Hydraulic Services Design Guide & Pipe Sizing Guide

216 Pages·2015·10.65 MB·English

Hydraulic Services Design Guide
1st Edition April 2014
Including amendments Sept 2015
HSDG_Cover.indd 1 9/11/2015 10:02 am
st
Hydraulic Services Design Guide – 1 Edition April 2014
Changes September 2015
Chapter 7 – Modifed wording concerning Soft Solder
Chapter 12 – Changes to Table 12.4 regarding velocities
Chapter 13 – Changes to example of insulation calculations
Chapter 15 – Added reference to AS/NZS 3666.1 and AS/NZS 3666.2
Chapter 17 – Changes to Table 17.1 regarding velocities
Chapter 18 – Update fushing requirements during installation

Table A
Changes to Hydraulic Services Design Guide 1st Edition April 2014
Hydraulic Services Design Guide Download the New Pipe Size App
st
1 Edition April 2014 (plus amendments 2015) – Chapter One 1 Free at www.copper.com.au
CA_All_Chapters_V11.indd 1 9/11/2015 10:02 am
1
Chapter
One
Chapter 1 – Introduction
International Copper Association Australia
Download the New Pipe Size App today, at www.copper.com.au 2
CA_All_Chapters_V11.indd 2 9/11/2015 10:02 am
Introduction
A New and Exciting Contemporary E-Design Guide on the
Fundamentals for Plumbing Services.
This Hydraulic Services Design Guide has About Us
been developed for the Australian and
New Zealand Hydraulic design engineers The International Copper Association
and plumbing contractors responsible for Australia (ICAA) is part of the global Copper
designing plumbing systems for commercial Alliance™, which has a history spanning
high rise and industrial buildings. more than 80 years.
This on-line resource is supported by a The Global ICA evolved out of the
Smartphone App and is available to designers International Copper Research Association
and contractors as an on the job reference and as (INCRA), which was formed in 1927. In 1989
an education resource for lectures and students. ICA was formed by 24 of the world’s leading
Copper producers who recognized the need
This Hydraulic Services Design Guide has to coordinate and integrate efforts in Copper
been developed by the International Copper promotion worldwide.
Association Australia with the support
of MM Kembla and Crane Copper Tube. Globalization and an increased demand
for Copper product technologies have
The Hydraulic Services Design Guide driven the Copper industry to expand its
will be reviewed and updated annually to vision for Copper.
ensure that designers, contractors and
students have the latest and most up to date Not only does this unique element propel
reference material into the future. technological advancements, but it fulflls
broad societal needs to protect the
It takes into account resource material environment and improve human health.
previously available in various technical Copper advances the delivery of basic
references (including Barrie Smith’s services (e.g., electricity and drinking
S“ election and Sizing o f Copper uT eb s of r water) to developing countries, adds
aW ter Piping Systems” and Paul Funnell’s convenience to the developed world,
P“ ipe Sizing of r uB ilding Services” ) and will and provides both with improved energy
help to improve the skill level of designers, effciency, reduced greenhouse gases and
plumbers and students alike. increased disease prevention.
Copper Alliance™
Gloab l CI A
Hydraulic Services Design Guide Download the New Pipe Size App
1st Edition April 2014 (plus amendments 2015) – Chapter One 3 Free at www.copper.com.au
CA_All_Chapters_V11.indd 3 9/11/2015 10:02 am
Within the Copper Alliance™, ICA maintains It is intended that this e-design manual
its global-level role in support of the world’s is read in-conjunction with appropriate
copper industry, and its governance structure plumbing and fre installation standards.
remains intact.
We would also like to recognize the
As global issues such as energy, climate contribution of Neil McPherson, Phil
change and health become more urgent, Nichols and those acknowledged in the
Copper plays an important role in almost development of this Hydraulic Services
every industry. The ICAA and its members Design Guide.
defend and grow markets for Copper based
on its superior technical performance and its The ICAA are committed to support the
contribution to a higher quality of life. training of professional designers and
installers in Australia and New Zealand and
The ICAA, MM Kembla, Crane Copper Tube we commend this Hydraulic Services Design
and its members and partners are pleased Guide to you.
to bring you this excellent resource to
improve your skills and design of hydraulic
plumbing systems in high-rise buildings.
oJ hn Fennell
Chief Executive Offcer
nI ternational Copper Association
Australia
Suite 1, Level 7, 100 William Street,
Sydney NSW 2011, Australia

Phone [phone]
Fax [phone]
E-mail
Contents
Chapter 1
Introduction.................................................................................................. Page 2
Chapter 2
The History of Copper.................................................................................. Page 6
Chapter 3
Copper Tube Production............................................................................... Page 12
Chapter 4
Copper Tube Specifcation............................................................................ Page 20
Chapter 5
Water Supplies............................................................................................. Page 32
Chapter 6
Limitations of Copper Tubes – Corrosion..................................................... Page 42
Chapter 7
Joining of Copper Tubes............................................................................... Page 52
Chapter 8
Pipework Installation..................................................................................... Page 60
Chapter 9
Pipe Supports, Anchors and Guides............................................................. Page 68
Chapter 10
Valves........................................................................................................... Page 78
Chapter 11
Design Principles - Cold Water and Heated Water Services Systems......... Page 94
Chapter 12
Cold Water Systems Design......................................................................... Page 104
Chapter 13
Heated Water Systems Design..................................................................... Page 118
Chapter 14
Design Guidelines for Selecting Heated Water Plant................................... Page 132
Chapter 15
Warm Water Systems................................................................................... Page 140
Chapter 16
Pumps........................................................................................................... Page 146
Chapter 17
Pipe Sizing Guide and Design Methods....................................................... Page 156
Chapter 18
Testing and Commissioning.......................................................................... Page 174
Chapter 19
Understanding the Sustainability of Copper................................................. Page 180
Chapter 20
Industry Terminology..................................................................................... Page 184
Appendix A
Acknowledgments........................................................................................ Page 192
Appendix B
Pipe Sizing Guide and Pipe Sizing Tabulation Sheet........................................... Page 196
ediuG ngiseD secivreS ciluardyH pA eziS epiP weN eht daolnwoD
1 ts 5102 stnemdnema sulp( 4102 lirpA noitidE enO retpahC – ) 5 ua.moc. repoc. w ta erF
HSDG_AUSTRALIA_Revised.indd 5 16/11/2015 12:02 pm
2
hC apter
wT o
hC apter 2 – hT e iH ts or y o f oC pper
International Copper Association Australia Download the New Pipe Size App
Download the New Pipe Size App today, at www.copper.com.au 6 Free at www.copper.com.au
CA_All_Chapters_V11.indd 6 9/11/2015 10:02 am
The History o f Copper
Copper has been an essential material to man since prehistoric times.
nI troduction
In fact, one of the major ‘ages’ or stages But copper and its principal alloys, bronze
of human history is named after a copper and brass, have always been more than a
alloy: bronze. means of decorative embellishment.
Copper was the frst metal used by man Although iron became the basic metal
in any quantity. The earliest workers in of every Western civilisation from Rome
copper soon found that it could be easily onwards, it was the copper metals, which
hammered into sheets and the sheets in were used when a combination of strength
turn worked into shapes, which became and durability was required.
more complex as their skill increased.
The ability to resist corrosion ensured that
After the introduction of bronze, a wide range copper, bronze and brass remained as
of castings also became possible. Many both functional and decorative materials
of the illustrations in the timeline (Figure during the Middle Ages and the successive
2.1) serve to show man’s progress as a centuries through the Industrial Revolution
metalworker, culminating in the priceless and on to the present day.
inheritance of the Renaissance craftsmen.
Figure 2.1
Timeline of Copper Production
Hydraulic Services Design Guide Download the New Pipe Size App
1st Edition April 2014 (plus amendments 2015) – Chapter Two 7 Free at www.copper.com.au
CA_All_Chapters_V11.indd 7 9/11/2015 10:02 am
Copper rO es
An ore is a rock (Figure 2.2) containing enough
valuable minerals to make it worth extracting. In the
case of copper, it is worth extracting when there is
about 2 kg of copper per 1,000 kg of ore (0.2%).
Copper minerals are found in over one
hundred varieties, although only a few have
been worked for copper on a large scale.
The most abundant ores are chalcopyrite and
bornite, which contain both copper and iron
Figure 2.2
sulphides. These account for about 80% of the
Natural Ore Rock
world’s known ores.
Processes
Copper is found in natural ore deposits around This is the highest-purity commercial metal
the world. Figure 2.3 explains the production route in existence and used in a wide variety of
taken from ore-containing rock to a fnal product. applications essential to modern living.
Figure 2.3
Production Route of Copper
Hydraulic Services Design Guide Download the New Pipe Size App
1st Edition April 2014 (plus amendments 2015) – Chapter Two 8 Free at www.copper.com.au
CA_All_Chapters_V11.indd 8 9/11/2015 10:02 am
Copper iM nerals Smelting with Fluex s
Copper minerals are found throughout the A fux is a substance, which is added to the
earth’s crust. They occur in both sedimentary ore to make it melt more easily. The solid
and igneous rocks. The outer 10 kilometres of calcine is heated to 1200°C and liquefes.
the crust contains 33 grams of copper for every Some impurities are removed forming a matte
tonne of rock and in some places volcanic (a mixture of liquid copper and iron sulphide).
activity, millions of years ago, deposited molten
copper in one location.It is these areas, which Conversion o f aM tte
are mined today as they contain enough copper
to make mining proftable. As well as the Air is blown into the liquid matte forming blister
valuable copper there is large amounts of waste copper, so called because the gas bubbles
rock (called gangue), which has to be removed. trapped in the solid form blisters on the surface.
Copper iM ning Anode Casting
The following gives an overview of how The blister is cast into anodes for electrolysis.
copper is extracted from its ore and
converted into pure metal. Electrolytic eR if ning
iM ning The copper is purifed to 99.99% by
electrolysis. The production route described
The ore is removed from the ground in either in Figure 2.3 shows the progression from
open pit or underground mines. a rock containing about 0.2% copper to a
copper cathode of 99.99% purity.
nU derground: Sinking a vertical shaft into
the earth to reach the copper ore and driving eL aching
horizontal tunnels into the ore.
pO enp- it: 90% of ore is mined using the open Leaching offers an alternative to copper mining.
pit method. Ores near the surface can be First, the ore is treated with dilute sulphuric
quarried after removal of the surface layers. acid. This trickles slowly down through the ore,
over a period of months, dissolving copper to
The rO e form a weak solution of copper sulphate.
The copper is then recovered by electrolysis.
An ore is a rock that contains enough metal This process is known as SX-EW
to make it worthwhile extracting. (solvent extraction / electrowinning).
Grinding Advantages of these processes are:
The ore is crushed and then ground into powder. • Much less energy is used than in
traditional mining
Concentrating • No waste gases are given off
• Low capital investment
The ore is enriched using a process called froth • Ability to be operated economically on a
fotation. Unwanted material (called gangue) small scale.
sinks to the bottom and is removed.
It can be used on ore with as little as 0.1%
oR asting copper - for this reason leaching extraction
is growing in importance.
This is where the chemical reactions start. The
powdered, enriched ore is heated in air between It is estimated that in 2011 SX-EW
500°C and 700°C to remove some sulphur and represented 17% of total copper refned
dry the ore, which is still a solid called calcine. production.
Hydraulic Services Design Guide Download the New Pipe Size App
1st Edition April 2014 (plus amendments 2015) – Chapter Two 9 Free at www.copper.com.au
CA_All_Chapters_V11.indd 9 9/11/2015 10:02 am