CRAC Unit Replacement Project – Airservices Mascot Sydney
As part of ongoing efforts to maintain efficient and reliable climate control systems, this project involved the replacement of the offline AC-4 CRAC unit with a new Stulz CRAC unit, provided by Airservices.
The scope included the safe disconnection, removal, and disposal of the existing unit, along with associated pipework, electrical and control cabling, ducting, and peripherals. In its place, the new CRAC unit was installed using the building’s existing hoisting system, with lifting operations performed by a licensed rigger via the first-floor hoist door.
Installation works involved the reconnection of the existing AC-4 submains and control cables, and the supply and fitting of a new maintenance isolator. To ensure optimal system performance and longevity, new copper piping with 25mm wall insulation was installed, and a ball valve was added following pipe freezing procedures.
A custom-fabricated transition duct piece was also installed between the new CRAC unit and the existing ductwork. This included a flexible canvas section to accommodate system movement. A temporary duct connection was fitted to allow for commissioning and initial operation while the permanent duct was being manufactured.
Further enhancements included the reinstallation of the differential pressure gauge, to ensure continuity in monitoring performance.
This upgrade ensures reliable climate control while maintaining full integration with the existing building services infrastructure.
