system description / overview - indian institute of ... tender - section...construction of new...

Construction of New Buildings for IIT Madras Research Park - Phase - II, SH: - HVAC Works - Package-1 Centralized Chiller plant, Building

internal & External HVAC pipe line works

System Description / overview of 79 Section 3

System Description / overview:

It is envisaged to provide high efficiency Central Air conditioning System for the subject project, based on the design basis, and requirements, as listed in the tender document. Chilled water System: It is proposed to provide a Water-cooled Chilled water system, using Chillers that offer high IPLV (Weighted average Power consumption based on seasonal load demand variation, considering full and part load operation of chillers). The design is based on a “High Delta T” operation of chillers, in order to reduce water flow rate, and thus, reduce the allied pumping energy, and optimize chilled water pipeline sizes, and thus optimize both Capital and Operating costs The Equipment configuration consists of 4 Nos. water-cooled Screw chillers with multiple compressors, to improve part load efficiency, and also to reduce starting current of individual chillers. Multiple compressors are also desirable in order to enhance in-built redundancy, as we do not plan to have a dedicated standby chiller. Each chiller will work in conjunction with cooling towers, and condenser water circulating pumps. The pumps will be located within the Plant room, whereas cooling towers will be located outdoors. Cooling towers will be of induced draft type. The condenser water pumps will have fixed speed operation Chilled water Circulation: This is in two circuits, namely Primary fixed speed plus secondary variable. Variable flow will be achieved by modulating the rotary speed of the pump, with the help of a Variable Frequency Drive (VFD) dedicated to each secondary pump. To support 2 circuits pumping, there will be a primary chilled water piping loop, and a secondary chilled water loop, connected to the load (AHUs). The two circuits will be linked to each other thru’ a “De-coupler line”. Depending upon the load indication (measured by sensing variation in the supply and return water temperatures), the chillers will be automatically enabled to load / unload, by activating the compressor slide valve, in order to balance instantaneous capacity with the load. At the same time, feedback about the pressure differential between supply and return water header will be used to determine the water flow rate requirement. Based on the requirement as assessed by inbuilt algorithms in the pump controller, the pump speed will be varied with the help of the VFD. This arrangement in intended to reduce pumping energy during partial load conditions Liquid based thermal Storage: In order to reduce the overall installed capacity of the system, it has been planned to have a liquid based thermal storage tank system. The objective is that due to sun travel, and ambient temperature fluctuation, the building load can fluctuate significantly, thru’ the day. It is therefore planned to allow excess refrigeration capacity available at night / early morning, and ‘store’ the refrigeration, for use during Peak load times (like afternoon). This will not only help to reduce the plant installed capacity, but also enable the advantage of enjoying potential savings arising from Dual Tariff structure expected to




become a reality, wherein, during non-peak-demand hours (Say from late night to early morning), lower electrical tariffs are expected to become a reality. Another advantage is it will help to drive down peak demand supplement charges, as well as reduce maintenance costs due to lower installed capacity. It was decided to go in for a liquid storage system, rather than an ice bank system, or a storage system with phase change, and low temperature operation. This is because of the deration in efficiency of the chiller, when operating at low temperature. Being a premier Engineering Technology & research institute, IITMRP would like to work with technologies and concepts that are energy efficient. Therefore, low temperature system was ruled out The tank will be located within the plant room, working on the principal of stratification (achieved due to variation in density of colder temperature of stored water, Vs higher density of higher temperature return water temperature). It is planned to have a pre-fabricated and pre-insulated tank, to be assembled at site, and made from corrosion resistant materials. These tanks will have dedicated circulation pumps, as shown in the tender drawings. The electrical supply distribution for the HVAC plant will be provided from within the plant room. In order to control, and optimize as well as to enable remote monitoring and operation of the system, a BMS System is envisaged. Tenderers are advised to also inspect site to assess feasibility of installing the chillers thru’ the hatch provided in the plant room roof slab. Also, to assess the feasibility of connecting the new proposed system to the existing HVAC system already installed in the previous phase/s. The connectivity to old system needs to be verified for physical connectivity of chilled water headers, and even more importantly, for integration with a common BMS system. The plant layout provided with the tender illustrates the above system design In Section-5. 1. SCOPE OF WORK

The general character and the scope of work to be carried out under this contract is illustrated in Drawings, Specifications and Schedule of Quantities. The Contractor shall carry out and complete the said work under this contract in every respect in conformity with the contract documents and with the direction of and to the satisfaction of the Owner’s site representative. The contractor shall furnish all labour, materials and equipment (except those to be supplied by the owner) as listed under Schedule of Quantities and specified otherwise, transportation and incidental necessary for supply, installation, testing and commissioning of the complete air conditioning system as described in the Specifications and as shown on the drawings. This also includes any material, equipment, appliances and incidental work not specifically mentioned herein or noted on the Drawings/Documents as being furnished or installed, but which are necessary and customary to be performed under this contract. The Package-1 Centralized Chiller plant, Building internal & External HVAC pipe line works comprise of following:

a. Chillers




b. Pumping system.

c. Cooling towers.

d. Chilled water storage tank.

e. Chiller plant manager

f. Variable Frequency Drives.

g. Automatic balancing valve & thermostats.

h. Expansion tank & Air separator.

i. Chilled water, condensing water, hot water and condensate drain piping inclusive of all valves and fittings.

j. Insulation of pipes, pumps and tanks.

k. Vibration isolators for all Air-Conditioning system like (Chiller, cooling tower, pumps, and Tanks etc)

l. Automatic controls and instruments.

m. Wiring and earthing from MCC panels to various refrigeration, air conditioning and mechanical ventilation equipment, control wiring and interlocking.

n. Cutting holes, chases and the like through all types of non structural walls, and finishing’s for All services crossings, including sealing, frame work, fire proofing, providing sleeves, and Cover plates, making good structure and finishes to an approved standard. No additional Payment shall be made by Owners on this account.

o. Balancing, testing and commissioning of the entire Air-Conditioning system of package -1 works.

p. Test reports, list of recommended spares, as-installed drawings, operation and maintenance manual for the entire Air-Conditioning and Ventilation installation.

q. Training of Owner’s Staff.

All equipments should be support open BAS system with RS-485 Interface & modbus

protocol.



Technical Spec. for Chillers of 79

TECHNICAL SPECIFICATION

FOR

CHILLERS




A - CHILLERS

SCOPE: The scope of this section comprises the supply, erection, testing, commissioning of Energy efficient Water-cooled Screw Chiller, control panel and valve package confirming of these specifications and in accordance with requirement of drawing and of the schedule of quantities. Each unit is completely assembled with all interconnecting refrigerant piping and internal wiring ready for field installation. The refrigerant used shall be Non-CFC refrigerant only (R134a). CAPACITY: The cooling capacity of the chilling packages, operating parameters, flow particulars etc. as shown in Schedule of Quantities (SOQ) WATER-COOLED CHILLER PACKAGE: The chiller package shall consist of two independent Refrigerant circuits each circuit with twin screw compressor, water cooled condenser, flooded cooler, all refrigerant piping & fittings, refrigerant feeding devices, valves, strainer, liquid moisture indicator, suction line insulation, first charge of & gas, starter panel & Micro-processor panel etc., all the components being mounted on welded steel base frame; the base frame, structural profiles & panels made of galvanized sheet steel shall be protected with primary coating & finished with acrylic paint. The machine shall be mounted on vibration isolators. All the chillers will be suitable for dual set point to operate at 6.5 deg C outlet – during normal mode as well as 5.5 deg C outlet temperature during charging mode. The machine mounted Microprocessor panel & star delta panel shall be suitable normal plant room applications and will be as per specifications. 1.0 COMPRESSOR:

Semi-hermetic screw compressors will be specifically designed for R134a & flooded evaporation application, featuring in high efficiency and energy saving. Precisely manufacturing technology and least moving component will be adapted resulting in reliable performance and simple maintenance.

The compressor, with its own capacity regulating electromagnetic valve and slide valve

together with micro-computer controlling system, should be able to adjust load output

automatically according to the requirement of processing, and achieve 10~100%

stepless of precision variable adjustment with minimum power consumption.

Dedicated Flooded Evaporator/Condenser Flooded evaporator/condenser with integral rippled tube will be modified to enhance the initiation of nucleate boiling sites and surface area, improving turbulent flow, resulting in increasingly overall heat transfer coefficient and high unit efficiency. The evaporator and condenser will be characterized by low pressure drops on both the gas side and the water side. The twin refrigerant circuits inside the flooded evaporator




and condenser will be designed with one compressor for each circuit to improve redundancy. The water side for both evaporator and condenser will be common with a partition to segregate the refrigerant circuits. Expansion Process: The electronic valve is adopted to grant the ideal operation of the evaporator in all conditions. The complete flooding of tubes is granted with a sophisticated detection of the refrigerant level in the heat exchangers. The fast processing of the acquired data allow a quick, fluctuation-free regulation, and therefore a highly Accurate adjustment to the swings of load and ambient conditions. Economizer has been adopted to improve unit efficiency.

2.0 Microprocessor Panel:

Inner structure of electrical cabinet, electrical components and circuit layout will be designed according to EN60204-1/IEC204-1 standard. Controlling power will be separated from main power by transformer so as to protect from interfere of electrical current. The power section will use a bar-type distribution system and interlock-door mains isolator for safety and reliability. Each load of compressor will be equipped with its own overload protector, fuse and contactor. Electric elements will be with features of excellent insulation, dust-proof and humidity proof, Electrical system of the unit should be in compliance with EMC code. Convenient application and maintenance Fully computer controlling, menu displaying, self-checking of unit, running, load adjusting and safety protection are all completed by computer control system. Daily operation is only to switch on starter. Multiple refrigerating systems are available for standby equipment. The unit is available of functions such as fault protection, memorizing and alarming. All faults are clearly displayed. Each return circuit has inspection valve with "pump down" function which is convenient for repairing.

Latest Control System

• Friendly interface Fully computer-controlled with no necessity of person duty; Objective user operational panel with multiple windows clearly displaying parameters of different categories; Graphical symbol inputting and displaying with convenient operation; convenient adjusting and setting of data input through menu and fast key combination.




• Control functions of the unit The unit adopts W3000 intelligent microcomputer control system with setting, adjusting and controlling functions, such as: stepless regulation of cooling capacity; inlet/outlet chilled water temperature regulation; Starting, unloading and stopping functions of compressor; starting delay function of compressor; time limiting function of each hour start of the compressor; operation timing function of compressor; and running time balance function of compressor.

• Protecting and alarming functions of unit Self-test when power on to avoid running with problem. Three lever password protection to prevent from mal-operation of persons without authorization. Overload, overheat and overvoltage protection and alarming of compressor; high discharge temperature protection and alarming of compressor. Water antifreeze protection, antifouling protection and alarming of evaporator; Protection and alarming of over high and low chilled water and cooling water temperature; protection and alarming of low water flow; Protection and alarming of low and high pressure of refrigeration system, and alarming of refrigerant leakage. • Fault processing function Automatically functioning protection of acousto-optic alarming, load reducing of compressor, stopping of compressor and stopping of unit according to each fault grade. Automatically identifying fault and instructing fault category. Black box function which automatically record on-site state and all data of fatal fault for providing analyzing data. 3.0 Performance of the unit TESTING:

a) The chiller manufacturer should offer performance test as per Eurovent / AHRI standards.

b) Cost for taking two representatives from client side to witness the chiller performance should be included in the pricing.

c) The IPLV of the chiller at ARI conditions should be less than 0.45 KW / TR. d) The performance of the unit should be shown matching to the software

selection within the tolerances as per the as perEurovent / AHRI standard 550/ 590 system.

4.0 Service back up

The manufacturer of the Chiller should have a full fledged company owned service centre in Chennai and should have factory trained manpower to service such equipment.




5.0 Submittals

a) The Manufacturer, shall prepare and forward all Shop drawings, before supply. These drawings, shall be approved by the Consultant.

b) Along with the Quotation, the Manufacturer, shall submit the complete Electrical, physical and refrigeration data, as per ARI conditions. This data shall also indicate flow of chilled / condenser water.

c) The Chiller Electrical and Plant Manager Panel, shall have provision to receive only XLP Aluminium armored cable.

d) The chiller shall be guaranteed for 12 months, from the date of handing over. e) Kindly indicate, pricing with full duty and under EPCG scheme.



Technical Spec. for Chiller Plant Manager of 79


FOR

CHILLER PLANT MANAGER




The objective of a Chiller Plant Manager

The objective of a Chiller Plant Manager is to manage the operation of Chillers, Water

pumps, Cooling towers and other accessories fitted in a Chiller Plant to suit the loading

requirements of a particular building. The Chiller Plant Manager will control the total

chiller plant such a way that the system will function at high efficiency with minimum

energy consumption.

The Plant Manager will be designed & developed through hardware and software

integration and programmed according to suit the requirements.

Also the Plant Manager has to be designed to suit with the protocols like Modbus,

BacNet etc. and ensures a seamless integration between the Chiller and Plant

Manager. The data can also be transferred smoothly at faster pace.

Technical Features of Plant Manager Chiller Sequencing Control 4 Chillers per group Specified Chiller sequencing order Automatic sequencing based on run time of chillers First on / last off chillers Auto start of standby chiller in case of failure of working chiller Any combination of the above Pump Control Capable of controlling 7 Chilled water pumps. Capable of controlling 7 Condensers water pumps. Motorized Valve Control Capable of controlling upto 7 motorized valves (Chilled water side). Capable of controlling upto 7 motorized valves (Condenser water side). Cooling Tower Fans : ON/OFF Cooling Tower fans Password Protection Alarms of all safeties Building Automation system Integration : With ModBus/BACNET/Lonworks protocol




Annexure – II : Equipment Summary

Chiller Plant Manager (CPM)

Equipment Summary (Water Cooled Chiller)

Sl. No Description

1 Water cooler chillers

2 Primary / Secondary chilled water pumps

3 Evaporator inlet motorized valve

4 Condenser water pumps

5 condenser inlet motorized valve

6 Cooling tower fans

7 Cooling towers motorized fans

Annexure – III: Data Point Summary

Sl. No Plant Manager for Water Cooled Chiller

1 Chiller on / off command

2 Chiller on off status

3 Chillers fault status

4 Chiller current set point

5 Chiller water outlet valve on / off command

6 Condenser water outlet valve on / off command

7 Chiller water outlet valve on / off status

8 Condenser water outlet valve on / off status

Sl. No Primary Chiller Water Pump

1 Pump auto / manual status

2 Pump on / off command




Sl. No Primary Chiller Water Pump

3 Pump operating hours

4 Pump trip status

5 Pump run status

Sl No. Condenser Chiller Water Pump

1 Pump auto / manual status

2 Pump on / off commend

3 Pump operating hours

4 Pump trip status

5 Pump run status

Sl No. Cooling Tower

1 CT Fan auto/ manual status

2 CT Fan on / off status

3 CT Fan run status

4 CT Fan trip status

6 CT Fan inlet / out motorized valve on / off commend

7 CT Common supply header line temperature

Annexure – IV: Plant Manager Sequence Operation Overview on HVAC Automation:- The Plant Manager will sequence all the four chillers on the outlet water temperature. Chiller Plant, Primary Water Pump, Condenser Water Pump & Cooling Tower Sequencing will be done according to the standard specification. Please refer Data Point Schedule, Device Schedule and Standard Sequence of Operation of further details. Chiller Plant Automation:- The Non-Chiller related instruments like Motorized Valve & Temperature Sensor would be connected to Plant Manger Controller to gather information for sequencing. There will be separate software driven program sequences the Chiller.




Chiller Sequencing:- The chiller will be sequenced based on the primary chiller’s chilled water supply header temperature. The supply header water temperature will be maintained to set point by sequencing all the chillers on one by one method. A time sequence will also be implemented for auto re-sequencing of chillers and ancillary equipments like chilled water pumps, condenser water pumps & cooling towers. Start & Stop command and other vital parameters related to chillers will be transmitted via software data points from the chiller microprocessor to the Plant Manager. Chiller Water Pump Sequencing:- The pumps will be sequenced as per the chiller requirement and also can be set to operate for particular time period as per the requirement of customer. Condenser Water Pump Sequencing:- The pumps will be sequenced as per the chiller requirement and also can be set to operate for particular time period per the requirement of customer. Cooling Tower Sequencing:- The cooling tower fan will be sequenced and operate as per the chiller requirement.



Technical Spec. for Cooling Tower of 79


FOR

COOLING TOWER




COOLING TOWERS

SCOPE Scope of this section comprises the supply, erection, testing and commissioning of cooling towers conforming to these specifications and in accordance with the requirements of the Schedule of Equipment. TYPE AND CAPACITY Cooling tower shall be vertical induced draft counter flow type FRP (Fiberglass Reinforced Plastic) cooling tower in cylindrical / square shape. Tower shall be suitable for location in the space shown in the applicable drawings. Tenderers shall confirm that the tower supplied by them can be accommodated in the space shown on the drawings. Cooling tower shall be of the capacity specified in the Schedule of Equipment. CONSTRUCTION Side casing shall be made out of FRP in a number of equal segments with both sides smooth surfaced for minimum resistance to air flow. Each section shall have adequate structural strength to withstand wind velocity of 60 M/second and earthquakes and vibrations. Fan deck shall be and integral part of the side casing. The water basin shall be made out of FRP in a bowl shape with a cylindrical/ square auxiliary suction tank at the bottom. It shall be provided with drain overflow, make-up water connections with quick fill and float valve. The water basin shall have hot dip galvanized suction strainer. The tower supporting structure shall be of hot dip galvanized M.S. LADDER Cooling tower shall be provided with ladder constructed out of hot dip galvanized M.S. tubes. FILLING The cooling tower filling shall be made out of rigid PVC film honeycomb design arranged in a such a manner to facilitate easy replacement. HOT WATER DISTRIBUTION SYSTEM Hot water distribution system shall consist of PVC sprinkler pipes screwed onto a head. Rotating type headers should be mounted on top of stand pipe which is centrally located on the tower. Sprinkler head shall be made out of aluminum alloy and fitted with ball bearings to take care of thrust and radial loads. Sprinkler assembly shall rotate at 5 to 7 rpm by reaction forces from the circulating water.




FANS Fans shall be of propeller type cast aluminum multi-blade aerofoil construction with adjustable pitch. The entire fan assembly shall be statically balanced. Outlet velocity of air shall not be less than 610 meters per minute and fan tip speed shall not exceed 4,750 meters per minute. Fan shall be direct driven. Fan motor shall conform to IP-55 and will be weather proof, adequately closed with externally threaded shaft. Fan motor shall be covered with hot dip galvanized fan guard. SOUND LEVEL Total sound intensity with all fans in operation shall not exceed 75 db. At a distance of 15 meters from the nearest face of tower. TESTING Tower performance curves shall be furnished. Acceptance test to demonstrate the performance of the installed cooling tower shall be conducted in accordance with the current A.S.M.E. power test code for the atmospheric water cooling equipment and test results shall show a tower capacity (computed from the performance curves within +/- 5 % of the specified capacity at the design W.B.)



Technical Spec. for Storage Tank of 79


FOR

STORAGE TANK



Technical Spec. for Storage Tank of 79

The tank size will be 11.35 mt x 6.70 mt x 4.35 mt and will be fabricated out of suitable thickness in Mild Steel ( ~ 15 mm) and will be braced suitably with a robust framework. The tank will be insulated with 50 mm thick external fire retardant insulation with a vapour barrier using aluminium cladding of suitable thickness. The tank will be complete with following connections:

1. Chilled water Charging from Chiller/s at bottom

2. Chilled water Discharging to load from bottom

3. Warm Water to Chiller/s for charging from tank

4. Warm Water In to tank from Load

The figure of Merit i.e. FOM = Quantity of Chilled water Available for cooling / Chilled water storage -will not be less than 85 – 90%. All supply and return water connections will be thru Radial Diffusers to lower entering and leaving water velocity to prevent mixing. The velocity should be less than 0.3 m/sec . The tank will be designed in such a way that the thermocline i.e. stratified region between warm and cold water is as thin as possible and the diffusers configuration and layout will be designed accordingly. Then tank design with all supporting data will be approved by the consultant before commencing the fabrication of tank. The design parameters will be as under: Storage Capacity ~ 800 Ton Hrs i.e. 300000 litrs @ 1.66 usgpm / TR Chilled water Charging – 5.5 deg C Warm Water Return – 14.5 deg C Charging Flow Rate : 616 usgpm



Technical Spec. for Variable Speed Pumping System of 79


FOR

VARIABLE SPEED PUMPING

SYSTEM




VARIABLE SPEED PUMPING SYSTEM This section includes: (1) Variable Speed Pumping Package consists of

a) Individual Components b) Pump Control Panel c) Adjustable Frequency Drive d) Sensor Transmitters e) Sequence of Operation

REFERENCES

A. Hydraulic Institute B. ANSI - American National Standards Institute C. NEMA - National Electrical Manufacturers Association D. UL - Underwriters Laboratories. Inc. E. ETL - Electrical Testing Laboratories F. CSA - Canadian Standards Association G. NEC - National Electrical Code H. ISO - International Standards Organization I. IEC - International Electro-technical Commission

SUBMITTALS Submittals shall include the following:

a) System summary sheet b) 2. Sequence of operation c) Shop drawing indicating dimensions, required clearances and location and size of

each field connection d) Power and control wiring diagrams e) System profile analysis including variable speed pump curves and system curve.

The analysis shall also include pump, motor and AFD efficiencies, job specific load profile, staging points, horsepower and kilowatt/hour consumption.

f) Pump data sheets Submittals must be specific to this project. Generic submittals will not be accepted. QUALITY ASSURANCE The pumping package shall be assembled by the pump manufacturer. An assembler of pumping systems not actively engaged in the design and construction of centrifugal pumps shall not be considered a pump manufacturer. The manufacturer shall assume "Unit Responsibility" for the complete pumping package. Unit responsibility shall be defined as responsibility for interface and successful operation of all system components supplied by the pumping system manufacturer. The manufacturer shall have a minimum of 20 years experience in the design and construction of variable speed pumping systems.




All functions of the variable speed pump control system shall be tested at the factory prior to shipment. This test shall be conducted with motors connected to AFD output and it shall test all inputs, outputs and program execution specific to this application. The manufacturer shall be fully certified by the International Standards Organization per ISO 9001. Proof of this certification shall be furnished at time of submittal. Bidders shall comply with all sections of this specification relating to packaged pumping systems. Any deviations from this specification shall be bid as a voluntary alternate clearly defined in writing. If no exceptions are noted, the supplier or contractor shall be bound by these specifications. ACCEPTABLE MANUFACTURERS Subject to compliance with the specifications, the following manufacturers shall be acceptable:

1. ITT Bell & Gossett 2. Aurora Pump Co. 3. Armstrong

MANUFACTURED UNITS Furnish and install as shown on the plans a Variable Speed Pumping System as manufactured by ITT Bell & Gossett or Arora Pump Co. The control system shall include as, a minimum, the programmable logic pump controller, adjustable frequency drive(s) and remote sensor/transmitters as indicated on the plans. Provide additional items as specified or as required to properly execute the sequence of operation. The variable speed pump logic controller, adjustable frequency drive(s) and remote sensor/transmitter(s) shall be supplied as individual components to the job site. Pump logic controller, adjustable frequency drives, sensor/ transmitters and related equipment shall be installed by the contractor’s mechanical team as shown on the plans. Line voltage power wiring shall be installed by the contractor’s electrical team as shown on the field connection drawings and wiring diagrams supplied with the pumping package. Low voltage (24 VDC and 115 VAC) wiring shall be installed by the contractor’s electronic team as shown on the field connection drawings and wiring diagrams supplied with the pumping package COMPONENTS Pump Logic Controller The Technologic pump logic controller assembly shall be listed by and bear the label of Underwriter's Laboratory, Inc. (UL). The controller shall meet Part 15 of FCC regulations pertaining to class A computing devices. The controller shall be specifically designed for variable speed pumping applications.




The controller shall function to a proven program that safeguards against damaging hydraulic conditions including: motor overload pump flow surges hunting end of curve The pump logic controller shall capable of accepting 16 analog inputs from zone sensor/transmitters indicated on the plans. The controller shall scan each analog input a minimum of once every 500 milliseconds. It will then select the analog signal that has deviated the greatest amount from its setpoint. This selected signal will be used as the command feedback input for a hydraulic stabilization function to minimize hunting. Each input signal shall be capable of maintaining a different set point value. The pump controller shall have additional analog input for a flow sensor. This input shall serve as the criteria for the end of curve protection Algorithm. The controller shall be field expandable to control up to 6 pumps in parallel and accept up to 16 analog inputs. This modification shall consist of nothing more than the addition of analog input modules and shall not require the use of special tools or factory reprogramming. Controllers not capable of being expanded to this level will not be acceptable. The hydraulic stabilization program shall utilize a proportional-integral-derivative control function. The proportional, integral and derivative values shall be user adjustable over an infinite range. The pump logic controller shall be self prompting. All messages shall be displayed in plain English. The operator interface shall have the following features:

a. Multi-fault memory and recall b. On-screen help functions c. LED pilot lights and switches d. Soft-touch membrane keypad switches.

The readout shall be two lines of forty 0.50" brightly lit fluorescent characters capable of displaying the following values:

a. Differential pressure in PSIG b. Pressure in PSIG c. Flow in GPM d. Temperature in degrees F or C e. Differential temperature in degrees F or C f. BTU calculation g. Kilowatt consumption h. Tons per hour calculation i. Wire to water efficiency calculation

The following communication features shall be provided to the BAS:

a. Remote system start / stop




b. Failure of any system component c. Process variable d. AFD speed

ADJUSTABLE FREQUENCY DRIVE The adjustable frequency drive(s) shall be pulse width modulation (PWM) type, microprocessor controlled design. The AFD, including all factory installed options, shall have CSA approval. Enclosure shall be NEMA 1 ventilated for installation as a wall mounted or free-standing unit, depending on the amp rating. AFD shall utilize a diode bridge rectifier to convert three phase AC to a fixed DC voltage. Power factor shall remain above 0.95 regardless of speed or load. AFDs employing power factor correction capacitors shall not be acceptable. Insulated gate bipolar transistors shall be used in the inverter section to convert the fixed DC voltage to a three phase, adjustable frequency, AC output. A DC line reactor shall be provided to minimize harmonic and current distortion of the input power line. The following customer modifiable adjustments shall be provided:

a. Accel time: 0.1 to 1800 seconds b. Decel time: 0.1 to 1800 seconds c. Minimum frequency: 0 HZ d. Maximum frequency: 120 HZ e. Analog input filter: 0.1 to 10 seconds f. Analog outputs: 10 to 1 gain g. Volts / Hertz ratio

Speed reference signal shall be customer selectable for 0-10 VDC or 4-20 mA. The AFD shall be suitable for elevations to 3300 feet above sea level without derating. Maximum operating ambient temperature shall not be less than 104 degrees F. AFD shall be suitable for operation in environments up to 95% non-condensing humidity. The AFD shall be capable of displaying the following information in plain English via a 40 character alphanumeric display:

a. Frequency b. Voltage c. Current d. Kilowatts per hour e. Fault identification f. Percent torque g. Percent power h. RPM




SENSOR / TRANSMITTERS Provide 8 Nos. field mounted differential pressure sensor transmitter(s) as indicated on the plans. Each sensor / transmitter shall transmit an isolated 4-20mA dc signal indicative of process variable to the pump logic controller via standard two wire 24 DC system. Unit shall have stainless steel wetted parts with two 0.25" male NPT process connections. It shall be protected against radio frequency interference and shall have a watertight, NEMA 4 electrical enclosure capable of withstanding 2000 PSI static pressure with a 0.5" NPT conduit connection. Accuracy shall be within 0.25% of full span. SEQUENCE OF OPERATION FOR DO The system shall consist of a Technologic pump logic controller, multiple pump/AFD sets with manual and automatic alternation and pump staging. The pumping system shall start upon the closure of customer's contact when the pump logic controller Mode of Operation selector switch is in the REMOTE position. When the pump logic controller selector switch is in the LOCAL position, the pumping system shall operate auto-matically. Sensor/transmitters shall be provided as indicated on the plans. Each sensor/transmitter shall send a 4-20mA signal to the pump logic controller, indicative of process variable condition. The pump logic controller shall compare each signal to the independent, engineer/user determined set points. When all set points are satisfied by the process variable, the pump speed shall remain constant at the optimum energy consumption level. The Technologic pump logic controller shall continuously scan and compare each process variable to its individual set point and control to the least satisfied zone. If the set point cannot be satisfied by the designated lead pump, the pump logic controller shall initiate a timed sequence of operation to stage a lag pump. The lag pump shall accelerate resulting in the lead pump(s) decelerating until they equalize in speed. Further change in process variable shall cause the pumps to change speed together. When the set point criteria can be safely satisfied with fewer pumps, the Technologic pump logic controller shall initiate a timed destage sequence and continue variable speed operation. As the worst case zone deviates from set point, the pump logic controller shall send the appropriate analog signal to the AFD to speed up or slow down the pump/motor. In the event of a system differential pressure failure due to a pump or AFD fault, the Technologic pump logic controller shall automatically start the next variable speed pump/AFD set in sequence and continue variable speed operation.




In the event of the failure of a zone sensor/transmitter, its process variable signal shall be removed from the scan/compare program. Alternative zone sensor/transmitters, if available, shall remain in the scan/compare program for control. The zone number corresponding to the failed sensor/transmitter shall be displayed on the operator interface of the pump logic controller. In the event of failure to receive all zone process variable signals, all AFDs shall maintain 100% speed, reset shall be automatic upon correction of the zone failure. PUMP or AFD fault shall be continuously scrolled through the display on the operator interface of pump logic controller until the fault has been corrected and the controller has been manually reset.



Technical Spec. for Pumps of 79


FOR

PUMPS




PUMPS SCOPE The scope of work under this Section comprises the supply, erection, testing and commissioning of pumps conforming to the specifications of the type and capacities specified in the Schedule of Equipments. Pumps shall be suitable for the purpose they are intended. CONSTRUCTION Pumps shall be as per I.S. 1520/1960 and shall be of the following construction : ________________________________________________________________ Pump Horizontal Monoblock ________________________________________________________________ 1. Casing Cast Iron/Cast Steel

2. Impeller Bronze

3. Shaft High Tensile Steel

4. Bearings Heavy Duty Ball/Roller Bearings

5. Base Plat Cast Iron/Fabricated M.S.

6. Flanges To I.S.S. 1536/1960

7. Packing Graphited Asbestos

8. Maximum Speed 450 R.P.M. Horizontal Split Casing Pump 900 R.P.M Monobloc Pumps

9. Driver SPDP Motor

10. Starter As per Schedule of Equipment ________________________________________________________________ Driver ratings shown are only tentative and Tenderers shall select their drivers at least 5% in excess of the maximum B.H.P. of the pump plus transmission lossers, if any. ACCESSORIES AND FITTINGS The following accessories shall be provided with each pump among other standard accessories required.

a) Coupling guard. b) Lubrication fittings and seal piping. c) Test and/or air vent.

INSTALLATION Pump shall be installed as per manufacturers recommendations. Pump set shall be mounted on concrete block which in turn is mounted on machinery isolation cork or any other equivalent vibration isolation fittings. The concrete foundation will be made by the Owner to the drawings and specifications of the Contractor and the isolation pads shall




be supplied by the Contractor. The Contractor shall, however, ensure that the foundation bolts are correctly embedded. Pumps sets shall preferably be factory aligned. However, necessary site alignment shall be done by competent persons. Before the foundation bolts are grouted and the couplings bolted, the bed plate levels and alignment results shall be submitted to the Engineer. TESTING Tenderers shall submit the performance curves of the pumps supplied by them. They shall also check the capacity and total head requirements of each pump to match his own piping and equipment layout. On completion of the entire installation, pumps shall be tested, wherever possible, for their discharge head, rate of flow and B.H.P. and test results shall be furnished as per section - 'TEST READINGS'. Where it is not possible, at least the discharge head and B.H.P. (as measured on the input side) shall be field tested. Test results shall correspond to the performance curves. Tenderers shall furnish the required testing instruments and arrange for their connection as required. PAINTING After complete installation and testing of pumps, accessories and fittings shall be given two coats, three mils each of approved finishing paint. The Pumps will be factory painted with touch-up after installation, if required.



Technical Spec. for Pressurized Expansion Tank of 79


FOR

PRESSURIZED EXPANSION

TANK



Technical Spec. for Pressurized Expansion Tank of 79

PRESSURIZED EXPANSION TANK DESCRIPTION Expansion tank as per ASME standard, with pre-charged bladder-type pressure vessel. The tank shall be capable to absorb expansion forces of heating / cooling system water, while maintaining proper system pressurization under varying operating conditions. The heavy duty bladder shall contain water thereby eliminating tank corrosion and water logging problems. CONSTURCTION System Connection: Forged Steel Shell: Carbon Steel Bladder: Heavy Duty Butyl Rubber Design & Constructed Per ASME Section VIII, Division 1 MAXIMUM OPERATING LIMITS Maximum Design Pressure: 125 psi (862 kPa) Maximum Operating Temperature: 240 ˚F (115˚C) TYPICAL SLPECIFICATIONS Install pre-charged steel expansion tank with replaceable heavy duty Butyl rubber bladder. The tank shall have x 1" or 1½" NPT system connection, ¾" NPT drain, and a .302" – 32 charging valve connection to facilitate the on-site charging of the tank to meet system requirements. The tank shall be fitted with lifting rings and a floor mounting skirt for vertical installation. The tank must be constructed in accordance with Section VIII of the ASME Boiler and Pressure Vessel Code and stamped 125 PSI (862 kPa) working pressure.



Technical Spec. for Piping of 79


FOR

PIPING




PIPING SCOPE Scope of this Section comprises the supply and laying of all pipes required for this project. The Engineer's drawings show the general layout of the piping and they are not meant as working drawings. On the award of the contract, the Tenderers shall prepare his own detailed working drawings. CONDENSER, CHILLED & COIL CONDENSATE DRAIN WATER PIPING All piping laid indoors shall be as follows : _______________________________________________________________

_ Pipe Size Material Joints & Sealing Fitting Material______ 15 mm - Welded Pipe i) Welded i) - 300 mm B S 534/1984 ii) Slip-on ii) 3 mm 3 ply rubber insert _______________________________________________________________

_ 350 mm & Welded Pipe i) Welded i) - Over B S 534/1984 ii) Slip-on ii) 3 mm 3 ply rubber insert _______________________________________________________________

_ Flanges shall be to I.S. 1536/1960. All piping shall be black steel unless otherwise stated. Pipes shall be new and from standard manufacturers. Pipes shall be given one primary coat of red oxide paint before being installed. Pipes shall be sloping towards drain points. Fittings shall be new and from standard manufacturers. Fittings shall be malleable casting of pressure ratings suitable for the piping system. Fittings used on welded piping shall be of the wieldable type. Flanges shall be new and from standard manufacturers. Supply of flanges shall include bolts, washers, etc. as required. Tee-off connections shall be through reducing tees, wherever possible. Otherwise ferrules welded to the main pipe shall be used. Drilling and tapping of the walls of the main pipe shall not be resorted to. All equipment and valve connections or connections to any other mating pipes, shall be through unions/screwed flanges upto 50 mm dia. and flanges (welded or screwed for G.S.) for larger dias. or as required for the mating connection. All welded piping is subject to the approval of the Architect / Engineer and sufficient number of flanges and unions shall be provided as required under 7.2.6. Valves shall be provided as shown in the applicable drawings conforming to the following specifications :




________________________________________________________________

Size Construction Ends _______________________________________________________________

_ 12mm to 50 mm Ball Valves i) Screwed Female 50mm & over Butterfly Valve i) Flanged _______________________________________________________________

_ Check valves shall be provided as shown on the drawings and conform to the following specifications :-

________________________________________________________________

Size Construction Ends

________________________________________________________________

12 mm to 65 mm Gun Metal i) Screwed Female 65 mm & over Gun Metal/C.I. ii) Flanged

________________________________________________________________

Swing check valves shall normally be used in all water services. Lift type valves may be used in horizontal runs. Air release and clean out plugs shall be provided and valves shall be suitable for 21 kg/sq.cm. test pressure. Strainers shall be preferably of the approved 'Y' type with C.I. or fabricated steel bodies designed to the test pressures specified for the gate valves. Strainers shall have removable bronze screen with 3 mm perforations and a permanent magnet. Strainers shall be provided with flanges or threaded sockets as required. They shall be designed so as to enable blowing out accumulated dirt and facilitate removal and replacement of all screen without disconnection of the main pipe. All strainers shall be provided with equal size isolating gate valves with rising spindles so that the strainer may be cleaned without draining the system. Strainers shall be provided on the suction side of each pump; and on inlet side of the heat exchange equipment. PIPING INSTALLATION The drawings indicate schematically the size and location of pipes. Pipe runs and sizes may, however, be changed to meet the site conditions. The Contractor, upon award of the work, shall prepare detailed working drawings, showing the cross section, longitudinal sections, details of fittings, locations of isolating, drain and air valves, etc.




They must keep in view the specific openings in buildings and other structures through which the pipes are designed to pass. Piping shall be properly supported on or suspended from stands, clamps, hangers, etc. as specified and as required. The Tenderer shall adequately design all the brackets, saddles, clamps, hangers, etc. and be responsible for their structural integrity. Pipe supports shall be of steel, adjustable for height and prime-coated with rust preventive paint and finish-coated black. Where pipe and clamp are of dissimilar material, a gasket shall be provided in between. Spacing of pipe supports shall not exceed the following: Pipe (mm) Spacing (Mtr.) 3 to 12 1.22 19 to 25 1.83 32 to 150 2.44 150 and above 3.05 Pipe hangers shall be fixed on walls and ceilings by means of metallic rawl plugs or approved shear fasteners. Vertical risers shall be parallel to walls and column lines and be straight and plumb. Risers passing from floor to floor shall be supported at each floor by clamps or collars attached to pipe and with a 12 mm thick rubber pad or any resilient material. Where pipes pass through the terrace floor, suitable flashing shall be provided to prevent water leakage. Risers shall also have a suitable elbow or concrete pipe support at the lowest point. Pipe sleeves of 50 mm larger diameter shall be provided wherever pipes pass through walls and the annular space filled with felt and finished with retaining rings. Cut-outs required in the floor slab for taking the various pipes are indicated in the drawings. Tenderers shall carefully examine the cut-outs provided and clearly point out wherever the cut-outs shown on the drawings do not meet with the requirements and indicate if any additional cut-outs are required. Piping work shall be carried out with minimum disturbance to the other work on the site. A programme of work shall be chalked out in consultation with the Engineer. Details of clamps, anchors, etc. shown in the various drawings are only tentative and the Contractor shall make sure that the clamps are adequate for the pipe support. Piping layout shall take due care of expansion and contraction in pipes. All pipes using screwed fittings shall be accurately cut to the required sizes and threaded in accordance with I.S. 554/1955 and burrs removed before laying. Open ends of the piping shall be blocked as the pipe is installed to avoid entrance of foreign matter. Wherever reducers are to be made in horizontal runs, eccentric reducers shall be used if the piping is to drain freely; in other locations, concentric reducers may be used.




Air valves shall be provided at all high points in the piping system for venting. Valves shall be of the double float type with G.M./C.I. body, vulcanite balls, rubber seating, etc. Air valves shall be of the sizes specified and shall be associated with an equal size gate valve with rising spindle. Mains Air Valves Upto 100 mm 25 mm 100 mm to 300 mm 38 mm Over 300 mm 50 mm Discharge from the air valves shall be piped through an equal sized G.S. pipe to the nearest drain or floor waste. Drains shall be provided at all low points in the piping system and shall be of the following sizes: Mains Drain Upto 300 mm 25 mm Over 300 mm 38 mm Drains shall be provided with gate valves of equal size with rising spindle. Drains shall be piped through equal size G.I. pipe to the nearest drain or floor waste. Piping shall be pitched towards drain points. PRESSURE GAUGES Pressure gauges shall be not less than 150 mm dia. dial and of appropriate range and be complete with shut off gauge cocks, etc. duly calibrated before installation. Pressure gauges shall be provided at the following locations a) Supply and return of chillers and condensers. b) Suction and discharge of pumps. c) Inlets and outlets of heat exchangers. d) Supply and return of all water. Care shall be taken to protect pressure gauges during pressure testing. THERMOMETERS Thermometers shall be either 150 mm dia. dial direct reading industrial type of appropriate range duly calibrated before installation. Thermometers shall be installed in separable wells. Thermometers shall be provided at the following locations:




a) Dial type thermometers on supply and return of chillers and condensers. b) Dial type thermometers on suction and discharge of pumps. c) Dial type thermometers on inlet and outlet of heat exchangers. EXPANSION TANK The Expansion Tank of adequate size shall be provided. The bottom of the tank shall be not less than 0.6 metre above the highest point of the chilled water system. PVC tanks may be provided unless otherwise stated. Tanks shall be insulated and finished with aluminium cladding and complete with float valve, gauge glass, drain, overflow, make-up water connections, ball valves and vent piping. TESTING All piping shall be tested to hydrostatic test pressure of at least one and half times the maximum operating pressure, but not less than 7 kg/sq.cm. for a period of not less than 24 hours. All leaks and defects in joints revealed during the testing shall be rectified to the satisfaction of the Engineer. Piping repaired subsequent to the above pressure test shall be re-tested in the same manner. Systems may be tested in sections and such sections shall be securely capped. The Engineer shall be notified well in advance by the Contractor of his intention to test a section or sections of piping and all testing shall be witnessed by the Engineer or his authorised representative. The Contractor shall make sure that proper noiseless circulation of fluid is achieved through all coils and other heat exchange equipment in the system concerned. If proper circulation is not achieved due to air bound connections, the Contractor shall rectify the defective connections. He shall bear all the expenses for carrying out the above rectifications, including the tearing up and re-finishing of floors, walls, etc. as required. No insulation shall be applied to piping until after the completion of the pressure testing to the satisfaction of the Engineer. The Contractor shall provide all materials, tools, equipment, instruments, services and labour required to perform the test and to remove water resulting from cleaning and/after testing. PAINTING After all uninsulated piping has been installed, tested and run for at least ten days for eight hours each, the piping shall be given two finish coats, 3 mils each, as per the colour indicated by the Engineer. The direction of flow of fluid in the pipe shall be visible marked in white arrows.



Technical Spec. for Insulation of 79


FOR

INSULATION




INSULATION

SCOPE The scope of work covers thermal insulation for: a) Cold Insulation i) pipes ii) ducts MATERIAL Following materials shall be used: a) Cold Insulation For Ducts 1) Closed cell chemically crossed linked polyethylene foam insulation having a thermal

conductivity not exceeding 0.0329 Kcal/hr-sq.mt-deg C/meter. 2) The density of material shall not be less than 34kg/cu.mt., capable to operate in the

range of 40–80 deg C to +110degC. 3) Insulation shall be provided with factory applied self-sticking adhesive on one side AIR DUCT INSULATION Duct located INDOOR spaces shall be insulated to the following thickness:

Location Layer Thickness Material a) Non Air Conditioned

space i) Cold Supply duct ii) Return duct

One One

13mm 13mm

Supreme / Supreme /

Duct insulation for OUTDOOR Spaces shall be as follows:

Material Thickness

(mm) Layers

Expanded polystyrene / Phenolic foam Polyurethane

50 25

One

Outdoor insulation shall be applied as follows: a) Clean the duct surface and apply two coats of hot bitumen at 1.5 kg/sqm for two

coats. b) Stick self adhesive insulation holding pins to all ducts over 400 wide. c) Stick insulation slabs & hold at 1000 mm centre with 1.0 mm dia galvanized steel

wire or PVC strapping & blind the surface with hot bitumen at 1.5 kg/sqm. Seal the joints with approved sealant.

d) Wrap 500g polythene faced Hessian & sealed with hot bitumen. e) Apply 2 coats of FOSTER ‘Sealtas’ or equivalent with MAST-A-FAB membrane

between coats so that a total thickness of 3mm is achieved.

Boiler Flues, Engine Exhaust pipes shall be insulated with 48 kg/cum unbonded fibre glass with galvanized wire netting on one side. The flue/pipe shall be thoroughly cleaned with wire brush to remove all milscale and painted with one coat of bitumastic paint. The




wool blankets 100mm thick shall be applied with the wire netting on the out side. The insulation shall be held in position by lacing with 1.0mm dia galvanized steel wire and covered with fibre glass tissue with 75mm overlapping. The finished surface shall be clad with 0.50mm thick aluminum sheets with 50mm overlap and fixed with self-tapping No. 8 sheet metal screws. b) Cold Insulation For Pipies The material used shall be tube form closed cell elastomeric Nitrile rubber foam for water pipes, suction lines, condensate drain pipes, while for sheet metal ducting, flat form closed cell elastomeric foam structure flexible thermal.

Elastomeric tubing (Polybond/Armaflex) self-extinguishing CFC free with a thermal conductivity of not more than 0.03w/m Degree C at 24C and suitable for a service temperature.

Cold pipe insulation shall be selected as follows for INDOOR spaces.

Application Thickne

ss (mm)

Layer (No.)

Pipe (mm dia)

Material

i) Chilled water supply & return within building

25

32

One

One

Upto 100mm Dia 125mm above

Polybond/Armaflex tube Polybond/Armaflex tube

ii) ii) Chilled water supply & re return outside building

50 One

All Expanded Polysterene moulded pipe section – 20 kg density

R ii) Refrigerant suction a) 3 to 5 °C suction b) -20 °C suction

13 16 25

One One One

Upto 25 Over 25 All sizes

Polybond/Armaflex - do – - do -

i) Coil drains a) 10 °C b) 3/5 °C c) -20 °C

9 13 25

One One One

-- -- --

- do – - do – - do -

i) TFA Air PVC Pipe

9 One Upto 200mm Dia

Polybond/Armaflex tube

Polystyrene / Phenolic foam pipe insulation shall be carried out with preformed pipe sections. The surface of the pipe shall be rendered dry and clean. Hot bitumen shall be applied uniformly at the rate of 1.5 kg/sqm. A similar layer of bitumen is applied on the inside surface and on the edge of the pipe section. All joints shall be staggered and sealed with Foam Seal. Polythene faced Hessian shall be wrapped and fixed in hot bitumen with an over lap of 75mm. Elastomeric insulation shall be in tube form and applied as follows:




i) Clean the pipe surface thoroughly. ii) Apply synthetic bonding sealant recommended by the manufacturers. iii) Slip the tubing or slit the tube and snap of the pipe. iv) Seal the joints with approved sealant.

OUTDOOR piping insulation shall generally follow the procedure for the INDOOR but the cement sand plaster shall be finished with 1.0mm coat of ‘sealfas’ coating. UNDERGROUND insulated pipes shall be protected with a 2.0mm coat of ‘Sealfas’ coating. EQUIPMENT, VESSELS & TANKS Insulation of Pumps for cold applications shall be the same as for the connected pipes. The pump surface shall be thoroughly cleaned and painted with one coat of bituminous paint. Hot bitumen is applied at 1.5 kg/sqm and the insulation slabs are cut and stuck to covered the entire surface. All joints shall be sealed and the insulation covered with 20 mm x 0.63 mm galvanized steel wire mesh and covered with a thick layer of hot bitumen and then clad with 0.8 mm aluminum sheet using sheet metal screws. Pump insulation shall be carried out in such a manner that pump split sections (Wherever applicable) or pipe connections could be disconnected without disturbing the pump insulation. All vessels and tanks shall be insulated according to the connected pipe. All vessels & tanks shall be thoroughly cleaned with wire brush and rendered free of milscale. Apply the surface with hot bitumen at 1.5 kg/sqm and stick the rigid insulation (in segments for cold insulation) holding it in position with 20mm x 0.63 mm galvanized wire mesh. Apply hot bitumen at 2.5 kg/sqm over the finished surface and wrap it with 6mm tar felt with 50mm over lapping. Retain the tar felt with 1 mm galvanized steel wire and finish with 0.63 thick aluminum cladding. UNDER DECK ROOF INSULATION Under-deck insulation shall be carried out using 13mm INSUshiled, FR, closed cell chemically polythylene insulation material. The normal density of the material shall be 33kg/m3 , The Material shall conform to BS 476 Part 7 . OVER DECK ROOF INSULATION WITH EXPANDED POLYSTYRENE

i) Clean the surface of the roof slab thoroughly. ii) Spread industrial air blown bitumen 85/25 conforming to IS 702-1961 uniformly

on the concrete surface at the rate of 2.5 kg/sqm. iii) Press heavy density (20 kg/cubic mt.) polystyrene slabs of 50mm thickness on to

the surface after blinding the polystyrene slab with hot bitumen at 1.5 kg/sqm. Expanded polystyrene should have a conductivity of not more than 0.03 Wm°C at 10 deg. C mean temperature.

iv) Seal all the joints between adjacent slabs with bitumen and cover the surface with hot bitumen at 2.5 kg/sqm and lay 500 gauge polyethylene sheet with 100 mm over lapping.

v) Lay 20 mm thick sand cement plaster (ratio 1:4) over 22 gauge 20 mm galvanized chicken wire mesh.




vi) Build cement mortar fillet all round at the junction of the roof slab and the parapet walls. This is done by construction a fillet of cement plaster at the junction of roof slab and parapet walls.

INSULATION OF CAVITY FLOOR

i) Clean the surface thoroughly and make it free from dust and other particles. ii) Place rigid Phinolic foam sheets 35 Kg/m3 density, 30 mm thick on the floor in

between the false floor supports. For vertical surfaces apply Foster / CPRX compound to the underside of the pre laminated board and press the same in position.

iii) Seal the joints between adjacent slabs with aluminum tape 50 mm wide. iv) Cover the floor insulation with 20 mm thick sand cement plaster (Ratio 1:4) over

22 gauge galvanized chicken wire mesh. v) Give two coats of suitable polyurethane paint to render the surface dust proof.

DUCT LINERS All discharge and return ducts connected to Air handling units and fan coil units shall be acoustically insulated for distance as shown: Duct Acoustic Lining material shall be open cell, non-fibrous material foam "INSUmelfoam" in 9mm thickness to be covered with 7mil 10x10 mesh glass cloth . The density of of foam shall be 8-11kg/cu. Open cell melamine foam shall quality the requisite fire characteristics for class '0' as per BS 476 parts 6&7. WALL & CEILING ACOUSTIC Walls and ceilings shall be acoustically insulated wherever shown on drawings or as required by the Engineer-in-charge. The wall/ceiling surface shall be cleaned and 50 x 50 x 0.8 mm G.I channel frame work of 600 x 600 mm fixed on the surface using wooden gutties and brass screw. 50 mm resin bonded fibre glass shall be cut to size and position within the frame work and held with 1.0 mm galvanized steel wire at 300 mm intervals. Cover the entire insulation with 0.8 mm thick aluminum sheets with 3 mm perforations at 5 mm staggered centers. The sheet shall be neatly cut and the edges reinforced with a 20 mm sheet fold and made into 995 x 995 mm panels. The panels shall be fixed on the frame work using cheese headed No. 8-20 mm sheet metal screws at 500 mm centers. Where the insulation thickness is 100mm. the framing channels shall be 50 x 100 and the remaining shall be as specified above. RETURN AIR ACOUSTIC BOXES The return air acoustic boxes wherever required shall be generally as shown on drawings and the acoustic insulation shall be applied as for duct lining. AIR TIGHT DOORS Air tight doors for AHU rooms shall be double leaf hollow steel doors of 50mm thick filled with honey comb fill. The doors shall be fixed with 3 point heavy duty hinges, mounted on a steel frame. The door shall have double acoustic seals on three sides and a single seal at the centre point. Doors shall have positive pressure latch with adjustable strike and push rod release. The door and frame shall be fabricated from combination of 14/16




SWG mild steel sheets and given two coats of grey oil paint over two coats of primer. The door performance shall be such that the leakage is not more than 10 cfm/100 sqft face area. MODE OF MEASUREMENT All duct insulation shall be measured on the basis of the duct prime surface area and excluding all openings for grilles, diffusers but including all flanges, dampers etc. In case of bends, tapers etc. the duct prime surface shall be determined on the basis of average dimensions. All pipe insulation shall be in linear measure along the centre line of the pipe over all fittings, excluding flanges and valves. Each independent flange insulation shall be measured as 300 mm equivalent length of piping. Insulation of flanges associated with equipment (equipment and mating flange) and valves (flanged or screw-ended valves with flanged tail pipes) shall form part of the valve or equipment. Insulation of valves together with the flanges as above shall be measured as 600 mm long equivalent length of piping. All pump insulation shall be measured as 1500 mm long piping of diameter equal to the suction size of the pump and this shall include the cost of insulation of the suction and discharge flanges. All equipment and roof and floor insulation shall be measured on the prime surface of the area to be insulated.



Technical Spec. for Energy Valves of 79


FOR

ENERGY VALVES




Energy Valve

Tender Specifications For pressure independent control valves from sizes 65mm to 150mm

� Energy Valve shall be rotary type with a characterizing disc to provide an equal percentage flow characteristics mounted in return water line of AHU.

� Energy Valve shall be Electronic Pressure Independent control Valve that measures coil energy using electromagnetic flow sensor with no moving parts and temperature sensor in supply and return water line.

� Valves shall be with flanged ends for sizes 65mm and above as per ISO7005-2. � The valve should be able to operate with Hot/Cold normal water and Upto 50%

Glycol-water mix media between -10/2…120 oC. � The nominal pressure of the valve shall be 1600 kPa (pressure rating PN16) � Rangeability of flow should be atleast 40:1 for the entire range of operation. � Energy valve should consist of self-regulating valve and balancing valves and

associated balancing should not be required on pipeline where Energy valves are installed.

� The valve should give a constant flow volume with various differential pressures in the range of 35…350 kPa. The differential pressure should not exceed 340 kPa. Closing pressure shall be 690KPa.

� Valves should be maintenance free and should not include replaceable cartridges.

� The accuracy of the flow sensor should be +/-6% and inlet length should be 5 times the nominal diameter.

� The control valves shall be with proportional actuators. � The rotary actuator shall be thermally decoupled with the control device. � The control valve should be operated by rotary electric actuator for maintenance

free operation. � The actuator should control by modulating and drive the ball of the valve, the

throttling device to the opening position command by the control signal flow requirement.

� The degree of protection of actuator shall be IP 54. � Actuators shall have push button for manual operation of the actuator by

disengaging the gears. � The material of construction for valve body shall be Cast Iron/Ductile Iron and for

ball and characterizing disc shall be SS. � The supply voltage for the actuator should be 24 V AC/DC or 230V. � Actuator shall have built in BACnet Application Specific Controller (B-ASC) � Actuator shall be with open protocol like Bacnet/IP for soft integration to BMS. � Actuator shall be with integrated web server for remote operation using Internet

Protocol Version 4 (TCP/IPv4)

� The parameterisation can be carried out simply and rapidly through the integrated web server.

� Actuator shall be with Delta T Manager that monitors coil performance and optimizes available energy to the coil.

� Actuator shall accept 0-10Vdc signal from controller and provide position feedback signal of 0-10Vdc.

� Actuator shall have inbuilt memory to store coil performance data and energy usage of last thirteen months




BOQ Descriptions The following section describes the energy valve to be included in the BOQ

� XXX mm, 2 way, Ball type, pressure independent control valve with flanged ends ISO7005-2, flow capacity of XX.XX l/s, PN16, equal percentage valve characteristic, GGG50 ductile iron body with stainless steel ball. Non spring return rotary type modulating actuator, torque XX Nm, running time 90s, close-off pressure 690 kPa, power supply 24 V AC/DC, control signal 0.5-10 V DC, feedback signal 0.5-10 V DC, with BACnet-MSTP / Bacnet-IP / TCP-IP connectivity and IP54 protection.

Installation guidelines For piping contractor

� The valve and actuator can be installed verticaly or horizontaly but should not be installed with the actuator facing downwards

� The pipe should have a straight run of 5D upstream to the valve � A ½“NPT female union should be welded in the inlet pipe to the coil for fixing the

thermowell � The valves are flanged to ISO 7005-2 standards � The valve and actuator assembly should be installed indoors

For control contractor

� The control contractor shall make provision for 24VAC/DC for operation of the actuator

� The control signal shall be 0.5-10VDC and feedback signal shall be 0.5-10VDC � The communication shall be using industry standard open protocol – BACnet

MS/TP Product models



Technical Spec. for Electrical Installation of 79


FOR

ELECTRICAL INSTALLATION




ELECTRICAL INSTALLATION SCOPE Scope of this section comprises the supply and installation of all electrical equipment such as motors, motor control centres, starters, cables, interlocks, etc. as required. CODES, STANDARDS AND STATUTORY REGULATIONS Codes, standards and statutory regulations to be used for design and constructions are given below. In general all equipment, material as well as design and constructions shall be in accordance with the latest issues of Indian and relevant standards currently in force. The installation shall be carried out in accordance with the Indian Electricity Act and Rules. ELECTRIC SUPPLY SYSTEM/RATED VOLTAGE 415 volts, 3 phase, 4 wire, 50 Hz with solidly grounded neutral. Variation in electric supply under which motor shall be operated continuously without any adverse effect will be as follows : a) Voltage : +/- 5% b) Frequency : +/- 5% variation c) Any combination of voltage and frequency. EQUIPMENT AND MATERIALS All equipment shall be as per specifications, and/or drawings supplied along with the tender documents. Equipment/materials shall be suitable for local climatic conditions as specified in the tender. All equipment shall be of robust construction. Enclosure of equipment shall be dust, damp and vermin proof. Equipment for outdoor installation shall have weather proof enclosures requiring no further protection by the purchaser. APPROVAL The Contractor shall be responsible for obtaining approval of drawings from statutory/local authority as required. MOTOR CONTROL CENTRE Motor control centre shall consist of incoming switch fuse units/isolator and a starter mounted inside the wall or floor mounting type cubile made out 2 mm thick MS sheet. Anti corrosion and phosphatising treatment shall be given to the sheets by a standard 5 tank/7 tank process. All feeders shall be provided with two position (on-off) isolators, load break and quick make and break type. All isolators shall be suitable for front of board operation. Isolators for motor feeders shall preferably be of the 'motor duty' type i.e. capable of interrupting the locked rotor current of induction motors, which will be 6/8 times the full load current. Incomer with earthing will be provided by owner for main and A.H.U. panel.




Isolators shall be interlocked with door to prevent opening or closing of the door in the closed ('ON') position of the isolator, in case of compartmental type of feeders. All live terminals on the isolators shall be adequately shrouded to prevent accidental contact and danger to the personnel. Caution name plate "CAUTION LIVE TERMINALS" shall be provided at all points where the terminals are likely to remain live and isolation if possible only at remote end e.g. Incoming Terminals of Incomer. FUSES & FUSE FITTINGS

a) All fuses shall be of the non-deteriorating, high rupturing capacity, link, mounted in suitable fuse carriers or fuse bases.

CONTACTORS

a) Contactors shall be magnetic, air break type, generally in accordance with BS 775/IS 2959.

b) All contactors in power circuits of motor starters or other feeders shall be adequately rated for the duty required and operating conditions.

c) Contactor coils shall preferably be of draw out type for easy replacement. Coil voltage shall be 220V AC. Contactor coils shall operate satisfactorily between 110% and 85% of the nominal coil voltage. Drop off voltage for AC coils shall be between 80% and 45% of the nominal voltage.

d) Making and breaking capacities of the contactors shall be suitable for AC2 and AC3 categories of duty as per IS 2959 unless the contactors are required for special duty such as inching or plugging duty or capacitor duty, in which case, they will be suitably derated.

e) Each contactor shall be provided with 4 normally open and 4 normally closed auxiliary contacts or as required by the control scheme. If necessary, auxiliary relays or contactors may be provided to obtain necessary number of auxiliary contacts. Auxiliary contacts shall preferably be convertible from NO to NC and vice versa.

PROTECTIVE DEVICES

a) All feeders shall be protected by appropriate protective devices such as fused, combined bimetallic thermal overload and single phasing preventor relays.

b) Current transformer, when specified, shall be of bar primary, ring type or wound type, and in accordance with IS 2705 or BS 2046 or BS 81. Class and ratio of CTs shall be specified. VA burden of CTs shall be suitable for the load burden.

c) Ammeters (96 square) voltmeters, PF meters, Run Hour meters and Kilowatt Hour meters shall be provided and shall be of industrial grade accuracy, suitable for flush mounting and in accordance with IS 1248. Suitable selector switches shall be provided in conjunction with ammeters and voltmeters.

d) Indicating Neon lamps used shall be of low voltage, low burden type with series resistor to increase lamp life and to protect equipment from short circuits caused by broken filaments. Lamp covers shall be provided with interchangeable coloured lenses of perspex or equivalent unbreakable materials. Lenses should not get discoloured in course of time, due to the heat generated by the lamps. Name plates showing the condition indicated by the lamp shall be affixed near to the lamps.




e) Rating of terminal blocks for power and control circuits shall be at least 30 Amps and 15 Amps respectively. Terminals in control circuits shall be suitable for receiving one conductor per terminals of specified sizes. Terminals for power circuits shall be designed for receiving aluminium conductors and shall be screw clamp type or equal. Terminals for control circuit shall be suitable for receiving copper conductors. Star/Lock/Shake proof or Spring Washers shall be provided to prevent sparking due to vibrations. Special terminals with copper strips mounted on insulating supports may be provided for large cables. Where terminals, suitable extension bars with off- set may be provided.

f) Location of controls for motor starters or other feeders shall be specified. Normally one 'stop' push button with stay-put feature (lockable) and one reset push button for hand resetting of BMR shall be provided on the door of the compartment. Colours used for push buttons shall be as follows : Stop push button - Red Start push button - Green Reset push button - Black (Note: In case 'Stop', and 'Reset' are combined, only red colours will be

used.) Name plates indicating the function of the push button shall be affixed near to the push buttons.

WIRING

a) Internal wiring of MCCs for power and control shall be carried out with copper conductor PVC insulated cables of PVC covered copper/ aluminium tapes.

b) Wiring of components mounted on doors shall be carried out with single strand 2.5

sq. mm copper conductor flexible cables. Wires and cables shall be neatly arranged and bunched together with suitable clamps made of insulating material. Wire harnesses shall be adequately supported along the MCC metal work.

c) Identification ferrules or tags shall be attached to each wire at each point connection.

d) Sizes of conductors for power wiring shall be determined by the manufacturers on the basis of full load current under specified conditions, protective fuse rating and appropriate rating factors as applicable. Minimum size of conductor shall be 2.5 sq. mm Minimum size of conductor for control wiring shall be 1.5 sq. mm.

e) The following colour code shall be used for determining the colours of wires used for internal wiring. Manufacturer shall obtain specific approval of the purchases, if this colour coding cannot be observed for any reason whatsoever : Earth - Green Neutral - Black 230V, A.C. phase - Red/Yellow/Blue, to neutral Black

f) All wiring shall be carried out in accordance with approval and certified panel wiring diagrams. Vendor shall check all wiring from point to point for correctness. All wires shall be numbered and the numbers shall be indicated on the relevant drawings.




EARTHING All metal work of the MCC and non-current carrying metallic parts of the equipment in the MCC shall be securely bonded together by adequate means e.g. use of earthing washer for bolted connections or tapped holes for mechanical connections. One copper earth bus running through the entire length of the MCC shall be provided preferably along with the terminal chambers. Size of the earth bus shall be such as to withstand phase to earth or 2 phases to earth short circuit for one second. The minimum size of the busbar shall be 25 x 3 mm. The terminals complete with hardware and cable sockets shall be provided on the earth bus for connection to external system.

NAME PLATES AND LABELS

a) One name plate giving designation of the MCC shall be affixed prominently on to the MCC. (Details of designation will be given). Each feeder shall also be labelled giving following details :

i) Feeder No. ii) Feeder Designation (Eqpt.Ref.No.etc.) iii) Description iv) Rating (HP/KW/Amps)

b) All components whether mounted inside the MCC or on the door shall be permanently and clearly labelled with their reference number and/or letter or their function (rating of fuse shall form part of the fuse designation).

c) Labels for feeder designation shall be of laminated plastic or rear engraved

perspex with white letters on black background.

d) Labels for feeder designation shall be fixed on the doors on respective feeders with chrome-plated self tapping screws. Designation labels shall be identical in size to permit interchanging if required later.

MISCELLANEOUS

a) All hardware used shall be plated or passivated to resist corrosion. Type of plating or passivation shall be subject to the approval of the Engineer. All fixing screws shall preferably be raised head type.

DRAWINGS

a) Contractor shall furnish the following to the Engineer for his approval before commencement of fabrication :

i) General Arrangement Drawing showing overall dimensions, arrangement of

feeders, foundation plan, positions of cables entries, weight of MCC and sections in which MCC will be despatched.

ii) Single Line Diagram for the MCC showing rating of various components

used for all feeders complete with feeder numbers, designations, descriptions, ratings, etc.




iii) Schematic and panel wiring diagrams for all feeders.

iv) Terminal plan for MCC, showing feeder numbers, terminal numbers and terminal markings.

b) After the final approval, six prints and one clear film reproducible of each of the

above drawings shall be furnished.

c) The Contractor shall note that he shall bear full responsibility for any error, discrepancies, omissions, etc. in the drawings irrespective of whether such drawings have been approved or not. Approval of drawings shall not relieve the Contractor of his liability to complete the work in accordance with the specifications and other conditions of contract nor shall it exonerate the vendor from any of his guarantees.

TESTING AND INSPECTION

a) The following tests shall be carried out on the Motor Control Centres after completion of all work :

i) All power and control circuits for MCCs shall be tested for insulation resistance

with a 500 volt megger, before and after the high voltage test.

ii) High voltage test shall be carried out on all power and control circuits at 2000 volts A.C. voltage applied for one minute.

iii) Low voltages continuity test on all power circuits shall be carried out from

busbars to the outgoing terminals of each feeder with switches and contactors in closed position.

iv) All control circuits and operations of equipment for all feeders shall be checked

with only control supply made available to ensure satisfactory opera-tion of all equipment such as push buttons, BMR reset, indicating lamps, timing relays, etc. All contactor coils shall be checked for presence of humming or chattering. Special requirements for various feeders indicated in the purchase data sheets shall also be checked.

v) Earth continuity test shall be carried out with a low voltage supply of not more

than 6 volts, between various non- current carrying metallic parts of equipment, steel work, etc. and the earth bus provided in the MCC.

vi) Operation of all instruments and meters provided on the MCC shall be checked.

b) All the tests listed above shall be carried out in the present of Owner's

representative, during final inspection. Contractor shall provide all facilities such as power supply, testing instruments and apparatus required for carrying out the tests.

c) Contractor shall give a notice of not less than two weeks for inspection and testing

by the Engineer’s representative.




ELECTRIC MOTORS Rating & Duty

a) Rating of the motors shall be as indicated in the Schedule of Equipment. Where the equipment supplied needs a higher rated motor, the Contractor shall clearly point out and motors shall be offered accordingly.

b) All motors shall be rated for continuous duty at maximum output.

c) Rated voltage for three phase motors shall be 415 volts.

Design Features

a) Motor body shall be of close grained cast iron construction and shall be provided with lifting hooks or eye bolts. The motor along with the fan and half coupling shall be dynamically balanced.

b) Fan provided for fan cooled motor shall be non-directional type.

Enclosure/Protections:

a) Enclosure for motors shall be totally enclosed fan cooled (TEFC) unless otherwise specified - SPDP motors shall be used only where the desired output is not obtainable in a TEFC frame.

b) All outdoor motors shall be TEFC weather proof type.

c) Degree of protection for all motors shall be IP 44 as per IS 491.

d) Two earthing terminals comprising terminals studs, two plain washers, one spring

washer and nut shall be provided on opposite sides of the frame. Studs shall be suitable to receive appropriate size of earth conductor.

Bearings: All motors shall have ball and/or roller bearings with limit lubricators. Terminal Box:

a) Terminal box shall be of ample size, suitable for termination of aluminium conductor cables (with cable sockets) which may be substantially derated for conditions of installation.

b) Motor terminals shall be of stud type, substantially designed and well insulated

from the frame. Each terminal shall be complete with two flat washers one lock nut.

c) Number of terminals shall be as given below :

Squirrel Cate Motors upto 3.7 Kw - 3 Nos. Squirrel Cage Motors above 3.7 Kw




(with tinned copper links for delta connection) - 6 Nos.

d) Terminal boxes of all motors shall be rotable in steps of 90 degrees, without disturbing the motor winding connections to the terminal block. Separate terminal box shall be provided for connections to anti-condensation heaters in case of motors about 50 HP. If heater terminals are provided in the main terminal box, then insulating barrier shall be provided between them with caution name plate affixed on the terminal box. "CAUTION - LIVE HEATER TERMINALS."

e) Separate terminal boxes for starter and motor leads to be provided for slip ring

motors. Where it is not feasible, an approved type of insulating barrier to be provided.

Temperature Rise The temperature rise of motors when tested in accordance with IS 325 shall not exceed the limits specified therein. Starting of Motors

a) All squirrel cage motors shall be suitable for full voltage starting. Motors of 10 HP and above will generally be started with star/delta or auto transformer starters which, in addition to protective devices, shall be provided with single phasing preventor.

b) Starting current at full voltage of slip ring motors shall be limited by the rotor

resistance starter. Motor manufacturer shall furnish appropriate value of external resistance required to limit the starting current as well as to obtain the required torque. However, starting current with slip rings shorted shall not exceed 600% of full load current. Starting current of squirrel cage motors with full voltage starting shall not exceed 600% of the full load current with tolerance specified in IS 325.

c) Starting torque of squirrel cage motor started on full voltage shall not be less than

200% of the full load torque. Pull out torque of motors shall not be less than 200% of the full load torque.

Insulation

a) All motors shall have Class 'D/F' insulation unless the ambient temperature or other conditions necessitate another class of insulation.

b) All materials used in the construction of motors shall be non-hygroscopic.

Painting All motors shall be painted in an approved manner using two priming coats and two finish coats. The final colour shall be to the Owner's requirements. Performance Particulars Following performance particulars for all motors to be furnished well in advance before finalising orders for motors :




a) Make b) Type c) Enclosure d) Class of Insulation e) Temperature Rise above 40 Deg.C ambient f) Rated Output g) Speed h) No load current i) Full load current j) Locked rotor current k) Starting torque (DOL) l) Efficiency at full load, 3/4 load, 1/2 load m) Power factor at full load, 3/4 load, 1/2 load n) Details of rating for space heater o) Max. size of aluminium conductor cable which could be connected to

motor p) Rotor current at rated output q) Value of rotor resistance for different torque values

MV DISTRIBUTION BOARDS Construction The salient features of constructions panels shall be as follows : a) Sheet Steel - 2 mm thick for frames, cable gland plates and

equipment mounting plates and1.6 mm thick for front and rear doors and covers

b) Welded construction, with shipping section bolted together. All such joints to

gasketted. Lifting lugs to be provided. c) The cubicles shall be totally dust and vermin proof conforming to IP 54 of IS 2147. d) All doors to be hinged type except busbar chamber covers which shall be bolted

type. The panel shall be of flush front design, suitable for access from front and rear. e) The construction shall be such as to facilitate easy extension at both ends. f) The design shall be such as to have individual feeders in separate compartments,

with proper barriers between adjacent feeders, busbar chamber and cable box chambers.

Painting All sheet steel work shall be properly cleaned and degreased. Rust and scale shall be removed by picking and phosphatising. After phosphatising, two coats of primer shall be applied followed by two coats of finishing synthetic enamel paint of approved shade as per IS-5. The painting shall be stove enamelled.




Air Circuit Breakers

a) The circuit breaker shall be air-break, horizontal draw-out feature shall show 3 positions viz. SERVICE, TEST and ISOLATED. These positions along with 'OPEN' and 'CLOSE' positions shall be visibly marked.

b) All positions shall have provisions for locking. The ACB shall have shutter

assembly and arc-chutes and mechanical trip features.

c) The ACB shall have 6 NO + 6 NC auxiliary contacts rated at 10 A, 240 V, AC.

d) 'RED' and 'GREEN' indicating lamps shall be provided on the cubicle.

e) The ACB door shall not have any lamps or instruments. All such accessories shall be mounted on a separate compartment.

f) The ACB shall have proper interlocks such that it cannot be 'plugged in or out''

'SERVICE' position, if the breaker is in 'ON' condition. It shall not be possible to operate as circuit breaker unless it is properly engaged in any of the three positions.

g) The ACB shall have series CI operated over- current and short-circuit releases with

facilities to mount the under voltage and shunt-trip releases.

h) The operating mechanism shall be independent, manual spring charged stored energy type. The mechanism shall ensure quick-break, quick make action and the ACB shall be trip-free in operation.

Air Break Switches

a) The air break switches shall be of AC23, (heavy) duty, quick make-quick break, fault- make type as per IS 4047. The contacts shall be silver plated.

b) The switches shall be capable of withstanding the mechanical and thermal stresses

produced by overloads and short circuits.

c) All switches of all ratings shall have interlocks with the compartment doors. Switches of 250 A and above shall be lockable in the 'OFF' position. All live parts shall be shrouded. It shall be possible to intention- ally defeat the interlocks if required.

d) 'RED' indicating lamp shall be provided for 'ON' indication.

Fuses All fuses shall be of HRC cartridge fuse-link type having a certified rupturing capacity of not less than 46 KA at 415 volts AC. The HRC fuses shall conform to IS 9224 1979. All fuses shall have visible indication to indicate 'Blown' condition.




HRC Fuse Carriers

a) The HRC fuse carriers/bases shall be of high grade phenolic mouldings. The contacts shall be silver plated and the contact blocks shall be suitable to receive the rated conductors of aluminium.

b) The fuse carriers shall have an aperture to view the conditions of HRC fuse

mounted inside. Contactors

a) The motor starter contactors shall be of the electro-magnetic, double-break, non-gravity type rated for uninterrupted duty suitable for operation under AC 3 utilisation category as per IS 2959. The contacts shall be silver plated.

b) 2 NO and 2 NC auxiliary contacts shall be included.

c) The operating coils shall have Class 'E' insulation of wire and shall be suitable for

operation of any specified control supply system. Thermal Overload Relays

a) The thermal overload relays shall be 3 element, positive action, ambient temperature compensated with a time lag and adjustable settings. The setting range shall be selected in accordance with the ratings of the motor. Thermal overall relays shall be provided with inbuilt single phasing preventor.

b) The relay shall be self-reset/hand reset as called for in the case of hand-reset, the

reset button shall be fixed on the compartment door. c) The relay shall have at least one 'NC' and one 'NO' or one change-over contact.

Moulded Case Circuit Breakers: (25 K breaking capacity)

a) The moulded case circuit breakers, MCCBs shall be provided where certified. The MCCBs shall conform to the latest applicable IS 2516-1977.

b) For AC Circuits the MCCBs shall be triple pole construction and shall have

independent manual opening and closing mechanism. The mechanism shall be quick-make and quick-break type and the breakers shall be trip-free in operation. The 'ON'. 'OFF' and 'TRIP' mechanism shall be clearly indicated.

c) Bolted type neutral link to be provided with TP MCCB.

d) It shall be possible to mount accessories on the MCCBs like shunt-trip and

undervoltage release, alarm contacts, etc.

e) The MCCBs shall have thermal/static trip devices.

f) The MCCBs shall have rupturing capacities as specified in BOQ/Single Line Diagram.




Miniature Circuit Breakers The MCBs shall be of single pole, double pole, triple pole or four pole as required. The MCBs shall be of magnetic type with a maximum rupturing capacity of 9 KA at 415 V. Current Transformers

a) The CTs shall be of dry type and shall have short-time withstand rating equal to the short-time withstand rating of the associated switchgear for 1 second.

b) The measuring instrument CTs shall be of 15 VA, minimum accuracy class 1.0 and

an instrument safety factor of 5.

c) The protection relay CTs shall be of 15 VA, minimum accuracy class 5P and an accuracy limit factor of 10.

Indicating Instruments and Meters

a) Electrical indicating instruments shall be 72 mm/96 mm/144 mm square size, suitable for flush mounting.

b) The zero adjustment shall be done from outside the cover.

c) The dials to be parallax free with black numerals on a white dial.

Indicating Lamps

a) Indicating lamps shall be of the filament type and of low watt consumption, provided with series resistors and HRC fuse link for promotion.

b) The lens shall be easily replaceable from the front.

Control and Selector Switches

a) The control and selector switches shall be of rotary type, adequately rated for the application but with a minimum rating of 10 Amps at 240 V AC and 1 Amp at 220 V DC. The plates shall have clear position markings.

b) The control switches shall have pistol grip handles spring return to normal. The

selector switches shall have oval knobs and shall be contact stay-put type. Push Buttons

a) The push buttons shall be of the momentary contact, push to actuate rated for 10 A at 240 V AC and 1 A 220 V DC. The 'START' push buttons shall be green and shrouded. The 'STOP' push button shall be red and unshrouded. All other push buttons shall be black.

b) The elements shall be enclosed with 1 'NO' and 1 'NC' contacts. It should be

possible to add on easily extra elements to increase the number of 'NO' and 'NC' contacts.




Main and Auxiliary Buses

a) The busbars shall be of high conductivity aluminium alloy of E91E grade. The busbar shall be of uniform cross-section throughout the length of the panels.

b) All main and auxiliary busbars shall be insulated with sleeves. The sleeves shall

be of high dielectric strength, non-corrosive and of phase and neutral colours.

c) The busbars shall be supported on cast epoxy/ resin/DMC/Fibreglass insulators and the spacing of the supports shall be such as to withstand the stresses of the short circuit currents. The busbar spacings shall be adequate for 3 phase voltage upto 600 V.

d) The busbar shall be a chosen for specific current ratings with a minimum density of

1 amp for sq.mm area. Internal Wiring

a) All internal wiring shall be carried out with 1100 V/650 V grades PVC insulated, stranded conductor copper wires. The minimum size of wires shall be 2.5 sq.mm copper and for CTs also 2.5 sq.mm copper.

b) All individual control and CTs wiring shall be labelled with engraved identifications

ferrules, yellow in colour with black letters.

c) All wiring shall be terminated on stud type terminal blocks through crimping sockets. No more than one connection shall be made on any one terminal block.

d) All spare auxiliary contacts of contactors and relays shall be wired to control

terminal blocks. Terminal Blocks

a) Terminal blocks for power and control shall be of reputed make stud type, with washers, nuts and lock-nuts. All adjacent terminals shall have insulating barriers.

b) All power terminal blocks shall be appropriately rated for current with a minimum of

30 Amps. The control terminal blocks shall be rated for a minimum of 10 A and suitable for at least 2 conductors each of 2.5 sq.mm.

c) All sets of power and control power terminal blocks shall be identified with

engraved plastic labels, black background and white letters. Identification Labels All labels shall be black plastic with white engravings of letters of minimum 6 mm sizes. Earthing All switchgears shall have continuous run of earth busbar. The size and materials of the earth busbar shall be specified.




Tariff Advisory Committee and CPRI Tested The switchgear shall be approved by the Tariff Advisory Committee (for Fire Insurance) and CPRI tested for short circuit test and enclosure test. Tests

a) High Voltage test at 2.5 KV. b) Power and Control Circuits Continuity Tests. c) Insulation Resistance Test with 1000 V Meggar. d) Operational Test. e) Three Sets of Test Certificates to be submitted.

Drawings: Three sets of general arrangement drawings and wiring diagrams of all types of feeders shall be submitted. CONTROL STATIONS Control station shall be of cast iron or cast aluminium enclosures, consisting of 'START' and 'STOP' push buttons and shall have stayput feature of twist unlock type. CABLE AND ACCESSORIES All cables shall be heavy duty PVC insulated armoured and PVC sheathed of 1.1 KV grade. Aluminium conductor cables shall be used for power and copper conductor cables shall be used for control wiring. GLANDS Glands used for termination shall be compression type. Cable glands shall be with single/double seal and cone and clamp for armoured clamping. For safe and indoor areas, glands with single seal and for outdoor installation and hazardous areas, gland with double seals will be used. For use in corrosive areas, glands shall be coated with rust proofing lacquer after installation and provided with PVC hoods. Cable lugs shall be of Dowell or equivalent approved make, suitable for connection of aluminium conductor cables. The cable lugs shall be of tinned copper and of soldering type for solid conductor cables. For stranded conductor cables, crimping type, tinned copper cable lugs shall be used. CONDUITS AND ACCESSORIES Conduits wherever used with prior approval of the Contractor shall be of GI heavy gauge/black enamelled/PVC. All accessories, such as junction boxes, shall be duly approved by competent authorities. Terminal blocks of adequate rating are to be provided in the junction boxes.




SADDLES Saddles to be used for cleating cables or conduits shall be fabricated from MS or aluminium strips or any other approved material and shall be painted and dried before installation with chemical works type paint. CABLE TAGS AND IDENTIFICATION FERRULES Cable tags and identification ferrules provided on cable cores/wires shall be of PVC/plastic. Cable tags shall be provided at every 15 meters and at all bends or change in routes. STRUCTURAL STEEL This shall include MS angles, channels, flats, etc. required for fabrication of cable trays, local supports for cables, control stations, etc. All steel sections shall be new and conform to IS 226. MISCELLANEOUS MATERIALS These shall include solders, fluxes, adhesive insulating tapes, PVC sleeves, petroleum conducting jelly, etc. EARTHING MATERIAL Copper strips or wires of suitable sections shall be used for earthing in accordance with IS 3403. All 3 phase 415 Volts equipment shall be earthed at two points and all single phase equipment at one point. PAINTING All metal work and metal parts of the MCC shall be thoroughly cleaned to remove ruse, scale grease or any other matter. Suitable anti-corrosion treatment such as phosphatising shall be given to the metal work. All exposed surfaces of the metal work shall then be given a priming coat of zinc chromate or equivalent and finished with two coats of paint of specified shade. DRAWING Contractor shall submit 3 copies of control of schematic wiring diagram for refrigeration unit showing all protections and interlocks for Consultant's review and approval. After the final approval six prints and one clear reproducible of each drawing shall be furnished. INSTALLATION Motor Control Centres Motor Control Centres shall be installed on welded construction channel framework. Framework shall be properly grouted by means of foundation bolts or anchor fasteners.




Cable Laying As far as possible, cable shall be run in built up trenches and on walls/ceiling. Cables shall be dressed and clamped to the wall/ceiling by means of GI strap saddles of minimum 3 mm thickness. Cables shall be kept away from wall ceiling by saddle bars of at least 6 mm thickness. Cables running in built-up trenches shall also be properly clamped when cable run is on side walls of trench. Cable entry into the building shall be through suitable GI pipes or hume pipes or trenches. All cable entry openings into the buildings shall be properly sealed with cold setting, PVC compound or other approved materials. Cable Termination PVC cables shall be terminated with compression type glands. For outdoor installation double seal compression glands shall be used. All cables shall be connected by means of suitable crimping type cable lugs. All connections shall be secure and vibration proof. All contact surface shall be coated with petroleum conducting jelly before connections are made. Earthing All metallic frame work and non-current carrying metallic parts and enclosures of electrical equipment such as MCCB, motors, control station, etc. shall be bonded to one another and earthed by means of two separate earth conductors and connected to the plant earthing system. Motors All motors shall be installed on a common foundation with the driver equipment coupled through flexible couplings or belt drive. Levelling and alignment of motor and driven equipment to be carried out as per IS 900 to avoid undue strain on motors. Insulation resistance of motor shall be measured before commissioning. In no case insulation resistance should be less than one meg ohm. If it is less than one meg ohm motor should be dried out as per procedure laid on IS 900. Pre- commissioning mechanical checks shall be carried out as per IS 900. Cable termination and earthing of motors shall be carried out by Electrical Contractor. On commissioning of motor, any defects like excess current, bearings getting hot, undue vibration or noise etc. are observed, it will have to be made good by the Contractor without any extra cost. TESTING AND COMMISSIONING Operation Test

a) Energise only control circuits and carry out closing and tripping operations. (Where AC supply derived from main supply is used for operation, the switchgear bus may be energised). Check tripping of circuit breakers by manual operation of protective




relay contacts. Check operation of mechanical closing and tripping devices. Check lockout conditions for closing of circuit breakers by simulating the required conditions. Check control, indications, sequence interlocks and alarms.

b) Polarity and connections of instrument transformers check for correctness of CT

and PT connections provided with transformer. Check electrical continuity of secondary circuits with ELV tester. Adjust spacing of arcing horns/rod gaps.

c) Check operation of instruments, meters, relays and tripping of circuit breakers by

primary/secondary injection as specified. This test will be carried out only if specifically called for by Contract Documents.

d) Check continuity of power circuits and earth continuity of all non-current carrying

metallic parts with a low voltage (6V or less) continuity tester.

e) Carry out IIV test on power and control circuits if specifically called for in Contract Documents.

Motors Check equipment for free movement of rotor and play, lubrication and for any other mechanical defects and direction of rotation. Check commutators, slip rings, brushes, brush- holders, etc. for satisfactory conditions. Insulation test of motors between winding and ground. Use 500 V megger for MV motors and 1000 V megger for HV motors. Check electrical continuity with ELV tester. Control Cables Carrying insulation test on all power and control circuits. Check all equipment for satisfactory operation and correct wiring. Wiring Insulation test between phases, between each phase and neutral and between each phase/neutral and ground. DC High Voltage Test on HV Cables in accordance with the relevant Indian Standards and Code of Practice. This test shall be carried out on cables, installed in final position and all joints and terminations have been made. The cables, however, may not be connected to the equipment so that the equipment may not be subjected to the test voltage. In case of lighting wiring, insulation test shall be carried out on lighting feeders with branch circuits open. Branch circuits shall be tested separately with lampholders, plug receptacles and lighting fittings in position but without lamps. In case of lighting circuits with lamp ballasts and glow starters insulation resistance may be measured between phase and ground only. In case of directly buried cables, insulation resistance of cables shall be measured before and after the back filling. Test all receptacles for correct phase sequence.




Earthing System Continuity test for earth continuity conductors with ELV tester. OPERATION TEST After successful completion of the above tests, operational tests shall be carried out by the Contractor for checking the connections done by him and satisfactory operation of all the equipment supplied by him. This test shall be carried out initially without energising power circuits. Various control conditions shall be similated for the purpose of this test. Any defects detected during the tests such as blown fuses, damage to devices, shall be rectified by the Contractors, free of cost.



List of Approved Makes of 79

LIST OF

APPROVED MAKES




Chiller : Climaveneta, York, Trane, Carrier Mcquay, Voltas, Mcquay, Voltas, Mcquay, Voltas, Mcquay, Voltas,

BluestarBluestarBluestarBluestar

AHU : Edgetech, ZECO, Ambience, Waves

Motors : Siemens, Bharat Bijlee, Kirloskar, Crompton.

Pumps : Grundfoss , ITT, Mather & Platt, ,

Cooling Tower : Bell, Mihir, Advance, Paharpur.

Fan Coil Units : Sinko, York, Trane, Media

2way Valve For FCU : Belimo

Energy Valve : Belimo

Pipes (ISI marked) : ITC, Jindal (Hisar),Tata

Motorized Butterfly Valve : Belimo

Butterfly Valves : Audco / ADVANCE

Gate Valves (ISI marked ) : Leader, Kirloskar, Sant

NR Valves : Kirloskar, Advance,Audco.

Auto Balancing Valves : Advance, Honeywell

Ball valve : RB, Rapid Cool,Zoloto, Sant

Pot / Y Strainer : Rapid Cool, Maharaja, Sant,Emerald.

Auto Air Vent Valve : Anergy, Rapid Control,RB.

Flow Switch : Rapid Cool, Indfoss.

Expanded Polystrene : Mettur Beardsell, Lloyds, Coolite.

Styrene Packaging, P R Packaging.

Fibreglass : Up Twiga, Owners Corning

Room Thermostats : Belimo, Honeywell, Siemens.

Centrifugal Fans / Axial flow fans : Kruger, Dynair, Wolter

Fire Dampers : Ruskin, Carryaire.

Extruded Aluminium Air Grille : Air Product, Dynacraft

Pressure gauges : H. Guru, Fiebig, Emerald.

Variable Speed Drives : ABB

Dry Scrubber : Nihal Enterprises / Trion




Closed Expansion Tank : Bell & Gossett, Armstrong, Grundfoss.

Air Separator : Bell & Gossett, Armstrong, Grundfoss.

Ducting Pre-Fabricated : Rollastar, Ductofab,Royal Aircon, ZECO.

XPLE Insulation (Thermal) : Superme / Trocellene

Fire Sealants : Birla 3 M, Hilti.

Vibration Isolator : Resistoflex ,Flexionics (USA), Kanwal Ind. Corp.

Heavy duty pipe support clamps : Hira Arosio.

Air Circuit Breaker (ACB) : Schneider Electric(Master Pact), Larsen &

Toubro (U Power), Siemens 3VL, ABB (E max)

Moulded Case Circuit Breaker (MCCB) : Schneider Electric (MG), Larsen & Toubro

(D Sine) Siemens 3WL, ABB ( T Max)

Miniature Circuit Breakers (MCB) : Schneider Electric, Larsen & Toubro, Siemens

Motor Protected Circuit Breakers (MPCB) : Schneider Electric, Larsen & Toubro, Siemens

Residual Current Circuit Breaker (RCCB) : Schneider Electric, Larsen & Toubro, Siemens

Power/Aux. Contactor : Schneider Electric, Larsen & Toubro, Siemens

Control Transformer/Potential : Automatic Electric, Pragati,

Transformers Gilbert & Maxwell

Current Transformer : Automatic Electric, Pragati,

(Epoxy Cast Resin) Gilbert & Maxwell

Protection Relay : Alostom, Siemens, L & T, ABB, Schneider

a.Electronic Digital Meters : Conserv

(A/V/PF/Hz/KW/KWH) with

LED Display

b.Electro_Magnetic Meters : Automatic Electric, Rishabh (L&T),

Vaishno

Static Power Meter & Logger : Enercon System Pvt. Ltd., CG Schlumberger

(SPML) Larsen & Toubro, Automatic Electric

PVC insulated XLPE : Polycab, Gloster, Batra & Henley, Skytone

aluminium/copper armoured

Cables

Cable Glands Double : Jainson, Comet, Baliga

Compression

Bimettalic Cable Lug : Dowell’s , Comet, Jainson




PVC insulated copper conductor : Finolex, stranded flexible wires, RB Kable

Timer : Schneider Electric, Larsen & Toubro,

Siemens, ABB




2. ASSOCIATED CIVIL WORKS

Following civil works associated with Air-Conditioning installation are excluded from the scope of this contract. These shall be executed by other agencies in accordance with approved shop drawings of and under direct supervision of the contractor.

a. RCC basin & supports & GI Joists for cooling towers.

b. Making of trenches and back filling the same after laying / pressure testing etc. of pipes.

3. ASSOCIATED SERVICES WORKS

Input required for the execution of such work by the other agencies shall be issued by the contractor and such input shall be incorporated in the shop drawings to be submitted by the contractor.

3.1 All associated ELECTRICAL WORKS listed below are excluded from the

scope of this contract. These shall be installed by other agencies in accordance with approved shop drawings of, and under direct supervision of the air conditioning contractor.

i. Providing earthing at the incoming of control panel in A/C plant room.

3.2 All associated PLUMBING WORKS listed below are excluded from the scope of this contract. These shall be installed by other agencies, in accordance with approved shop drawings of, and under direct supervision, of the air conditioning contractor.

i. Providing soft makeup water at cooling tower, air washers, hot water expansion tank and at chilled water expansion tank.

ii. Providing floor drains in cooling tower area

iii. Disposal of condensate drain.

4. BUILDING AUTOMATION SYSTEM

The scope of HVAC Contractor shall include the following for the interface to Building Automation System.

a. Stop/Manual/ Auto switches along with potential free contacts for monitoring the manual operation status, to be provided for those equipment whose start / stop is controlled by Building Automation System.

b. Potential frees ‘NO’ contacts for monitoring ‘Run’ status of equipment wherever required.

c. Sockets /Nipples with shut-off valve for mounting sensors/transmitters on pipe lines.

d. Installation of all motorized control valves with provision of counter flanges, nut-bolts and gaskets shall be provided by the HVAC contractor. Interface cards (0-10 V or 4-20 mA) if required shall be the scope of HVAC contractor




for operation of valves & all the mixing valve shall be calibrated by HVAC contractor (if it is supplied by them) before connecting it to BAS.

e. The space provision in all the equipment panel ( MCC) such as Pumps, Chillers etc. for mounting Current/ Potential transformers & transducers and power supply to the transducer shall be provided by the HVAC contractor. Separate current transformers shall be provided by HVAC contractor for monitoring current / KWH (wherever required) through BAS.

f. The installation of current transformer & Transducer along with wiring between Current Transformer & Transducer up to the terminal block shall be provided by the HVAC contractor. All transducers shall be supplied by BAS contractor.

g. The low voltage BAS Cables shall be brought upto the electric panel by BAS contractor and all terminations into the electrical panels shall be made by HVAC contractor after satisfying himself of the wiring system. It is to be clearly understood that the final responsibility for the sufficiency, adequacy and conformity to the contract requirements, of the HVAC system, lies solely with the contractor.

h. Provision for mounting level switch on cooling tower sump & expansion tank shall be provided by HVAC contractor. Level switches shall be supplied by BAS contractor.

i. 32 Amps MCB on HVAC plant room panel for power supply to BAS Panel.

j. All necessary Hardware/ Software shall be made available by the HVAC Contractor on the chiller Microprocessor panel for the integration of chiller panel to Building Automation System for remote monitoring / controlling of all parameters of chiller thru BAS.

5. PROJECT EXECUTION AND MANAGEMENT

The Contractor shall ensure that senior planning and erection personnel from his organization are assigned exclusively for this project.

The project management shall be through modern technique. The Contractor’s office at site shall be fully equipped with fax, internet facility, computers, plotter and photocopier. Erection engineer and supervisors shall be provided with mobile communication system so that they can always be reached.

For quality control & monitoring of workmanship, contractor shall assign at least one full-time engineer who would be exclusively responsible for ensuring strict quality control, adherence to specifications and ensuring top class workmanship for the air conditioning installation.

The Contractor shall arrange to have mechanized & modern facilities of transporting material to place of installation for speedy execution of work.




6. PERFORMANCE GUARANTEE

The contractor shall carry out the work in accordance with the Approved shop drawings, Specifications, Schedule of Quantities and other documents forming part of the Contract.

The contractor shall be fully responsible for the performance of the selected equipment (installed by him) at the specified parameters and for the efficiency of the installation to deliver the required end result.

The contractor shall guarantee that the HVAC system as installed shall maintain the inside conditions in the air-conditioned spaces as described under “Basis of Design” in the specifications.

Complete set of architectural drawings is available in the Architect/Consultant’s office and reference may be made to same for any details or information. The contractor shall also guarantee that the performance of various equipment individually, shall not be less than the quoted capacity; also actual power consumption shall not exceed the quoted rating, during testing and commissioning, handing over and guarantee period.

7. BYE-LAWS AND REGULATIONS

The installation shall be in conformity with the Bye-laws, Regulations and Standards of the local authorities concerned, in so far as these become applicable to the installation. But if these Specifications and Drawings call for a higher standard of materials and / or workmanship than those required by any of the above regulations and standards, then these Specifications and Drawings shall take precedence over the said regulations and standards. However, if the Drawings and specifications require something which violates the Bye-laws and Regulations, then the Bye-laws and Regulations shall govern the requirement of this installation.

8. DRAWINGS

The HVAC Drawings listed under Section 5.0, which may be issued with tenders, are diagrammatic only and indicate arrangement of various systems and the extent of work covered in the contract. These Drawings indicate the points of supply and of termination of services and broadly suggest the routes to be followed. Under no circumstances shall dimensions be scaled from these Drawings. The architectural/interiors drawings and details shall be examined for exact location of equipment, controls, grilles and diffusers.

The contractor shall follow the tender drawings and coordinated services drawings in preparation of his shop drawings, and for subsequent installation work.

Maximum headroom and space conditions shall be maintained at all points. Where headroom appears inadequate, the contractor shall notify the Architect/Consultant/Owner’s site representative before proceeding with the installation. In case installation is carried out without notifying, the work shall be rejected and contractor shall rectify the same at his own cost.




The contractor shall examine all architectural, structural, plumbing, electrical and other services drawings and check the as-built works before starting the work, report to the Owner’s site representative any discrepancies and obtain clarification. Any changes found essential to coordinate installation of his work with other services and trades, shall be made with prior approval of the Architect/Consultant/Owner’s site representative without additional cost to the Owner. The data given in the Drawings and Specifications is as exact as could be procured, but its accuracy is not guaranteed.

9. TECHNICAL DATA

Each tendered shall submit along with his tender, the technical data for all items listed in section-3 in the indicated format. Failure to furnish complete technical data with tenders may result in summary rejection of the tender.

10. SHOP DRAWINGS

10.1 All the shop drawings shall be prepared on computer through AutoCAD System based on Architectural Drawings, site measurements and Interior Designer’s Drawings. All heat load calculations shall be done using latest version of HAP/Trace/ISHRAE HLCP only. Within four weeks of the award of the contract, contractor shall furnish, for the approval of the Architect/Consultant, two sets of detailed shop drawings of all equipment and materials including layouts for Plant room, cooling towers, fan coil units, ventilation fans; detailed piping drawings showing exact location of supports, flanges, bends, tee connections, reducers, valves, fittings, pipe insulation etc; electrical panels inside/outside views, power and control wiring schematics,. These shop drawings shall contain all information required to complete the Project as per specifications and as required by the Architect/ Consultant/Owner’s site representative. These Drawings shall contain details of construction, size, arrangement, operating clearances, performance characteristics and capacity of all items of equipment, also the details of all related items of work by other contractors. Each shop drawing shall contain tabulation of all measurable items of equipment/materials/works and progressive cumulative totals from other related drawings to arrive at a variation-in-quantity statement at the completion of all shop drawings. Minimum 6 sets of drawings shall be submitted after final approval along with CD.

Each item of equipment/material proposed shall be a standard catalogue product of an established manufacturer strictly from the manufacturers listed in Section 3.0

When the Architect/Consultant makes any amendments in the above drawings, the contractor shall supply two fresh sets of drawings with the amendments duly incorporated along with check prints, for approval. The contractor shall submit further 6 sets of shop drawings to the Owner’s site representative for the exclusive use by the Owner’s site representative and all other agencies. No material or equipment may be delivered or installed at the job site until the contractor has in his possession, the approved shop drawing for the particular material/equipment/installation.

10.2 Shop drawings shall be submitted for approval four weeks in advance of planned delivery and installation of any material to allow Architect/Consultant ample time for scrutiny. No claims for extension of




time shall be entertained because of any delay in the work due to his failure to produce shop drawings at the right time, in accordance with the approved programmed.

10.3 Manufacturer’s drawings, catalogues, pamphlets and other documents submitted for approval shall be in 3 sets. Each item in each set shall be properly labeled, indicating the specific services for which material or equipment is to be used, giving reference to the governing section and clause number and clearly identifying in ink the items and the operating characteristics. Data of general nature shall not be accepted.

10.4 Samples of all materials like valves controls, insulation, pre-mounded pipe section, control wires etc shall be submitted to the Owner’s site representative prior to procurement. These will be submitted in two sets for approval and retention by Owner’s site representative and shall be kept in their site office for reference and verification till the completion of the Project. Wherever directed a mockup or sample installation shall be carried out for approval before proceeding for further installation.

10.5 Approval of shop drawings shall not be considered as a guarantee of measurements or of building dimensions. Where drawings are approved, said approval does not mean that the drawings supercede the contract requirements, nor does it in any way relieve the contractor of the responsibility or requirement to furnish material and perform work as required by the contract.

10.6 Where the contractor proposes to use an item of equipment, other than that specified or detailed on the drawings, which requires any redesign of the structure, partitions, foundation, piping, wiring or any other part of the mechanical, electrical or architectural layouts; all such re-design, and all new drawings and detailing required therefore, shall be prepared by the contractor at his own expense and gotten approved by the Architect/Consultant/ Owner’s site representative. Any delay on such account shall be at the cost of and consequence of the Contractor.

10.7 HVAC Contractor shall prepare coordinated services shop drawings based on the drawings prepared by Electrical, Plumbing & Low Voltage Contractors to ensure adequate clearances are available for installation of services for each trade.

Where the work of the contractor has to be installed in close proximity to, or will interfere with work of other trades, he shall assist in working out space conditions to make a satisfactory adjustment. If so directed by the Owner’s site representative, the contractor shall prepare composite working drawings and sections at a suitable scale, not less than 1:50, clearly showing how his work is to be installed in relation to the work of other trades. If the Contractor installs his work before coordinating with other trades, or so as to cause any interference with work of other trades, he shall make all the necessary changes without extra cost to the Owner.

10.8 Within four weeks of approval of all the relevant shop drawings, the contractor shall submit 3 copies of a comprehensive variation in quantity statement, and itemized price list of recommended (by manufacturers) imported and local spare parts and tools, covering all equipment and materials in this contract. The Project Manager shall make




recommendation to Owner for acceptance of anticipated variation in contract amounts and also advise Owner to initiate action for procurement of spare parts and tools at the completion of project.

11. QUIET OPERATION AND VIBRATION ISOLATION

All equipment shall operate under all conditions of load without any sound or vibration which is objectionable in the opinion of the Owner’s site representative. In case of rotating machinery sound or vibration noticeable outside the room in which it is installed, or annoyingly noticeable inside its own room, shall be considered objectionable. Such conditions shall be corrected by the Contractor at his own expense. The contractor shall guarantee that the equipment installed shall maintain the specified at dB / NC levels.

12. ACCESSIBILITY

The Contractor shall verify the sufficiency of the size of the shaft openings, clearances in cavity walls and suspended ceilings for proper installation of his ducting and piping. His failure to communicate insufficiency of any of the above shall constitute his acceptance of sufficiency of the same. The Contractor shall locate all equipment which must be serviced, operated or maintained in fully accessible positions. The exact location and size of all access panels, required for each concealed control damper, valve or other devices requiring attendance, shall be finalized and communicated in sufficient time, to be provided in the normal course of work. Failing this, the Contractor shall make all the necessary repairs and changes at his own expense. Access panel shall be standardized for each piece of equipment / device / accessory and shall be clearly nomenclature / marked.

13. MATERIALS AND EQUIPMENT

All materials and equipment shall conform to the relevant Indian Standards and shall be of the approved make and design. Makes shall be strictly in conformity with list of approved manufacturers as per Section 3.0. Technical specification of all equipment data sheet should be submitted along with NIB Envelop-3. Chiller factory Test inspection shall be carried out at the works for the assembled chiller in presence of Consultants / PMC / Clients

14. MANUFACTURERS INSTRUCTIONS

Where manufacturer has furnished specific instructions, relating to the material and equipment used in this project, covering points not specifically mentioned in these documents, such instructions shall be followed in all cases.

15. ELECTRICAL INSTALLATION

The electrical work related to air conditioning services, shall be carried out in full knowledge of, and with the complete coordination of the contractor. The electrical installation shall be in total conformity with the control wiring drawings prepared by the contractor and approved by the Architect / Consultant. All air conditioning equipment shall be connected and tested in the presence of an authorized representative of the contractor.




The air conditioning system shall be commissioned only after the contractor has certified in writing that the electrical installation work for air conditioning services has been thoroughly checked, tested and found to be totally satisfactory and in full conformity with the contract Drawings, Specifications and manufacturer’s instructions. It is to be clearly understood that the final responsibility for the sufficiency, adequacy and conformity to the contract requirements, of the electrical installation work for air conditioning services, lies solely with the contractor.

16. BALANCING, TESTING AND COMMISSIONING

Balancing of all air and water systems and all tests as called for the Specifications shall be carried out by the contractor through a specialist group, in accordance with the Specifications and ASHRAE Guide lines and Standards. Performance test shall consist of three days of 10 hour each operation of system for each season.

The results for summer, monsoon and winter air conditioning in quadruplicate shall be submitted for scrutiny. Four copies of the certified manufacturers performance curves for each piece of equipment, high lighting operational parameters for the project, shall be submitted along with the test certificates. Contractor shall also provide four copies of record of all safety and automatic control settings for the entire installation.

The installation shall be tested again after removal of defects and shall be commissioned only after approval by the Owner’s site representative. All tests shall be carried out in the presence of the representatives of the Architect/Consultant and Owner’s site representative.

17. COMPLETION DRAWINGS

Contractor shall periodically submit completion drawings as and when work in all respects is completed in a particular area. These drawings shall be submitted in the form of two sets of CD’s and four portfolios (A-1 or A-0 size) each containing complete set of drawings on approved scale indicating the work as - installed. These drawings shall clearly indicate complete plant room layouts, ducting and piping layouts, location of wiring and sequencing of automatic controls, location of all concealed piping, valves, controls, dampers, wiring and other services. Each portfolio shall also contain consolidated control diagrams and technical literature on all controls. The contractor shall frame under glass, in the air-conditioning plant room, one set of these consolidated control diagrams.

18. OPERATING INSTRUCTION & MAINTENANCE MANUAL

Upon completion and commissioning of part HVAC system the contractor shall submit a draft copy of comprehensive operating instructions, maintenance schedule and log sheets for all systems and equipment included in this contract. This shall be supplementary to manufacturer’s operating and maintenance manuals. Upon approval of the draft, the contractor shall submit four (4) complete bound sets of typewritten operating instructions and maintenance manuals; one each for retention by Consultant and Owner’s site representative and two for Owners Operating Personnel. These manuals shall also include basis of design, detailed technical data for each piece of equipment as installed, spare parts manual and recommended spares for 4 year period of maintenance of each equipment.




19. ON SITE TRAINING

Upon completion of all work and all tests, the Contractor shall furnish necessary operators, labour and helpers for operating the entire installation for a period of fifteen (15) working days of ten (10) hours each, to enable the Owner’s staff to get acquainted with the operation of the system. During this period, the contractor shall train the Owner’s personnel in the operation, adjustment and maintenance of all equipment installed.

20. MAINTENANCE DURING DEFECTS LIABILITY PERIOD

20.1 Complaints

The Contractor shall receive calls for any and all problems experienced in the operation of the system under this contract, attend to these within 10 hours of receiving the complaints and shall take steps to immediately correct any deficiencies that may exist.

20.2 Repairs

All equipment that requires repairing shall be immediately serviced and repaired. Since the period of Mechanical Maintenance runs concurrently with the defects liability period, all replacement parts and labour shall be supplied promptly free-of-charge to the Owner.

21. UPTIME GUARANTEE

The contractor shall guarantee for the installed system an uptime of 98%. In case of shortfall in any month during the defects liability period, the Defects Liability period shall get extended by a month for every month having shortfall. In case of shortfall beyond the defects liability period, the contract for Operation and Maintenance shall get extended by a month for every month having the shortfall and no reimbursement shall be made for the extended period.

The Contractor shall provide log in the form of diskettes and bound printed comprehensive log book containing tables for daily record of all temperatures, pressures, humidity, and power consumption. Starting and stopping times for various equipment, daily services rendered for the system alarms, maintenance and record of unusual observations etc. Contractor shall also submit preventive maintenance schedule.

Each Tenderer shall submit along with the tender, a detailed operation assistance proposal for the Owner’s site representatives/Consultant’s review. This shall include the type of service planned to be offered during Defects Liability Period and beyond. The operation assistance proposal shall give the details of the proposed monthly reports to the Management.

The Tenderers shall include a list of other projects where such an Operation Assistance has been provided.




22. LIST OF MAIN DOCUMENTS AND SUBMITTALS

S. No. Items Remarks a.

4-Copies of Performa Invoice 4- sets of Technical Literature Packing Specifications.

b. Performance Guarantee

c. All Permits / Licenses

d. Technical Data

e. Manufacturer’s Drawings, Catalogues & Pamphlets & Other Documents

f. Variation in Quantity Statement.

g. Electrical Installation Certificate.

h. Results of Summer, winter & Monsoon Tests.

j. Operating Instructions & Maintenance Manual

k. Soft water & Power Requirement

m. Testing, Adjusting and Balancing

Note : The above list is only for guide line of the contractor. The contractor shall thoroughly check all document and submittals required as per the tender document and submit them in time as per the requirement.




LIST OF BUREAU OF INDIAN STANDARDS CODES

IS : 277 - 1992 Galvanized steel sheet (Plain & Corrugated) wire for fencing. IS : 554 - 1985 (Reaffirmed 1996) Dimensions for pipe threads where pressure tight joints are required on the threads. IS : 655 - 1963 (Reaffirmed 1991) Metal air ducts. IS : 659 – 1964 (Reaffirmed 1991) Air conditioning (Safety Code) IS : 660 – 1963 (Reaffirmed 1991) Mechanical Refrigeration (Safety Code) IS : 694 - 1990 (Reaffirmed 1994) PVC insulated (HD) electric cables for working voltage upto and including 1100 volts. IS : 732 - 1989 Code of practice for electrical wiring. IS : 780 - 1984 Sluice valves for water works purposes. IS : 822-1970 (Reaffirmed 1991) Code of procedure for inspection of welds. IS : 1239 (Part - I) - 1990 Mild steel tube IS : 1239 (Part - II) - 1992 Mild steel Tubulars and other wrought steel pipe fittings. IS : 1255 - 1983 Code of Practice for installation and

Maintenance of Power Cables upto and including 33 KV rating (Second Revision)

IS : 1554 - 1988 (Part – I) PVC insulated ( Heay Duty) electric cables for working voltages pto and including 1100 volts. IS : 1897 - 1983(Reaffirmed 1991) Copper bus bar / strip for electrical purposes IS : 2379 - 1990 Colour code for the identification of pipelines. IS : 2551 - 1982 Danger notice plate IS : 3043 - 1987 Code of practice for earthing. IS : 3103 – 1975 (Reaffirmed 1999) Code of practice for Industrial Ventilation. IS : 3837 – 1976 (Reaffirmed 1990) Accessories for rigid steel conduit for electrical wiring. IS : 4736 – 1986 (Reaffirmed 1998) Hot-dip zinc coatings on steel tubes.




IS : 4894 - 1987 Centrifugal Fan. IS : 5133 - 1969 (Part-I) (Reaffirmed 1990) Boxes for the enclosure of electrical accessories. IS : 5216 – 1982 (Part-I) (Reaffirmed 1990) Guide for safety procedure and practices in electrical work. IS : 5312 (Part-I) - 1984 (Reaffirmed 1990) Swing - check type reflux Non return valves for water works IS : 5424 – 1989 (Reaffirmed 1994) Rubber mats for electrical purposes. IS : 5578 & 11353-1985 Marking and identification of conductors IS : 6392 – 1971 (Reaffirmed 1988) Steel pipe flanges. IS : 8623 - 1993 Low voltage switchgear and control gear Assemblies (Requirement for type / partly

type tested assemblies) IS : 8623 - 1993 Bus Bar trunking system (Part - II) IS : 8828 - 1996 Circuit Breakers for over current protection For house hold and similar installation. IS : 9537 - 1981 (Part II) Rigid Steel Conduits for electrical wiring IS : 10810 - 1988 Methods of test for cables. IS : 13947-1993 (Part-I) General rules for low voltage swtich gears

and control gears. IS : 13947-1993 (Part-II) Circuit Breakers IEC 947 - 2 IS : 13947 - 1993 (Part-III) Swiches, disconnectors and fuse for low voltage switch gear and control gear. IS : 13947 - 1993 (Part-IV) Low voltage switch gear and control gear for contactors and motor starters IS : 13947 – 1993 (Part-V) Control Circuit Devices. BS : EN:779 – 1993 Filters ASHRAE Hand Books American Society of Heating Refrigeration & Air-conditioning .

Application 2007. Fundamentals 2009.




Systems & Equipment 2008. ASHRAE Indoor air quality Standard 62.1-2010.

ASHRAE Standard 90.1-2010. ASHRAE 52.1-2007. ASHRAE 52.2-2007.

IEC Relevant Sections ECBC 2007 <Revised Version May 2008>