7/22/2017 Increasing Productivity in HVAC Layout Work - Issue Oct-Dec 1999

Issue : October-December 1999

Increasing Productivity in HVAC Layout Work

By N. S. Rao
Chief Executive
Engisoft Solutions, Mumbai
Rao is a B Tech. (Hons.) from I.I.T., Mumbai, 1970. His company develops CADD
software for HVAC ducting layouts and other applications as a part of Authorized
Developers' Network of AutoDesk, USA.

HVAC project engineers look at several aspect of a layout drawing to enable better
planning and coordinaton. Some of these requirements are listed in Table 1. This article
will examine how computerized layout making through Design based software can meet
these requirements and increase the productivity.

CAD Vs CADD Software

An invoice can be prepared either on a word processor or an accounting software. When it
is prepared on an accounting software the number of checks and calculations such as taxes,
duties and totaling are done automatically. In addition, books are updated and trial

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balance is prepared. The productivity of the system gets enhance greatly when an
accounting software is used. Similarly, in HVAC ducting layouts one can get a quantum
jump in productivity and enhance return on investment by using special design based
software.
The drafting software is generally termed as Computer Aided Drawing (CAD) whereas
the design based software is called Computer Aided Design & Drawing (CADD). In case of
CAD software the inputs such as sizing are to be given by the user and it only enhances the
speed of the drafting process. The CADD software performs groups of design operations
and their results are used by the software to make the drawing and reports.

Table 1 : HVAC Engineer's needs

Layout Drawings
Quiet Layouts Fast Changes
Accurate BOQs
Piece-wise Ducts Diffusers, Grilles
Insulation Areas
Acoustic Thermal
Interference Checks
Ducts Piping Co-ordination
Fabrication
Gauge wise area 3D Visualization
Installation
3D Visualization Supports…

The relative time saving with CADD software for various operations is shown in Fig.1.
HVAC engineers can benefit not only from the saving of time for drafting but also from
sizing. BOQs and compilation of data for both fabrication and intallation. The time saved
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in operations other than drafting is quite substantial. When this time saving and the
accuracy of information is considered together, the benefits are impressive.

Integrated Approach
Some softwares have separate modules for sizing, drawing and so on. When all the
modules are integrated it is easier to design, draw and get the repots. The integrated
software also allows you to interface the outputs with other MIS systems, check
interferences and obtain detailed bill of quantities for the project. It is also possible to
transfer the data from the drawing directly to the duct manufacturing factory. The
integrated approach benefits various departments in the company as shown in Table 2.

Ease of Operation
In design based software the menus are simple and self explanatory e.g., Placing Diffuser,
Single Line Routing and so on. These can be operated with ease even by those who do not
have skills in computerized drafting. In one instance a manager without any prior
experience of Auto CAC produced an actual drawing with just two hours of training.
The diffusers can be selected from built-in tables based on the airflow and the velocity.
These can be placed rapidly on the drawing by clicking two pints - such as two corners of
the room or the two end points of the corridor as in Fig 2. The routing can be indicated by
drawing Single Lines.

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The diffusers can be picked up in a group and connected to the required Single Line as
shown in Fig 3.

Based on the friction factor, maximum velocity and height available, sizing is done
automatically and shown on the Single Lines as indicated in Fig 4. These sizes can be
changed, if required, at the Single Line stage itself.

The Single Lines can be converted rapidly to Double Lines as shown in Fig 5.

The sections can be derived automatically by selecting the required area and indicating
the direction. This ensures that the sections are based on the actual data of the Double
Lines, including the height to Bottom of the Duct. A typical section is shown in Fig 6.

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3D drawings are generated from the double line drawings automatically as in Fig 7.
One can see the 3D drawing from different directions. You can also see the ducting and
other services such as piping, if drawn in 3D. This improves visualization.

Bill of Quantities
CADD software provides extensive BOQs for various items. These items are shown the
drawing. This ensures that no item is missed out for procurement. Typical BOQs are shown
in Table 3.
Some of the BOQs available are:

Ducting
Insulation
Diffusers/Grillers
Linear Diffusers
Plenums
Wall cut-outs
Duct Supports
Dampers - VCD, Fire etc.
Silencers
Elbows + Splitter Vanes
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Ducting BOQ
Each piece of a duct is tagged and the finished dimensions, height, width and length, along
with the gauge of sheet are obtained from the drawing instantly. These BOQs are shown on
standard software such as Excel. They can be combined together for several drawings and
an accurate estimate of the gauge wise sheet area for the project can be obtained.

Sales Estimates
Approximate guage wise duct areas along with acoustic and thermal insulation areas can
be obtained at the Single Lines stage. These can be used for more accurate sales estimates.
Standards for Guages
You can set your own tables so that the BOQs for the same drawing are obtained as per
IS, SMACNA or any other standard.

Modified BOQs
When a layout is modified you can immediately get the new BOQs. This ensures that the
revisions are taken into account. The accurate modified BOQs help in discussing in detail
with the consultant or client the changes and their implications.
Typical BOQs from a design software are shown in Table 3.

Sheet or Coil Width

It is possible to set the sheet or coil width (2400 or 1200 mm). The drawing will
automatically show the markings as per this setting. This helps in better co-ordination
during installation.

Interface with MIS, ERP

The information generated from the CADD software can be transferred to other MIS
systems including ERP. It minimizes delays and errors in compilation of data. It can be
transferred directly to the MIS software. As the data used for project analysis is based on
actual drawings, it leads to better co-ordination and planning.

Table 3 : Typical Bill of Quantities from a CADD software

Piece wise BOQ of Ducts
No Type CFM Width 1 Width 2 Height 1 Height Length Gauge
2
1 RO 3200 575 575 1195 G22
2 RC 3200 575 575 1195 G22

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3 RD 2400 475 400 475 400 400 G22

4 EL 800 475 400 475 400 500 G22

Diffuser/Grille Summar
Ref. Item S/R Type Size CFM Qty.
SDF 1 Diffuser S 4 Way 381 x 381 700 10
RDF 1 Diffuser R 4 Way 381 x 381 700 10
SGR 1 Grille S 305 x 150 150 5
PL 1 Plenum S 1200x220x64 400 1

Piece-wise Areas of Ducts

No G18 G20 G22 G24 Acc. Insulation Th. Insulation
1 5.46 5.46 6.6
2 5.56 5.56 6.6

Guage-wise Summary
Surface Area (Sq. M) Insulation
G18 G20 G22 G24 Acoustic Thermal
Area(Sq.M) Area(Sq.M)
11.02 11.02 13.2

Procurement
The above information can be used to plan, order and move materials to the site. Manual
take-offs take enormous time on large projects. If these are changes in the layout drawing
then it takes a lot more time to recalculate. CADD software provide accurate information
along with tag numbers. The tag numbers help in ordering, and keeping track of the
material movement to the project. It is also possible to customize the BOQs with the
material codes.

Smart Software

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Software which performs smart operations go a long way in project ordination. It is

possible to check interferences with beams and other ducts abased on Single Lines, even
before making double line layouts. This helps in reducing the changes after making the
Double line layout. Rapid editing of Double line ducts can be performed with smart
software. For e.g., if the false ceiling level changes at the last minute, then the software can
automatically change the height of diffuser location and adjust the collars so that the Bill of
Quantity reflects these changes immediately.

Factory Fabricated Ducting

The use of factory fabricated ducting on sites has several advantages. When the layouts are
made on CADD software it is possible to send them electronically by email or floppy to the
factory. The factory can pick up the data from the drawings directly and fabricate on the
same day. This not only avoids mistakes in manual take-offs but also gives the designer the
advantages of making required modifications till practically the last minute, without losing
on the delivery schedule.
There is already a well established company offering factory fabricated ducting in
India. Consultants and contractors can design layouts based on the CADD software and
send the files electronically to this factory to take advantage of the benefits.

Fabrication at Site
The availability of accurate piece wise BOQ for the ducts makes it easier to monitor the
fabrication and its progress. Now-a-days a computer is available on major project sites. It
is possible to discuss with the fabricator the intricacies by showing the 3D ducting from
different angles. Even those who are not formally trained to interpret the plans and
sections can easily understand by looking at 3D drawings. This will avoid mistakes in
conceptualization and fabrication. HVAC engineers can explain different groups involved
in the project the implications of modifications by using the 3D drawings.

Factory Fabricated Ducting

The use of factory fabricated ducting on sites has several advantages. When the layouts are
made on CADD software it is possible to send them electronically by email or floppy to the
factory. The factory can pick up the data from the drawings directly and fabricate on the
same day. This not only avoids mistakes in manual take-offs but also gives the designer the
advantage of making required modifications till practically the last minute, without losing
o the delivery schedule.

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There is already a well established company offering factory fabricated ducting in

India. Consultants and contractors can design layouts based on the CADD software and
send the files electronically to this factory to take advantage of the benefits.

Building Layouts in 3D
CADD software modules allow quick conversion of 2D architectural drawings into 3D, with
respect to the elements which are of importance to the HVAC layout. Seeing the beams and
ducts in 3D helps in better visualization and leads to more efficient co-ordination.

Implementation
Drafting softwares are easier to implement. An organization can derive the benefits of a
design software only when persons with vision and authority see its benefits, and take
personal interest in implementing it. Quick implementation is easier when the operating
managers have bands-on training on the software to understand the capabilities and
enable them to guide others.

Selection of Basic System

It is advisable to go for standard platforms in computers (such as Pentium series) and basic
CAD software such as Auto CAD. One should go for non-standard configurations only if
there is a strong need for it.

System Requirements
Design softwares are available on different platforms such as Unix, Windows, NT etc. Most
of the common applications can be performed on Windows NT/98 on Pentium based
computers available currently in the market. Some CADD softwares have their own back-

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end software and others operate on the most widely used software AutoCAD. They
customize the Auto CAD so that benefits of design and drawing are available to the user
easily and fast.

Selection of Software
It would be advisable to make a list of preferred options to short list the software. An
example of such a check list is shown in Table 4. One should see a demonstration and
samples of actual drawings produced using the software

When to Invest
One should modify existing methods to take advantage of new technology. It is easier to do
this when there is some free time available - a lull in the projects. When the industry is
facing the need to restructure, it is advisable to look at the current methods and the return
on investment on the existing computers.

Investment Modes
You can invest in software and get depreciation benefits by purchasing outright. Today
there are options for hire-purchase or even monthly rental.
You can choose the option most suited based on your usage and budget. Some
companies allow you to start with basic modules and add on advanced modules as and
when required.

Rental Option - the Flexible Way

The rental option is like having a draftsman in your office but paying him on a monthly
basis only when you have actual work. Some softwares allow you rentals as low as the
salary of a draftsman. If for some reason you do not wish to continue you can stop further
rentals and yet retain the software so that when you need it again you can pay and activate
it immediately. When you have a large project requiring several copies of the software for a
temporary duration, you can tent the extra copies for that period.

Table 4 - Typical check list for selection of CADD

software

Suitable for Indian design conditions

Operates on standard PCsImplemented in Indian
companies

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Used on actual project in IndiaAccredited Developers

(ADN)
Customizable in India
Cost-benefit analysis

Conclusion
Today there is growing awareness that more number of computers do not necessarily give
higher productivity. Managers are also realizing that large investments in hardware do not
give returns if they are used only for drafting. Innovative approach to rationalize the
methods of working will result in both short term and long term benefits. More design can
be done with less people and less computers.

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