditioning (revised )
(Amendment 1 )
G3
IS 660 : 1963 (reaffirmed 1991)
Safety code of mechanical refrigeration .
(revised )
G4
I5 8188 : 1976 (reaffirmed 1988)
Code of practice for treatment of wate r
industrial cooling systems .
G8
IS 1391 : Part I a Part II
Room airconditioners (unitary and split) (2n d
revision )
G9
IS 8362 : 1977 (reaffirmed 1991)
Copper and copper alloy rolled plates fo r
condensers and heat exchangers .
G3
15 2370 : 1963 (reaffirmed 1991 )
G5
Sectional cold rooms . (walk in type )
IS 8667 : 1977 (reaffirmed 1993)
Cl
Purchasers data sheet for cooling towers fo r
process industry .
IS 2371 : 197 3
Solid drawn copper alloyed tubes fo r
condensers, evaporators, heaters and coole r
tubes using saline hard water. (withdrawn)
(superseded by IS 1545, 1982 )
IS 9612 : 1980 (reaffirmed 1991)
Aluminium tubes for refrigeration purposes .
G2
IS 10470 : 1983 (reaffirmed 1991)
Air cooled heat exchangers (Amendment 1 )
G7
IS 2372 : 1991
Timber for cooling towers (1st revision )
IS 10617 : Part I, Part II a Part III, 198 3
(reaffirmed 1991 )
Hermetic compressors .
G2/G2/G 2
GI
IS 3315 : 1994
G4
Evaporative air coolers . (Desert coolers) (2n d
revision )
IS 3615 : 1967 (reaffirmed 1991)
G7
Glossary of terms used in refrigeration and airconditioning .
IS 4831 : 1968 (reaffirmed 1991)
Recommendation on units and symbols fo r
refrigeration .
G4
IS 10873 : 1983 (reaffirmed 1993)
Data sheet for air cooled heat exchangers .
G1
IS 11327 : 1985 (reaffirmed 1991)
G3
Requirements for refrigerants condensing units .
IS 11329 : 1985 (reaffirmed 1991)
Finned type heat exchangers for roo m
airconditioners (Amendment 1 )
G2
G2
IS 5111 : 1993
Testing of refrigeration compressors (1s t
revision )
G1 1
IS 11330 : 1985 (reaffirmed 1991)
Oil separator s
G1
IS 6272 : 1987 (reaffirmed 1991)
Industrial cooling fans (Man coolers) (1s t
revision)
G5
IS 12357 : 1988 (reaffirmed 1993)
Suppliers data sheet for clean air equipment s
(Laminar flow )
IS 11338 : 1985 (reaffirmed 1991)
Thermostats for use in refrigeration ,
airconditioners etc .
G2
28 2
SP 7 : 1983 Group 4
National Building code .
ISHRAE Installation Guid e
Rs . 350/ .
Earthing transformers .
IS 12776 : 1989
Galvanized stand for earthirg .
G2
CHIMNEYS
Fuses
IS 1649 : 1962 (reaffirmed 1992)
G8
Code of practice for design and construction o f
flues chimneys for domestic heating appliances .
(1st revision )
I5 4998 : Part I, 1992
Criteria for design reinforced concret e
chimneys .
G6
IS 6533 : Part I & Part II, 1989
G8/G 8
Code of practice for design and construction o f
steel chimneys .
IS 2208 : 197 6
HRC fuse links upto 650 V .
IS 2086 : 1963 G 7
Carriers and bases used in rewirable type electri c
fuses upto 650 Volts .
IS 3106 : 196 6
Code of practice for selection, installation an d
maintenance of fuses . (Upto 650 V) (With drawn )
Motor s
ELECTRICAL WIRES a CABLES, LT &
HT GRAD E
IS 282 : 1963
Hard drawn copper conductors for overhea d
power transmission .
G4
IS 325
motors .
Specification for 3 phase induction
G8
IS 900 : Code of practice for installation an d
maintenance of induction motors .
Gi l
IS 398 : 1976 Part I a Part II G3/G 4
Alluminium Conductors for overhead transmissio n
purposes .
Specification for 1 phase small AC an d
IS 996
G8
universal motors .
IS 694 : 1977 Part I & Part II
G4
PVC Insulated cables for voltage upto 1100 V
with copper and aluminium conductor s
respectively .
IS 1231 : Dimensions of 3 phase foot mounte d
motors .
G6/G 4
IS 1554 : 1981 Part I & Part II
PVC insulated (heavy duty) cables for workin g
voltage upto 1 .1 KV and upto 11 KV grad e
respectively .
15 692 : 1973 G I l
Paper insulated, lead sheathed cables for electri c
supply.
IS 732 : 198 9
Code of practice for electrical wiring installation .
Earthin g
IS 3043 : 196 6
Code of practice for earthing .
IS 3151 : 1965
IS 2148 : Specification for flame proof motors .G1 I
IS 2223 : Dimensions of 3 phase flange mounte d
G5
motors .
S 2253 : Types of constructions and mounting o f
G4
motors
IS 2968 : Dimensions of slide rail for electri c
motors .
G2
IS 4722 : 1968
Rotating electric machines .
G9
IS 1580 : 1983
Service conditions for electrical equipment .
G2
SP : 30 1985
National electrical code .
G3
G5
Rs . 600/ -
ISHRAE Installation Guide
28 3
Switch Gear & Controls
Noise & Vibratio n
IS 2607 : 198 1
Air break isolators for voltage not exceedin g
1000 V.
G5
IS 2526 : 1963 (reaffirmed 1991)
Code of practice for acoustical design o f
auditoriums and conference halls . (Amendment 1) .
IS 2516 : 1980 Part I & Part I I
Circuit breakers A . 0
IS 2264 : 1963 (reaffirmed 1994)
Preferred frequencies for acoustica l
measurements .
IS 2959 : 197 5
Contactors of A .C . for voltage upto 1100 V .
IS 2675 : 1975 G 4
Enclosed distribution fuse boards and cutouts fo r
and upto 1000 V.
IS 4237 : 1982
G8
General requirements for switch-gear an d
control gear for voltages not exceeding 1000 V
AC or 1200 V DC .
IS 8544 : 1977 Part I to Part I V
Motor starter for voltages not exceeding 1000 V.
15 8623 : 1993 Part I & Part II
G15/G 7
Low voltage switch gear and control gea r
assemblies .
IS 3914 : Code of practice for selection o f
starters for AC induction motors . (Withdrawn )
15 4821 : Specification of cable glands .
G4
IS 10118 : 1982, Part I to Part IV G3/G11/G7/G1 0
Code of practice for selection, installation and
maintenance of switch gear and control gear.
Wiring Accessorie s
IS 3854 : 1966
Switches for domestic and similar purposes .
G8
IS 1293 : 1967
3 pin plugs and sockets outlets .
G9
IS 3837 : 1976
Accessories for electrical wiring .
G4
15 2509 : 197 3
Rigid non metalic conduits .
IS 9537 : 1981 Part 1 to Part4
Conduits for electrical insulation .
G5/G4/G4/G 4
G1
IS 3483 ; 1965 (reaffirmed 1991) G 5
Code of practice for noise reduction in Industria l
buildings .
IS 3932 : 196 6
Sound level meter for general purpose use .
(incorporated in IS 9779 )
IS 4954 : 1968 (reaffirmed 1991) G 4
Recommendations for noise for abatement in tow n
planning .
IS 4758 : 1968 (reaffirmed 1994)
Methods of measurement of noise emitted b y
machines .
G4
15 9736 : 1981 (reaffirmed 1991)
Glossary of terms applicable to acoustics i n
buildings .
G3
IS 9901 : Part I & Part II - Part-9 (reaffirme d
1991) G5/G 4
Measurement of sound insulation in building s
and building elements .
G4
IS 9989 : 1981 (reaffirmed 1991)
Assessment of noise with respect to communit y
response .
IS 9876 : 1981 (reaffirmed 1991)
G4
Guide to the measurement of air born e
acoustical noise and evaluation of its effects o n
man .
15 10423 : 1982 (reaffirmed 1994)
Personal sound exposure meter.
G4
IS 11446 : 1985 (reaffirmed 1990)
Measurement of air borne noise emitted b y
compressors units intended for outdoor use .
G4
G8/G 7
IS 12998 : Part I & Part II, 1991
Test code and method of measurements of air
284
ISHRAE Installation Guid e
borne noise emitted by electrical machiner y
(superseding IS 6098, 1971 )
IS 12710 : 1989
Glossary of terms used in acoustic emissio n
testing .
IS 3076 : 1985 (reaffirmed 1991)
Low density polyethylene pipes for portabl e
water supplies . (2nd revision, Amendment 1 )
G2
IS 5822 : 1994
G7
Code of practice laying o f electrically welded
steel pipes for water supoly (2nd revision )
IS 11050 : Part I, Part II & Part III, 198 4
(reaffirmed 1991 )
Rating of sound insulation in buildings and o f
buildin g
elements .
G2/G4/G 2
IS 14280 : 1995
G6
Mechanical vibration - balancing - shaft an d
fitment key convention .
IS 14259 : 1995 G 2
Vibration and shock - Isolators, procedure o f
specifying characteristics .
IS 12065 : 1987
G7
Permissible limits of noise level for rotatin g
electrical machines .
15 1950 : 1962 (reaffirmed 1991) G 7
Code of practice for sound insulation of no n
industrial buildings. (Amendment - 1 )
IS 7194 : 1994
G8
Assessment of noise exposure during work fo r
hearing conversation purpose .
IS 4729 : Measurement and evaluation o f
vibration for motors . (Withdrawn) .
IS 638 : 1979 (reaffirmed 1993 )
Gaskets .
IS 6392 : 1971 (reaffirmed 1988)
Steel pipe flanges (Amendment 1 )
G5
G1 1
IS 10773 : 1995
G3
Wrought copper
tubes for refrigeration an d
airconditioning purposes .
Pump And Valve s
I5 778 : 1984 (reaffirmed 1990)
G7
Copper alloy gate, globe and check valves fo r
water works purposes . (4th revision )
(Amendments 2 )
IS 779 : 1994
Water meters (domestic type) (6th revision )
(Amendments 1 )
G7
IS 780:
1984 (reaffirmed 1990)
G7
Sluice valves for water works purposes . (50 t o
300 mm size) (6th revision, Amendments 3 )
G3
G4/G11
IS 1520 : 198 0
Horizontal centrifugal pumps for clear, cold ,
fresh water(2nd revision )
IS 2685 : 1971 (reaffirmed 1992)
G2
Code of practice for selection, installation an d
maintenance of sluice valves . (1st revision )
IS 1367 : Part 1 to Part 18
Technical supply conditions for threaded stee l
fasteners .
IS 2501 : 1995
Solid drawn - copper tubes for genera l
engineering purposes . (3rd revision)
IS 6630 : 1985 (reaffirmed 1990)
Seamless ferrite alloy steel pipes for hig h
temperature steam service . (1st revision )
1984 (reaffirmed 1990)
G5
IS 781:
Cast copper alloy, screw down, bib taps and sto p
valves for water services . (3rd revision ,
amendment 1 )
Pipe & Fitting s
IS 1239 : Part I & Part II 1990/199 2
Mild steel. tubes and fittings .
G4
G3
G7
IS 2906 : 1984 (reaffirmed 1990)
Specification for sluice vatve for water work s
purposes 350 to 1200 mm size (3rd revision ,
318
ISHRAE Installation Guid e
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3 16
ISHRAE Installation Guide
temperature will remain liquid before evaporating
into its gaseous form or state .
Volume, Specific : The volume of a substance pe r
unit mass ; the reciprocal of density.
Velocity : A vector quantity which denotes, at once ,
the time rate and the direction of a linear motion .
W
Velocity Head : The pressure needed to accelerate
the fluid being pumped .
Water Hammer : Banging of pipes caused by th e
shock of closing valves (faucets) .
Velocity Reduction Method : A method of duct
sizing where arbitrary reductions are made in
velocity after each branch or outlet .
Watt (W) : A measure of electric power equal to a
current flow of one ampere under one volt o f
pressure ; or one joule per second in SI units .
Velocity, Outlet : The average discharge velocity
of primary air being discharged from the outlet,
normally measured in the plane of the opening .
Watt Transducer : A device which converts a
current signal into a proportional millivolt signal .
Used to interface between current transformer s
and a load management panel .
Velocity, Room : The average sustained, residual
air velocity level in the occupied zone of the
conditioned space ; e .g ., 65, 50, 35 fpm .
Velocity, Terminal : The highest sustained
airstream velocity existing in the mixed air path at
the end of the throw,
Ventilation : The process of supplying or removin g
air, by natural or mechanical means, to or from an y
space . Such air may or may not have bee n
conditioned .
Vernal Equinox : The position of the sun midwa y
between its lowest and highest altitude ; during the
spring it occurs March 21 . The sunlit period i s
approximately the same length as the autumna l
equinox .
(see also AUTUMNAL EQUINOX)
Viscosity : That property of semifluids, fluids, an d
gases by the virtue of which they resist a n
instantaneous change of shape or arrangement o f
parts . It is the cause of fluid friction wheneve r
adjacent layers of fluid move with relation to eac h
other.
Volatility : Volatility surface tension and capillary
action of a fluid are incidental to environmenta l
systems . Volatility is the rapidity with which liquid s
evaporates extremely rapidly and therefore is highl y
volatile .
'
Voltage (E) : The electromotive force in an electrica l
circuit . The difference in potential between tw o
unlike charges in an electrical circuit is its voltag e
measured in "volts : (V) .
Voltage Drop : The voltage drop around a circui t
including wiring and loads must equal the suppl y
voltage .
Volume : Cubic feet per pound of dry air in the airwater vapor mixture as used in psychrometrics .
Wavelength : The distance between two similar an d
successive points on an alternating wave . Th e
wavelength is equal to the velocity of th e
pro pa ga Lion divided by the frequency of th e
alternations .
Weight : The amount of force a substance exert s
under pull by the earth's gravitational field and tha t
force is measured in pounds in United States . .
Wet Bulb Temperature (WB) : The temperatur e
registered by a thermometer whose bulb is covere d
by a saturated wick and exposed to a current o f
rapidly moving air. The wet bulb temperature also
represents the dew point temperature of the air,
where the moisture of the air condenses on a col d
surface .
Wet Bulb Depression : Difference between dry bul b
and wet bulb temperatures .
Winter Solstice : The shortest sunlit day of th e
year at which the sun is at the lowest altitude ; i t
occurs December 21 .
Wye Service : An arrangement of the utilit y
transformers . Abbreviated : Y .
Z
Zoning : The practice of dividing a building int o
small sections for heating and cooling control . Eac h
section is selected so that one thermostat can b e
used to determine its requirements .
ISHRAE Installation Guide
of latent and sensible heat at terminal coils appear s
simultaneously. Total heat also is called enthalpy ,
both of which can be defined as the quantity o f
heat energy contained in that substance .
Total Pressure Method : A method of duct sizin g
which allows the designer to determine all frictio n
and dynamic losses in each section of a duct syste m
(including the total system) .
Toxic Fluids : Gases or liquids which are poisonous ,
irritating and/or suffocating .
Tracking Collector: A solar energy collector tha t
constantly positions itself perpendicular to the su n
as the earth rotates .
Transducer : The means by which the controlle r
converts the signal from the sensing device int o
the means necessary to have the appropriat e
effect on the controlled device . For example, a
change in air pressure in the pneumati c
transmission piping .
Transformer : The system power supply - a
transformer is an inductive stationary device whic h
transfers electrical energy from one circuit t o
another. The transformer has two windings, primary
and secondary . A changing Voltage applied to one o f
these, usually the primary, induces a current t o
flow in the other winding . A coupling transforme r
transfers energy at the same voltage, a step-dow n
transformer transfers energy at a lower voltage ,
and a step-up transformer transfers energy at a
higher voltage .
Transmission : The means by which a signal is move d
from one point of origin to the point of action .
Transmission, coefficient of Heat : Any one of a
number of coefficients used in the calculation o f
heat transmission by conduction, convection, an d
radiation, through various materials an d
structures .
Transmittance, Thermal (U factor) : The time rate
of heat flow per unit area under steady condition s
from the fluid on the warm side of a barrier to th e
fluid on the cold side, per unit temperatur e
difference between the two fluids .
U
Utility Service : The utility company. Also, th e
amount and configuration of voltage supplied by a
utility company. There are four main types o f
commercial utility services : 208V AC wye, 480 V A C
wye, 240 V Ac delta, and 480 V AC delta .
315
Utility Transformer : Primary and secondary coil s
of wire which reduce (step down) the utility supply
voltage for use within a facility.
Unitary System : A room unit which performs par t
or all of the air conditioning functions . It may o r
may not be used with a central fan system .
Unloader : A device on or in a compressor fo r
equalizing the high and low side pressures for a
brief period during starting, in order to decreas e
the starting load on the motor ; also a device fo r
controlling compressor capacity by rendering on e
or more cylinders ineffective .
V
Vacuum : Any pressure less than that exerted b y
the atmosphere .
Vacuum, Breaker : A device to prevent a suctio n
in a water pipe .
Valve, Modulating : A valve which can be positione d
anywhere between fully on and fully off t o
proportion the rate of flow in response to a
modulating controller (see modulating control) .
Valve, Two-Position : A valve which is either full y
on or fully off with no position between . Also calle d
an on-off valve . "
Vane Ratio : In air distributing devices, the rati o
of depth of vane to shortest opening widt h
between two adjacent grille bars .
Vapor : A gas, particularly one near to equilibriu m
with the liquid phase of the substance and whic h
does not follow the gas laws . Usually used instead o f
gas for a refrigerant, and, in general, for any gas
below the critical temperature .
Vapor, Saturated : Vapor in equilibrium with it s
liquid ; i .e ., when the numbers per unit time o f
molecules passing in two directions through th e
surface dividing the two phases are equal .
Vapor, Superheated : Vapor at a temperatur e
which is higher than the saturation temperatur e
(i .e ., boiling point) at the existing pressure .
Vapor, Water : Used commonly in air conditionin g
parlance to refer to steam in the atmosphere .
Vapor Barrier : A moisture-impervious layer applie d
to the surfaces enclosing a humid space to preven t
moisture travel to a point where it may condens e
due to lower temperature .
Vapor Pressure: Vapor pressure denotes the lowes t
absolute pressure that a given liquid at a given
314
ISHRAE Installation Guid e
Temperature, Saturation : The temperature a t
which no further moisture can be added to the ai r .
water vapor mixture . Equals dew point temperature .
refrigeration cycle, the net heat absorbed b y
the working substance is exactly equal to th e
net work done .
Temperature, Wet-bulb : Thermodynamic wet bul b
temperature is the temperature at which liquid o r
solid water, by evaporating into air, can bring th e
air to saturation adiabatically at the sam e
temperature . Wet bulb temperature (withou t
qualification) is the temperature indicated by a we t
bulb psychrometer constructed and used accordin g
to specifications .
The Second Law : (1) It is impossible for a self acting machine, unaided by any external agency,
to convey heat from a body of towe r
temperature to one of higher temperatur e
(Cfausius) ; (2) It is impossible to deriv e
mechanical work from heat taken from a bod y
unless there is available a body of lowe r
temperature into which the residue not so use d
may be discharged (Kelvin) ; (3) It is impossibl e
to construct an engine that, operating in a
cycle, will produce no effect other than th e
extraction of heat from a reservoir and th e
performance of an equivalent amount of wor k
(Zemansky) .
Temperature, Wet Bulb Depression : Differenc e
between dry bulb and wet bulb temperatures .
Temperature Difference, Mean : Mean o f
difference between temperatures of a flui d
receiving and a fluid yielding heat .
Terminal Velocity : The maximum airstream velocity
at the end of the throw.
Therm : Measurement used by gas utilities for billin g
purposes . 1 Therm = 100 cubic feet of gas = 100,00 0
Btu .
Thermal Capacity : The ability of a medium to hol d
heat .
Thermal Expansion Valve : The metering device o r
flow control which regulates the amount of liqui d
refrigerant which is allowed to enter th e
evaporator .
Thermistor : Semiconductor material that responds
to temperature changes by changing its resistance .
Thermocouple : Device for measuring temperature
utilizing the fact that an electromotive force i s
generated whenever two junctions of two dissimila r
metals in an electric circuit are at differen t
temperature levels .
Thermodynamics, Laws of : Two laws upon whic h
rest the classical theory of thermodynamics . Thes e
taw have been stated in many different, bu t
equivalent ways .
The First Law : (1) When work is expanded i n
generating heat, the quantity of heat produced
is proportional to the work expended ; and ,
conversely, when heat is employed in th e
performance of work, the quantity of heat whic h
disappears is proportional to the work don e
(Joule) ; (2) If a system is caused to change fro m
an initial state to a final state by adiabati c
means only, the work done is the same for al l
adiabatic path connecting the two state s
(Zemansky) ; (3) In any power cycle or
Thermodynamic Wet Bulb Temperature : Th e
temperature at which water, by evaporating int o
air, can bring the air to saturation adiabatically a t
the same temperature.- The wet bulb temperature
measured with an appropriate psychrometer ca n
approach the thermodynamic wet bulb temperatur e
(also called the Adiabatic Saturation Temperature) .
Thermostat : An instrument which responds t o
changes in temperature and which directly o r
indirectly controls temperature .
Thermosyphon : Circulation of a fluid by makin g
use of the change in density of a material when it i s
heated and coated . Also called Natural Circulation .
Throttling Range : The amount of change in th e
variable being controlled to make the controlle d
device more through the ruff length of its stroke .
Throw : The horizontal or vertical axial distanc e
an airstream travels after leaving an air outle t
before the maximum stream velocity is reduced t o
a specified terminal level ; e .g ., 200, 150, 100 or 5 0
fpm .
Tic Mark : Hatch mark on drawing raceway symbol ,
showing number of wires.
Ton (of Refrigeration) : A useful refrigeratin g
effect equal to 12,000 Btuh ; 200 Btu/min .
Total Dynamic Head : Dynamic discharge hea d
(static discharge head, plus friction head, plu s
velocity head) plus dynamic suction lift, or dynami c
discharge head minus dynamic suction head .
Total Heat (Enthalpy) : Total heat is the sum of th e
sensible heat and latent heat in an exchang e
process . In many cases, the addition or subtractio n
31 3
ISHRAE Installation Guide
operate by a variation in the conditions of on e
electrical circuit to affect the operation of device s
in the same or another circuit . General purpos e
switching relays are used to increase switchin g
capability and isolate electrical circuits, such as i n
systems where the hating and cooling equipmen t
have separate power supplies, and provid e
electrical interlocks within the system .
System : A series of ducts, conduits, elbows, branc h
piping, etc . designed to guide the flow of air, gas o r
vapor to and from one or more locations . A fa n
provides the necessary energy to overcome th e
resistance to flow of the system and causes air o r
gas flow through the system . Some components of a
typical system are louvers, grilles, diffusers, filters ,
heating and cooling coils, air pollution contro l
devices, burner assemblies, volume flow contro l
dampers, mixing boxes, sound attenuators, th e
ductwork and related fittings .
System, Central Fan : A mechanical, indirect syste m
of heating, ventilating, or air conditioning, in whic h
the air is treated or handled by equipment locate d
outside the rooms served, usually at a centra l
location, and conveyed to and from the rooms b y
means of a fan and a system of distributing ducts .
System, Closed : A heating or refrigerating pipin g
system in which circulating water or brine i s
completely enclosed, under pressure abov e
atmospheric, and shut off from the atmospher e
except for an expansion tank .
System, Duct : A series of ducts, conduits, elbows ,
branch piping, etc . designed to guide the flow o f
air, gas or vapor to and from one or more locations .
A fan provides the necessary energy to overcom e
the resistance to flow of the system and causes ai r
or gas flow through the system . Some component s
of a typical system are louvers, grilles, diffusers ,
filters, heating and cooling coifs, energy recover
y
devices, burner assemblies, volume dampers, mixin g
boxes, sound attenuators, the ductwork an d
related fittings .
System, Flooded : A system in which only part o f
the refrigerant passing over the heat transfe r
surface is evaporated, and the portion no t
evaporated is separated from the vapor an d
recirculated .
System, Gravity Circulation : A heating o r
refrigerating system in which the heating or coolin g
fluid circulation is effected by the motive head du e
to difference in densities of cooler and warme r
fluids in the two sides of the system .
System, Run-around : A regenerative-type, closed ,
secondary system in which continuously circulate d
fluid abstracts heat from the primary system flui d
at one place, returning this heat to the primar y
system fluid at another place .
System, Unitary : A complete, factory-assembled an d
factory-tested refrigerating system comprising on e
or more assemblies which may be shipped as on e
unit or separately but which are designed to b e
used together.
System Curve : A graphic presentation of th e
pressure vs . volume flow rate characteristics of a
particular system .
System Effect Factor : A pressure loss factor whic h
recognizes the effect of fan inlet restrictions, fa n
outlet restrictions, or other conditions influencin g
fan performance when installed in the system .
T
Temperature, Absolute Zero : The zero point o n
the absolute temperature scale, 459 .69 degree s
below the zero of the Fahrenheit scale, 273 .1 6
degrees below the zero of the Celsius scale .
Temperature, Critical : The saturation temperatur e
corresponding to the critical state of the substanc e
at which the properties of the liquid and vapor ar e
identical .
Temperature, Dewpoint : The temperature a t
which the condensation of .water vapor in spac e
begins for a given state of humidity and pressure
as the temperature of the vapor is reduced . Th e
temperature corresponding to saturation (10 0
percent relative humidity) for a given absolut e
humidity at constant pressure .
Temperature, Drybulb : The temperature of a ga s
or mixture of gases indicated by an accurat e
thermometer after correction for radiation .
Temperature, Effective : An arbitrary index which
combines into a single value the effect o f
temperature, humidity, and air movement on th e
sensation of warmth or cold felt by the human body.
The numerical value is that of the temperature o f
still, saturated air which would induce an identica l
sensation .
Temperature, Mean Radiant (MRT) : Th e
temperature of a uniform black enclosure is whic h
a solid body or occupant would exchange the sam e
amount of radiant heat as in the existing nonuniform environment .
_
312
barometric pressure . At these standard conditions ,
the density of air is 0 .075 pounds per cubic fee t
and the density of water is 62 .4 pounds per cubi c
foot .
Standard Rating : A ring based on tests performe d
at Standard Rating Conditions .
Starter : Basic contactor with motor overloads ,
etc ., added . a motor starter is an adaption of th e
basic contactor which includes overload relays .
Starters for large motors may include reactors, ste p
resistors, disconnects, or other features require d
in a more sophisticated starter package .
State : Refers to the form of a fluid, either liquid ,
gas or solid . Liquids used in environmental system s
are water, thermal fluids such as ethylene glyco l
solutions, and refrigerants in the liquid state . Gase s
are steam, evaporated refrigerants and the airwater vapor mixture found in the atmosphere . Som e
substances, including commonly used refrigerants ,
may exist in any of three states . A simple example i s
water, which may be solid (ice), liquid (water), o r
gas (steam or water vapor) .
Static Head : The pressure due to the weight of a
fluid above the point of measurement .
Static Regain Method : A method of duct sizin g
wherein the duct velocities are systematicall y
reduced, allowing a portion of the velocity pressur e
to convert to static pressure offsetting the duc t
friction losses .
Static Suction Head : The positive vertical heigh t
in feet from the pump centerline to the top of th e
level of the liquid source .
Static Suction Lift : The distance in feet betwee n
the pump centerline and the source of liquid belo w
the pump centerline .
Step Controller : See Sequencer.
Stratified Air : Unmixed air in a duct that is in therma l
layers that have temperature variations of mor e
than five degrees .
Structure-Borne Noise : A condition when the soun d
waves are being carried by a solid material . Soun d
waves in this state are inaudible to the human ear ,
since they cannot carry energy to it . Airborne nois e
can be created from the radiation of structureborne noise into air. Structure-borne noise may b e
propagate by shear waves, tension-compressio n
waves, bending waves, or complicated combinatio n
of waves .
Subcooling : The difference between the
ISHRAE Installation Guid e
temperature of a pure condensable fluid belo w
saturation and the temperature at the liqui d
saturated state, at the same pressure .
Subcooling Specific : The difference betwee n
specific enthalpies of a . pure condensable flui d
between liquid at a given temperature belo w
saturation and liquid at saturation, at the sam e
pressure .
Sublimation : A change of state directly from soli d
to gas without appearance of liquid .
Suction Head: The positive pressure on the pum p
inlet when the source of liquid supply is above th e
pump centerline .
Suction Lift : The combination of static suction lif t
and friction head in the suction piping when th e
source of liquid is below the pump centerline .
Suction Piping : The piping which returns gaseou s
refrigerant to the compressor. Sizes must be- larg e
enough to maintain minimum friction to preven t
reduced compressor and system capacity but mus t
be small enough to produce adequate velocity t o
return oil to the compressor .
Sun Effect : Solar energy transmitted into spac e
through windows and building materials .
Sun Rights (Solar Rights) : A legal questio n
concerning the rights to non-interrupted use o f
the sun's radiant energy, such as shading of sola r
collectors by a neighbors' building .
Superheat : The difference between th e
temperature of a pure condensable fluid abov e
saturation and the temperature at the dry saturate d
state, at the same pressure .
Superheat, Specific : The difference betwee n
specific enthalpies of a pure condensable flui d
between vapor at a given temperature abov e
saturation and vapor at dry saturation, at the sam e
pressure .
Surface, Heating : The exterior surface of a heatin g
unit . Extended heating surface (or extende d
surface), consisting of firs, pins, or ribs whic h
receive heat by conduction from the prime surface .
Prime surface : heating surface having the heatin g
medium on one side and air (or extended surface )
on the other.
Surge Suppressor : A device that reduces harmoni c
distortion in line voltage circuits by clipping off
transient voltages which are fed through the powe r
lines from operating equipment .
Switching Relays : Relays are devices which
.xs
ISHRAE Installation Guide
Sound Absorption : (1) The process of dissipatin g
or removing sound energy. (2) The propert y
possessed by materials, objects, and structures ,
such as rooms, of absorbing sound energy . (3) Th e
measure of the magnitude of the absorptiv e
property of a material, an object, or a structure ,
such as a room .
Sound Attenuator : A device or equipment tha t
prevents, reduces, or absorbs sound .
Sound Power Level of a Source(Lw) : The ratio ,
expressed in decibels, of its sound power to th e
reference sound power which, by divide d
agreement, is either 10 -73 or 10 -12 watts . Th e
reference power should always be stated .
Sound Power of a Source (W) : The rate at whic h
sound energy is radiated by the source . Withou t
qualification, overall sound power is meant but ofte n
sound power in a specific frequency band i s
indicated .
Sound Pressure (p) : An alternating pressur e
superimposed on the static or barometric pressur e
by sound . In analogy to alternating voltage, it ca n
be measured or expressed in several ways, such a s
maximum sound pressure or instantaneous soun d
pressure . Unless such a qualifying word is used, i t
is the effective or root-mean-square pressur e
which is meant .
Sound Pressure Level (Lp) : The squared ratio ,
expressed in decibels, of the sound pressure unde r
consideration to the reference pressure which, b y
agreement, is 0 .0002 dynes per square centimeter.
The reference pressure should be stated if it is no t
implied .
This concept is more properly, but mor e
cumbersomely, called "effective-sound-pressuresquared level," since effective pressures are implie d
and it is pressure-squared which is proportional t o
power to energy.
Sound Transmission Class : The preferred singl e
figure rating designed to give a preliminary estimat e
of the sound insulation properties of a partition . A
standard contour which defines transmission los s
as a function of frequency is fitted to th e
transmission loss curve according to the rule s
outlined in ASTM E413-73, "Standard Classificatio n
For Determination of Sound Transmission Class' .
Sound Transmission Coefficient : The soun d
transmission coefficient of a partition is th e
fraction of the incident sound power transmitte d
through it when the sound fields on both sides of
31 1
the partition are diffuse .
Sound Transmission Loss of a Partition (TL) : Th e
ratio, expressed in decibels, of the incident soun d
power on the source side of the specimen to th e
transmitted sound power on the receiving side whe n
the sound fields on both sides of the specimen ar e
diffuse .
When the sound fields are not diffuse, a qualifyin g
word is necessary, such as normal incidence soun d
transmission loss, or field transmission loss .
Specific Heat : Specific heat (Cp) is the amount of
heat energy in Btu's required to raise th e
temperature of one pound of substance one degre e
Fahrenheit . The following are specific heat value s
at standard conditions :
water - Cp = 1 .00 Btu/lb/° F
air - Cp = 0 .24 Btu/lb/° F
Using these values in simple equations, gallons pe r
minute or cubic feet per minute may be determine d
in a system if the Btu per hour and the temperatur e
difference are known .
Specific Volume : The reciprocal of density and i s
used to determine the cubic feet of volume, if th e
pounds of weight are known . Both density an d
specific volume are affected by temperature and
pressure . The specific volume of air under standar d
condition is 13 .33 cubic feet per pound and th e
specific volume of water at standard conditions i s
0 .016 feet per pound .
Spread : The divergence of the airstream in a
horizontal or vertical plane after it leaves the outlet .
Stage Differential : Change in temperature at the
thermostat needed to turn heating or coolin g
equipment off once it is turned on .
Staging Interval : The minimum time period fo r
shedding or restoring two sequential loads .
Stagnant Air Area : An area within a space wher e
the air velocity is less than 25 fpm .
Standard Air Density (d) : Standard air density ha s
been set at 0 .075 lb/cu .ft . This correspond s
approximately to dry air at 70°F and 29 .92 in . Hg i n
metric units, the standard air density is 1 .204 1
kg 3 /m at 20°C and at 101 .325 kPa .
Standard Conditions : The standard condition s
referred to in environmental system work for ai r
are : dry air at 70°F, and at an atmospheric pressur e
of 29 .92 inches mercury (in .Hg .) . For water ,
standard conditions are 68°F at the same
310
Sensible Heat Factor : The ratio of sensible heat t o
total heat .
Sensible Heat Ratio, Air cooler : The ratio o f
sensible cooling effect to total cooling effect of a n
air cooler.
Sensing Device : A device that keeps track of th e
measured condition and its fluctuations so tha t
when sufficient variation occurs it will originat e
the signal to revise the operation of the syste m
and offset the change . Example : a thermostat "bulb" .
A sensing device may be an integral part of a
controller.
Sensing Element : The first system element or grou p
of elements . The sensing element performs the initia l
measurement operation .
Sensitivity : The ability of a control instrument t o
measure and act upon variations of the measur e
condition .
Sensor : A sensing element .
Sequencer : A mechanical or electrical device tha t
may be set to initiate a series of events and t o
make the events follow in sequence .
Sequencing Control : A control which energize s
successive stages of heating or cooling equipmen t
as its sensor detects the need for increased heatin g
or cooling capacity . May be electronic o r
electromechanical .
Series Circuit : One with all the elements connecte d
end to end . The current is the same throughout bu t
the voltage can be different across each element .
Service Drop : The overhead service wires tha t
serve a building .
Service Switch : One to six disconnect switches o r
circuit breakers . Purpose is to completel y
disconnect the building from the electric service .
Set Point : The value of the controlled condition a t
which the instrument is set to operate . The se t
point in the example in 'differential" might be 69 1 /
2°, the mid point of the differential .
Shading Loss : The loss of collector efficienc y
caused by the shading of the absorber plate b y
collector edges or components . The shading loss
usually varies with the angle of incidence of th e
isolation .
ISHRAE Installation Guid e
kW demand set point .
Shed Mode : A method of demand control tha t
reduces kW demand through shedding and restorin g
toads .
Shielded Cable : Special cable used with equipmen t
that generates a low voltage output . Used t o
minimize the effects of frequency "noise" on th e
output signal .
Short Circuit : An electric circuit with zero load ;
an electrical fault .
Short Cycling : Unit runs and then stops at shor t
intervals ; generally this excessive cycling rate i s
hard on the system equipment .
Should or It is Recommended : Term used t o
indicate provisions which are not mandatory bu t
which are desirable as good practice .
Single-phasing : The condition when one phase of a
multiphase (polyphase) motor circuit is broken o r
opened . Motors running when this occurs ma y
continue to run but with lower power output an d
overheating .
Solar Altitude : The angular elevation of the su n
above the horizon .
Solar Azimuth : Angle between true south an d
projection of earth-sun line on a horizontal plane .
Solar Collector : Any device which collects sola r
energy and transforms it to another usable form o f
energy .
Solar Energy : The photon energy originating fro m
the sun's radiation in the wavelength region fro m
0 .3 to 2 .4 micrometers ; the radiant energy of th e
sun, whether it be direct, diffuse or reflecte d
radiation .
Solar Time : The time of day based on the relativ e
position of the sun with respect to a position o n
the earth's surface . Solar noon is that instant o n
any day at which the sun reaches its maximu m
altitude for that day .
Solenoid Air Valves : EP switches with a n
electromagnetic coil in the valve topworks tha t
opens or closes the valve from normal position . A
spring returns the valve to the normal position whe n
the colt is de-energized .
Shall or Will : Where shall or will is used as a provisio n
specified, that provision is mandatory if complianc e
with the standard is claimed .
Sane : One sone is defined as the loudness of a 100 0
Hz tone having a sound pressure of 40 dB . Two sone s
is twice as loud as the 40 dB reference sound of on e
sone, etc .
Shed : To de-energize a Load in order to maintain a
Sorbent : See absorbent .
ISHRAE Installation Guide
responsible for the result in the controlled space .
The resetting controller is commonly called th e
master, and the controller being reset is commonl y
called the submaster (stave) .
Reset Ratio : The ra(io of change in outdoo r
temperature to the change in control poin t
temperature . For example, a 2 :1 reset ratio mean s
that the control point will increase 1 degree fo r
every 2 degrees change in outdoor temperature .
3 09
level heard by an occupant of a room is called th e
Room Effect . The magnitude of the Room Effec t
depends upon the amount of sound absorption i n
the room (Sabins), the distance between th e
termination of the duct and the nearest observe r
and the directivity factor of the source .
Room Velocity : The residual air velocity level i n
the occupied zone of the conditioned space (e .g . ,
65, 50, 35 fpm) .
Resistance (Q) : The opposition which limits th e
amount of current that can be produced by a n
applied voltage in an electrical circuit, measured i n
ohms .
-
Running Current : The current that flows throug h
a load after inrush current . Usually called "full loa d
current ."
Resistance, Thermal : The reciprocal of therma l
conductance .
S
Return Air : Air returned from conditioned o r
refrigerated space .
Reverberant Sound Field : A space in which soun d
persists because of continuous refelctions . A
reverberant field is not necessarily diffuse .
Reverberation : The persistence of sound in a n
enclosed space after the sound source has stopped .
In a reverberation room, it is characterized by th e
decay or dying away of the sound .
Reverberation Room : A highly sound reflectiv e
room in which special care has been taken to mak e
the sound field as diffuse as possible .
Reverberation Time : The reverberation time o f
an enclosed space is the number of seconds required ,
or that would be required were the decay rate to
remain constant, for the sound pressure level t o
decrease by 60 seconds .
Riser Diagram : Electrical block-type diagra m
showing connection of major items of equipment .
It is also applied to signal equipment connections .
Also generally applied to multistorey buildings fo r
vertical hydronic piping and duct work .
Riser Shaft : A vertical shaft designed to hous e
electric cables, piping and ductwork .
Sabin : The unit of acoustic absorption . One sabi n
is one square foot of perfect sound-absorbin g
material .
Saturation Degree of : The ratio of the weight o f
water vapor associated with a pound of dry air t o
the weight of water vapor associated with a poun d
of dry air saturated at the same temperature .
Seasonal Energy Efficiency Ratio (SEER) : The tota l
quantity of heat delivered or removed by heatin g
or cooling equipment in Btu divided by the tota l
electrical energy input in kilowatt hours over a n
entire season .
Seasonal Performance Factor : The ratio of th e
total quantity of heat delivered by a heat pump ,
(including supplement resistance heaters) to th e
total quantity of energy input (includin g
supplementary resistance heaters) for the tota l
annual heating hours below 69 0 F.
Secondary Air : The air surrounding an outlet tha t
is captured or entrained by the initial outle t
discharge airstream (furnished by a supply duct o r
fan) .
Secondary Service : Voltage service up to 60 0
volts .
Seismic : Subject to or caused by an earthquake .
Room Criteria Curves (RC Curves) : Curves simila r
to NC curves that represent a close approximatio n
to a well balanced, bland-sounding spectru m
Semi-Extended Plenum : A trunk duct that i s
extended as a plenum from a fan or HVAC unit t o
serve multiple outlets and/or branch ducts .
Room Dry Bulb : The actual temperature of th e
conditioned room or space as measured with a n
accurate thermometer.
Sensible Heat : Sensible heat is any heat transfe r
that causes a change in temperature . Heating an d
coaling of air and water that may be measured wit h
a thermometer is sensible heat . Heating or coolin g
coils that simply increase or decrease the ai r
temperature without a change in moisture conten t
are examples of sensible heat .
Room Effect : The difference between the soun d
power level discharged by a duct (through a diffuser
or other termination device) and the sound pressure
308
ISHRAE Installation Guid e
Proportional Band : The range of values of a
proportional positioning controller through whic h
the controlled variable must pass to move the fina l
control element through its full operating range .
Commonly used equivalents are "throttling range"
and "modulating range" .
Proportional Control : See Modulating Control .
Psychrometer : An instrument for ascertaining th e
humidity or hygrometric state of the atmosphere .
Psychrometric Chart : A graphical representatio n
of the thermodynamic properties of moist air.
Pull Box : A metal cabinet inserted into a condui t
run for the purpose of providing a cable pullin g
point . Cable may be spliced in these boxes .
Pulsing Demand Meter : A meter which generates a
pulse in correspondence with each revolution o f
kWh meter . Pulses are recorded on paper o r
magnetic tape . Pulse can also be the signal t o
demand control equipment .
Pure Tone : A pure tone sound that has a uniqu e
pitch and is characterized by a sinusoidal variatio n
in sound pressure with time . The frequenc y
spectrum of a pure tone shows a single line at a
discrete frequency.
Pyranometer : A measurement device to determin e
local values of total (direct and diffuse) isolation .
Pyrometer : An instrument for measuring hig h
temperatures .
Pyrheliometer : A measurement device to determin e
local values of direct insolation .
R
Raceway : Any support system, open or closed, fo r
carrying electric waves .
Radiation (Acoustic) : The process of turnin g
structure-borne noise into airborne (or some othe r
fluid-borne) noise .
Radiation, Thermal : The transmission of hea t
through space by wave motion ; the passage of hea t
from one object to another without warming th e
space between .
Radius of Diffusion : The horizontal axial distanc e
an airstream travels after leaving an air outle t
before the maximum stream velocity is reduced to
a specified terminal level ; e .g ., 200, 150 or 100
fpm .
Random Incidence : If an object is in a diffus e
sound field, the sound is said to strike the object
at random incidence .
Real Time : Time measured according to the tim e
of day (1PM, 2 PM, etc .) . Different from th e
"electronic time" of a cycling device .
Receiver : An auxiliary storage receptacle fo r
refrigerant when the system is pumped down an d
shut down .
Reflected Isolation : The portion of the total sola r
energy reaching a surface (windows, wall, collector )
which has been reflected by an adjoining surface .
Reflectivity : The property of a material tha t
determines its ability to reflect radiant energy.
Refrigerant : The fluid used for heat transfer in' a
refrigerating system, which absorbs heat at a lo w
temperature and a low pressure of the fluid an d
rejects heat at a higher temperature and a highe r
pressure of the fluid, usually involving changes o f
state of the fluid .
Regenerated Noise : Duct noise, which is generate d
by air turbulence in the duct or fittings .
Register : A grille equipped with an integral dampe r
or control valve .
Relative Humidity (RH) : The ratio of water vapo r
in the air as compared to the maximum amount o f
water vapor that may be contained .
Relay : An electomechanical switch that opens o r
closes contacts in response to some controlle d
action . Relay contacts can be normallyopen (N .O . )
and/or normally closed (N .C .) . Relays may b e
electric, pneumatic, or a combination of both . P E
and EP switches are relays .
Relay, Thermal : A switching relay in which a smal l
heater warms a bimetal element which bends t o
provide the switching force .
Remote Temperature Set Point : Ability to set a
temperature control point for a space from outsid e
the space . Often used in public areas .
Reset : A process of automatically adjusting th e
control point of a given controller to compensat e
for changes in outdoor temperature . The hot dec k
control point is normally reset upward as th e
outdoor temperature drops . The cold deck contro l
point is normally reset downward as the outdoo r
temperature increases .
Reset Controllers : Two controllers operatin g
together ; one sensing a condition other than tha t
of the controlled space and changing the set poin t
of the second controller, which is directly
ISHRAE Installation Guide
impedance (Z) expressed as a decimal between zer o
and one (p .f . = R/Z) . When the power factor equal s
one, all consumed power provides useful work .
Power Factor Charge : A utility charge for "poor "
power factor. It is more expensive to provide powe r
to a facility with a poor power factor (usually les s
than 0 .8) .
Power factor Correction : Installing capacitors o n
the utility service's supply line to improve the powe r
factor of a building .
Power Supply : The voltage and current source fo r
an electrical circuit . A battery, a utility service ,
and a transformer are power supplies .
Predicting Method : Method of determining whe n
load shedding should occur. A formula is used t o
arrive at a preset kilowatt limit . Then the actua l
amount of energy accumulated during the utility' s
demand intervals is measured . A projection is mad e
of the actual rate of energy usage during the res t
of the interval . If the predicted value exceeds th e
preset limit, loads will be shed .
Preheating : In air conditioning, to heat the ai r
ahead of other processes .
Pressure : The normal force exerted by a
homogeneous liquid or gas, per unit of area, on th e
wail of its container.
Pressure, Absolute : Pressure referred to that o f
a perfect vacuum . It is the sum of gauge pressure
and atmospheric pressure .
Pressure, Atmospheric : It is the pressur e
indicated by a barometer. Standard atmosphere i s
the pressure equivalent to 14 .696 psi or 29 .921 in .
of mercury at 32°F.
Pressure, Critical : Vapor pressure correspondin g
to the substance's critical state at which the liqui d
and vapor have identical properties .
Pressure, Gauge : Pressure above atmospheric .
Pressure, Hydrostatic : The normal force per uni t
area that would be exerted by a moving fluid on a n
infinitesimally small body immersed in it if the bod y
were carried along with the fluid .
Pressure, Partial : Portion of total gas pressure o f
a mixture attributable to one component .
Pressure, Static (SP) : The normal force per uni t
area that would be exerted by a moving fluid on a
small body immersed in it if the body were carrie d
along with the fluid . Practically, it is the norma l
force per unit are at a small hole in a wall of the
307
duct through which the fluid flows (piezometer) o r
on the surface of a stationary tube at a point wher e
the disturbances, created by inserting the tube ,
cancel . It is supposed that the thermodynami c
properties of a moving fluid depend on stati c
pressure in exactly the same manner as those o f
the same fluid at rest depend upon its unifor m
hydrostatic pressure .
Pressure, Total (TP) : In the theory of flow of fluids ,
the sum of the static pressure and the velocit y
pressure at the point of measurement . Also calle d
dynamic pressure .
Pressure, Vapor : The partial pressure exerted b y
the water vapor contained in air.
Pressure, Velocity (Vp) : In moving fluid, th e
pressure capable of causing an equivalent velocity,
if applied to move the same fluid through an orific e
such that all pressure energy expended is converte d
into kinetic energy.
Pressure Drop : Pressure loss in fluid pressure, a s
from one end of a duct to the other, due to friction ,
dynamic losses, and changes in velocity pressure .
Pressure Regulator : Automatic valve between th e
evaporator outlet and compressor inlet that i s
responsive to pressure or temperature ; it function s
to throttle the vapor flow when necessary t o
prevent the evaporator pressure from falling belo w
a preset level .
Primary Air : The initial airstream discharged by a n
air outlet (the air being supplied by a fan or suppl y
duct) prior to any entrainment of the ambient air .
Primary Control : A device which directly o r
indirectly controls the control agent in respons e
to needs indicated by the controller . Typically a
motor, valve, relay, etc .
Primary Element : The portion of the controlle r
which first uses energy derived from the controlle d
medium to produce a condition representing th e
value of the controlled variable ; for example, a
thermostat bimetal .
Primary Service: High voltage service, above 60 0
volts .
"Process" Hot water : Hot water needed fo r
manufacturing processes over and above th e
'domestic hot water" that is for the personal use o f
industrial workers .
Properties, Thermodynamic : Basic qualities use d
in defining the condition of a substance, such a s
temperature, pressure, volume, enthalpy, entropy .
3 06
accomplish the transfer of thermal energy. Th e
prime element in a passive solar system is usuall y
some form of thermal capacitance .
Peak Demand : The greatest amount of kilowatt s
needed during a demand interval .
Peak Load Pricing : A pricing principle that charge s
more for purchases that contribute to the pea k
demand and, thereby, cause the expansion o f
productive capacity when the peak demand exceed s
the peak power capacity (less minimum exces s
capacity) . In the electric power industry, this mean s
charging more for electricity bought on or nea r
the seasonal peak of the utility or on or near th e
daily peak of the utility. The latter requires specia l
meters ; the former does not .
Performance Factor : Ratio of the useful outpu t
capacity of a system to the input required to obtai n
it . Units of capacity and input need not b e
consistent .
Phase : Part of an AC voltage cycle . Residentia l
electrical service is 2-phase ; commercial facilitie s
are usually 3-phase AC voltage .
Phan : A measurement of loudness level. The loudnes s
level in phons of any sound is the sound pressur e
level of the 1000-Hz reference tone which is equall y
loud to the sound being rated . The loudness of 1
sone corresponds to a loudness level of 40 phons i n
accordance with the definition of the sone ; a tw o
fold change of loudness in sones is associated wit h
a 10-phan change in loudness level .
Photovoltaic Conversion : Use of semiconducto r
or other photovoltaic devices that convert sola r
radiation directly to electricity .
Pilot Duty Relay : A relay used for switching load s
such as another relay or solenoid valve coils . Th e
pilot duty relay contacts are located in a secon d
control circuit . Pilot duty relays are rated in voltamperes (VA) .
Pitch : The pitch of a sound depends primarily on its
frequency . In music, sounds of higher frequencies
are referred to as treble notes, while those of lowe r
frequencies are referred to as bass notes .
Planting Screen : Bushes or other planting tha t
hides a refrigerant compressor.
Plenum : An air compartment connected to one o r
more distributing ducts .
Plug-in-Bus Duct : Bus duct with built-in power tap off points . Tap-off is made with a plug-in switch ,
circuit breaker, or other fitting .
ISHRAE Installation Guid e
Pneumatic : Operated by air pressure .
Pneumatic-Electric (PE) Switches : Device tha t
operates an electric switch from a change of ai r
pressure .
Point, Critical : Of a substance, state point at whic h
liquid and vapor have identical properties ; critica l
temperature, critical pressure, and critical volum e
are the terms given to the temperature, pressure ,
and volume at the critical point . Above the critica l
temperature or pressure, there is no demarcatio n
line between liquid and gaseous phases .
Point of Duty : A statement of air volume flow rat e
and static or total pressure at a stated densit y
and is used to specify the point on the system curv e
at which a fan is to operate .
Point of Operation : Used to designate the singl e
set fan performance values which correspond t o
the point of intersection of the system curve an d
the fan pressure-volume curve .
Point of rating : A statement of fan performanc e
values which to one specific point on the fa n
pressure-volume curve .
Polarity : The direction of current flow in a D C
circuit . By convention, current flows from plus t o
minus . Electron flow is actually in the opposit e
direction .
Pole : An electrical connection point . In a panel, th e
point of connection . On a device, the terminal tha t
connects to the power .
Potable Water : Water that is safe to drink .
Potential Transformer : A voltage transformer . Th e
voltage supplied to a primary coil induces a voltage
in a secondary coil according to the ratio of th e
wire windings in each of the coils .
Potentiometer : An elecromechanical device havin g
a terminal connected to each and to the resistiv e
element, . and a third terminal connected to th e
wiper contact . The electrical input is divided a s
the contact moves over the element, thus makin g
it passible to mechanically change the resistance .
Power (P) : Expressed in watts (W) or kilowatt s
(kW), and is equal to :
in DC circuit, P = El and P = 12 R
in AC circuit, P = El x Power factor
Power Factor (pf) : A quantity that relates the voltamperes of an AC circuit to the wattage (power =
volt-amperes x power factor) Power factor also i s
the ratio of the circuit resistance (R) to the
ISHRAE Installation Guide
305
Noise Reduction (NR) : The difference between th e
average sound pressure levels of two spaces . Usually
these two spaces are two adjacent rooms called ,
respectively, the source room and the receivin g
room .
linear air diffuser located in the ceiling, whic h
provides a horizontal distribution pattern o f
primary and secondary air over the occupied zon e
and induces low velocity secondary air motio n
through the occupied zone .
Normally open (or Normally closed) : The positio n
of a valve, damper, relay contacts, or switch whe n
external power or pressure is not being applied t o
the device . Valves and dampers usually are returne d
to a "normal' position by a spring .
Outlet, Slotted : A long, narrow air distributio n
outlet, comprised of deflecting members, locate d
in the ceiling sidewall, or sill, with an aspect ratio n
greater than 10, designed to distribute supply ai r
in varying directions and planes, and arranged t o
promote mixing of primary air and secondary roo m
air.
0
Octave Band (0 .B .) : A range of frequency wher e
the highest frequency of the band is double the
lowest frequency of the band . The band is usuall y
specified by the center frequency .
Offset : Term used to describe the differenc e
between the set point and the actual operating o r
control point .
Outlet, Vaned : A register or grille equipped wit h
vertical and or horizontal adjustable varies .
Outlet Velocity : The average velocity of ai r
emerging from an opening, fan or outlet, measure d
in the plane of the opening .
Output : Capacity, duty, performance, ne t
refrigeration produced by system .
Ohm (R) or (V) : A measure of pure resistance in an
electrical circuit .
Outside Air Opening: Any opening used as anentry
for -air from outdoors .
-
Ohm's Law : The relationship between current an d
voltage in a circuit . It states that current i s
proportional to voltage and inversely proportiona l
to resistance . Expressed algebraically, in DC circuit s
I E/R ; in AC circuits I = E/Z.
Overall Coefficient of Heat Transfer (therma l
transmittance) : The time rate of heat flow throug h
a body per unit area, under steady conditions, fo r
a unit temperature difference between the fluid s
on the two sides of the body.
"On-off" Control : A two position action which allow s
operation at either maximum or minimum condition ,
or on or off, depending on the position of th e
controller.
Overcurrent Device : A device such as a fuse or a
circuit breaker designed to protect a circuit agains t
excessive current by opening the circuit .
Opaque : Not permitting transmission of radian t
energy .
Overload : A condition of excess current ; mor e
current flowing than the circuit was designed t o
carry .
Open Circuit ; The condition when eithe r
deliberately or accidentally, an electrical conducto r
or connection is broken or open with a switch .
Override : A manual or automatic action taken t o
bypass the normal operation of a device or system .
Operating Point : The value of the controlle d
condition at which the controller actually operates .
Also called control point .
P
Optimum Operative Temperature : Temperatur e
that satisfies the greatest possible number o f
people at a given clothing and activity level .
Out Contacts : Those relay contacts which complet e
circuits when the relay coil is deenergized . Als o
referred to as "normally closed contacts" .
Outgassing : The emission of gases by materials an d
components, usually during exposure to elevate d
temperature, or reduced pressure .
Outlet, Ceiling ; A round, square, rectangular, or
Package A/C unit : Consists of a factory-mad e
assembly which normally includes an indoo r
conditioning coil, compressor(s), condensing coil ,
and may include a heating function as well .
Parallel Circuit : One where all the elements ar e
connected across the voltage source . Therefore ,
the voltage on each element is the same but th e
current through each may be different .
Passive Solar System : An assembly of collectors ,
thermal storage device(s), and transfer media whic h
converts solar energy into thermal energy and i n
which no energy in addition to solar is used to
304
ISHRJ&E Installation Guide
Louver : An assembly of sloping vanes intended t o
permit air to pass through and to inhibit transfe r
of water droplets .
Melting Point : For a given pressure, th e
temperature at which the solid and liquid phases o f
the substance are in equilibrium .
Low Limit Control : A device which normall y
monitors the condition of the controlled mediu m
and interrupts system operation if the monitore d
condition drops below the desired minimum value .
Microbar : A unit of pressure equal to 1 dyne/cm 2
(one millionth of the pressure of the atmosphere )
Low Side : The refrigerating system from th e
expansion point to the point where the refrigeran t
vapor is compressed ; where the system is at o r
below evaporated pressure .
Low Temperature Cutout : A pressure o r
temperature actuated device with sensing elemen t
in the evaporator, which will shut the system dow n
at its control setting to prevent freezing chille d
water or to prevent coil frosting . Direct expansio n
equipment may not use this device .
Low Voltage : In the control industry, a powe r
supply of 25 volts or less .
M
MCM : Thousand circular mil - used to describe larg e
wire sizes .
Manometer : An instrument for measurin g
pressures : especially a U-tube partially filled with a
liquid, usually water, mercury, or a light oil, s o
constructed that the amount of displacement o f
the liquid indicates the pressure being exerted o n
the instrument .
Mass : The quantity of matter in a body as measure d
by the ratio of the force required to produce give n
acceleration, to the acceleration .
Mass Law (Sound) : The law relating to th e
transmission loss of sound barriers which says tha t
in a part of the frequency range, the magnitude o f
the loss is controlled entirely by the mass per uni t
area of the barrier . The law also says that th e
transmission loss increases 6 decibels for eac h
doubling of frequency or each doubling of the barrie r
mass per unit area .
Master (Central) Control : Control of all outlets fro m
one point .
Maximum "No-Flow" Temperature : The maximu m
temperature that will be obtained in a componen t
when the heat transfer fluid is not flowing throug h
the system .
Media : The heat transfer material used in rotar y
heat exchangers, also referred to as matrix .
Micron : A unit of length, the thousandth part of 1
mm of the millionth of a meter.
Microprocessor : A small computer used in loa d
management to analyze energy demand an d
consumption such that loads are turned on and of f
according to a predetermined program .
Modulation : Of a control, tending to adjust b y
increments and decrements .
Modulating Control : A mode of automatic contro l
in which the action of the final control element i s
proportional to the deviation, from set point, o f
the controlled medium .
Modulating Controllers : Constantly repositio n
themselves in proportion to the requirements o f
the system, theoretically being able to maintain a n
accurately constant condition .
Motor Control Center : A single metal enclose d
assembly containing a number of motor controller s
and possibly other devices such as switches an d
control devices .
Multipole : Connects to more than 1 pole such as a
2-pole circuit breaker.
Multistage Thermostat : A thermostat whic h
controls auxiliary equipment for heating or coolin g
in response to a greater demand for heating o r
cooling .
N
N .C . : Normally closed contacts of a relay. Contact s
are close-circuited when the relay is de-energize d
N .O . : Normally open contacts of a relay. Contact s
are open-circuited when relay is deenergized .
Neutral : The circuit conductor that is normall y
grounded at zero voltage difference to the ground .
Nocturnal Radiation : Loss of energy by radiatio n
to the night sky.
Noise : Any undesired sounds, usually of differen t
frequencies, resulting in an objectionable o r
irritating sensation .
Noise Criteria Curves (NC Curves) : Curves tha t
define the limits which the octave band spectru m
of a noise source must not exceed if a certain leve l
of occupant acceptance is to be achieved .
ISHRAE Installation Guide
kVA kilowatts is equal to KVA times power factor.
the motor reaches its full open position .
Kilowatt : 1000 watts . Abbreviated : kW.
Limit Control : A temperature, pressure, humidity ,
dew point or other control that overrides th e
demand control and/or duty cycler to prevent an y
affect on the business operation from loa d
management, malfunction, or abnormal conditions .
Also called "load override' .
Kilowatt-Hour : A measure of electrical energ y
consumption . 1000 watts being consumed per hour .
Abbreviated : kWh .
kW Demand : The maximum rate of electric powe r
usage required to operate a facility during a period
of time, usually a month or billing period . Ofte n
called "demand" .
kWh Consumption : The amount of electric energ y
used over a period of time ; the number of kWh use d
per month . Often called "consumption' .
L
Lag : A delay in the effect of a changed condition at
one point in the system, on some other condition t o
which it is related . Also, the delay in action of th e
sensing element of a control, due to the tim e
required for the sensing element to reac h
equilibrium with the property being controlled ; i .e . ,
temperature lag, flow lag, etc .
i
S
Langley : Standard unit of insolation measurements ,
1 Langley = 1 cal/ s q .c m . (1 langley/mina= 221 Btuh /
sq .( t .) .
Y
0
Latent Heat of Fusion : The heat required to chang e
a solid to a liquid at the same temperature ; i .e . ic e
to water .
C
e
r
Latent Heat of Vaporization : The amount of hea t
necessary to change a quantity of water to wate r
vapor without changing either temperature or
pressure . When water is vaporized and passes int o
the air, the latent heat of vaporization passes into
the air along with the vapor. Likewise, latent heat
is removed when water vapor is condensed .
e
e
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30 3
Law of Partial Pressure, Dalton's : Each constituen t
of a mixture of gases behaves themodynamically a s
if it alone occupied the space . The sum of th e
individual pressures of the constituents equals th e
total pressure of the mixture .
Level (L) : The ratio expressed in decibels of two
quantities proportioned to power or energy th e
second of which is a standard reference quantity .
Light Emitting Diode : A low current and voltag e
light used as an indicator on load managemen t
equipment . Abbreviated : LED .
Limit : Control applied in the line or low voltag e
control circuit to break the circuit of conditions
move outside a preset range . In a motor, a switc h
which cuts off power to the motor windings when
Line Slide : The side of a device electrically closes t
to the source of current .
Line Voltage : In the control industry, the norma l
electric supply voltages, which are usually 120 o r
240 volts .
Liquefaction : A change of state to liquid ; generall y
used instead of condensation in cases of substance s
ordinarily gaseous .
Liquid Sight Glass : The glass ported fitting in th e
liquid line used to indicate adequate refrigeran t
charge . When bubbles appear in the glass, there i s
insufficient refrigerant in the system .
Liquid Solenoid Valve : The electrically operate d
automatic shutoff valve in the liquid piping whic h
closes on system shutdown to close off receive r
discharge when used in pump down cycle and whic h
prevents refrigerant migration in any system .
Load : The amount of heat per unit time imposed o n
a refrigerant system, or the required rate of hea t
removal .
Load Factor : This is a ratio expressing a customer's
average actual use of the utility's capacity provide d
versus the maximum amount used .
Load Management : The control of electrical Load s
to reduce kW demand and kWh consumption .
Load Programmer : Any device which turns load s
on and off on a real time, time interval, or kW deman d
basis .
Load Side : The side of a device electrically farthes t
from the current source .
Locked Rotor Current : See "Inrush Current" .
Loudness : The subjective human definition of th e
intensity of a sound . Human reaction to sound i s
highly dependent on the sound pressure an d
frequency .
Loudness Level : A subjective method of ratin g
loudness in which a 1000 Hz tone is varied i n
intensity until it is judged by listeners to be equally
as loud as a given sound sample . The loudness leve l
in "phons" is taken as the sound pressure level, i n
decibels, of the 1000 Hz tone .
30 2
of water vapor present in saturated air at the same
temperature and barometric pressure ;
approximately, it equals the ratio of the partia l
pressure or density of the water vapor in the air ,
to the saturation pressure or density, respectively ,
of water at the same temperature .
Humidity, Specific : Weight of water vapor (steam )
associated with 1 lb . weight of dry air, also calle d
humidity .
Hunting : A condition which occurs when the desire d
condition cannot be maintained . The controller ,
controlled device and system, individually o r
collectively, continuously override or "overshoot "
the control point with a resulting fluctuation an d
lass of control of the condition to be maintained .
Hydrostatic Pressure ; The pressure at any poin t
in a liquid at rest ; equal to the depth of the liqui d
multiplied by its density.
Hygroscopic : Absorptive of moisture, readily
absorbing and retaining moisture .
Impedance (2) : The quantity in an AC circuit tha t
is equivalent to resistance in a DC circuit, inasmuc h
as it relates current and voltage . It is composed o f
resistance plus a purely AC concept called reactanc e
and is expressed, like resistance, in Ohms .
"In" Contacts : Those relay contacts which complet e
circuits when the relay armature is energized . Also
referred to as Normally Open Contacts .
Inch of Water On . w.g.) : A unit of pressure equal
to the pressure exerted by a column of liquid wate r
1 inch high at a temperature of 39 .2°F.
Incidence, Angle of: The angle at which insolatio n
strikes a surface .
Indicator : A term used to describe any device suc h
as a thermometer or pressure gauge which is use d
to indicate the condition at a point in the syste m
but which does not provide any controlling actio n
or effect on the system operation .
Inductance : The process when a second conducto r
is placed next to a conductor carrying AC curren t
(but not touching it), the everchanging magneti c
field will induce a current in the second conductor .
Induction : The capture of part of the ambient ai r
by the jet action of the prlilfary airstrea m
discharging from a controlled device .
Inductive Loads : Loads whose voltage and curren t
are out-of-phase . True power consumption for
ISHRAE Installation Guid e
inductive loads is calculated by multiplying it s
voltage, current, and the power factor of the load .
Infiltration: Air flowing into a building as through a
wall, crack, etc .
Input Override Relay : A relay that allows the dut y
cycle to be inhibited on specific channels becaus e
of inputs from outdoor temperature, spac e
temperature, case temperature, time-of-day, etc .
Sometimes called "duty cycle control relay" .
Inrush Current: The current that flows the instan t
after the switch controlling current flow to a loa d
is closed . Also called . .locked rotor current' .
Insertion Loss : The insertion loss of an element o f
an acoustic transmission system is the positive o r
negative change in acoustic power transmissio n
that results when the element is introduced .
Insolation : The total amount of solar energ y
reaching a surface per unit of time .
Instantaneous Rate : Method for determining whe n
load shedding should occur. Actual energy usage i s
measured and compared to a present kilowatt level .
If the actual kilowatt level exceeds a designated
set point, loads will be shed until the actual rat e
drops below the set point .
Insulation, Thermal : A material having a relativel y
high resistance to heat flow and used principally t o
retard heat flaw.
Interstage Differential : In a multistage HVA C
system, the change in temperature at th e
thermostat needed to turn additional heating o r
cooling equipment on .
Isentropic : An adjective describing a reversibl e
adiabatic process ; ;a change taking place a t
constant entropy .
Isobaric : An adjective used to indicate a chang e
taking place at constant pressure .
Isothermal : An adjective used to indicate a chang e
taking place at constant temperature .
J
Junction Box : Metal box in which tap to circui t
conductors is made . Junction is not an outlet, sinc e
no load is fed from it directly.
K
Kilovolt Ampere : Product of the voltage times th e
current . Different from kilowatts because o f
inductive loads in an electrical system . Abbreviated :
ISHRAE Installation Guide
Heat, Specific : The ratio of the quantity of hea t
required to raise the temperature of a given mas s
of any substance one degree to the quantit y
required to raise the temperature of an equal mass
of a standard substance (usually water at 59°F )
one degree .
Heat, Total (Enthalpy) : The sum of sensible hea t
and latent heat between an arbitrary datum poin t
and the temperature and state unde r
consideration .
Heat Capacity : The amount of heat necessary t o
raise the temperature of a given mass one degree .
Numerically, the mass multiplied by the specifi c
heat .
Heat Conductor : A material capable of readily
conducting heat . The opposite of an insulator o r
insulation .
Heat Exchanger : A device specifically designed to
transfer heat between two physically separate d
fluids .
Heat of Fusion : Latent heat involved in changin g
between the solid and the liquid states .
Heat of Vaporization : Latent heat involved in th e
change between liquid and vapor states .
Heat Pump : A refrigerating system employed to
transfer heat Into a space or substance . Th e
condenser provides the heat while the evaporato r
is arranged to pick up heat from air, water, etc . By
shifting the flow of air or other fluid, a heat pum p
system may also be used tc cool the space .
Heat Transfer Medium : A fluid used in the transpor t
of thermal energy.
Heat Transmission : Any time-rate of heat flow ;
usually refers to conduction, convection an d
radiation combined .
Heat Transmission Coefficient : Any one of a number
of coefficients used in the calculation of hea t
transmission by conduction, convection, an d
radiation, through various materials an d
structures .
Heating, Regenerative (or Cooling) : Process o f
utilizing heat, which must be rejected or absorbed
in one part of the cycle, to perform a useful functio n
in another part of the cycle by heat transfer.
I
Hidden Demand Charge : Electric bill charges tha t
are based on cents per kWh per kW demand contain
a hidden demand charge . A low load factor for a
building then penalizes the energy used throug h
this "hidden` charge .
301
High Limit Control : A device which normally monitor s
the condition of the controlled medium an d
interrupts system operation if the monitore d
condition becomes excessive .
High Pressure Cutout: A pressure actuated switc h
to protect the compressor from pressure ofte n
caused by high condenser temperatures an d
pressure due to fouling and lack of water or air.
High Side : Parts of the refrigerating syste m
subjected to condenser pressure or higher ; th e
system from the compression side of the compresso r
through the condenser to the expansion point of
the evaporator.
Horsepower : Unit of power in foot-pound-secon d
system; work done at the rate of 550 ft-lb per sec ,
or 33,000 ft-lb per min .
Not Deck : The heating section of a multizon e
system .
Hot Gas Bypass : The piping and manual, but more
often automatic, valve used to introduc e
compressor discharge gas directly into th e
evaporator. This type of arrangement will maintai n
compressor operation at light loads down to zer o
by falsely loading the evaporator and compressor .
Hot Gas Piping : The compressor discharge pipin g
which carries the hot refrigerant gas from th e
compressor to the condenser. Velocities must b e
high enough to carry entrained oil .
Humidifier : A device to add moisture to air.
Humidifying Effect : The latent heat of vaporizatio n
of water at the average evaporating temperatur e
times the weight of water evaporated per unit o f
time.
Humidistat : A regulatory device, actuated b y
changes in humidity, used for the automatic contro l
of relative humidity.
Humidity : Water vapor within a given space .
Humidity, Absolute : The weight of water vapo r
per unit volume .
Humidity, Percentage : The ratio of the specifi c
humidity of humid air to that of saturated air a t
the same temperature and pressure, usuall y
expressed as a percentage (degree of saturation ;
saturation ratio )
Humidity Ratic :,,The ratio of the mass of the wate r
vapor to the mass of dry air contained in the sample .
Humidity, Relative : The ratio of the mcl fractio n
of water vapor present in the air, to the mot fraction
r
3 00
ISHRAE Installation Guid e
effects of the boundaries are negligible over th e
region of interest . In the free field, the soun d
pressure level decreases 6 dB for a doubling o f
distance from a point source .
Freezing Point : Temperature at which a given liqui d
substance will solidify or freeze on removal of heat .
Freezing point of water is 32°F.
Frequency : The number of vibration, waves, o r
cycles of any periodic phenomenon per second . I n
architectural acoustics, the interest lies in th e
audible frequency range of 20 to 20,000 cps Hert z
(cycles per second) .
Frequency
Spectrum :
Usually a visua l
representation of a complex sound or noise whic h
has been resolved into frequency components . Th e
detailed nature of a complex sound may be studie d
by obtaining its frequency spectrum . Frequenc y
spectra are commonly obtained in octave bands ,
1/3 octave bands, and various narrow bands .
Friction : Friction is the resistance found at th e
duct and piping walls . Resistance creates a stati c
pressure loss in systems . The primary purpose of a
fan or pump is to produce a design volume and th e
other dynamic pressure losses of the components .
Friction Head : The pressure in psi or feet of th e
liquid pumped which represents system resistanc e
that must be overcome .
Gas Constant : The coefficient "R" in the perfec t
gas equation .
PV MRT.
Gradual Switches : Manual adjustment device s
which proportion the control condition i n
accordance with the position of the switch .
Grains of Moisture : The unit of measurement o f
actual moisture contained in a sample of air . (700 0
grains = one pound of water) .
Gravity, Specific : Density compared to density o f
standard material ; reference usually to water or t o
air .
Grille : A louvered or perforated covering for an ai r
passage opening which can be located on a wall ,
ceiling or floor.
Ground : Zero voltage, or any point connected t o
the earth or "ground' .
Ground Bus : A busbar in a panel or elsewhere ,
deliberately connected to ground .
Ground Conductor : Conductor run in an electrica l
system, which is deliberately connected to th e
ground electrode . Purpose is to provide a groun d
point throughout the system . Insulation colo r
green . Also called "green ground" .
Ground Fault : An unintentional connection t o
ground .
Full Load Current : See Running Current .
Fumes : Solid particles commonly formed by th e
condensation of vapors from normally solid material s
such as molten metals . Fumes may also be formed b y
sublimation, distillation, calcination, or chemica l
reaction wherever such processes create airborn e
particles predominantly below one micron in size .
Such solid particles sometimes serve as condensatio n
nuclei for water vapor to form smog .
G
GFI, GFCI : Ground fault (circuit) interrupter - a
device that senses ground faults and reacts b y
opening the circuit .
Gang : One wiring device position in a box .
Gas : Usually a highly superheated vapor which ,
within acceptable limits of accuracy, satisfies th e
perfect gas laws .
Gas, Inert : A gas that neither experiences no r
causes chemical reaction nor undergoes a chang e
of state in a system or process ; e .g ., nitrogen o r
helium mixed with a volatile refrigerant .
H
Head, Dynamic or Total : In flowing fluid, the su m
of the static and velocity heads at the point o f
measurement .
Head, Static : The static pressure of fluid expresse d
in terms of the height of a column of the fluid, or o f
some manometric fluid, which it would support .
Head, Velocity : In a flowing fluid, the height o f
the fluid or of some manometric fluid equivalent t o
its velocity pressure .
Heat : The form of energy that is transferred by
virtue of a temperature difference .
Heat, Latent : Change of enthalpy during a chang e
of state, usually expressed in Btu per lb . With pur e
substances, latent heat is absorbed or rejected a t
a constant temperature .
Heat, Sensible : Heat which is associated with a
change in temperature ; specific heat exchange o f
temperature ; in contrast to a heat interchange i n
which a change of state (latent heat) occurs .
ISHRAE Installation Guide
29 9
Fan Propeller : A propeller or disc type wheel withi n
a mounting ring or plate and including drivin g
mechanism supports for either belt drive or direc t
connection .
Type "A" : A flue listed for use with oil, gas, or coa l
burning equipment .
Fan, Tubeaxial : A propeller or disc type wheel withi n
a cylinder and including driving mechanism support s
for either belt drive or direct connection .
Fluid : Gas, vapor, or liquid .
Fan Vaneaxial : A disc type wheel within a cylinder ,
a set of air guide vanes located either before o r
after the wheel and including driving mechanis m
supports for either belt drive or direct connection .
Fault : A short circuit - either line to line, or line to
ground .
Fee Line : A pipe that supplies water to items suc h
as a boiler or a domestic hot water tank .
Filter : A device to remove solid material from a fluid .
Filter-Drier : A combination device used as a straine r
and moisture remover.
Fin : An extended surface to increase the hea t
transfer area, as metal sheets attached to tubes .
Fixed Collector : A permanently oriented collecto r
that has no provision for seasonal adjustment o r
tracking of the sun .
Flanking Transmission (Sound) : The reduction i n
apparent transmission loss of a wall caused by soun d
being carried around the wall by other paths .
(Structure-borne, leaks, etc . )
Flat-Plate Collector : A collector without externa l
concentrators or focusing devices, usuall y
consisting of an absorber plate, cover plates, back
and side insulation and a container.
Floating Action Controllers : Essentially tw o
position type controllers which vary the positio n
of the controlled devices but which are arrange d
to stop before reaching a maximum or minimu m
position .
Flow, Laminar or Streamline : Fluid flow in whic h
each fluid particle moves in a smooth pat h
substantially parallel to the paths followed by al l
other particles .
Flow, Turbulent : Fluidflow in which the fluid move s
transversely as well as in the direction of the tub e
or pipe axis, as opposed to streamline or viscous
flow.
Flue: A special enclosure incorporated into a buildin g
for the removal of products of combustion to th e
out -a f . doors .
Type "B" : A manufactured flue listed for use wit h
gas burning equipment .
Fluid Head : The static pressure of fluid expresse d
in terms of the height of a column of the fluid, or o f
some manometric fluid, which it would support .
Fluid, Heat Transfer : Any gas, vapor, or liquid use d
to absorb heat from a source at a high temperatur e
and reject it to a lower temperature substance .
Fluid Dynamics : Fluid Dynamics is used to describ e
the condition of motion of a fluid within a system .
The velocity of a fluid is based upon the cross sectional area and the volume of a fluid passin g
through it . The importance of this property is tha t
volume may be determined for air or water system s
when the area and velocity are known .
Fluid Statics : Fluid Statics as applied to TAB work ,
refers to a condition of a quantity of fluid at rest .
It is the direct result of gravity and weight . Stati c
pressure is used in both air and water testing t o
determine the potential for the movement of flui d
within a system . Pressures in air systems ar e
normally measured in units of inches of water (in .
w .g .) . A pressure unit of one inch of water i s
equivalent to the static pressure found at the bas e
of a column of water one inch high . Pressures i n
water systems are normally measured in pounds pe r
square inch (psi), but are converted to feet of wate r
(ft . w .g .) for the purpose of evaluating pump an d
equipment performance .
Focusing Collector : A collector using some type o f
focusing device (parabolic mirror, fresnel lens, etc . )
to concentrate the insolation on an absorbin g
element .
Force : The action on a body which tends to chang e
its relative condition as to rest or motion .
Forced Circulation : Circulation of heat transfe r
fluid by a pump or fan .
Free Area : The total minimum area of the opening s
in the air outlet or inlet through which air can pass .
Free Delivery-Type Unit : A device which takes i n
air and discharges it directly to the space to b e
treated without external elements which impos e
air resistance .
Free Sound Field (Free Field) : A free sound field i s
a field in a homogenous, isotropic medium free fro m
boundaries . In practice, it is a field in which the
298
ISHRAE Installation Guide
Electromechanical : Converting electrical inpu t
into mechanical action . A relay is a n
electomechanicat switch .
Equivalent Duct Diameter : The equivalent duc t
diameter for a rectangular duct with sides o f
dimensions a and b is 4/at) .
Electro-Pneumatic (EP) Switches : Switches tha t
open or close an air line valve from an electrica l
impulse .
Evaporation : Change of state from liquid to vapor.
Emissivity : The property of a surface tha t
determines its ability to give off radiant energy.
Emittance : The ratio of the radiant energy emitte d
by a body to the energy emitted by a black body a t
the same temperature .
Energy : Expressed in Kilowatt-hours (kWh) or watt hours (Wh), and is equal to the product of powe r
and time .
energy = power x tim e
kilowatt-hours = kilowatts x hour s
watt-hours = watts x hou r
Energy (Consumption) Charge : That part of a n
electric bill based on kWh consumption (expresse d
in cents power kWh) . Energy charge covers cost of
utility fuel, general operating costs, and part o f
the amortization of the utility's equipment .
Energy Efficient Ratio (ER), Cooling : The ratio
of net cooling capacity in Btuh to total electri c
input in watts under designated operatin g
conditions .
Engine : Prime mover, device for transforming fue l
or heat energy into mechanical energy .
Enthalpy : The total quantity of heat energ y
contained in a substance, also called total heat ;
the thermodynamic property of a substance define d
as the sum of its internai energy plus the quantit y
Pv/J, where P = pressure of the substance, v = it s
volume and J = the mechanical equivalent of heat .
Enthalpy, Specific : A term sometimes applied t o
enthalpy per unit weight .
Entrainment : The capture of part of th e
surrounding air by the airstream discharged fro m
an outlet (sometimes called secondary air motion) .
Entropy : The ratio of the heat added to a substance
to the absolute temperature at which it is added .
Entropy, Specific : A term sometimes applied t o
entropy per unit weight .
Equal Friction Method : A method of duct sizin g
wherein the selected duct friction loss value is use d
constantly throughout the design of a low pressur e
duct system .
Evaporative Cooling : The adiabatic exchange o f
heat between air and a water spray or wette d
surface . The water approaches the wet-bul b
temperature of the air, which remains constan t
during its traverse of the exchanger.
Evaporator : The heat exchanger in which th e
medium being cooled, usually air or water, gives u p
heat to the refrigerant through the exchange r
transfer surface . The liquid refrigerant boils into a
gas in the process of heat absorption .
Exfiltration : Air flow outward through a wall, leak ,
membrane, etc .
Extended Surface : Heat transfer surface, one o r
both sides of which are increased in area by th e
addition of fins, discs, or other means .
F
Face Area : The total plane area of the portion of a
grille, coil, or other items bounded by a line tangen t
to the outer edges of the openings through whic h
air can pass .
Face Velocity : The velocity obtained by dividin g
the air quantity by the component face area .
Fahrenheit : A thermometric scale in which 32 (°F )
denotes freezing and 212 (°F) the boiling point o f
water under normal pressure at sea level (14 .696psi )
Fail Safe : In load management, returning all load s
to conventional control during a power failure .
Accomplished by a relay whose contacts are normall y
closed .
Fan, Centrifugal : A fan rotor or wheel within a scrol l
type housing and including driving mechanis m
supports for either belt drive or direct connection .
Fan Performance Curve : Fan performance curv e
refers to the constant speed performance curve .
This is a graphical presentation of static or tota l
pressure and power input over a range of air volum e
flow rate at a stated inlet density and fan speed . I t
may include static and mechanical efficienc y
curves . The range of air volume flow rate which i s
covered generally extends from shutoff (zero ai r
volume flow rate) to free delivery (zero fan stati c
pressure) . The pressure curves are generall y
referred to as the pressure-volume curves .
ISHRAE Installation Guide
Domestic Hot Water : Potable hot water a s
distinguished from hot water used for hous e
heating .
Draft : a) A current of air, when referring to th e
pressure difference which causes a current of ai r
or gases to flow through a flue, chimney, heater, o r
space ; or b) to a localized effect caused by one o r
more factors of high air velocity, low ambien t
temperature, or direction of air flow, whereby mor e
heat is withdrawn from a person's skin than is norma l
dissipated .
Drier : A manufactured device containing a
desiccant placed in the refrigerant circuit . It s
primary purpose is to collect and hold within th e
desiccant, all water in the system in excess of th e
amount which can be tolerated in the circulatin g
refrigerant .
29 7
Dynamic Discharge Head : Static discharge hea d
plus friction head plus velocity head .
Dynamic Insertion Loss : The dynamic insertion los s
of a silencer, duct lining or other attenuating devic e
is the performance measured in accordance wit h
ASTME 477 when handling the rated airflow : It i s
the reduction in sound power level, expressed i n
decibels, due solely to the placement of the soun d
attenuating device in the duct system .
Dynamic Suction Head : Positive static suctio n
head minus friction head and minus velocity head .
Dynamic Suction Lift : The sum of suction lift an d
velocity head at the pump suction when the sourc e
is below pump centerline .
E
Drift : Term used to describe the difference betwee n
the set point and the actual operating or contro l
point .
Economizer : A system of dampers, temperature an d
humidity sensors, and motors which maximizes th e
use of outdoor air for cooling .
Drip : A pipe, or a steam trap and a pipe considere d
as a unit, which conducts condensation from th e
steam side of a piping system to the water or retur n
side of the system .
Effect, Humidifying : Latent heat of wate r
vaporization at the average evaporatin g
temperature times the number of pounds of wate r
evaporated per hour in Btuh .
Droop : Terms used to describe the differenc e
between the set point and the actual operating o r
control point .
Effect, Sun : Solar energy transmitted into space
through windows and building materials .
Drop : The vertical distance that the lower edge o f
a horizontally projected airstream drops betwee n
the outlet and the end of its throw .
Dry bulb, Room : The d ;y bulb (dewpoint, etc . )
temperature of the conditioned room or space .
Dry Bulb Temperature : The temperatur e
registered by an ordinary thermometer. The dry
bulb temperature represents the measure o f
sensible heat, or the intensity of heat .
Dry Bulb Temperature Adjusted (tooth) : Th e
average of the air temperature (to) and the mea n
radiant temperature (tr) at a given location . Th e
adjusted dry bulb temperature (tadb) i s
approximately equivalent to operative temperatur e
(to) at air motions less than 80 fpm when it is les s
than 120°F.
Duct : A passageway made of sheet metal or othe r
suitable material, not necessarily leaktight, use d
for conveying air or other gas at low pressures .
Dust : An air suspension (aerosol) or particles of an y
solid material, usually with particle size less tha n
100 microns .
Effect, Total cooling : The difference between th e
total enthalpy of the dry air and water vapo r
mixture entering a unit per hour and the tota l
enthalpy of the dry air and water vapor (and water )
mixture leaving the unit per hour, expressed in Bt u
per hour.
Effective Area : The net area of an outlet or inle t
device through which air can pass, equal to th e
free area times the coefficient of discharge .
Effectiveness (Efficiency) : The ratio of the actua l
amount of heat transferred by a heat recover y
device to the maximum heat transfer possibl e
between the airstreams (sensible heat/sensibl e
heat, sensible heat/total heat, or total heat/tota l
heat) .
Elasticity of Demand : The change in quantity o f
electricity (or other commodity) purchased as a
result of a change in its price . Demand fo r
electricity is "elastic" when it increases o r
decreases in response to decreases or increases ,
respectively, in the price for the electricity .
Electrical Circuit : A power supply, a load, and a
path for current flow are the minimum requirement s
for an electrical circuit .
296
Lowering the moisture content of the air passin g
through it ; (2) An absorption or adsorption devic e
for removing moisture from air .
Dehydration : (1) removal of water vapor from ai r
by the use of absorbing or adsorbing materials ; (2 )
removal of water from stored goods .
Delta Service : An arrangement of the utilit y
transformers . Commonly shown "S .
Demand : The probable maximum rate of water flo w
as determined by the number of water supply fixtur e
units .
Demand Charge : That part of an electric bill base d
on kW demand and the demand interval, expresse d
in dollars per kilowatt . Demand charges offse t
construction and maintenance of a utility's nee d
for a large generating capacity.
Demand Control : A device which controls the k W
demand level by shedding loads when the kW deman d
exceeds a predetermined set point .
Demand Interval : The period of time during whic h
kW demand is monitored by a utility service, usuall y
15 or 30 minutes long .
Demand Load : The actual amount of load on a
circuit at any time . The sum of all the loads whic h
are ON . Equal to the connected load minus the load s
that are OFF.
Demand Reading : Highest or maximum demand fo r
electricity an individual customer registers in a
given interval, example, 15 minute interval . Th e
metered demand reading sets the demand charg e
for the month .
Density : The ratio of the mass of a specimen o f
substance to the volume of the specimen . The mas s
of a unit volume of a substance . When weight ca n
be used without confusion, as synonymous wit h
mass, density is the weight per unit volume .
ISHRAE Installation Guid e
Dew Point Depression : The difference between dry
bulb and dew point temperatures (°F DB °F DP )
Dew Point Temperature : lt d,) The temperature a t
which moist air becomes saturated (100% relativ e
humidity) with water vapor when cooled at constan t
pressure .
Dielectric Fitting : An insulating or nonconductin g
fitting used to isolate electochemically dissimila r
materials .
Differential : The difference between the point s
where a controller turns "on" and "off" . If a
thermostat turns a furnace on at 68° and th e
differential is 3°, the burner will be turned off a t
71 °
Diffuse Sound Field : A diffuse sound field is a spac e
in which at every point the flow of sound energy i n
all directions is equally probable . (It is often assume d
that in a diffuse field, the sound pressure level ,
averaged through time, is everywhere the same . )
Diffuser : A circular, square, or rectangular ai r
distribution outlet, generally located in the ceilin g
and comprised of deflecting members dischargin g
supply air in various directions and planes, an d
arranged to promote mixing of primary air wit h
secondary room air.
Direct Acting : Instruments that increase contro l
pressure as the controlled variable (such a s
temperature or pressure) increases ; while reverse
acting instruments increase control pressure as th e
controlled variable decreases .
Direct Current (DC) : A source of power fo r
electrical circuit which does not reverse th e
polarity of its charge .
Direct Field : The sound in a region in which all o r
most of the sound arrives directly from the sourc e
without reflection .
Desiccant : Any absorbent or adsorbent, liquid o r
solid, that will remove water or water vapor from a
material . In a refrigeration circuit, the desiccan t
should be insoluble in the refrigerant .
Directivity Factor : The ratio of the sound pressur e
squared at some fixed distance and on the axis o f
maximum response to the mean square soun d
pressure at the same distance averaged over al l
directions from the source .
Design Working Pressure : The maximum allowabl e
working pressure for which a specific part of a
system is designed .
Discharge Stop Valve : The manual service valve a t
the leaving connection of the compressor.
Dewpoint, Apparatus : That temperature whic h
would result if the psychrometric process occurrin g
in a dehumidifier, humidifier of surface-cooler wer e
carried to the saturation condition of the leavin g
air while maintaining the same ratio of sensible t o
total heat load in the process .
Discrete Logic : Electronic circuitry composed o f
standard transistors, resistors, capacitors, etc . ,
as compared to microprocessor circuits where th e
logic is condensed on a single chip (integrate d
circuit) .
ISHRAE Installation Guide
exchange of heat between air and water spray o r
wetted surface . The water assumes the wet-bul b
temperature of the air, which remains constan t
during its traverse of the exchanger .
Cooling, Regenerative : Process of utilizing hea t
which must be rejected or absorbed in one part o f
the cycle to function usefully in another part of th e
cycle by heat transfer .
Cooling Coil : An arrangement of pipe or tubin g
which transfers heat from air to a refrigerant o r
brine .
Cooling Effect, Sensible : Difference between th e
total cooling effect and the dehumidifying effect ,
usually in watts (Btuh) .
Cooling Effect, Total : Difference between the tota l
enthalpy of the dry air and water vapor mixtur e
entering the cooler per hour and the total enthalp y
of the dry air and water vapor mixture leaving th e
cooler per hour, expressed in watts (Btuh) .
Cooling Range : In a water cooling device, th e
difference between the average temperatures o f
the water entering and leaving the device .
Core Area : The total plane area of that portion o f
a grille, included within lines tangent to the oute r
edges of the openings through which air can pass .
Corresponding Values : Simultaneous values o f
various properties of a fluid, such as pressure ,
volume, temperature, etc ., for a given condition o f
fluid .
Corrosive : Having chemically destructive effect o n
metals (occasionally on other materials) .
Counterflow : In heat exchange between two fluids ,
opposite direction of flow, coldest portion of on e
meeting coldest portion of the other .
Critical Velocity : The velocity above which flui d
flow is turbulent .
Cross Connection : Any physical connection o r
arrangement between two otherwise separat e
piping systems, one of which contains potable wate r
and the other either water of unknown o r
questionable safety or steam, gas, chemicals, o r
other substances whereby there may be a flow fro m
one system to the other, the direction of flo w
depending on the pressure differential between th e
two systems .
Crystal
Formation,
Zone of Maximum :
Temperature range in freezing in which mos t
freezing takes place, i .e ., about 25°F to 30°F fo r
water.
29 5
Curb Box : Access to an underground valve at th e
street curb . It controls water service to a hous e
or building .
Current (I) : The electric flow in an electric circuit ,
which is expressed in amperes (amps) .
Cycle : A complete course of operation of workin g
fluid back to a starting point, measured i n
themodynamic terms (functions) . Also in general fo r
any repeated process on any system .
Cycle, Reversible : Theoretical thermodynami c
cycle, composed of a series of reversible processes ,
which can be completely reversed .
D
DMV : Drainage, waste and vent .
Dalton's Law of Partial Pressure : Each constituen t
of a mixture of gases behaves thermodynamicall y
as if it alone occupied the space . The sum of th e
individual pressures of the constituents equals th e
total pressure of the mixture .
Damper : A device used to vary the volume of ai r
passing through an air outlet, air inlet or duct .
Deadband : In HVAC, a temperature range in which
neither heating nor cooling is turned on ; in load
management ; a kilowatt range in which loads are
neither shed nor restored .
Decay Rate : The rate at which the sound pressur e
level in an enclosed space decreases after the soun d
source has stopped . It is measured in decibels pe r
second .
Decibel (dB) : A decibel i s ' a division of a logarithmi c
scale for expressing the ratio of two quantitie s
proportional to power or energy. The number o f
decibels denoting such a ratio is ten time th e
logarithm of the ratio .
Degree Day : A unit, based upon temperatur e
difference and time, used in estimating fue l
consumption and specifying nominal heating load o f
a building in winter. For any one day, when the mean temperature is less than 65°F, there exist as man y
degree days as there are Fahrenheit degree s
difference in temperature between the mea n
temperature for the day and 65°F.
Dehumidification : The condensation of water vapo r
from air by cooling below the dewpoint or remova l
of water vapor from air by chemical or physica l
methods .
Dehumidifier : (1) An air cooler or washer used for
294
steam ; in air conditioning, water extracted fro m
air, as by condensation an the cooling o f
refrigeration machine .
Condensation : Process of changing a vapor int o
liquid by extracting heat . Condensation of stea m
or water vapor is effected in either stea m
condensers or dehumidifying coils, and the resultin g
water is caned condensate .
Condenser : The heat exchanger in which the hea t
absorbed by the evaporator and some of the hea t
of compression introduced by the compressor ar e
removed from the system . The gaseous refrigeran t
changes to a Liquid, again taking advantage of th e
relatively large heat transfer by the change of stat e
in the condensing process .
Condenser : Electrical - see "Capacitor"
Condensing Unit, Refrigerant : An assembly o f
refrigerating components designed to compress an d
liquify a specific refrigerant, consisting of one o r
more refrigerant compressors, refrigeran t
condensers, Liquid receivers (when required) and
regularly furnished accessories .
Conditioned Space : Space within a building whic h
is provided with heated and/or cooled air o r
surfaces and, where required, with humidificatio n
or dehumidification means so as to maintain a spac e
condition falling within the "comfort zone" .
Conditions, Standard : A set of physical, chemical ,
or other parameters of a substance or system whic h
defines an accepted reference state or forms a
basis for comparison .
Conductance, Electrical : The reciprocal (opposite )
of resistance and is the current carrying ability o f
any wire or electrical component . Resistance is th e
ability to oppose the flow of current .
Conductance, Surface Film : Time rate of heat flo w
per unit area under steady conditions between a
surface and a fluid for unit temperature differenc e
between the surface and fluid .
Conductance, Thermal : Time rate of heat flo w
through a body (frequently per unit area) from on e
of its bounding surfaces to the other for a uni t
temperature difference between the two surfaces ,
under steady conditions .
Conductivity, Thermal : The time rate of heat fla w
through unit area and unit thickness of a
homogeneous material under steady condition s
when a unit temperature gradient is maintained i n
the direction perpendicular to area . Materials are
ISHRAE Installation Guid e
considered homogeneous when the value of th e
thermal conductivity is not affected by valuation in thickness or in size of sample within the rang e
normally used in construction .
Conductor, Thermal : A material which readil y
transmits heat by means of conduction .
Conduit : A round cross-section electrical raceway ,
of metal or plastic .
Connected Load : The sum of all loads on a circuit .
Connection in Parallel : System whereby flow i s
divided among two or more channels from a commo n
starting point or header.
Connection in Series : System whereby flow
through two or more channels is in a single pat h
entering each succeeding channel only after leavin g
the first or previous channel .
Contactor : Electromagnetic switching device .
Control : A device for regulation of a system o r
component in normal operation, manual o r
automatic . If automatic, the implication is that i t
is responsive to changes of pressure, temperatur e
or other property whose magnitude is to b e
regulated .
Control Diagram (ladder diagram) : A diagram tha t
shows the control scheme only. Power wiring is no t
shown . The control items are shown between tw o
vertical lines ; hence, the name-ladder diagram .
Control Point : The value of the controlled variabl e
which the controller operates to maintain .
Controlled Device : One which receives th e
converted signal from the transmission system an d
translates it into the appropriate action in th e
environmental system . For example : a valve open s
or closes to regulate fluid flow in the system .
Controller : An instrument which receives the signa l
from the sensing device and translates that signa l
into the appropriate corrective measure . Th e
correction is then sent to the system controlle d
devices through the transmission system .
Convection: Transfer of heat by movement of fluid .
Convection, Forced : Convection resulting fro m
forced circulation of a fluid, as by a fan, jet o r
pump .
Convection, Natural : Circulation of gas or liqui d
(usually air or water) due to differences in densit y
resulting from temperature changes .
Cooling, Evaporative : Involves the adiabatic
ISHRAE Installation Guide
Cathodic Protection : The process of providin g
corrosion protection against electrolytic reaction s
that could be deleterious to the performance o f
the protected material or component .
Ceiling outlet : A round, square, rectangular, o r
linear air diffuser located in the ceiling whic h
provides a horizontal distribution pattern o f
primary and secondary air over the occupied zon e
and induces low velocity secondary air motio n
through the occupied zone .
Celsius (Formerly Centigrade) : A thermometri c
scale in which the freezing point of water is calle d
0°C and its boiling point is 100°C at norma l
atmospheric pressure (14 .696 psi) .
Change of State : Change from one phase, such a s
solid, liquid or gas, to another.
Changeover : The process of switching an ai r
conditioning system from heating to cooling, or vic e
versa .
Channel : Term use to describe output of a loa d
management system . Usually corresponds to a
specific relay .
Chemical Compatibility : The ability of material s
and components in contact with each other to resis t
mutual chemical degradation, such as that cause d
by electrolytic action .
Circuit : An electrical arrangement requiring a
source of voltage, a closed loop of wiring, a n
electric load and some means for opening and closin g
it .
Circuit Breaker : A switch-type mechanism tha t
opens automatically when it senses an overloa d
(excess current) .
Clearing a Fault : Eliminating a fault condition by
some means . Generally taken to mean operation o f
the over-circuit device that opens the circuit an d
clears the fault .
Clo Value : A numerical representation of a clothin g
ensemble's thermal resistance . 1 Clo = 0 .88 sq . ft .
h°F/Btu .
Coefficient of Discharge : For an air diffuser, th e
ratio of net area or effective area at ven a
cantracta of an orificed airstream to the free are a
of the opening .
Coefficient of Expansion : The change in lengt h
per unit length or the change in volume per uni t
volume, per deg . change in temperature .
Coefficient of Performance (COP), Heat Pump :
The ratio of the compressor heating effect (heat
293
pump) to the rate of energy input to the shaft o f
the compressor, in consistent units, in a complet e
heat pump, under designated operating conditions .
Coil : A cooling or heating element made of pipe o r
tubing .
Cold Deck : The cooling section of a mixed air zonin g
system .
Collector Azimuth : The horizontal angle betwee n
true south and a line which is perpendicular to th e
plane of the collector that is projected on a
horizontal plane .
Collector Plate : The component of a solar collecto r
which transfers the heat from solar energy to a
circulating fluid .
Collector (Solar) : An assembly of component s
intended to capture usable solar energy .
Combustion : The act of process of burning .
Comfort Chart : A chart showing effectiv e
temperatures with dry-bulb temperatures an d
humidities (and sometimes air motion) by which th e
effects of various air conditions on human comfor t
may be compared .
Comfort Cooling : Refrigeration for comfort a s
opposed to refrigeration for storage o r
manufacture .
Comfort Zone : (Average) the range of effectiv e
temperatures over which the majority (50 percen t
or more) of adults feels comfortable ; (extreme) th e
range of effective temperatures over which one o r
more adults feel comfortable .
Common Neutral : A neutral conductor that i s
common to, or serves, more than one circuit .
Compressibility : The ease which a fluid may b e
reduced in volume by the application of pressure ,
depends upon the state of the fluid as well as th e
type of fluid itself . In TAB work, consider that wate r
may not be compressed . Air is a compressible gas ,
but that factor is usually not considered durin g
normal testing and balancing procedures .
Compressor : The pump which provides the pressur e
differential to cause fluid to flow and in the pumpin g
process increases pressure of the refrigerant t o
the high side condition . The compressor is th e
separation between low side and high side .
Concentrator : A reflective surface or refractin g
lens for directing insolation onto the absorbe r
surface .
Condensate : The liquid formed by condensation o f
a vapor. In steam heating, water condensed from
292
ISHRAE Installation Guid e
as the result of energy conversion from sound t o
motion or heat .
Autumnal Equinox (See Also Vernal Equinox) :
The position of the sun midway between its lowes t
and highest altitude during the autumn ; it occur s
on September 21 .
Auxiliary Contacts : A set of contacts that perfor m
a secondary function, usually in relation to th e
operation of a set of primary contacts .
Averaging Element : A thermostat sensing elemen t
which will respond to the average duct temperature .
Azimuth Angle (Solar) : The angular direction o f
the sun with respect to the south .
B
Backflow : The unintentional reversal of flow in a
potable water distribution system which may resul t
in the transport of foreign materials or substance s
into the other branches of the distribution system .
Background Noise : Sound other than the wante d
signal . In room acoustics, the irreducible noise leve l
measured in the absence of any building occupants .
gas-filled, or gas-and-liquid filled . Changes i n
temperature produce pressure changes within th e
bulb which are transmitted to the controller.
Building Envelope: The elements of a building whic h
enclose conditioned spaces through which energ y
may be transferred to or from the exterior.
Bus Bar : A heavy, rigid metallic conductor whic h
carries a large current and makes a commo n
connection between several circuits . Bus bars are
usually uninsulated and located where the electrica l
service enters a building ; that is, in the mai n
distribution cabinet .
Bus Duct : Am assembly of heavy bars of copper or
aluminium that acts as a conductor of larg e
capacity.
Bypass : A pipe or duct, usually controlled by valv e
or damper, for conveying a fluid around an element
of a system .
C
Barometer : Instrument for measuring atmospheri c
pressure .
_
Calibration : Process of dividing and numbering th e
scale of an instrument ; also of correcting o r
determining the error of an existing scale, or of
evaluating one quantity in terms of readings o f
another.
Bimetallic Element : One formed of two metal s
having different coefficients of thermal expansio n
such as are used in temperature indicating an d
controlling devices .
Capacitance : The property of an electric curren t
that permits the storage of electrical energy in a n
electrostatic field and the release of that energ y
at a later time .
Boiling Point : The temperature at which the vapo r
pressure of a liquid equals the absolute externa l
pressure at the liquid-vapor interface .
Capacitor (condenser) : An electrical device tha t
will store an electric charge used to produce a powe r
factor change .
Branch Circuit : Wiring between the las t
overcurrent device and the branch circuit outlets .
Capacity, Latent : The available refrigeratin g
capacity of an air conditioner for removing laten t
heat from the space to be conditioned .
Breakout Noise : The term used in Great Britai n
for the transmission or radiation of noise from som e
part of the duct system to an occupied space in th e
building . In the United States, the terms "flanking '
and "duct radiation" are more frequently used ;
however, the term "breakout noise" seems mor e
descriptive .
British Thermal Unit (Btu) : The Btu is defined a s
the heat required to raise the temperature of a
pound of water from 59° to 60°F.
Btuh : Number of Btu's transferred during a period
of one hour.
Bulb : The name given to the temperature sensin g
device located in the fluid for which control o r
indication is provided . The bulb may be liquid-filled,
Capillary : The name given to the thin tube attache d
to the bulb which transmits the bulb pressur e
changes to the controller or indicator. The cros s
sectional area of the capillary is extremely smal l
compared to the cross section of the bulb so tha t
the capillary, which is usually outside of th e
controlled fluid, will introduce the smallest possibl e
error in the signal being transmitted from the bulb .
Capillary Tube : The capillary tube is a meetin g
device made from a thin tube approximately 2 to 2 0
feet long and from 0 .025 to 0 .090 inches in diamete r
which feed liquid directly to the evaporator . Usuall y
limited to systems of 1 ton or less, it performs all o f
the functions of the thermal expansion valve whe n
property sized .
ISHRAE Installation Guide
conditioner before being again supplied to th e
conditioned space .
Air, Reheating of : In an air conditioning system ,
the final step in treatment, in the event th e
temperature is too low .
Air, Return : Air returned from conditioned o r
refrigerated space .
Air, Saturated : Moist air in which the partia l
pressure of the water vapor is equal to the vapo r
pressure of water at the existing temperature . Thi s
occurs when dry air and saturated water vapo r
coexist at the same dry-bulb temperature .
Air, Standard : Dry air at a pressure of 29 .92 in . H g
at 69 .8 F temperature and with a specific volume o f
13 .33 ft ./lb .
Air Changes : A method of expressing the amount o f
air leakage into or out of a building or room in term s
of the number of building volumes or room value s
exchanged .
Air Conditioner, Unitary : An evaporator,
compressor, and condenser combination ; designe d
in one or more assemblies, the separate part s
designed to be assembled together .
Alr, Conditioning, Comfort : The process o f
treating air so as to control simultaneously it s
temperature, humidity, cleanliness and distributio n
to meet the comfort requirements of occupants o f
the conditioned space .
Air Conditioning Unit : An assembly of equipmen t
for the treatment of air so as to control ,
simultaneously, its temperature, humidity ,
cleanliness and distribution to meet th e
requirements of a conditioned space .
Air Cooler : A factory-encased assembly of element s
whereby the temperature of air passing throug h
the device is reduced .
Air Diffuser : A circular, square, or rectangular ai r
distribution outlet, generally located in the ceilin g
and comprised of deflecting members dischargin g
supply air in various directions and planes, an d
arranged promote mixing of primary air wit h
secondary roam air.
Air gap : An air gap in a potable water distributio n
system is the unobstructed vertical distanc e
through the free atmosphere between the lowes t
opening from any pipe or faucet supplying water t o
a tank, plumbing fixture or other device and th e
floor level rim of the receptacle .
Air Washer : A water spray system or device for
29 1
cleaning, humidifying, or dehumidifying the air .
Airborne Sound : Sound which reaches the poin t
of interest by radiation through the air.
Algae : A minute fresh water plant growth which . .
forms a scum on the surfaces of recirculated wate r
apparatus interfering with fluid flow and hea t
transfer .
Alternating Current (AC) : A source of power fo r
an electrical circuit which periodically reverses th e
polarity of its charge .
Ampacity : A wire's ability to carry current safely,
without undue heating . The term formerly used t o
describe the characteristic was current-capacit y
of the wire .
Amperage : The flow of current in an electrica l
circuit measured in "amperes," abbreviated "amps "
(A )
Amplitude of Ground Surface Temperatur e
Variation : Peak Annual fluctuation of ground surfac e
temperature about a mean value .
Anemometer : An instrument for measuring th e
velocity of a fluid .
Anticipating Control : One which, by artificia l
means, Is activated sooner than it would be withou t
such means, to produce a smaller differential of th e
controlled property. Heat and cool anticipators are _
commonly used in thermostats .
Anticipators : A small heater elements in two .
position temperature controllers which deliberatel y
cause false indications of temperature in th e
controller in an attempt to minimize the overrid e
of the differential and smooth out the temperatur e
variation in the controlled space .
Approach : In an evaporative cooling device, th e
difference between the average temperature o f
the circulating water leaving the device and th e
average wet-bulb temperature of the entering air .
In a conduction heat exchanger device, th e
temperature difference between the leaving .
treated fluid and the entering working fluid .
Aspect Ratio : In air distribution outlets, the rati o
of the length of the core opening of a grille, face ,
or register to the width . In rectangular ducts, th e
ratio of the width to the depth .
Aspiration : Production of movement in a fluid by
suction created by fluid velocity .
Attenuation : The sound reduction process in whic h
sound energy is absorbed or diminished in intensity
r0
)a
n
..
0
3
2 90
ISHRAE Installation Guid e
GLOSSARY
A
International Standard is 32 .174 ft . per second pe r
second .
A-Scale : A filtering system that has characteristic s
which roughly match the response characteristic s
of the human ear at low sound levels (below 55 d B
Sound Pressure Level, but frequently used to gaug e
levels to 85 dB) . A-scale measurements are ofte n
referred to as dB(A) .
Actuator : A controlled motor, relay or solenoid i n
which the electric energy is converted into a
rotary, linear, or switching action . An actuator ca n
effect a change in the controlled variable b y
operating the final control elements a number o f
times . Valves and dampers are examples o f
mechanisms which can be controlled by actuators .
Absolute Pressure : Air at standard conditions (70 F
air at sea level with a barometric pressure of 29 .9 2
in . Hg .) exerts a pressure of 14 .696 psi . This is th e
pressure in a system when the pressure gauge read s
zero . So the absolute pressure of a system is th e
gauge pressure in pounds per square inch added t o
the atmospheric pressure of 14 .696 psi (use 14 . 7
psi in environmental system work) and the symbo l
is "psi s
Absorbent : A material which, due to an affinity fo r
certain substances, extracts one or more suc h
substances from a liquid or gaseous medium wit h
which it contacts and which changes physically o r
chemically, or both, during the process . Calciu m
chloride is an example of a solid absorbent, whil e
solutions of lithium chloride, lithium bromide, ban d
ethylene glycols are liquid absorbents .
Absorber Surface : The surface of the collecto r
plate which absorbs solar energy and transfers i t
to the collector plate .
Absorptance : The ratio of the amount of radiatio n
absorbed by a surface to the amount of radiatio n
incident upon it .
Absorption : A process whereby a material extract s
one or more substances present in an atmospher e
or mixture of gases or liquids accompanied by th e
material's physical and/or chemical changes .
Absorption Unit : Is a factory tested assembly o f
component parts producing refrigeration fo r
comfort cooling by the application of heat . Thi s
definition shall apply to those absorption units whic h
also produce comfort heating .
Acceleration : The time rate of change of velocity ;
i .e ., the derivative of velocity ; with respect to
time .
Acceleration due to Gravity : The rate of increas e
in velocity of a body falling freely in a vacuum . It s
value varies with latitude and elevation . The
Adiabatic Process : A thermodynamic proces s
during which no heat is added to, or taken from, a
substance or system .
Adjustable Differential : A means of changing th e
difference between the control cut . in and cutou t
points .
Adsorbent : A material which has the ability to caus e
molecules of gases, liquids, or solids to adhere t o
its internal surfaces without changing th e
adsorbent physically or chemically . Certain soli d
materials, such as silica gel and activated alumina ,
have this property .
Adsorption : The action, associated with th e
surface adherence, of a material in extracting on e
or more substances present in an atmosphere o r
mixture of gases and liquids, unaccompanied b y
physical or chemical change . Commercial adsorben t
materials have enormous internal surfaces .
Aerodynamic Noise : Also called generated noise ,
self-generated noise ; is noise of aerodynamic origi n
in a moving fluid arising from flow instabilities . I n
duct systems, aerodynamic noise is caused b y
airflow through elbows, dampers, branch wyes ,
pressure reduction devices, silencers and othe r
duct components .
Air, Ambient : Generally speaking, the ai r
surrounding an object .
Air, Dry : Air without contained water vapor ; ai r
only.
Air, Outdoor : Air taken from outdoors and ,
therefore, not previously circulated through th e
system .
Air, Outside : External air, atmosphere exterior t o
refrigerated or conditioned space ; ambien t
(surrounding) air.
Air, Recirculated : Return air passed through th e
288
ISHRA E Installation Guid e
NOTES
28 7
ISHRAE Installation Guide
IS 3792 : 1978 (reaffirmed 1992)
Guide for heat insulation of non industria l
buildings (1st revision )
GB
IS 4671 : 1984 (reaffirmed 1990)
G5
Expanded pofystyerene for thermal insulatio n
purposes
(1st revision )
G6
IS 7240 : 1974
Code of practice for thermal insulation of col d
storages .
IS 7413 : 1981
G7
Code of practice for thermal industria l
application and finishing of thermal insulatin g
materials at temperature above 40 deg . C to 70 0
Deg. C (Superseded by IS 14164, 1994)
IS 8154 : 1993
G3
Preformed calcium silicate insulation (fo r
temperatures upto 650 Deg . C) (1st revision)
IS 8183 : 199 3
Bonded mineral wool . (1st revision)
G3
15 9403 : 1980 (reaffirmed 1990 )
G4
Method of test for thermal conductance and
transmittance of built up sections by means of
guarded hot box .
Dimensions, Dimensional stability, apparen t
density, water vapour transmission rate, volum e
percent of open and closed cells, heat distortio n
term ., co-efficient of linear thermal expansio n
at low temp ., flame height, time of burning an d
loss of mass, water absorption, flexura l
strength, compressive strength, horizonta l
burning characteristics, determination o f
flammability by oxygen index .
G2/G2/G1/G2/G3/G4/G2/G3/G3/G2/G2/G2/G 2
IS 11246 : 1992
Glass fibre reinforced polyester resin (1s t
revision )
G3
IS 12436 : 1988 (reaffirmed 1994)
G1
Preformed rigid polyurethane foams for therma l
insulation .
IS 13204 : 199 1
Rigid phenolic foams for thermal insulation .
G2
IS 13205 : 199 1
G3
of
practice
for
the
application
of
Code
polyurethane insulation by the in-situ pouring
method .
Ventilatio n
IS 9428 : 1993
Preformed calcium silicate insulation for
temperature upto 950 Deg C . (1st revision)
G3
IS 2312 : 1967 (reaffirmed 1991)
G6
Propeller type AC ventilation fans . (1st revision )
(Amendments 7 )
IS 9489 : 1980 (reaffirmed 1992)
Method of test for thermal conductivity of
materials by means of heat flow meter.
G3
IS 3103 : 1975
G5
Code of practice for industrial ventilation (1s t
revision )
IS 9742 : 199 3
G2
Sprayed mineral woof insulation . (1st revision )
(amendment 1)
IS 9842 : 199 4
G4
Preformed fibrous pipe insulation (1st revision)
IS 10556 : 1993 (reaffirmed 1990) G 2
Code of practice for storage and handling o f
insulation materials .
IS 11239 : Part 1 to Part 1 3
Method of test for cellular thermal insulatio n
materials .
IS 3588 : 1987 (reaffirmed 1991 )
Electric axial flow fans . (1st revision)
G6
IS 4894 : 1987 (reaffirmed 1991)
Centrifugal fans (1st revision )
. G7
286
IS 1644 : 1988 (reaffirmed 1993)
Code of practice for fire safety of building s
(general) : Exit requirements and persona l
hazard .
ISHRAE Installation Guid e
G5
IS 1646 : 1982 (reaffirmed 1990)
G8
Code of practice for fire safety of building s
(general) : Electrical installation (1st revision) .
IS 3786 : 1983 (reaffirmed 1991)
Methods for computation of frequency an d
severity rates for industrial injuries an d
classification of industrial accidents . (1s t
revision )
G7
IS 3768 : 1989 (reaffirmed 1994)
G5
Ventilation ducting . Venyl coated, flexible (1s t
revision )
IS 7613 : 1975 (reaffirmed 1991)
Method of testing panel type air filters fo r
airconditioning purpose .
G6
Thermal Insulatio n
IS 334 : 1982 (reaffirmed 1991)
Glossary of terms relating to bitumin and tar .
(2nd revision )
G3
IS 3808 : 1979 (reaffirmed 1990)
G4
Method of test for non combustibility of buildin g
materials (1st revision )
IS 661 : 1974 (reaffirmed 1990)
G4
Code of practice for thermal insulation of col d
storages . (2nd revision) (Amendments 2 )
IS 5311 : 1969 (reaffirmed 1990)
Code of safety for carbon tetra chloride .
IS 1397 : 1990
Kraft paper (2nd revision )
G4
IS 6382 : 1984 (reaffirmed 1990)
G7
Code of practice for design and installation o f
fixed carbon dioxide for fire extinguishin g
system (1st revision )
IS 7969 : 1975 (reaffirmed 1991)
G3
f
Safety code for handling and storage o
building material s
(Amendment 1 )
Sheet Metal Work
IS 277 :
1992
G3
Galvanised Steel sheet (5th revision, Amendment s
(2) )
IS 513 : 1994
Cold rolled low carbon steel sheets .
G4
IS 655 : 1963 (reaffirmed 1991)
Metal air ducts (revised) (Amendments - 3 )
G1
15 1079 : 1994
Hot rolled carbon steel sheets .
G3
15 1977 : 1975 (reaffirmed 1992)
Structural steel (ordinary quality) .
G4
15 2062 : 1992
Steel for general structural purposes .
G4
G2
G2
IS 2094 : 1995
Heaters for bitumin and emulsion (2nd revision )
G7
IS 3069 : 1994
Glossary of terms, symbols and units relatin g
thermal insulation materials (1st revision) .
to
IS 3129 : 1985 (reaffirmed 1990)
Low density particle boards . (1st revision )
G5
IS 3144 : 1992 G 9
Mineral wool thermal insulations - Methods of
tests . (2nd revision )
G6
15 3346 : 1980 (reaffirmed 1990)
l
Method of determination of therma
conductivity of thermal insulation materials ( 2
slab guarded hot plate method) (1st revision )
G3
IS 3677 : 1985 (reaffirmed 1990)
l
Unbonde d rock and slag wool for therma
insulation .
(2nd revision) (superseding IS 5696)
G3
IS 3690 : 1974 (reaffirmed 1990)
Unbonded glass wool for thermal insulation (1s t
revision )
G1 3
IS 3716 : 1978 (reaffirmed 1991)
Application guide for insulation co-ordinatio n
(1st revision) (Amendments 2 )
28 5
ISHRAE Installation Guide
amendments 3 )
IS 3233 : 1965 (reaffirmed 1992) G 7
Glossary of terms for safety and relief valves an d
their parts .
IS 12992 : 1993, Part I, 1990 Part II
Safety relief valves .
IS 13095 : 1991
Butterfly valve for general purposes .
IS 4854 : Part I, II, 1969, Part III 1984G10/G5/G 4
Glossary of terms for valves and their parts .
Refrigerant Gas & Lubricants
IS 5312 : Part 11984, Part II 1986 (reaffirme d
1990,1991) Swin g
G4/G 4
check type non return valves .
IS 310 : 1954
Methods of sampling and test for lubricants .
(Part I & Part II) (Superseded by IS 1447 and I S
1448 )
IS 5659 : 1970 (reaffirmed 1991)
Pumps for process water (Amendment 1 )
G4
G3
15 8092 : 1992 (reaffirmed 1990)
G1 0
Code for inspection of surface quality of stee l
castings for valves, fittings and other pipin g
components . (Visual method) (1st revision) .
IS 8418 : 1977 (reaffirmed 1990)
Horizontal centrifugal self priming pumps .
G13/G 3
IS 718 : 197 (reaffirmed 1991) G7
Carbon tetra Chloride (2nd revision) (Amendment s
2)
IS 4578 : 1989 G 2
Lubricating oils for refrigeration machinery (1s t
revision )
G3
IS 8472 : 1977 (reaffirmed 1993)
G3
Regenerative self priming pumps for clear. cold,
fresh water. (Amendments 2 )
IS 9137 : 1978 (reaffirmed 1993)
G11
Code for acceptance test for centrifugal, mi x
flow and axial pumps . class C . (Amendments 4)
IS 9542 : 1980 (reaffirmed 1993) G 2
Horizontal centrifugal mono set pumps for clear ,
cold, fresh water . (Amendment 1 )
IS 10596 : Part I, II, III & IV , 1983 (reaffirme d
1993 )
Code of practice for selection, installation ,
operation and maintenance of pumps fo r
industrial applications .
G2/G3/G2/G 5
IS 10981 : 1983 (reaffirmed 1993)
G1 2
Class of acceptance test for centrifugal mixe d
flow and axial flow pumps - Class B
IS 11745 : 1986 (reaffirmed 1991)
Technical supply conditions for positiv e
displacement pumps . reciprocating .
G8
IS 12969 : 1990
Method of test for quality characteristic o f
valves .
G2
15 6849 : Part I & Part II, 199 3
Positive displacement vacuum pumps .
G2
IS 9466 : 1980 (reaffirmed 1993 )
Viscosity classification of industrial liquid
Lubricants .
G2
IS 10609 : 1983 (reaffirmed 1991 )
Refrigerants . Number . designation .
G2
Safety
G2
IS 954 : 1989
Functional requirements for carbon dioxid e
tender for fire brigade use . (2nd revision )
IS 1641 : 1988 (reaffirmed 1993)
G3
Code of practice for fire safety of building s
(general) : General principles of fire grading an d
classification . (1st revision)
IS 1642 : 1989
G7
Code of practice for fire safety of buildings .
(general) : Details of construction (1st revision )
(1645 supersedes 1642 )
G3
IS 1643 : 1988 (reaffirmed 1993)
Code of practice for fire safety of building s
(general) :
Exposure hazard (1st revision )
e