MEP Techniques to Optimize HVAC Systems

Discussing the trends and digitalisation all around, industry experts deliberated about integration of IoT, AI and MEP techniques to optimise and commissioning of HVAC Systems.

Pandemic accelerated the need for evolution and digitisation and MEP is a happening area. Mechanical, electrical and plumbing (MEP) market driven by growing infrastructure development has good prospects in receding pandemic times. A growing impending need is to impart training to prepare technicians: to meet needs of skilled manpower for optimisation. Everyone, consumer or HVAC contractor – all are getting ready to grab and utilise opportunities lost during pre-pandemic times.

Recently, growing IT, IoT and artificial intelligence in HVAC systems and digitalisation is influencing HVAC market for contractors. Today, the house owners want to update themselves about MEP for HVAC in case of repairs needed. Much of energy produced by HVAC systems need to be optimised. Global mechanical, electrical, and plumbing (MEP) services market is consistently driven by increasing infrastructural development worldwide. And, the requirement of the developed economies to upgrade their existing infrastructure is in turn expected to create highly conducive environment for growth of the global mechanical, electrical, and plumbing (MEP) services market.

Asia Pacific is expected to account for the largest share over the forecast period owing to numerous infrastructural activities taking place in the countries that include China, India and Indonesia.

Recently, Thermal Control Business Update hosted an interactive session on Talking about trends and, digitalisation industry experts deliberated upon IoT, AI and techniques to commissioning and optimise HVAC Systems in the recent times. The distinguished panellists included, Pradeep Kumar, Head -MEP design, at Landmark Group; Ajaj Kazi, Project Director, Voltas Limited and Suhas Randive, MEP Consultant, Design Engineers.

IoT uses collected data to identify opportunities and inefficiencies that gets us to real time and safety is our prime concern. During the panel discussion experts shared their views to the query raised as the session went on.

IoT and AI role as alerts systems to detect refrigerant leaks and location in HVAC scheme of things

Pradeep Kumar remarked, IoT will predict these kinds of things. Also, we have occupancy sensors and humidity and sensors, CO2 sensors. So, it will predict all these things, it will alert everything what we think so that means apart from HVAC we can club fire alerts, we can club human alerts also, and whatever. We think where we have negligence. I can say we can overcome the manual failure.

Opportunities for market growth, and utility of BIM for quality consistence in projects

Ajaj Kazi said, yes, in terms of opportunity, huge opportunities are available and there are very few who can deliver on time and this is where everybody has to scale up; scale up their learnings and scale up their resources. Huge opportunities are available; you name any segment even for each and every place, as we say we put the air into the system, same way we put the energy into system, so lot of hours are available in terms of BIM, yes, it helps a lot and it actually reduces the cost. It gives the consistency and the quality which customer needs. Now, one of the projects which I am working on currently is, around 1 crore sq. ft. area. Without BIM, you cannot even think of doing this project; 60 to 70 percent of the work has been fabricated outside. The BIM uses a fabrication drawing, it goes out to the fabricator, and it comes back and easily gets in. If you talk about dependability on people the problem is what we do is we try to compare everything, you know. Apple to orange and this is where the problem is realised. So, if you talk about the advantages – all will always think about material and labour cost and he will try to say no. But, if you can see the deficiencies or inefficiencies and the cost was that the cost of quality, the cost of safety, if you put together, you will be always better off. And the very, very important thing is peace of mind that you get for consistent result. And, in case to deal with emerging situations, the mindset will change.

Upcoming challenges that industry demands

Sharing his opinion that I’m just pointing out on the challenges part, Pradeep Kumar said, see, why I use challenge is because in current market situation, we have a lot of challenges. While we will do an AutoCAD drawing; an AutoCAD will be moving to BIM and there is a lot more implementation in that, in practicality, when we do execution for IoTs and other things. As I mentioned, we have a software plus hardware combination, if we are going to install the hardware in current situation. It’s one of many challenges, right! If we can’t execute it properly! And a lot of other things I have to cut down; we have to reinitiate this kind of hardware into the existing system, which is why I’m emphasising on AutoCAD on the BIM, because currently, if you go by the drawing and all, we haven’t had proper drawing for those things, and slowly, we are evaluating towards BIM and also, we are much ahead of the design drawing. And also, if we go into that thing, probably we had a better drawing as well. Currently, we have not had this kind of challenge where we don’t have a proper bill drawing and all. So, we have that kind of initial challenges and all other challenges like Internet connectivity, then sometimes, we will be unpredictable on a climate condition. Also, if Google says, tomorrow will be rainy, sometimes wondering, if we do a pre-plan with the help of IoT, like what I explained, we can do with the pre planning with the help of IoT and all. So, if you do a pre planning with the Google and other assistance, it may fail sometimes because our system is not so robust in present conditions.

Challenges to MEP projects for HVAC during planning, installation and for sustainability

Suhas Randive noted that during planning and installation there should be proper co-ordination of utility services such as HVAC, Electrical, Plumbing and Fire. HVAC, electrical, plumbing and fire should be installed in such a manner that they should not fall on each other. Also, Utility services equipment should be placed with easy maintenance and service for longer sustainability.

Steps for pre-commissioning of project

Suhas provided detail view and said, steps needed to be considered at pre-commissioning of project include Chilled Water System; Water cooled chilled water system, for which plant room should be clean and there should be no debris in plant. All plant room doors are fitted and lockable, as far as HVAC systems are concerned. Water should be clean and soft. Before commissioning manufacturer engineer should verify the system and Air-cooled chilled water system should be installed at the open area exposed to ambient location. No obstacle should be there, dust should not settle on condenser coil. Before commissioning manufacturer engineer should verify the system.

Similarly, Fire Detection, firefighting; Electrical; Direct Expansion (DX System) and Variable Refrigerant Flow (VRF) System should be given utmost importance. Liquid pipe and suction should be insulated with EPDM/ Nitrile Rubber. The units installed should be easily accessible for clearance services. Outdoor unit location shall be installed considering the noise sensitivity of adjoining space building. All the more, before commissioning manufacturer engineer should verify the system.

Pumps available as vertical or horizontal are to be installed with proper foundations. Inlet and Outlet of pipe should be properly joined and manufacturer engineer should verify the system. The pipe shall be provided with easily removable section (Flange/ Joints) for cleaning or replacement. The pipe work shall be complete with suitable provision for air purging and draining of water. All water systems should be flushed and it should be vented, filled and chemical cleaned. Moreover, all manual and automatic control valves are open or pre-set, as required. All strainers are to be cleaned.

New industrial corridors opening up and impact on the HVAC industry

Ajaj remarked, if you can address that, in industrial corridors, industrial air conditioning is a good; say opportunities are available for HVAC. Most of you know HVAC industry is focusing on the commercial or comfort. And, because I think it will slow the growth in industrialisation. Now this opportunity is emerging and is going to give a lot of opportunities for people to think about and start giving very good designs to the new industrial corridors and industrialists can save a lot of energy. The HVAC is the energy guzzler of a lot of energy by HVAC system. So how do we deal you know, energy efficient projects are going to be a key differentiator between the good company and the not so good company; who can move the normal projects, but it’s going to open up a lot of possibilities.

Challenges and the need of MEP coordination in building and industrial project

Suhas elaborated upon challenges and need of MEP coordination stating that for HVAC System: selection of right equipment, installation of equipment i.e., pumps, AHUs, piping, ducting, duct insulation, acoustic insulation, thermal insulation, air terminal i.e., grill, diffuser, damper is needed. Electrical system requires selection of transformer, diesel generator as essential power, main electrical panel, LT Distribution board, lighting layout as per the workstation needs be designed with proper rating of switchgears, earthing etc.

The plumbing system consisting of Hydro-pneumatic system / Overhead Tank should be designed as per NBC norms that include soil pipe, vent storm water, drain trunk etc. Even fire system must adhere to NBC norms with proper location of fire hydrant; sprinkler and smoke detector selection. Further, Utility services equipment should be placed with easy maintenance and service for longer sustainability, Suhas added.

Pradeep stressed, it is very much needed because I will say it is impacting on the cost part, it will be impacting on time part and the quality of all three will be impacted if you are not well coordinated, if you are well coordinated, it will save a lot of time, quality will improve definitely and obviously the cost will be optimised if we are well connected.

Automation, post Covid technical improvements and 3D in design part used in MEP We are slowly moving towards that said Pradeep, like we are to AutoCAD; secondly, we are moving towards BIM and we are slowly moving towards them to optimise our design also like if I feed my design to Revit or BIM it will give me a quantification. We are slowly moving towards it will take time what I feel. So, it is not as you see that you don’t see large adaption of automation and industrialisation, I mean design industry will take time because of a lot of challenges we have as we feel compared to other market in other industries. Like, we have a small designer available in pan India which won’t afford that much software cost and all, which is very high and so we have to take a baby step towards that. So, we don’t have to worry and it will be adopted in upcoming days and also, we will be in on no beginners we can see that.

Suhas remarked 3D gives the vision of how the utility services (HVAC, Electrical, Plumbing and Fire) have been installed. And, how it helps us find out if any utility services such as piping, lighting, grill, detectors, sprinklers or ducting are in loop on each other and how it can change and be modified accordingly. In fact, Drawings made in 3D are as good as an execution drawing. Further, industry is moving from 4.0 to 5.0 in HVAC system, automation system helps us operate air-conditioning wherein we can sit in any corner of the world and operate the HVAC System.

Standards available for implementation and commissioning of HVAC system

Prominently, ASHRAE, ISHRAE; Indian standard (IS); NBC-2016: National Building Code Eurovent: Europe’s Industry Association for Indoor Climate; SMACNA: Sheet Metal and Airconditioning Contractors National Association; AMCA: Air Movement and Control Association and ASTM: American Society for Testing and Materials are being used meticulously, mentioned Suhas.

Automation is happening in MEP sector; having a trained pool of manpower is essential, how do you see the availability of trained manpower and trend happening in the industry.

Ajaj expressed, currently, it is very difficult if you look at the manpower available now, it is around still 40 to 50 percent of what was supposed to be. So, we have to go outside and do the prefabrication which is the way to move ahead; it is already coming in some way in India. So, we have to establish some of the shops which can also employ you know, so, if you have an employment channel there also; so, they can do this work, we can get them trained in our specific areas about work. A lot of other activities can be prefabricated outside and it has been demonstrated also in India, that with the right coordination, it can be done and we can reduce a lot of dependency on the labour obviously, site installation will require a lot of labour. For instance, in a little less time a lot of innovations can be done at site to reduce the dependence on the paper by using machines and techniques, so that the dependency on the labour can be reduced and we will be sort of say instead of 10 people we can use 4 people.

So, with the machine, we can improve the productivity, because you can see in India, none of the projects are completed on time; you can take the reports and find out not only in India but also across the world. So, it is very important to be on time, we have to be productive and deliver the projects on time by looking at using the hybrid model, of using available manpower and taking a lot of works outside the site; do outside and then take it to that site and install it. And, that is going to be the way and that has taught us this lesson in this Covid conditions to go out in that way.

Final note

I talked about the IoT and I will conclude in that way, said Pradeep. Our country is moving towards a smarter way of working and slowly we will be in a bracket where we will see a lot of difference in our working also. I can say, we are moving towards a smart working rather than working hard earlier. Well, we are working very hard. Now, we are moving towards a smarter working. In design also we are moving towards ‘Revit’ and being in execution, we are also moving towards the smarter way of execution. And in in some of our site we used to have CCTV cameras. Covid taught us a lot but we are not used to go to site. So, we implemented the cameras and Wi-Fi’s and other things to monitor the sites and also now due to this pandemic, we think why we are spending on this thing and also, we start reducing our operational costs also. So, this pandemic, taught a lot towards smarter way of working. So, we are becoming smarter day-by-day. And, I hope in another one or two years, we will be competent enough to compete in the world towards the smarter way of investing, concludes Pradeep.