VRF/VRV BASED HVAC SYSTEM

Key Functions of VRV/VRF-Based HVAC Systems:
Energy Efficiency:
- Variable Refrigerant Flow: The system adjusts the refrigerant flow to each indoor unit based on the required cooling or heating load. This reduces energy consumption since only the necessary amount of refrigerant is circulated.
- Inverter Technology: The compressors in VRV/VRF systems typically use inverter technology, allowing them to operate at variable speeds. This adaptability helps in reducing power consumption and ensures the system operates efficiently under partial load conditions.
Individual Zone Control:
- Multi-Zone Capability: VRV/VRF systems can control multiple zones independently, allowing for different temperature settings in different areas or rooms. This is ideal for buildings with varying cooling or heating needs across different spaces.
- Flexible Installation: The system allows for a wide range of indoor units (e.g., wall-mounted, ceiling-mounted, ducted) to be connected to a single outdoor unit, providing flexibility in design and installation.
Heat Recovery:
- Simultaneous Heating and Cooling: Some VRV/VRF systems offer heat recovery capabilities, meaning they can simultaneously cool some zones while heating others. This is particularly useful in buildings where different areas have different thermal needs at the same time.
- Efficient Heat Exchange: The system can transfer heat from one zone to another, reducing the overall energy consumption by reusing the heat that would otherwise be wasted.
Comfort and Air Quality:
- Stable Indoor Climate: The precise control of refrigerant flow ensures that the indoor temperature remains stable, enhancing occupant comfort.
- Improved Air Quality: Many VRV/VRF systems are equipped with advanced filtration systems to improve indoor air quality by removing dust, allergens, and other contaminants.
Quiet Operation:
- Low Noise Levels: Due to the use of inverter compressors and advanced design, VRV/VRF systems generally operate quietly, which is particularly important in residential and office environments.
Scalability and Adaptability:
- Modular Design: VRV/VRF systems are highly scalable, making them suitable for small to large-scale projects. The system can be expanded easily by adding more indoor units without needing significant modifications to the existing setup.
- Long Piping Lengths: These systems can accommodate long refrigerant piping lengths, providing greater flexibility in the placement of indoor and outdoor units, which is beneficial in high-rise buildings.
Application of VRV/VRF Systems:
- Commercial Buildings: Such as offices, hotels, and shopping malls, where multiple zones need different temperature controls.
- Residential Complexes: Especially in large homes or apartment buildings where independent temperature control is desired in different rooms.
- Mixed-Use Buildings: Where there are varying heating and cooling demands throughout the day in different sections of the building.
Advantages of VRV/VRF Systems:
- Energy Savings: The system’s ability to adjust the refrigerant flow according to the load results in significant energy savings.
- Comfort and Flexibility: With the ability to customize the indoor climate for different zones, it provides enhanced comfort.
- Longer Lifespan: Due to less wear and tear from operating at reduced capacity, VRV/VRF systems tend to have a longer lifespan compared to traditional HVAC systems.
Challenges:
- Initial Cost: The upfront cost of VRV/VRF systems is typically higher than traditional HVAC systems.
- Complexity: The system is complex to design, install, and maintain, requiring skilled professionals.
Overall, VRV/VRF-based HVAC systems offer a high level of efficiency, comfort, and flexibility, making them an increasingly popular choice for modern buildings.
A VRV (Variable Refrigerant Volume) or VRF (Variable Refrigerant Flow) based HVAC system is composed of several key components that work together to regulate temperature and maintain comfort within a building. Here’s a breakdown of the essential components:
1. Outdoor Unit
- Compressor: The heart of the VRV system, it compresses the refrigerant and is typically equipped with inverter technology to vary the speed and control the flow of refrigerant based on demand.
- Heat Exchanger: Facilitates the exchange of heat between the refrigerant and the outdoor air. In cooling mode, it dissipates heat, and in heating mode, it absorbs heat from the outdoor air.
- Fan: Helps in the heat exchange process by moving air over the heat exchanger.
- Electronic Expansion Valve (EEV): Controls the flow of refrigerant into the evaporator, ensuring the proper amount is sent to each indoor unit.
2. Indoor Units
- Evaporator Coil: Located inside the indoor units, this coil allows the refrigerant to absorb heat from the indoor air (in cooling mode) or release heat into the indoor air (in heating mode).
- Blower/Fan: Circulates indoor air over the evaporator coil to distribute conditioned air into the space.
- Air Filter: Captures dust, allergens, and other particles from the air before it is circulated into the room, improving indoor air quality.
- Drain Pan and Pump: Collects and removes condensate (moisture) produced during the cooling process.
3. Refrigerant Piping Network
- Refrigerant Lines: Copper pipes that carry the refrigerant between the outdoor unit and the indoor units. Typically, there are two or three refrigerant lines, depending on whether the system is 2-pipe or 3-pipe.
- Insulation: Surrounds the refrigerant lines to prevent heat loss or gain during the transfer of refrigerant, ensuring efficiency.
4. Branch Selector Boxes (for Heat Recovery Systems)
- Function: Used in heat recovery VRV/VRF systems to control the flow of refrigerant to different indoor units. They allow simultaneous heating and cooling by directing the refrigerant appropriately.
- Multiple Ports: These boxes can have multiple ports to connect to different indoor units, enabling precise control over the temperature in various zones.
5. Control System
- Central Controller: Provides centralized control over the entire VRV/VRF system, allowing users to monitor and adjust the temperature in different zones.
- Individual Controllers: Wall-mounted or remote controllers that allow users to adjust settings for each indoor unit or zone independently.
- Sensors: Temperature, humidity, and occupancy sensors that provide data to the control system to optimize the operation of the system.
6. Refrigerant
- Refrigerant (e.g., R-410A, R-32): The working fluid that circulates through the system, absorbing and releasing heat to cool or heat the indoor space.
7. Expansion Devices
- Electronic Expansion Valves (EEVs): These are installed in both the outdoor and indoor units and regulate the amount of refrigerant entering the evaporator coil, optimizing the system’s efficiency and performance.
8. Power Supply Unit
- Electrical Components: Includes power supply cables, breakers, and other electrical components necessary to power the VRV/VRF system.
9. Communication Network
- Wiring and Control Cables: Used to connect the outdoor unit, indoor units, and control systems, allowing for communication between different components of the system.
10. Optional Components
- Heat Recovery Ventilator (HRV): An optional component that can be integrated into the system to provide fresh air ventilation while recovering heat from the exhaust air, further improving energy efficiency.
- Air Purification Modules: Additional filtration or air purification systems can be integrated to enhance indoor air quality.
These components work together to create an efficient and flexible HVAC system that can adapt to the varying needs of different zones within a building. The modular design allows for scalability and customization, making VRV/VRF systems a preferred choice for modern buildings.
The system shall be air-cooled, type central air conditioning system consisting of outdoor units, indoor units and refrigerant piping, cabling between indoor and outdoor units.The system shall be based on refrigerant R-410.
INSULATION WORK
a) Material Specifications:
Insulation Material : Closed Cell elastomeric Nitrile Rubber foam, Fire retardant
Class „O‟
Make : Armacell/Aeroflex
Adhesive : As recommended by manufacturer.
Application Procedure:
Clean the surface of the duct to be insulated free from dust grease and other matter.
Prepare the pieces of sheet as per the dimensions of the duct and apply the adhesive on the duct surface, the sheet surface as well as the edges of the sheets & leave it for 2-3 minutes for drying.
Once the adhesive is half dry and tacky, bring both the ends of insulation where the adhesive is applied in contact and stick them well. Ensure that both the surfaces are matched properly.
Apply self adhesive black cotton tape on all the joints. Before fixing the tapes it must be ensured that all the joints are sealed properly.
M.S. WELDED PIPING FOR WATER DUTY
Pipes shall be mild steel ERW (electric resistance welded) type in class-C (heavy class) construction as per IS 1239/IS 3589. For sizes of 150NB and lower, they will be in class-C (heavy class) construction as per IS 1239. For higher sizes, they will be conforming to IS 3589, and shall have wall thickness as below:
- For size 200NB to 300 NB : 5.56mm For sizes 350NB to 500NB : 6.35mm
- Tolerance on thickness shall be +/- 10%. Tolerance on diameter will be +/ -0.75% max.
All bends will have radius of 1.5D, unless stated otherwise. Bends shall be forged type, made out of pipe having the same specifications as the pipe being used for straight piping. Ends shall be beveled suitable for butt- welding.
All tees and reducers shall be factory fabricated with ends suitable for butt- welding. For branching from pipes, only factory-fabricated tees shall be used. Puncturing of pipes and welding branch pipes shall not be permitted. Where the branch pipe size is substantially smaller than that of the main pipe, weld-o-lets shall be used for making the branch.
For pipe sizes of 40NB and below, socket-weld type forged tees, elbows and reducers shall be used.
All flanges will be made out of M.S. plates and shall conform to British standard Table-F
Valves shall be of wafer type butterfly valves for 50 mm and higher sizes, and of ball type for lower sizes. Non-return valves shall be of wafer type for 50 mm and higher sizes, while for lower sizes gun-metal lift type check valves shall be used.
Material specifications of butterfly and wafer type non-return valves shall as follows:
Body and Disc: High grade cast iron as per IS:210, grade FG200/GG25, coated with epoxy or nylon.
Shaft : Stainless steel
Seat/seal Rings: EPDM
The butterfly valves shall be provided with suitable notch plate and lock for locking the valve in required position.
The wafer type non-return valves shall be preferably with a back-up spring to avoid the disc getting stuck in open position.
Ball valves shall be of 3-piece design and have the following material specifications.
Body : Cast steel ASTM A216 Gr. WCB
Ball & Stem : Stainless steel AISI 304/316 Seat & Seal : PTFE
Ball valves shall have screwed ends when used in GI screwed piping, while they will have socket weld ends when used in MS welded piping.
Strainers shall be of pot type for pipeline size of 150 NB and above, while the lower size lines shall have Y type strainers. Strainer body shall be of heavy duty cast iron as per IS 210 Gr. 20 close grained. The strainer element shall be made of brass of stainless steel. The end connections shall be flanged. The cover shall also be easily openable flanged cover. Flush out cocks shall be provided on strainers of sizes 150 NB and above.
All nut-bolts shall be of reputed make, correct diameter and length as per the flange tables and requirements of the equipment. Nut-bolts shall be hot-dip galvanized to prevent corrosion
Gaskets shall be of fabric-reinforced non hardening rubber, 3mm thick.
Piping scheme shall be as per the CONSULTANT’s schematic drawing and duly approved VENDOR’s drawing.
Pipe ends shall be cut by hacksaw only, and shall be beveled by grinding before making a butt-weld joint. After preparing the ends, the joint shall be tack-welded leaving a uniform gap between the ends for weld penetration. Grinding before starting the filler run shall clean the root run of the weld joint.
All welding work shall be carried out by generator type welding machines, using SUPERBOND-S or equivalent welding electrodes. All welders shall be pre-qualified by preparing sample joints.
Before starting full welding on the joints, the complete section of piping shall be fitted up in position for inspection and approval of the Engineer-in-charge. Finish welding shall be carried out only after getting approval of the fit-up.
All slip-on flanges shall be welded from outside as well as inside to the pipe. All welded joints shall be cleaned of flux and surplus metal deposition.
Piping shall be supported on supports fabricated out of MS rolled section like channels and angles. Galvanized “U” clamps shall be provided at each support. Insulated piping shall be supported on two high density molded polyurethane half round sections as saddles and clamped. Wooden saddles shall be coated with termite proof paint.
All horizontal lines shall be in perfect level checked by a level gauge. All vertical lines shall be in perfect plumb. Lines shall run parallel or at exact right angles to the nearby lines and structures.
Spacing of supports shall not exceed the figures below:
Line size (MM NB) : 25 50 75 100 125 150 200
Max. Spacing (Mtr.) : 2 3 3.5 4 4.5 5 6
Purging/drain cocks shall be fixed at all highest/lowest points of the line wherever there are upward/downward loops in the line respectively, which can cause accumulation of air/dirt in the line.
After completion of installation, the pipelines shall be hydraulically tested for leaks by a test-pump. The entire line shall be visually inspected for leaks while it is under pressure. Minimum test pressure shall be 7 Kg/cm2.
All valves shall be fully open during the test. Delicate instruments and equipments shall be isolated during the test. All temporary supports shall be removed before leak testing.
After completion of testing, the entire piping shall be flushed with water 3 times to clear it of any dirt inside, by filling the lines from highest point and draining them from the lowest point. Circulation pumps shall not be operated for flushing the lines.
Pipes shall be insulated with closed cell nitrile rubber foam. For pipe sizes 50NB and lower, sleeves shall be used. For higher sizes, sheets shall be used. Thickness of the insulation for chilled water piping shall be 38 mm, applied in two layers – 25mm+13mm.
The insulation shall be applied as follows:
- Clean the surface of the pipe to be insulated free from dust grease and other
- In case of insulation with sleeves, select the correct ID of the insulation tube suitable for the pipe to be insulated and slit the pipe along its length using a sharp knife. Ensure that the cut is straight. Apply a thin coat of adhesive on both the cut surfaces of the insulation tubing and leave it for 2-3 minutes for
- In case of insulation with sheets, prepare the pieces of sheet as per the circumference of the pipe and apply the adhesive on the pipe surface, the sheet surface as well as the edges of the sheets.
- Once the adhesive is half dry and tacky, bring both the ends of insulation tubing or sheets where the adhesive is applied in contact and stick them well. Ensure that both the surfaces are matched properly.
- Apply self adhesive black cotton tape on both the longitudinal and the circumferential Before fixing the tapes it must be ensured that all the joints are sealed properly.
- In case of pipes exposed to the atmosphere, one layer of reinforced Aluminium foil (HARVEY or equivalent) has to be fixed over the insulation. For sealing the joints Aluminium foil self adhesive tape 1″ width is to be used. For indoor pipes no finish is
After completion of the testing and flushing, the entire pipeline and the supporting structures shall be painted with two coats of red-oxide primer, followed by two coats of synthetic enamel paint of approved shade.
Piping which is to be insulated is to be painted which red-oxide primer only.
DRAIN PIPING
The drain piping shall be made out of rigid PVC pipes of 10 Kg/cm2 class. The piping shall be supported by clamping on MS angle 25mm x 3mm running continuously below the pipe. The piping shall be insulated with 9 mm thick nitrile rubber sleeve tightly fixed on the surface of the pipe. All the insulation joints shall be sealed by BOPP adhesive tape.
The drain pan shall be connected to rigid PVC pipe by braided PVC flexible pipe with appropriate adapters.
All pipes support/clamps shall be painted with red oxide primer followed by two coats of synthetic enamel finish paint.
MANUAL BALANCING VALVES
Valve should be a double regulated Globe type balancing valve. Should be min PN16 rated. Valve insert with hand-wheel and pre setting display. Valve should have threaded ends up to sizes 50 mm and flanged for above 50 mm.
Valve shall be equipped with two pressure test cocks for differential measurements. Material specifications of balancing valves shall as follows:
Body: High grade cast iron as per IS:210,
grade FG200/GG25, coated with epoxy or nylon.
Bonnet: Cast Iron.
Insert: Carbon Steel, chromium plated with PTFE seat ring Gasket: Graphite
Stem: Stainless Steel.
Handwheel: Ductile Iron
Balancing of the valves done by the hand held computer with digital display, integrated valve database and which is capable of calculating the actual flow rates in the valves. It should have Rechargeable batteries, It should have the possibility to connect up to two temperature sensors.
List of Approved makes
Sr.No. | Equipment/Material | Makes |
---|---|---|
1. | VRF System | :Daikin/Hitachi/Mitsubishi Electric( Imported machines and non-China) |
2. | Aluminium Grilles/Diffusers | : Caryaire / Cosmos /Air-pro |
3. | Insulation: Nitrile Rubber Foam | : Armacell/Aeroflex |
4. | G.I. Sheets | : SAIL/ Jindal/ Tata/ Essar |
5. | MS/GI Pipe | : Tata/Zenith/Jindal. |
6. | P.V.C. pipe and fittings | : Supreme/Prince. |
7. | Welding Rods | : Advani Oerlikon |
8. | Anchor Fasteners | : Hilti/Fisher |
9. | Electric Cables | : CCI/Gloster/Universal/ICC |
10. | Copper Piping | : Rajco/Mandev |
11. | Underdeck Insulation | : Beardsell/U.P. Twiga |