HVAC

HANDBOOK
2016

Cube Construction & Engineering Limited (Rev-01) Page 1

 INDEX

Sr. No. Description Page No.

Basic Conversation of HVAC
1 3
Basic Formula of HVAC
2 5
Mode Of Measurement for Ducting
3 9
Mode Of Measurement for Duct Insulation/Acoustic Lining
4 11
Mode Of Measurement for Piping
5 12
Mode Of Measurement for Piping Insulation
6 13
Mode Of Measurement for Grills Diffuser & Damper
7 14
Execution Instruction for Ducting
8 15
Execution Instruction for Piping
9 19
Execution Instruction for Ducting Insulation
10 24
Execution Instruction for Piping Insulation
11 25
Air Filters
12 26
Valves & Fixtures
13 27
Basic Electrical Standard for HVAC
14 28
Inspection Standard
15 30
Abbrivation
16 32

Cube Construction & Engineering Limited (Rev-01) Page 2

  BASIC CONVERSATION OF HVAC

 1 m= 100 cm
 1 m=1000 mm
 1 m= 3.28 ft
 1 cm=10 mm
 1 Inch=2.54 cm
 1 Inch=25.4 mm
 1 Inch=25400 μm
 1 ft=12 inch
 1 ft=0.304 m
 1 ft=30.48 cm
 1 TR=12000 BTU/Hr ……………………………………………… ( For Chiller)
 1 TR=15000 BTU/Hr ……………………………………………… (For Cooling Tower)
 1 TR=200 BTU/Min
 1 TR=400 CFM (Approx for calculation)
 1 TR=3024 Kcal/hr
 1 TR = 3.516 KW
 1 TR = 4.71 HP
 1 TR=2.67 USGPM or 2.4 USGPM
 1 KVA = 0.8 KW
 1 KW=1.340 HP
 1 KW=1000 Watt
 1 KW=3413 BTU
 1 HP=2545 Btu/hr
 1 HP=0.746 KW
 1 HP=0.8 TR ( For VRV System)
 1 lb/h=500 GPM
 1 m2=10.76 ft2
 1 m3=35.28 ft3
 1 m3=1000 Liter
 1 ft2=0.09 m2
 1 ft3=0.028 m3
 1 Bar=14.5 PSI

Cube Construction & Engineering Limited (Rev-01) Page 3

  m3/Hr=4.4 USGPM
 CFM =0.558 X m3/Hr(CMH)= CMH/1.7
 USGPM= 0.2242 m3/hr
 1 LPM=0.2642 USGPM
 1 FPS=0.305 m/s
 1 m/s=3.28 FPS
 Area(A)= L*W ……………………………………………………………(For Rectangular)
 Area (A) = ∏r2 or ∏ (D2/4). …………………………………………… (For Circle)
 Area(A)= a*b………………………………………………………………..(for Square)
 Area(A)=1/2 b X h…………………………………………………………(For Triangle)
 Degree C’=K(Kelvin)-273
 Perimeter(P)= a +b +c +d………………………………………………(For Square)
 Perimeter(P)= 2L+2W…………………………………………………..(For Rectangular)
 Perimeter (P) = ∏D or 2∏r………………………………………… (For Circle)
 Area(A)= 1/2 b*h………………………………………………………….(for Triangle)
 Volume(V)= l*w*h………………………………………………………..(for Rectangular)
 Volume(V)= ∏r2h or ∏(D2/4) *h…………………………………….(For Cylindrical Solid)
 1 Btu/lb=0.555 Kcal/kg
 1 Kcal/kg=1.8 Btu/lb
 Steel Density= 7.85 g/cm3
 Steel Density = 7850 Kg/m3
 1 lbs (Pound)= 0.45 Kg
 IKW/TR = 3.516 / COP
 1 US Gallon = 3.785 Liter
 No. of Air Changes(N)=60 X CFM/ft3
 1 TR = 3782.5 Kcal/hr (For Cooling Tower)

Cube Construction & Engineering Limited (Rev-01) Page 4

  BASIC FORMULA OF HVAC

 TR= (FPM X USGPM X 10 Fᵒ /12000 )

 Fahrenheit Fᵒ=(Cᵒ X 9/5) +32 Degree Cᵒ
 Degree Cᵒ= (Fᵒ-32) X 5/9 Fahrenheit Fᵒ
 RH=Moisture Present/Moisture Air can Hold
 CFM=Area(ft2) X Velocity(Ft/min)……………………(For Point Measurement)
 Motor RPM=(60Hz X 120)/No. of Pole
 CFM= ……..BTU/Hr/ (1.08 X Temp. Difference)
 Coil Face Area(Sq. ft)=Fin Height (Inches) X Fin Length(Inches) /144
 CFM= Coil face Area(Sq. ft) X Face Velocity (Ft/min)
 3Ph Amps = Watts/(Volts X 1.73)
 1 Ph Amps = Watts/Volts
 1 BTU/HR = 0.3 Watts
 1 KW = 860 Kcal/HR

 For Puff Support Block=

Volume V(r) =L X B X H (For Rectangular Block) m3
Volume V(c) = (Pi X r2 X h) /2 (For semi Circle) m3
Volume of Puff Block (V) = V(r) – V(c)
Weight of Puff block (W) = ---------------kg
Density (d) = Weight/Volume
= W/V kg/m3 ………………… (Density Range 160 -220 kg/m3)
 For Duct Insulation=
Volume (V) = (L X B X H) m3
Weight (W) = ----------- Kg
Density (d) = Weight/Volume
=W/V kg/m3

Cube Construction & Engineering Limited (Rev-01) Page 5

  Air Changes= CFM X 60 min/Volume of Room (Ft3)

 Pump BKW Calculation =

Water Flow rate (m3/hr) X Head (Mtr) X Specific Gravity (Water)
3.672 X Efficiency (%)
 Pump BHP Calculation =

Water Flow rate (USGPM) X Head (Ft.) X Specific Gravity (Water)

3.963 X Efficiency (%)

 Quantity of fresh air required(L/s) =

Air Change Rate (changes per hr) x Room volume (m³) x 1000
_______________________________________________________
3600

 M.S Pipe Weight(kg) = Density(g/cm3) X (OD2 – (OD-2XT)2 X L m X π/4000

 Cooling Tower TR Calculation = LPM X 0.2642 = _____USGPM
= USGPM ÷ 4.4 = ______M3/hr (CMH)
= M3/hr X 1000 X ΔT = _____Kcal/hr
=Kcal/hr ÷ 3600 = ______ TR (For CT)

HEAT REJECTION CAPACITY (Q) = m s ∆t

Where
m = mass = Flow rate in LPH
s = specific gravity of fluid = specific gravity of water = 1
∆t = Cooling Range in ºC = (Hot Water Temp. - Cold Water Temp.) = 5 ºC

Cube Construction & Engineering Limited (Rev-01) Page 6

Cube Construction & Engineering Limited (Rev-01) Page 7
 As per NBC Standards

ACPH

Sr.No. Area Normal Case of Fire

1 Corridors 15 30

2 Chiller Plant Room 12 30

3 Electrical Room 12 30

4 Toilets & Wash Area 10 20

5 Store 10 20

6 CSSD Area 15 30

7 Staircase Pressurization 15 30

8 Lift Lobby 15 30

9 Basement 15 30

Cube Construction & Engineering Limited (Rev-01) Page 8

  MODE OF MEASUREMENT OF HVAC

MOM for Ducting

 Payment for ducting shall be on the basis of the final finished sheet
surface area of the ducting including all material and labour for
installed duct
 The rates/Sq.mtr of the external surface shall include of all wastage,
flanges, gasket for joints ,bolts and nuts, duct support and hanger
,vibration isolation pads or suspenders, flexible connections, inspection
doors, dampers, turning vanes, straight vanes and any item which will
be required to complete the external insulation and acoustic lining
work.
 The external area shall be calculated by measuring the overall width
and depth (Including the corner joints) in the center of the duct section
from flange face to flanges face in case of duct length with uniform
cross section. Total area will be arrived at by adding up the area of all
duct section.
 In case of tapper pieces average width and depth will be worked out as
follows:
W1=Width of small cross section
W2=Width of large cross section
D1=Depth of small cross section
D2=Depth of large cross section

 Avg. Width=W1+W2/2
 Avg. Depth=D1+D2/2
 Width and depth in the case of taper pieces shall be measured at the
edge of the collar of the flanges for duct sections flatted with angle iron
flanges, otherwise at the bottom of the flange where the flanges are of
duct sheet

Cube Construction & Engineering Limited (Rev-01) Page 9

  For Circular pieces the diameter of the section midway between large
and small diameter shall be measured and adopted as the mean
diameter for calculating the surface area of the taper piece.
 Duct measurement for calculation of area shall be taken before
application of insulation.
 For the special pieces like bends, branches and tees etc, same principle
of area measurements as for liner and outer periphery along the
curvature angle of the piece shall apply.
 Bends, Elbows, Transformation Pieces shall be measured along the
centre line and measured as per site duct work.
 Canvas connections, duct structure supports, stiffening members,
frames etc shall not be measured separately and shall form part of duct
work.

Cube Construction & Engineering Limited (Rev-01) Page 10

 MOM for Duct Insulation/Acoustic Lining

 Insulation item is provided separately for various thicknesses as per

Tender Specification and shall be paid for an area basis of un-insulated
duct.
 The area of the duct to be insulated shall be measured before
application of insulation.(the area of duct and area of duct insulation
shall be same)

Cube Construction & Engineering Limited (Rev-01) Page 11

 MOM for Piping

 Piping shall be measured in unites of length along the center line of

installed pipes including all pipe fittings, flanges, (With gasket and nuts
and bolts for jointing), unions, bends, elbows, tees, concentric, and
eccentric reducers, inspection pieces, expansion loops, ceiling/floor
mounted supports.
 The above accessories shall be measured as part of piping work along
the center line of installed pipes and no special rates for these
accessories shall be permitted.
 The rates for center line linear measurement of piping shall include all
wastage allowances, pipe supports includes hangers, MS channel,
wooden haunches, nuts and check nuts, vibration isolator suspension
where specified or required, and cost of excavation, bedding, back
filling and finishing, Painting as required to complete the piping
installation as per specification.
 None of These above items will be separately measured nor paid for.
However, all valves
(gate/globe/butterfly/check/balancing/Purge/drain/PIBC etc...)
,strainers, orifice plates, temp. Gauges, Pressure gauges shall be
separately measured and paid as per their individual unit rates, which
shall also include their insulation as per specification.
 Flanges ,Structure supports, Flexible pipe connection wherever
required shall not be measured separately as they are form part of
piping work
 For Thermometer wells & Pressure gauges sockets no measurements
shall be done separately.
 Piping Measurement shall be taken before application of the
insulation

Cube Construction & Engineering Limited (Rev-01) Page 12

 MOM for Piping Insulation

 Piping Insulation shall be measured in unites of length along the center

line of the installed pipe, strictly on the same basis as the piping
measurement described above.
 The Linear Measurement shall be taken before application of the
insulation.
 All valves, orifice plates and strainers shall be separately measured and
paid as per their individual unit rates, which shall also include their
insulation as per specification.
 The thickness of insulation shall be as per mentioned in Tender
Specification.
 For insulation of bends, elbows, tees, tapper etc shall be measured
along with the centre line of pipe and shall be measured in meter.

Cube Construction & Engineering Limited (Rev-01) Page 13

 MOM for Grills & Diffuser and Damper

 Grills and Diffuser and damper shall be measured on cross sectional

area basis excluding flanges.
 All grills /Diffusers/Fire Damper areas will be measured in terms of
effective area (Neck Area)
 Any Extruded aluminum grills/diffusers having area less than 0.1
sq.mtr shall be accounted as 0.1 sq.mtr.
 Duct dampers shall be measured in Sq.mt in terms of effective area.
 Fresh air dampers shall be measured as effective areas only. No
separate measurements for bird screen inlet/outlet louvers shall be
done.
 The material thickness of grill ,diffuser and damper as below,
Type Diffuser Grills V.C Damper
Frame 18 G 18 G 18 G
Louvers 18 G 24 G 24 G
MOC Alu.Powder Coated Alu.Powder Coated Alu.Powder Coated

Cube Construction & Engineering Limited (Rev-01) Page 14

 EXECUTION INSTRUCTION FOR HVAC WORK
Ducting
 All ducts shall be fabricated from galvanized steel sheet (GSS)
confirming to IS :277-1962 or Aluminum sheet confirming to IS:737
with accompanying factory test certificates of following thickness as
indicated,

Ducting Standard
As per IS 277 As per IS 737 As per SMACNA Duct
Duct Size(mm) G.I Site Al Fabricated G.I Factory Flanges Supports Rod Support
Sr.No
Fabricated Fabricated Shape Spacing
Width Gauge mm Gauge mm Gauge mm mm mm Mtr
1 0 300 24 0.63 22 0.8 26 0.5 C&S Cleats 25×25×3 8 2.4
2 301 600 24 0.63 22 0.8 26 0.5 C&S Cleats 25×25×3 8 2.4
3 601 750 24 0.63 22 0.8 26 0.5 TDF Type E 25×25×3 8 2.4
4 751 1000 22 0.8 20 1 24 0.63 TDF Type E 40×40×5 10 2.4
5 1001 1500 22 0.8 20 1 24 0.63 TDF Type H 40×40×5 10 2.4
6 1501 1800 20 1.0 18 1.25 22 0.8 TDF Type J 50×50×5 12 2
7 1801 2100 20 1.0 18 1.25 20 1.0 TDF Type J 50×50×5 12 2
8 2101 2250 20 1.0 18 1.25 20 1.0 TDF Type J 50×50×5 12 2
9 2251 Above 18 1.25 16 1.60 20 1.0 TDF Type J 50×50×5 12 2

 Sheets used shall be produced by Hot dip process and galvanizing shall
be class VIII light coating of zinc ,nominal 120gm/Sq. m surface
area.(Total coating on both side)
 In case of factory fabricated duct the G.I raw material should be used in
coil-form (instead of sheet) so as to limit the longitudinal joints at the
edges only irrespective of cross section dimensions.
 For factory fabricated duct confirming to SMACNA-1995 Standards.
 All duct flanges /cleats and related hardware and accessories, rod
supports shall be zinc-coated (galvanized) and factory fabricated.
 For all factory fabricated ducts shall be made on CNC profile for
required accuracy of dimensions.

Cube Construction & Engineering Limited (Rev-01) Page 15

  The fabricated duct dimensions should be as per approved shop
drawings and all connecting sections are dimensionally matched to
avoid any gaps.
 To obtain required perpendicularity, permissible diagonal tolerance
shall be 1.0 mm per meter.
 For factory fabricated duct each and every duct pieces should be
identified by color codes stickers which shows specific part numbers,
job name, drawing name, drawing number, area of installation, duct
size and gauge.
 Ducts shall be straight and smooth on the inside longitudinal seams
shall be airtight and at comers only, which shall be either Pittsburgh or
snap button punch as per SMACNA practice, to ensure air tightness.
 Duct using lock formal machine at site shall not be accepted.
 MS Flanges shall be used for ducts for the AHU having HEPA filters.
 Ducts above 750 mm wide to be provided with MS angle supports.
 Additional hangers shall be provided in ducts near smoke/fire damper
connections.
 All ducts shall be fabricated and installed in workman like manner,
conforming to relevant BIS standard.
 Round exposed ducts shall be die formed for achieving perfect circle
configuration.
 RTV sealant (make as per tender) to be applied for all ducts joints of the
critical areas as per tender specification.
 Fire retarding flexible connection (double heavy canvas sleeve) to be
fitted to the suction and delivery of all fans.
 The flexible connections are not to be less than 150 mm and not more
than 300 mm between faces.
 Duct passing through brick or masonry, wooden frame/gypsum
partition shall be provided within the opening to make the duct leak
proof.

Cube Construction & Engineering Limited (Rev-01) Page 16

  Neoprene or self adhesive rubber lining minimum 6 mm thick instead of
felt shall be used between duct flanges and between duct and duct
supports in all ducting installation.
 The spacing between duct supports should not greater than 2.0 meter.
 All ducts shall be supported from the RCC slab by means of fully
threaded GI rods of 10mm-12mm dia. with MS slotted double C
Channel of 3mm -5 mm thickness at the bottom. The rods shall be
anchored to R.C slab using metallic expansion fasteners.
 Pull out test to be carried out for all anchor fasteners before hanging of
duct.

G.I. Sheet - Details

Tolerance
Thickness Maximum Minimum
Sr No. Maximum Minimum tolerance(+&-)
in mm allowed allowed
in mm in mm in %
thickness thickness
1 0.4 0.06 0.06 0.46 0.34 -15
2 0.5 0.07 0.07 0.57 0.43 -14.0
3 0.63 0.09 0.09 0.72 0.54 -14.3
4 0.8 0.1 0.1 0.9 0.7 -12.5
5 0.9 0.11 0.11 1.01 0.79 -12.2
6 1 0.12 0.12 1.12 0.88 -12.0
7 1.12 0.12 0.12 1.24 1 -10.7
8 1.25 0.13 0.13 1.38 1.12 -10.4
9 1.4 0.14 0.14 1.54 1.26 -10.0
10 1.6 0.15 0.15 1.75 1.45 -9.4
11 1.8 0.16 0.16 1.96 1.64 -8.9
12 1.9 0.17 0.17 2.07 1.73 -8.9
13 2 0.18 0.18 2.18 1.82 -9.0
14 2.24 0.19 0.19 2.43 2.05 -8.5
15 2.5 0.2 0.2 2.7 2.3 -8.0
16 2.8 0.21 0.21 3.01 2.59 -7.5
17 3.15 0.22 0.22 3.37 2.93 -7.0
18 3.55 0.24 0.24 3.79 3.31 -6.8
19 4 0.25 0.25 4.25 3.75 -6.3
20 4.3 0.25 0.25 4.55 4.05 -5.8
21 4.67 0.27 0.27 4.94 4.4 -5.8

Cube Construction & Engineering Limited (Rev-01) Page 17

 G.I Sheet Thickness Chart
G.I Sheet
Gauge Thickness Standard G.I Sheet Dimension Volume Density
Wt.
mm Width(ft) Length(Ft) SFT Width(mm) Length(mm) SQM M3 (Kg/m3) Kg/SQM
26 G 0.50 4 8 3.0 1219 2438 3 0.001486 7850 11.67
24 G 0.63 4 8 3.0 1219 2438 3 0.001873 7850 14.70
22 G 0.8 4 8 3.0 1219 2438 3 0.002378 7850 18.67
20 G 1.0 4 8 3.0 1219 2438 3 0.002973 7850 23.34
18 G 1.25 4 8 3.0 1219 2438 3 0.003716 7850 29.17
16 G 1.50 4 8 3.0 1219 2438 3 0.004459 7850 35.01

Cube Construction & Engineering Limited (Rev-01) Page 18

 Piping
 All Chilled water & Condenser water pipes and fittings shall be of MS C
class (Heavy Class) Confirming to BIS 1239 for pipe size up to 150 mm
and for pipe size 200mm dia. and above shall be as per BIS 3589 having
minimum 6mm thickness as per below indicated,

MILD STEEL PIPES CONFIRM TO IS : 1239 (PART I) – 1979

Nominal Bore Outside Diameter Light (A-Class) Thickness Weight Medium (B-Class) Thickness Weight Heavy (C-Class) Thickness Weight

Inch mm Inch mm mm kg/mtr mm kg/mtr mm kg/mtr

1/8" 3 mm 0.406 10.32 1.80 0.361 2.00 0.407 2.65 0.493

1/4" 6 mm 0.532 13.49 1.80 0.517 2.35 0.650 2.90 0.769

3/8" 10 mm 0.872 17.10 1.80 0.674 2.35 0.852 2.90 1.02

1/2" 15 mm 0.844 21.43 2.00 0.952 2.65 1.122 3.25 1.45

3/4" 20 mm 1.094 27.20 2.35 1.410 2.65 1.580 3.25 1.90

1" 25 mm 1.312 33.80 2.65 2.010 3.25 2.440 4.05 2.97

1.1/4" 32 mm 1.656 42.90 2.65 2.580 3.25 3.140 4.05 3.84

1.1/2" 40 mm 1.906 48.40 2.90 3.250 3.25 3.610 4.05 4.43

2" 50 mm 2.375 60.30 2.90 4.110 3.65 5.100 4.47 6.17

2.1/2" 65 mm 3.004 76.20 3.25 5.840 3.65 6.610 4.47 7.90

3" 80 mm 3.500 88.90 3.25 6.810 4.05 8.470 4.85 10.1

4" 100 mm 4.500 114.30 3.65 9.890 4.50 12.10 5.40 14.4

5" 125 mm 5.500 139.70 - - 4.85 16.20 5.40 17.8

6" 150 mm 6.500 165.10 - - 4.85 19.20 5.40 21.2

Cube Construction & Engineering Limited (Rev-01) Page 19

 BIG DIAMETER ERW PIPES CONFIRM TO IS 3589

NominalBore NominalBore NominalBore NominalBore NominalBore NominalBore NominalBore NominalBore

Wall
7" NB 193.7 8" NB 219.1 10" NB 273 mm 12" NB 323.7 14" NB 355.6 16" NB 406.4 18" NB 457mm 20" NB 508 mm
Thickness
mm OD mm OD OD mm OD mm OD mm OD OD OD

mm Kg/mtr Kg/mtr Kg/mtr Kg/mtr Kg/mtr Kg/mtr Kg/mtr Kg/mtr

4.85 22.59 25.62 32.07 38.13 - - - -

5.20 24.17 27.43 34.34 40.85 - - - -

5.60 26.00 29.28 36.93 43.93 48.11 - -

6.00 27.88 31.53 39.50 47.02 51.49 61.00 69.00 -

6.35 29.34 33.28 41.73 49.67 54.43 62.35 70.50 78.50

7.01 32.77 36.76 46.43 55.45 61.82 69.04 - -

7.94 - 41.00 50.95 61.85 67.98 77.94 87.80 -

8.18 - 42.56 53.42 65.12 - - - -

9.53 - 51.50 60.24 73.75 81.21 93.13 105.00 117.00

12.70 - - - - 107.28 123.30 139.00 155.00

 Piping Measurement Tolerance as below,

(a) Thickness

(1) Butt welded Light tubes +Not limited

- 8 percent

Medium and Heavy tubes + Not Limited

- 10 percent

(2) Seamless Tubes +Not Limited

- 12.5 percent

(b) Weight :

(1) Single tube (light series) +10 percent

- 8 percent

(2) Single tube +10 percent

(medium & heavy Series)

 All Joints in the pipe system shall generally do by welding, unless

mentioned otherwise, or directed at site incharge.
 All welding shall be done by qualified welders and shall strictly confirm
to BIS code of procedure for manual metallic welding of mild steel as
per BIS-823.
Cube Construction & Engineering Limited (Rev-01) Page 20
  All pipes and their MS structures supports shall be thoroughly cleaned
and given one primary coat of red oxide for M.S Pipe /Zinc chromate for
G.I Pipe and two coat of synthetic enamel paint before being installed.
…………………………………………………………………………(For Cooling Water)
 All pipes and their MS structures supports shall be thoroughly cleaned
and given one primary coat red oxide for M.S Pipe /Zinc chromate for
G.I Pipe and two coat of Black Japan paint before Insulation being
installed……………………………………………………………(For Chilled Water)
 All chilled water piping will rest on PUF blocks 48 kg/cum density neatly
molded or teak wooden block of 2 ½” thickness with groove to the
radius of pipes and seated on MS angle/Channel support with proper
painted
 Fittings used on welded piping shall be of the weldable type.
 The Supply of flanges shall also include supply of bolts and nuts and
suitable asbestos/fiber rubber insertion gaskets (minimum 3mm thick)
 Pipe bends shall be prefabricated type up to 150 mm dia.
 Pipe bends fabricated at site shall be provided with segments of bend
not exceeding 15 degree angle.
 90 degree bend shall thus be provided with 6 nos. welding joints.
 Pipes shall be cut with power saw/Hacksaw only, followed by hand
grinding to provide V- groove on both pipe end.
 All chilled water piping and fitting shall be pressure tested, then
insulated as described under the insulation section.
 The piping, fittings & Supports shall be painted with one coat of red
oxide paint & two coat of black Japan before application of insulation.
(for Nitirle rubber)
 Two coat of synthetic enamel paint confirming to code IS 2379 after
insulation application.(for sand cement plaster)
 The direction of flow of fluid in the pipes shall be visibly marked with
identifying arrows after Insulation.

Cube Construction & Engineering Limited (Rev-01) Page 21

  Auto air vent with ball valve & drain valve of suitable size shall be
provided in the chilled & condenser water piping at highest point and
lowest point in the riser respectively.

Riser(Shaft) Pipe Size Auto Air Vent with Ball Valve Drain Ball Valve

Up to 150 mm 15 mm 15 mm
150 to 200 mm 20 mm 20 mm
250 to 300 mm 25 mm 25 mm
350 to 400 mm 32 mm 32 mm
Above 400 mm 40 mm 40 mm

 Piping shall be properly supported on MS structure or suspended from

stands, clamps, hangers, adjustable for height, primer coated with rust
preventive paint and finish coated black.

Pipe Size Rod Dia (mm) Base Support Spacing Between

Support(mtr)
Up to 40 mm 10 Clamp Support 1.5
50 to 125 mm 10 Clamp Support 2.0
125 to 150 mm 15 ISMC 75 2.0
150 to 200 mm 15 ISMC 75 2.5
250 mm 20 ISMC 100* 2.5
300 mm 22 ISMC 150* 2.5
350 to 400 mm 25 ISMC 150* 2.5
450 to 500 mm 32 ISMC 150* 2.5
600 mm 32 ISMC 200* 2.5

 Pipe sleeves, 50mm larger diameter than pipes shall be provided

wherever pipes pass through walls and slabs and angular space filled
with fiber glass and finished with retainer rings.
 All pipes shall be accurately cut to the required sizes in accordance with
IS 554 and proper grind and burrs removed before lying.
 Open ends of the piping shall be closed as the pipe is installed to avoid
entrance of foreign matter.

Cube Construction & Engineering Limited (Rev-01) Page 22

  Eccentric reducers shall be used for horizontal pipe runs for the piping
to drain freely; In vertical pipes concentric reducers shall be used.
 All piping shall be rested to hydrostatic test pressure of at least 2.5
times maximum of operating pressure, but not less than 10 kg/cm2 for
period of not less than 24 hours.
 All leaks and defects in joints revealed during the testing shall be
rectified and gotten approved at site.
 Vertical risers shall be parallel to walls and column lines and shall be
straight and plumb.
 Bull heading in water/refrigerant piping shall be avoided.
 All pipe work shall be carried out in a workman like manner, causing
minimum disturbance to the existing services, building, rods, and
structure.

Copper Pipe Standard For Indoor Unit & VRV System

Tube wall Insulation Wt Per

Pipe Size(mm) Pipe Size(Inch))
Thickness Thickness Kg/RMT

41.3 mm O.D. 1 5/8 1.4 19 1.59

38.1 mm O.D 1 1/2 1.3 19 1.35
34.9 mm O.D. 1 3/8 1.2 19 1.16
31.8 mm O.D 1 1/4 1.1 19 0.94
28.6 mm O.D 1 1/8 1.0 19 0.79
25.4 mm O.D 1 1.0 13 0.70
22.2 mm O.D. 7/8 1.0 13 0.61
19.1 mm O.D. 3/4 1.0 13 0.52
15.9 mm O.D. 5/8 1.0 13 0.43
12.7 mm O.D. 1/2 0.8 13 0.27
9.5 mm O.D. 3/8 0.8 13 0.20
6.4 mm O.D. 1/4 0.8 13 0.13

Cube Construction & Engineering Limited (Rev-01) Page 23

 Ducting Insulation
 The thickness of insulation shall be as per the tender specification or
BOQ.
 Duct surfaces shall be cleaned with cotton/wire brush to remove all
grease, Oil, dirt, etc prior to carrying out insulation work.
 Measurement of surface dimensions shall be taken properly to cut
insulation sheets to size with sufficient allowance in dimension.
 Insulation material shall be fitted under compression and no stretching
on material should be allowed.
 A thin film of adhesive shall be applied on the back of the insulating
material sheet and then on to the metal surface.
 When adhesive is tack dry, insulating material sheet shall be placed in
position and pressed firmly to achieve a good bond.
 All longitudinal and transverse joints shall be sealed as per
manufacturer recommendations.
 The adhesive shall be strictly as per Tender or recommended by the
manufacturer.

Cube Construction & Engineering Limited (Rev-01) Page 24

 Pipe Insulation
 The thickness of insulation shall be as per the tender specification or
BOQ.
 All chilled water pipes shall be insulated after pressure tested.
 Brush and clean all piping and fittings to remove all dust, rust, dirt,
mortar and oil.
 Apply 2 coats primer & black Japan Paint on pipe before insulation.
 The Insulation shall be continuous over the entire run of piping fittings
and valves.
 Insulated pipe shall be marked with arrow to indicate the direction of
flow.
 Only tubular insulation (for 1st layer in case of multi layered insulation)
shall be used

Cube Construction & Engineering Limited (Rev-01) Page 25

 Air Filters
 Pre Filter (EU-3/EU-4) :- The pre filter shall be capable of filtering dust up to 10
micron size with an efficiency of 90%.The efficiency of filter shall be as per
ASHRAE 52-76/BS-6540 initial pressure drop shall not exceed 5.0 WC (Water
Column) & Final pressure drop shall not exceed up to 7.5 mm WC at rated flow
filter shall be provided with suitable handles

 Fine Filter (EU-7) :- The pre filter shall be capable of filtering dust up to 5 micron
size with an efficiency of 95%.The efficiency of filter shall be as per Euro vent class
and BS EN 779 Class initial pressure drop shall not exceed 15 WC (Water Column)
& Final pressure drop shall not exceed up to 25 mm WC at rated flow filter shall
be provided with suitable handles

 HEPA Filter (EU-9) :- The pre filter shall be capable of filtering dust up to 0.3
micron size with an efficiency of 99.99%.The efficiency of filter shall be as per EN
1822 initial pressure drop shall not exceed 30 WC (Water Column) & Final
pressure drop shall not exceed up to 60 mm WC at rated flow filter shall be
provided with suitable handles

Cube Construction & Engineering Limited (Rev-01) Page 26

 Valves & Fixtures
 All Valves shall be heavy duty conforming to BIS 5155/5152/780
 Valves shall be suitable for not less than 16 kg/Sq.cm gauge working
pressure.
 Pot strainers shall be fabricated out of MS sheet with bronze/SS 304
basket of sizes as under.

Pipe Size Pot Dia Pot H.T Basket Dia Thickness of MS Plate
Basket HT
(mm) (mm) (mm) (mm) Basket Thickness
50 300 400 200 240 6
80 350 450 250 250 24 G 6
100 450 500 300 280 6
125 500 600 330 340 8
150 540 700 360 390 8
200 610 815 400 470 22 G 8
250 800 955 550 510 8
300 1000 1105 750 580 8
350 1190 1300 895 678 12
400 1350 1500 1020 785 12
20 G
450 1518 1700 1060 890 12
500 1690 1800 1100 900 12
600 2000 2200 1500 1160 12

 Pot strainers shall be fabricated out of MS plate up to 100mm dia. pipes

shall be fabricated of 6mm thick MS sheet.125 to 300 mm dia. Pipes of
8mm thick and higher sizes shall be made of 12mm thick MS Sheet.

Cube Construction & Engineering Limited (Rev-01) Page 27

 Basic Electrical Standard for HVAC Work
 Cable Core Identification
 1 Core Cable:-Red/Black/Yellow/Blue
 2 Core Cable: - Red and Black
 3 Core Cable: - Red, Yellow and Blue
 3.5/4 Core Cable :- Red, Yellow, Blue & Black

 Maximum permissible number of 650/1100 volt grade PVC insulated

wires that may be drawn into rigid non metallic or GI Conduits are as
given below,
Maximum Number of Wires within conduit
Sizes of Wires (Sq.mm) Size (mm)
20 25 32 40 50
1.5 5 10 10 - -
2.5 5 8 8 - -
4.0 3 7 7 - -
6.0 2 5 5 - -
10.0 - 3 3 6 -
16.0 - 2 2 - 6
25.0 - - - 4 6
35.0 - - - 3 5

 Capacity of Earthing wire sizes as below ,

Cable Cables Sizes

Sr.No. Motor Capacity
Run Copper Wire GI Wire Dia.
1 Up to 5.5 KW 1 3 Sq.mm 4 mm
2 7.5 to 18.75 KW 1 4 Sq.mm 6 mm
3 18.75 to 50 KW 1 25 X 3 mm Strip 25 X 6 mm Strip
4 51 to 89 KW 1 25 X 6 mm Strip 32 X 6 mm Strip

Cube Construction & Engineering Limited (Rev-01) Page 28

  Power wiring ,cabling shall be of the following size,
Cables Sizes
Sr.No. Motor Capacity Cable Run Aluminum Cable Run Copper
Armored
1 Up to 5 HP motors 1 3C X 4 Sq.mm 1 3C X 2.5 Sq.mm
2 6 To 7.5 HP 1 3C X 6 Sq.mm 1 3C X 2.5 Sq.mm
3 10 To 15 HP 2 3C X 6 Sq.mm 1 3C X 4 Sq.mm
4 20 To 25 HP 2 3C X 16 Sq.mm 1 3C X 6 Sq.mm
5 30 To 35 HP 2 3C X 25 Sq.mm 1 3C X 10 Sq.mm
6 40 To 50 HP 2 3C X 35 Sq.mm 1 3C X 16 Sq.mm
7 60 To 75 HP 1 3C X 70 Sq.mm 1 3C X 35 Sq.mm
8 100 HP 1 3C X 95 Sq.mm 1 3C X 50 Sq.mm
9 125 HP 2 3C X 120 Sq.mm 1 3C X 70 Sq.mm
10 150 HP 2 3C X 120 Sq.mm 1 3C X 95 Sq.mm
11 250 HP 2 3C X 120 Sq.mm 1 3C X 120 Sq.mm
12 400 HP 3 3C X 120 Sq.mm 2 3C X 120 Sq.mm
13 600 HP 3 3C X 120 Sq.mm 2 3C X 120 Sq.mm

 Type & Capacity of Starter, Contactor & Overload Relay

Sr.No. Motor Capacity Starter Contactor Phase Relay Range

1 50/ 60 HP Star Delta 70 Amps. 30-50 Amps.
2 40 HP Star Delta 45 Amps. 20-33 Amps.
3 30 HP Star Delta 45 Amps. 20-33 Amps.
4 25 HP Star Delta 32 Amps. 14-23 Amps.
5 20 HP Star Delta 32 Amps. 14-23 Amps.
6 15 HP Star Delta 25 Amps. 9-25 Amps.
7 10 HP Star Delta 16 Amps. 9-15 Amps.
8 7.5 HP D.O.L 16 Amps. 9-15 Amps.
9 5 HP D.O.L 16 Amps. 6-10 Amps.

Cube Construction & Engineering Limited (Rev-01) Page 29

 Inspection Standard
Ducting
Inspection: - Thickness (Gauge) of Sheet, Make of Sheet, Weight of
Sheet, Size of Sheet
MOC: - Material Specification
Instruments: - Micrometer, Vernier Caliper, Weight machine,
Measuring Tape
MTC: - Material Test Report
Tolerance: - Thickness ± 10 %

Piping
Inspection: - Thickness of Pipe, Make of Pipe, ID/OD of Pipe, length of
Pipe
MOC: - Material Specification
Instruments: - Micrometer, Vernier Caliper, Measuring Tape
MTC: - Material Test Report
Tolerance: - Thickness- For A Class Pipe +Not limited / - 8%
For B Class Pipe +Not limited / -10%
For C Class Pipe +Not limited / -10%

Piping /Ducting Insulation

Inspection: - Thickness of Insulation, Make of Insulation, Density of
Insulation, Type of Insulation.
MOC: - Material Specification
Instruments: - Micrometer, Vernier Caliper, Measuring Tape, Weight
machine
MTC: - Material Test Report
Tolerance: - Density - ± 5 %

Cube Construction & Engineering Limited (Rev-01) Page 30

 Valves & Fixtures
Inspection: - Pressure Rating of Valves, Make of Valves, Type of Valves,
Weight of Valves, Material of Valves.
MOC: - Material Specification
Instruments: - Micrometer, Vernier Caliper, Measuring Tape, Weight
machine
MTC: - Material Test Report

Grills /Diffuser & Dampers

Inspection: - Make Type, Neck & Face Size, Material, thickness (Gauge)
MOC: - Material Specification
Instruments: - Micrometer, Vernier Caliper, Measuring Tape, Weight
machine
MTC: - Material Test Report

 Before material acceptance to check require documents (e.g. MTC,

Warranty certificates, Manual, Material Specification) for other HVAC
equipments as per PO or Tender requirement.

Cube Construction & Engineering Limited (Rev-01) Page 31

 ABBERIVATION
 HVAC : Heating Ventilation And Air Conditioning
 MM : Millimeter
 CM : Centimeter
 M : Meter
 Ft : Foot
 µm : Micrometer
 TR : Tons of Refrigeration
 BTU : British Thermal Unit
 CFM : Cubic Feet per Minute
 Kcal : Kilo Calorie
 HR : Hour
 KW : Kilowatt
 HP : Horse Power
 lb : Pound
 PSI : Pound per Square Inch
 GPM : Gallons per Minute
 LPM : Liters per Minute
 FPS : Feet per Second
 m/s : Meter per Second
 : Pie = 22/7 or 3.14
 RH : Relative Humidity
 RPM : Rotation per Minute
 BKW : Break Kilo Watt
 NBC : National Building Code
 ACPH : Air Change per Hour
 MOM : Mode of Measurement
 SMACNA : Sheet Metal and Air Conditioning National Association
 CNC : Computer Numerical Control

Cube Construction & Engineering Limited (Rev-01) Page 32

  BOQ : Bill of Quantity
 ASHRAE : American Society of Heating, Refrigerating, and Air-
Conditioning Engineers
 Amp : Ampere
 MTC : Material Test Certificate
 MOC : Material of Component
 CT : Cooling Tower
 IPLV : Integrated Part Load Value
 NPLV : Non Standard Part Load Value
 Db : Decibel ( For Sound level measurement)
 CBRI : Central Building Research Institute ( For Panel)
 AMCA : Air Movement and Control Association ( For Fans )
 NFPA : National Fire Protection Association ( For Fire Equipments)
 UL :- Underwriters Laboratories (For Fire Dampers)
 GDCR : General Development Control Regulations
 CTI : Cooling Tower Institute ( For Cooling Tower)
 AHRI : Air Conditioning Heating & Refrigeration Institute (For Chiller &
AHU)
 ASME :American Society of Mechanical Engineering ( For Air Vessels)
 IP-(44,54,55,56,65,66) : International Protection ( For Exposed Panels)
 NEMA :National Electrical Manufacturers Association

Cube Construction & Engineering Limited (Rev-01) Page 33

 THANK YOU

CUBE CONSTRUCTION ENGINEERING LTD.

Cube Construction & Engineering Limited (Rev-01) Page 34

Cube Construction & Engineering Limited (Rev-01) Page 35