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3E Plus Software
By Darrell Peil
FAQs
A new kind of HVAC system is emerging in the United States commercial building space conditioning market. This new system utilizes variable
refrigerant flow (VRF) or variable refrigerant volume (VRV) technology and uses an evolved heat-pump technology with heat recovery systems and
sub-cooling built in, which increases effectiveness and efficiency. The use of this evolved technology makes these systems a good option for
certain kinds of commercial construction projects that require high levels of flexibility when it comes to occupant comfort or for retrofit projects.
VRF/VRV systems require slightly different considerations for completion of the insulation portion of the project, and include challenges that
mechanical insulation contractors will have to overcome. There are many considerations that are important when designing the project, selecting
the insulation materials and methods, estimating the project, buying the materials, and planning labor requirements.
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Multi-type ductless split systems and VRF/VRV systems have been around for almost 3 decades, but they are new to the U.S. HVAC market. As
American engineers become familiar with the technology, and especially as they learn of its energy-efficiency advantages, they may become a
more popular option. Market forecasts predict the growth of these kinds of HVAC systems to be as much as 230% from 2013 through 2020. This
means more mechanical insulation contractors will be asked to provide pricing and insulation services for these systems as they appear on
projects.
A quick review of air-conditioning principles might be useful in describing multi-type ductless split systems and VRF/VRV technologythe most
basic principle being that air conditioning removes heat from the space to be cooled by pushing refrigerant through a cycle. HVAC systems are
based on the fluid dynamics that when a refrigerant expands, it becomes cooler; and when it is compressed, it becomes warmer. Changing phases
from fluid to gas, or from gas to a fluid, adds to the cooling/warming effect. The cycle is comprised of 4 elements common to all HVAC systems: a
compressor, a condensing unit, a metering device (or expansion valve), and an evaporator or heat sink.
A multi-type air-conditioning system operates on the same principles as a split-type air-conditioning system, however in this case there are
multiple evaporator unitsor fan-coil unitsconnected to 1 external condensing unit. These simple systems were designed mainly for small to
medium commercial applications where the installation of ductwork was eithertoo expensive, or aesthetically unacceptable. The 2-pipe, small-bore
refrigerant piping system, which connects each indoor fan coil and the outdoor unit(s) requires much less space and is easier to install than
ducting associated with other types of systems. These systems are 2-pipe systems, like classic split-system heat pumps. Both pipelines need to
be insulated to accommodate the reversal of the refrigerant flow and the pipe service temperature as the system changes from heating to cooling
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or cooling to heating.
The term VRF or VRV refers to the ability of the system to control the amount of refrigerant flowing to each of the evaporators, enabling the use
of many evaporators of differing capacities and configurations, individualized comfort control, simultaneous heating and cooling in different zones,
and heat recovery from 1 zone to another. Similar to ductless multi-split systems, which can also connect 1 outdoor section to several
evaporators, VRF/VRV systems are different in one important respect. Unlike multi-split systems, which turn on and off depending on whether the
room to be cooled is too warm or not warm enough, VRF/VRV systems constantly modulate the amount of refrigerant being sent to each
evaporator. VRF/VRV flow systems with heat recovery (VRF/VRV-HR) capability can operate simultaneously in heating and/or cooling mode,
enabling heat to be used rather than rejected as it would be in traditional heat pump systems. Most VRF/VRV systems are 3-pipe systems, with all
3 lines requiring insulation.
VRF/VRV systems are typically distributed systemsthe outdoor unit is kept at a location such as the top of the building, and all the evaporator
units are installed at various locations inside the building. Typically the refrigerant pipe work (liquid and suction lines) is very long, running in
several hundreds of feet in length for large multi-story buildings. This is different from typical split-system or package-unit HVAC systems that
have short piping runs to an evaporator coil, and extensive duct runs to convey the cooled or warmed air throughout the occupied spaces.
This change in thermal conveyance systems has the effect of turning an HVAC
project into a major pipe insulation job with a small amount of duct, instead of a
medium to large duct insulation project with a small amount of equipment-related
piping to be insulated.
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important feature in multi-tenant buildings if energy costs are charged explicitly to each tenant. VRF/VRV provides an alternative and realistic
choice to traditional central systems. It captures many of the features of chilled water systems, while incorporating the simplicity of direct
exchange (DX) systems.
The misconception that VRF/VRV systems do not require the services of an insulation contractor may prove to be a significant problem resulting in
a loss of market share in many kinds of commercial HVAC installations, including offices, educational facilities, medical facilities, and lightproduction facilities, among others. If HVAC contractors perceive that these systems are just larger residential HVAC systems, and owners or
designers do not challenge that assumption, insulation contractors may not be seen as necessary and thus, these systems may not be properly
insulated, severely damaging long-term performance.
A somewhat similar set of circumstances occurred with traditional types of DX air-conditioning systems, both with duct and piping. If the
misconception that these systems can be insulated by anyone persists, insulation contractors will lose the opportunity to provide a proposal for
correct and effective insulation services, damaging the scope of the insulation market and leading to less effective and efficient systems.
Mechanical insulation contractors will need to continue to represent to design professionals and owners that enlisting their labor is crucial to an
effective insulation system. While the first impulse of designers and owners may be to look for corrective action through changes in material
selections, the most common cause of failed applications is poor installation due to inexperience. The insulation industry has seen this before when
mechanical contractors made it standard practice to self-perform, like in small commercial duct insulation jobs or large retail refrigeration system
projects.
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It is imperative that insulation contractors understand the complexities of these systems, and make the design and ownership communities aware
of why the insulation installation needs to be completed by a competent and well-trained insulation professional, as these 2 communities are
crucial to affecting practices in new projects.
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using the same piping system. Many producers of VRV/VRF systems are requiring insulation materials that have upper service temperatures of
+248F or hotter. One producers installation instructions, for example, require insulation that is rated for a continuous service temperature of
212F or greater. This is critical, since many insulation contractors are unaware of this requirement, as are most mechanical contractors.
Unfortunately in some cases, an HVAC contractor may or may not make the insulation contractor aware of this requirement until some portion of
the material has been installed, requiring removal of the first insulation installation and forcing the contractor to reinsulate. It may also lead to the
wrong material being purchased, requiring a return and repurchase.
Unique in HVAC, and more like refrigeration, the piping can be hot or cold depending on system operations for occupant comfort, and whether or
not the fan-coil unit is running as an evaporator coil (cold) or a condenser coil (hot). Because sub-cooling is used in some VRF/VRV systems, the
cold piping is below 40F, sometimes below freezing, requiring installations as detailed as chilled water or even refrigeration installations to make
the insulation last. Installation of the insulation needs to be treated like a true refrigeration systemcompletely insulated, including solenoid
valves, unit connections, fittings, and pipe supports. The insulation system also needs to be thoroughly sealed so condensation and ice formation
is not a problem when operating in the cooling mode.
Piping
In these systems, refrigeration pipe work up to 500 feet long is feasible. A difference from VRF/VRV systems early years is the amount of pipe that
can be used in installations. The piping network was limited to approximately 1,000 feet in 2004; but in 2013, the typical piping network limit has
increased to approximately 3,280 feet per condensing unit. Two major kinds of piping systems are being used in the installation of multi-split and
VRF/VRV systems: copper and aluminum. Traditional already cleaned refrigerant (ACR) hard copper that is brazed together is still common, and is
insulated using traditional practices that have been used for many years. Aluminum is a newer piping material that was recently introduced to the
industry for piping these systems. Aluminum piping for multi-split and VRF/VRV systems is sized like traditional ACR copper, but is connected with
mechanical crimped connectors and fittings. These fittings present a challenge to the insulation contractor, since they require special fabrication
of covers that can accommodate them. The work is more comparable to insulating a threaded steel piping system than a brazed or sweat copper
piping system.
In a VRV/VRF system, each indoor unit is branched off from the 3 pipes using solenoid valves and each of these pipes requires insulation of the
proper inside diameter and thickness. Each of the solenoid valves also requires insulating, increasing the amount of fabrication of valve insulation
significantly. A special type of wye fitting is used for the branch piping and that must also be insulated. These wye fittings present the insulator
with a challenge in designing an effective method of covering them, and such a solution is still being sought. Fortunately, when this process is
developed, it should become a fairly routine, production-type work that allows the project to keep pace.
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save much time and expense in effectively providing a correct insulating support method. It is extremely important to understand which trade is
going to be responsible for providing this part of the project, and working toward the best solution from the beginning. Fortunately, many of these
piping systems are being run with strut and strut clamps as the pipe support and anchoring system. There are multiple products available that
install easily and cost effectively with this kind of system. For other types of pipe support and anchoring methods, like clevis hangers or split-ring
hangers, the job becomes a bit more tedious, but time-tested methods of high compressive strength materials, in combination with the main
insulation material, can do the job effectively. Wood blocks do not fit the category of properly supporting a refrigeration pipe, and have been
removed from the National Commercial and Industrial Insulation Standards manual.
Controlling Condensation
Vapor dams are important in these systems, since they do have a high chance of generating condensation, and are especially important in systems
that are roof mounted. There are a high number of these systems that are being mounted on the roofs of multistory buildings with many pipe lines
running into a single mechanical chase leading to the lower floors of the structure. Condensation can easily run down the line into the fan-coil unit
in the building and flow out, damaging building contents, ceilings, drywall, carpets, etc.
Hand-in-hand with providing vapor dams as a way of controlling condensation or icing troubles is sufficient sealing of all joints, seams, and
penetrations. Installations can be difficult and even present problems at valve access ports, valve operators, valve stems, test ports, strainer
ports, and pipe terminations at the fan-coil units or at the condenser. Pipe support/anchoring is another tricky area, as discussed above. All these
areas must be properly sealed against water vapor intrusion, as must all circumferential and longitudinal pipe insulation seams. It is also important
to be sure the products being used are vapor retarder products. Quite often, weather barrier coatings that are breather coatings are mistaken for
vapor barrier products. Fish-mouthing or voids in closure materials of all kinds can leave small entrances that water vapor finds fast and easily.
Preventing Corrosion
Corrosion of piping should also be considered when these piping systems are being insulated. As mentioned above, these piping systems are being
installed in building chases in heavy multiples, and may be very hard to access for service after installation. Since the most severe operating
condition will be when the system is in the cooling mode, this should be the primary consideration. Additionally, the heat of the system, when the
piping is in the heating mode, is in the ideal temperature range commonly identified as the most prone to inducing corrosion under insulation.
Avoiding the introduction of moisture that can help accelerate corrosion is critical in the installation of the insulation system. Sealing against water
and water vapor intrusion needs exceptional attention, since many of these systems are roof-mounted and subject directly to whatever weather
comes along, in addition to being highly susceptible to condensation troubles.
This same moisture can leach corrosive components out of insulation materials, and create a caustic solution that can accelerate corrosion under
insulation. Pinholes can also leak refrigerant and cost the building owner significant expense in lost refrigerant, and there is also an expense
associated with identifying the leaking areas, and repairing leaking pipes. Insulation contractors should evaluate the ability of a material to
contribute to corrosion on piping. Materials that have been tested using a recognized ASTM test method for corrosion contribution, such as ASTM
C 692 or ASTM C 1617, should be considered. Not all products have undergone this testing, but many have since there are a large number of
applications that require the use of non-corrosive products.
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develop solutions that are effective and realistic for this new technology.
Author
Darrell Peil
Darrell Peil is Vice-President of Marketing and Technical Sales for Aeroflex USA, Inc., as well as Regional Sales Manager serving the upper half of
North America. Currently a member of ASHRAE and ASTM, he serves on the committees for ASTM C 534, C 1534, and C 1427. He is the current
Chair of the ASHRAE TC 1.8 Handbook Subcommittee. Mr. Peil has been associated with the building mechanical systems industry since 1982,
holding various roles in the contracting, distribution and manufacturing segments of the industry. During that time, he has served in several
positions requiring in-depth work with business and product development, systems design, specifications, standards, and codes. He can be
reached at dpeil@aeroflexusa.com.
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