0001 spec ion system

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Page 1 of 13 Effective from Nov. 2010 RDSO/2009/EM/SPEC/0001, (Rev. 0) Amdt.1

GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

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SPECIFICATION FOR

CENTRALIZED AIR VENTILATION WITHAIR COOLERS OF WAITING ROOM AND

DEPARTURE LOUNGE AT THE STATIONS

Specification No. RDSO/2009/EM/SPEC/0001, (Rev.0)Amdt.1

SN

Amendment Revision ReasonNo. Date No. Date

1. 1 08.11.2010 - - Clause Nos. 13.0 (Guarantee), 14.0 (After sales service) and16.0 (ISO 9000 Accreditation) Deleted as per Railway Boardsletter No. 2006/ Elect.(G)/150/9/Pt. dated 10.09.2010

ISSUED BY -

ELECTRICAL ENERGY MANAGEMENT DIRECTORATERESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW 226 011

Approved by

Executive Director / EEM


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INDEX

Clause No. Description Page

1.0 Foreword 3

2.0 Reference Standards 33.0 General Requirement of Air Ventilation 3

4.0 Design & General Construction 4

5.0 Installation & Operation 8

6.0 General & Safety Requirement 8

7.0 Noise 9

8.0 Protection 9

9.0 Tests

10.0 Marking 12

11.0 Instruction & Maintenance Manual 12

12.0 Training

13.0 Guarantee : Deleted 13

14.0 After Sales Service : Deleted 13

15.0 Infringement of Patent Rights 13

16.0 ISO Accreditation : Deleted 13


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SPECIFICATIONS FOR CENTRALIZED AIR VENTILATION WITH AIRCOOLERS OF WAITING ROOM & DEPARTURE LOUNGE AT THE STATIONS

1.0 Foreword:

This specification defines the objective, guidelines and requirementfor the design, manufacture, supply. Installation, testing and

commissioning of centralized air ventilation with air cooler atwaiting room, passenger halls etc at stations of Indian Railways.

2.0 Reference Standards

IS:694 :1990: PVC Insulated Cables for working voltages up to &including 1100V

IS:325 :1970: Three phase induction motor. IS:4691 :1985: Degree of protection provided by enclosure for

rotating electrical machines

IS:6272 : 1987: Cooling fan. IS:302: 1979: General & safety requirements for electrical

appliances.

IEC 60529:2001: Degree of protections provided on enclosures (IPCode)

IS:2184: 1968: Flame proof enclosures for electricals apparatus.

IS:4722: 1968: Rotating electrical machines IS:2992: 1965: Insulation resistance testers. IS:4728: 1975: Terminal marking & direction of rotation electrical

machinery.

IS:3615: Various technical terms used in air conditioning. IS:9542: Horizontal centrifugal mono block pump. ASHRAE Standard 62.1-2001

Note: Latest version of the above specifications shall be referred to.

3.0 General Requirement of Air Ventilation

The total minimum out side fresh air introduced into an enclosureby positive ventilation method shall be related to the numbers ofoccupants in the enclosure at any time. The national consensusstandard for out side air ventilation is ASHRAE Standard 62.1-2001. Calculation for ventilation required can be done as shown

below :-


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No. of person per 10 sq. meter of floor area : 15 (assumed)Ventilation required per person : 25.5 CMH

Total ventilation required : 25.5X15 =382.5 CMHper 10 sq. meter floor

area

Therefore, depending on the floor area and occupancy of that area,requirement of fresh air can be calculated for designing ofventilation system. It shall be possible to control the humidity ofindividual location through suitable control such as regulation of

circulation of cool water.

To determine volumetric flow rate, the average measured air velocityis multiplied by the cross sectional area of a duct. For example, if aduct is 0.61 meter by 0.61 meter (cross-sectional area- 0.3721square meter) and the average measured air velocity is 2741 meter

per hour. The resulting volumetric flow rate is 2741 meter / hr x

0.3721 square meter or 1020 CMH.

4.0 Design & General Construction

In this system cooling is due to adiabatic exchange of heat betweenair & water spray or wetted surface. A good indicator of proper

ventilation is the level of carbon dioxide present in a space. Carbondioxide is a normal by product of respiration, combustion and otherprocess. Elevated level of Carbon dioxide may indicate that

additional ventilation is required. ASHRAE Standard 62recommends an indoor level not to exceed about 700 ppm above

outdoor ambient air which is typically about 300 to 400 ppm. Suchsystem comprises of Air handling unit, Ducting and watercirculation system. The tenderer shall also take into account thelevel of humidity prevailing in different regions while designing thesystem.

4.1 Air Handling Unit (AHU)

AHU shall be double skin horizontal floor mounted, low noise,sturdy, screw-less cabinet construction and better thermallyinsulated. All components shall be mounted on an integral baseframe and be designed to prevent condensation on the exterior skin.

Alternatively, AHU can be vertical type to occupy lesser floor spaceor ceiling suspended type requiring no floor space. Selection of thetype of AHU shall be based on the rating and the site condition.

4.1.1 Casing

(i) The AHU base frame shall be of 14G galvanized steel sheet.


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(ii) Frame of AHU shall be made of smooth rounded extrudedaluminum anodized profiles with fiber glass corner joints.

(iii) Insulated panel shall be fixed on the aluminum frame using overlapdesign wedges to achieve screw less construction for easy assembly.3.0mm thick special gasket shall be fixed on frame below the panels

for improved air tightness of the cabinet and better thermal andacoustic performance.

(iv) These double skin sandwiched panels shall be made ofOuter skin: 0.6mm, 23G pre-painted galvanized sheet with PVC

guard film.

Inner skin: 0.6mm, 23G plain galvanized sheet.

(v) Panel shall be 25mm thick, pressure injected with polyurethanefoam using CFC-Free, R-141b blowing agent. Uniform PUF density

of 38+/-2kg/m3.

(vi) The casing shall be designed in such a way that humidificationsection is fitted inside in a modular way.

4.1.2 Pre-Filter Section

(i) The main purpose of the filtration system is to remove largerparticles and to protect the cooling system from dirt build-up.

(ii) Pre-filter provided shall be of synthetic non woven type washable

HDPE and supported with aluminum frame.

(iii) Filter efficiency shall be 90% for 20 micron (Eurovent class EU-3 asper EN799).

4.1.3 Humidification Section.

Humidification section consists of cellulose pad, water circulationpump and sump for water storage. This section shall be modular foreasy fitment inside the AHU

Cellulose pad

Humidification section shall be double skin with 0.6mm, 23Gstainless steel, 304 grade for inner skin & 0.6mm, 23G prepaintedGI sheet for outer skin. Cellulose pads on side/sides of thehumidification section shall be provided for the purpose of watercirculation. Designing of pads shall be done for air inlet velocity notexceeding 10058 meter/hour. Desired efficiency of the cooling padsshall not be less than 90% and thickness shall not be less than200mm(8).


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Sump

Water sump shall be fabricated of 1.2mm 18G thick stainless steelgrade304.

Pump

(i) Water circulating pump shall be monoblock type with IP-55protection.

(ii) Water level switch to be provided for safety against wet run ofpump.

(iii) Size & material of float valve 20mm dia, heavy duty brass

(iv) PVC droplet eliminator to be provided.

4.1.4 Fan & Motor

A fan is an air moving device comprising a wheel or blades andhousing.

(i) Fan and motor shall be mounted on aluminum extruded slide railbase frame to adjust belt tension without disturbing motoralignment.

(ii) Fan section shall be provided with an access for easy in servicing.(iii) View port shall be provided at fan door panel which would help

monitoring fan & motor status.

(iv) Door limit switch shall be provided to automatically trip fan withthe door is open.

(v) Factory fitted opposed blade aerofoil aluminum volume controldamper to facilitate balancing.

(vi) Aluminum die cast powder coated hinges shall be provided.(vii) The forward curved double inlet double width (DIDW) centrifugal

fan shall be AMCA (Air movement & control association) certified.

(viii) Fan & motor assemblies shall be mounted on anti-vibration pads toprevent noise/vibration transmission. Spring isolators to beprovided at fan-motor for anti vibration.

(ix) The fan blade shall be designed for maximum efficiency and quietoperation.


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(x) The fan shall be statically dynamically balanced. Whole fanassembly shall be trim-balanced to ISO-1940 and AMCA 204-G 2.5standard.

(xi) No readily flammable material shall be used in the construction offan. Molded parts, if used, shall be of such materials as willwithstand the maximum temperature attained in the adjacentcomponent parts.

(xii) The impeller and scroll shall be made of galvanized steel sheet.(xiii) Motor shall be standard frame with open drip-proof enclosure and

shall be suitable to operate at 415V +/- 10%, three phases.

(xiv) Fan motors are to have a maximum rotating speed of 1500 rpm.(xv) Motor shall be 4-pole, TEFC with class F insulation and IP-55

degree of protection.

(xvi) Fan rotating speed is to be in accordance with air flow amounts andfans are to be belt driven where speed differentials exist betweenmotor and fan.

(xvii) Driven set of V-belt and pulley (statically and dynamically balanced)to be provided

4.2 Air Ducting

A passageway made of GSS complete with necessary supporthanger, nut bolts and gaskets etc, used for conveying air at low

pressure. Air velocity is seldom uniform across any section of an airduct. The shape of a duct, its turn and branches and friction all

effect the movement of air. In general air tends to move slowertoward the edges or corners and faster in the center of a duct.

All metal duct work shall confirm to the requirement of IS : 644.

Duct size and GSS sheet thickness shall be designed as per thefollowing table:-

Type of duct Air Velocityinside duct

GSS sheetthickness

Main Duct 4 - 7 m/s 18G

Main branch Duct 3 - 5 m/s 20G

Branch Duct 1 - 3 m/s 22G


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4.2.1 Air Grills

Powder coated extruded section aluminum grills, with GI volumecontrol dampers shall be provided with the duct as fresh air inlet in

ventilated area.

4.2.2 Air Outlets:

Provision of air outlet of capacity at least 80% of inlet air shall beprovided in the ventilated area. It may include windows, ventilator,exhaust port etc. If room is covered from all side duct of suitable

size with 22G GSS sheet shall be provided as air outlet.

4.3 Control Panel

Control panel shall be provided with powder coated control box tohouse isolator single phasing preventor and contactors for startingof the motor. Control panel shall be compatible with BMS. On-offtrip indications and luminous push buttons shall be provided.Provision shall also be made to connect control value, fire dampers,modulating motor and door switch.

5.0 Installation and operation

All ventilation equipment works such as fan & motor, filter andduct work etc, shall be located at convenient places to facilitate

periodical inspection, cleaning and maintenance. Duct-work shallconform to IS: 655 (specification for metal air ducts).

The system with acceptable noise level or below should be designed.

Suitable noise damping method shall be applied.

6.0 General and Safety Requirement

6.1 Protection against Electric Shock

In the assembled fan motor & monoblock pump, live parts shall not

be accessible to the standard test finger. This requirement isapplicable for all positions in normal use.

6.2 Electric Insulation

The electric insulation of the fans motor & mono-block pump shallbe adequate and the leakage current in normal use shall not beexcessive. The insulation resistance shall be not less than 10 M .


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There shall be no breakdown of the insulation when the both issubjected to high voltage test or flash test, as the case may be.

6.3 Finish

All the surface of both fan motor and blades shall be of corrosionresisting material or shall be suitably and durably protected against

corrosion.

6.4 Interchangeability

The motor of the fan & mono-block pump of a particular size and

model shall be interchangeable such that the performance of thefan & pump keeps with in limits specified in this standard.

6.5 Silent Operation

Precautions shall be taken in the manufacture of fan, motor andpump to ensure a reasonable degree of silence at all speeds.

7.0 Noise

Careful consideration must be given to preventing noisetransmission via the duct work system, through phonic insulationand construction devices, to limit the level of acoustic pressure tothe requirement. The extent of noise levels should not exceed 60 dbgenerated by the ventilation equipments. Noise measurement

should be done 1 metre away from the end wall and 1.4 meterabove the floor level as per relevant standard. Velocity of air fromthe grill / diffuser should be 3.0 m/sec. in SDCL condition at theheight of 1.6 meters from the floor.

8.0 Protection

Following protections shall be provided

Transient voltage protection Over current protection Short circuit protection Thermal protection The protect the equipment against over load, facility for automatic

tripping and disconnecting within 5 seconds shall be provided incase the load current goes beyond 120% of the rated capacity.

Metal oxide varistors (MOVs) shall be provided against highpotential transient voltage spikes.

MCCBs/MCBs of appropriate rating shall be provided along withHRC fuses of suitable capacity, to isolate internal/external faults.


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9.0 Tests

In respect of tests for which testing facility is not available with themanufacturer, the same may be carried out at NABL accredited testhouse/laboratory

9.1 Type Test

Type test of the complete system shall be witnessed and cleared byRDSO. The successful tenderer shall prepare detailed test plan andget it approved by RDSO prior to commencement of the tests.

(a) Air delivery(i) Air delivery measurement at suction end Air velocity shall be

measured at different points on suction end. Its average value

should be multiplied by suction area to calculate air delivery.

(ii) Air delivery measurement at delivery end -In this test, air velocityshall be measurement at all diffusers / grills fitted inside ventilationarea very closely at three points on each grill. Average value of thisvelocity should be multiplied by grills area and then number ofgrills provided in a ventilation area to calculate air delivery.Air delivery measured at delivery end shall not be less than thedesigned air delivery..

(b) Pressure drop in the air ductThe pressure drop shall be measured across the full length of theventilated area at diffuser grill. Pressure drop at farthest point maybe kept within permissible limits by suitable design of ducting.

Pressure drop measurement should be done with differentialpressure transducers. During measurement of Pressure Drop in

the air duct. Following points should be kept into mind.

(i) Same length of the sensor should be inserted into the grill duringall measurement

(ii) Sensor of the Pressure meter should be kept in the same directionduring all measurement

(iii) No obstacle / baffle should be there inside the duct/betweensensor and air flow during measurement of Pressure drop.


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(c) Noise Measurement Noise measurement should be done 1 meter away from the end walland 1.4 meter above the floor level. In above condition, noise levelshould not exceed 60 db.

(d) The fan motor shall be required to pass the tests CL. 23.1, 23.2,23.4, 23.5, 14.0, 13.1,25.0, 24.0, 15.0, 16.0, 26.0 of IS:325 (Latestversion).

(e) The mono-block pump shall be required to pass the tests CL.23.2,27.0 of IS: 325, CL.10.0 of IS: 8418 and IP-55 protection test as per

IS: 4691.

(f) Fan & Motor efficiency Most efficient fan & motor and pump shallbe used by the manufacturer. Efficiency of the fan & motor and

pump shall be proved by the manufacturer.

(f) Fan Speed The speed of rotation of the fan shall be determined byrunning the motor and pulley PCD. The speed of rotation also shallbe determined by the test voltage and its rated frequency. Themethod of measurement shall be such that the speed of the fan isnot appreciably affected.

(h) Leakage Current Test- This test shall be carried out in accordancewith 13.2 of IS : 302-1979 .

No design change shall be undertaken by manufacturer after typetest without prior approval of RDSO.

9.2 Acceptance Test

These are the tests which are being conducted before acceptance.

(a) Air delivery

(b) Fan speed

(c) The motor shall be required to pass the tests CL.23.1, 23.2, 23.4,14.0, 25.0, 24.0, 16.0, 26.0 of IS: 325.

(d) The mono-block pump shall be required to pass the test CL.22.3.2of IS: 325 except para f & g of CL.22.3.2.

9.3 Routine test

Those tests which are being conducted on each and every

ventilation system before supplying to the user.


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(a) Air delivery

(b) Fan speed

(c) The motor shall be required to pass the tests CL.23.1, 23.2, 23.4,

24.0, 25.0 of IS: 325

(d) The mono-block pump shall be required to pass the test CL.22.3.2of IS: 325 except para f of CL. 22.3.2.

10.0 Marking:

Each centralized ventilation system shall be provided with a ratingplate of weatherproof material fitted on the front panel in a visibleposition; containing the following information

1. Type2. Specification No.3. Serial No.4. Month and year of manufacture5. Air delivery6. Rated speed7. Make of the all equipments8. Power consumption in KW9. Impeller diameter10. Weight of the Unit.

All markings/indications shall be placed in the vicinity of thecomponents to which they refer & shall not be placed on removableparts. The content of the rating plate shall be indelibly marked byetching or engraving.

11.0 Instruction / Maintenance Manual

Three copies of instruction manual containing the followinginformation, shall be supplied along with each centralizedventilation system.:

Instructions for installation Wiring diagram indicating the components & their rating. Drawing showing general mounting arrangement of centralized

ventilation system and its various components.

Bill of material containing list of components, their ratings andmake.

Step by step maintenance & trouble shooting procedure.


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12.0 Training

Training shall be arranged to railway operating & maintenance staffwithout extra cost after functionally completion of the unit.

Training shall include a discussion on equipment design andlayout, demonstration on routine operation, maintenance &

trouble-shooting procedure.

13.0 Guarantee : Deleted

14.0 After Sales Service : Deleted

15.0 Infringement of patent rights

15.1 Indian Railways shall not be responsible for infringement of patent

rights arising due to similarity in design, manufacturing process,use of similar components in the design & development of this item

and any other factor not mentioned herein which may cause such adispute. The entire responsibility to settle any suchdisputes/matters lies with the manufacturer/supplier.

16.0 ISO 9000 accreditation : Deleted

0001 spec ion system

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