PROPOSED IT BUILDING & CLUB HOUSE

TENDER DOCUMENT FOR

AIR CONDITIONING AND MECHANICAL VENTILATION

SUNTEC
TECHNO PARK,
TRIVANDRUM, KERALA

TECHNICAL SPECIFICATION

1
VOLUME II – TECHNICAL SPECIFICATIONS

04: AIR CONDITIONING AND MECHANICAL VENTILATION

SECTION 04.01 – GENERAL REQUIREMENTS

SECTION 04.02 – STATUATORY REQUIREMENTS

SECTION 04.03 – SCOPE OF WORK

SECTION 04.04 – DESIGN CRITERIA & SYSTEM DESCRIPTION

SECTION 04.05 – COOLING TOWERS

SECTION 04.06 – PUMPS

SECTION 04.07 – AIR HANDLING UNITS/FAN COIL UNIT

SECTION 04.08– HEAT RECOVERY UNIT

SECTION 04.09– VENTILATION FANS

SECTION 04.10 – WATER TREATMENT

SECTION 04.11 – SIDE STREAM FILTRATION SYSTEM

SECTION 04.12 – PIPING & VALVES

2
SECTION 04.13 – AIR DISTRIBUTION SYSTEM

SECTION 04.14 – INSULATION

SECTION 04.15 – TESTING AND BALANCING

SECTION 04.16 – DATA / INFORMATION TO BE FURNISHED WITH THE BID

SECTION 04.17 – VFD

SECTION 04.18 – ACMV RELATED ELECTRICAL WORKS

SECTION 04.19 – SCHEDULE OF MAINTENANCE CONTRACT

SECTION 04.20 – SCHEDULE OF DEVIATION

SECTION 04.21 – VRV SYSTEM

SECTIOM 04.22 – LIST OF APPROVED MAKES

3
 SECTION 4.01
GENERAL REQUIREMENTS

4
1.0 SCOPE

This specification covers the requirements of supply, installation, testing and

commissioning of Air conditioning and Mechanical Ventilation system for the
proposed Suntec Office Tower Phase 1 & Clubhouse at Trivandrum.

1.1 GENERAL INFORMATION

The Special / Particular Instruction and conditions of contract as described in this

document are intended to amplify the General conditions of contract and shall be read
in conjunction with specifications of work, drawings and all other documents forming
part of this Contract wherever the context so requires. The following clauses shall be
considered as an extension and not in limitation of obligation of the contractor.

All expenses incurred by the CONTRACTOR in connection with obtaining information

for submitting this tender including his visits to the site or efforts in compiling the
tender shall be borne by the CONTRACTOR and no claims for reimbursement shall be
entertained.

Notwithstanding the sub-division of the documents into separate sections and

volumes every part of each shall be deemed to be supplementary to and
complementary of every other part and shall be read with and into the CONTRACT.

Wherever it is mentioned in the specification, that the CONTRACTOR shall perform

certain work or provide certain facilities, it is understood that the CONTRACTOR shall
do so at his own cost.

2.0 OBLIGATION OF CONTRACTOR

The obligation of Contractor in fulfilment of ACMV works are stated below:

 Procurement, fabrication and supply

 Inspection and testing
 Expediting and co-ordinating with other agencies
 Scheduling and Monitoring
 Training the Client’s representative in the Operation & Maintenance of the Plant
 Erection, checking and testing
 Commissioning

5
 Carrying out performance tests to meet the specification requirement and to the full
satisfaction of EMPLOYER
 Providing Guarantee
 Maintenance during Guarantee/Defects Liability period
 Final documentation

Checking up the equipment and other materials to ensure that the same are as per the
specifications laid down in description of work and drawings and also to make sure
that they are in proper condition to be taken up for erection.

Drawing – up a detailed time schedule and to organise the erection work in conformity
with the time schedule.

Arranging for the procurement and ensuring availability at the site at the required
time of all the erection tools, necessary tackle, required for the erection work such as
cranes, air compressor, welding sets, oxy-acetylene cutters, electric and pneumatic
drills, steel wedges for levelling and grouting, scaffolding gay wire testing and cleaning
equipment and all other construction equipment necessary for proper erection.

Arranging for procurement and ensuring availability at site at the time of all
consumable construct materials for erection work such as welding electrodes, oxygen,
acetylene and other welding gases, greases, petrol, cotton waste and all temporary
fastening such as tack bolts clips, cleats and other materials, chemicals for cleaning
and such other materials as may be needed to execute the handling and erection
works.

Engaging and allotting an adequate number of engineers, erectors of all the required
categories (Supervisory, skilled and unskilled labour) for carrying out different items
at different stages of the erection work.

Assembling and installing of all items of machinery / equipment at their proper places
at the plant site. The erection work will cover necessary operations such as, handling,
sorting, stacking, unpacking, cleaning, assembling, bottling welding riveting, erecting,
site fabrication, instrument cable laying and jointing, earthing, erecting, site
fabrication, instrument cable laying and jointing, earthing, treatment for underground
pipe protection, painting, thermal insulation and manual / mechanical / chemical
cleaning, testing and other operations, provision of inserts, embedded plates in walls /
roof / floor for erection of ducting, piping etc. Installation of all instruments –
measuring and controlling of the plant. All control wiring also forms part of erection
work.

Where different components of equipment are interconnected to form a complete

system, their characteristics of performance and capacities shall be matched in order
to ensure efficient, economical, safe and sound operation of the complete system.

6
 Checking up of each individual items of plant equipment and also each pipeline, to
ensure that the erection of these items has been properly carried out in conformity
with the technical specification.

After all the installation and assembly work is completed the entire plant assembly
including the pipe lines shall be checked up, by proper tests applicable to ensure that
individual items of equipment, including pipe line have been properly installed.

Machines like compressors, pumps shall be checked up by actual working to satisfy

that their alignment has been properly made and there are no mechanical faults.

Pipe lines shall be checked up by hydraulic tests to make sure that all valves, flanges
etc., have been properly fitted up to that there are no leakages or wrong connection of
interconnecting valves, pipes etc. Similarly all duct work shall be tested to ensure that
air leakages rates are within the limits prescribed in the specification.

Instruments shall be checked up individually to make sure that they are in proper
working order. The testing shall be in accordance with INDIAN STANDARDS or
accepted International Standards. All instruments used for testing and measurements
shall be calibrated instruments acceptable to National level standards.
The performance of the aforesaid services should confirm strictly to the ENGINEER'S
technical specification, which forms an integral part of ‘THIS CONTRACT’.

It is only after the entire plant assembly has been thoroughly checked up on the lines
indicated above and found satisfactory that erection work shall deemed to be
completed and the plant considered READY FOR COMMISSIONING.

The Contractor shall also provide in his cost, framed duct layouts for the public areas
to be mounted centrally for the convenience of the fire protection staff.

Plant and equipment details shall also be prominently displayed in engraved plastic
name plates.

3.0 QUALITY ASSURANCE REQUIREMENTS

General

Quality Assurance (QA) requirements form an integral part of the contract and all
contractors are required to comply.

Scope

The scope of QA requirements is as follows:

7
 a) Preparation of a Quality Assurance Plan by the Contractor, which is referred
to as “CONTRACTOR’S QUALITY PLAN” or CQP. Contractors / system
integrators to submit their QC plan including QC process flow chart, mock
up inspections, quality assurance site inspections forms templates for all
MEP trades as a part of this bid.

b) Performance of:
- Quality Assurance (QA) and
- Quality Control (QC) activities at site

c) Documentation of the above

4.0 TENDER DRAWINGS

The Drawings issued with this Specification are for guidance of the CONTRACTOR and
show the approximate positions of all items of equipment, etc. The actual and final
position of all items of equipment shall be determined at site and approved by the
Consulting ENGINEER. CONTRACTOR is to ensure that their proposal will meet with
all the current rules and regulations of the relevant authorities in India.

5.0 SHOP DRAWINGS

a) Before any work is put in hand, the Contractor shall submit Eight (8) sets of
dimensioned Drawings showing all details of the equipment, piping, wiring,
ductwork and materials etc. to be used, to the Consulting ENGINEER for review.
The Contractor shall not commence final connection works until the Drawings
are reviewed by the Consulting ENGINEER.

b) Review of Drawings by the Consulting ENGINEER does not exonerate the

Contractor from any responsibility under the Contract terms and conditions.

c) The detailed Shop Drawings, prepared at a minimum scale of 1:100, plus

necessary detail plans and cross sections at a scale of 1:50, showing complete
detail of each item of specially fabricated equipment shall be submitted to the
Consulting ENGINEER for his review before proceeding with fabrication. These
Drawings shall be based upon the floor plans and the following specifications.
These Drawings shall include accurately dimensioned details and locations of
any special wall openings that are required where items of equipment extend
through walls.

d) If early review is required, the Contractor shall advise the Consulting

ENGINEER to this effect when submitting the drawings.

e) The Contractor shall forward eight (8) sets of the reviewed shop drawings to
the Consulting engineer for distribution to interested parties.

8
6.0 WORKING DRAWINGS

The Contractor shall at all times maintain on site, in good order and condition, a
complete set of all Drawings and Documents necessary for the proper execution and
checking of the Works. These Drawings and Documents shall be made available on
request to the Consulting ENGINEER or other authorised persons on site. Any
amendment shall be indicated on the Drawing, dated and signed by the Authorised
person in charge, with reasons stated if possible.

7.0 AS- BUILT DRAWINGS

a) Two sets of as-built paper prints of diagrams and schedules as in the opinion of
the Consulting engineers, which shows an accurate record of the work as
installed by the Contractor to be submitted to the Consulting ENGINEER for
approval. When approved, the Contractor shall submit three (3) sets of paper
prints, one (1) set of soft copy of the approved As-Installed Drawings for
reference and record for the Consulting ENGINEER.

b) Such records shall include the preparation of properly dimensioned drawings

showing the following:

i) General arrangement of all services

ii) Cable routes, types of fixings, layout, support and other particulars;

iii) The detailed layout of all equipment, plant chambers, etc;

iv) Conduit runs, pipe runs, duct work, etc.

v) A system diagram giving means of identification, circuit labelling and

mounting level of equipment, etc., provided under the Sub-Contract;

vi) Schedules of all equipment installed.

c) All Drawings submitted by the Contractor shall have in the bottom right hand
corner in addition to the Contractor’s name, title, scale, date and drawing
number, the title of the project and subject of the drawings.

d) The retention sum or final payment will not be released until all such drawings
and records have been received and approved by the Consulting ENGINEER.

e) One copy of the schematic drawing, isometric or layout drawing showing all
equipment, controls, connections, etc. shall be framed and hung in the relevant
Plant Room or location as directed by the Consulting ENGINEER.

9
8.0 TESTING AND COMMISSIONING

a) General

Testing shall mean providing that all of the systems efficiently meet the performance
specified while in operation. The systems shall be tested in the presence of the
Consulting ENGINEER who requires at least two full working days prior notice to
enable him to attend.

The Contractor shall arrange for representatives of any of his own sub-Contractor to
be in attendance.

It shall be the responsibility of the Contractor to supply all necessary testing

equipment including pitot tube and manometer, anemometer, newly calibrated
pressure gauge, etc. Provision of all testing equipment and the appropriately skilled
labour shall have been included in the Tender Price.

Should anyone of the tests reveal a fault, the Consulting ENGINEER will order that the
fault be corrected and re-tested prior to acceptance. All fees connected with testing of
equipment payable by Contractor to any of the relevant Government Authority shall
be borne by the Contractor.

b) Commissioning Test

i) The complete installation or any part thereof shall be tested, both before and
after being commissioned to check the performance in operation. All fees
connected with testing of equipment payable by the Contractor to any of the
relevant Government Authority or expert from the Supplier shall have been
included in the Tender Sum.

ii) The contractor shall be represented by a competent person approved by the

Consulting ENGINEER during the whole of the period required for the tests.

iii) All materials and equipment supplied or erected under this Contract which fail
the tests shall be replaced or rectified at once by the Contractor without cost to
the EMPLOYER.

iv) The Contractor shall supply all necessary instruments, apparatus, connections,
skilled and unskilled labour required for the tests to be conducted in the
presence of the Consulting ENGINEERS, make accurate records of all tests
carried out and furnish the Consulting ENGINEERS with four (4) COPIES OF
THE Test Certificates and Schedule of Test Results in approved form.

10
 v) The Contractor shall prepare a detailed and comprehensive check list for use
during commissioning and testing. At least four (4) months prior to the start of
commissioning, the Contractor shall commence gathering information required
for this check list. Two (2) months prior to the start of commissioning, the
Contractor shall submit to the Consulting ENGINEER his proposed check list for
approval as follow:-

1) Ensure that all items that should be checked are included.

2) Produce a permanent record of the commissioning checks carried out.

iii) Accordingly, the checklist must be built from information contained in the
Specification, from Suppliers, SUB-CONTRACTOR’s and Contractor’s installation
and commissioning similar equipment and systems.

iv) The detail of the checklist must be such that it can be completed with a reading
or a tick, which means that every device listed, has been checked.

c) Reliability Tests After Commissioning

i) The installation shall be required to operate within the specified limits

of its rating either continuously or intermittently as may be convenient
without failure of any kind for a period of on (1) calendar month before
the provisional taking over certificate is issued. Final taking over and
acceptance certificate will be issued only after 72 hours performance
test in peak summer, peak monsoon, and peak winter.

ii) Should any failure occur due to or arising from faulty design, materials
or workmanship, but not otherwise sufficient to prevent the commercial
use of the installation, the reliability test period of one (1) calendar
month shall be recommenced after the Contractor has remedied the
cause of failure to the satisfaction of the Consulting ENGINEER. The onus
of proving that any failure is due to any other cause shall rest with the
Contractor.

d) Testing and Adjustment During and After the Maintenance Period

In addition, the Contractor shall perform such test as may be directed at any time
during the Maintenance period to satisfy the Consulting ENGINEER that the
installation complies with the specified requirements.

11
9.0 OPERATING MANUALS

The Contractor shall prepare three (3) copies of an operating manual, in a stiff-
covered ring binder two (2) for the EMPLOYER and one (1) for the Consulting
ENGINEER, describing the operation and maintenance of the whole system and
including:-

a) Installation and commissioning reports, as built drawings, handover reports,

and green building commissioning reports.

b) Operating instruction for all equipment

c) SUB-CONTRACTOR’s pamphlets for all equipment including head / flow curves

for all pumps with impeller size marked;

d) List of spares recommended;

e) Schedule of Recommended Maintenance.

Practical completion will be certified after the receipt of the above operating manual
by the Consulting ENGINEER.

10.0 IDENTIFICATION AND LABELLING

Parts of the Works shall be properly labelled and identified. The contractor shall carry
out the following work:-

i) Machine engraved traffolyte nameplates shall be provided to identify majority

of equipment. Similar labels will indicate the function of ancillary equipment
such as gauges, control valves, switches, indicating lights, push buttons, relays
and other indicating devices.

ii) Lettering shall be black on white background. Nameplates for major items of
equipment shall be engraved in lettering of at least 6 mm. Labels identifying
ancillary equipment shall be engraved in lettering of at least 3 mm.

iii) Identification lettering shall be applied to all pipe work and to all conduit at the
following spacing: -

1) For all concealed runs in walls or ceiling spaces, every 5 metres but at least
once.

2) For exposed runs, every 10 metres but at least once for each exposed section.

12
 The identification shall consist of stencilled painted black lettering 25 mm high
naming the services.

11.0 PLANT OPERATION

The EMPLOYER shall have free and unrestricted use of the Contract Works or any part
thereof which the Consulting ENGINEER may deem suitable without any interference
whatsoever from the Contractor and such use by the EMPLOYER shall not relieve the
Contractor of any liabilities or obligations in regard to the Contract.

12.0 TESTING

Routine and type for various items of equipment shall be performed at the SUB-
CONTRACTOR's works and test certificates shall be furnished. The EMPLOYER or his
authorised representative reserves the right to be present during the tests.

After notification to the EMPLOYER that the installation has been completed, the
Contractor shall make under the direction of EMPLOYER such tests and inspections as
have been specified or as the EMPLOYER shall consider necessary to determine
whether or not the full intent of the specifications have been fulfilled and whether
further tests shall be considered necessary. The Contractor shall bear all the expenses
thereof.

The Contractor shall operate, test and adjust all air-conditioning, ventilation and
exhaust system units, fan motors, all air handling appliances provided in connection
with the installation and shall make all necessary adjustments and corrections thereof
including the adjustments of all regulating dampers. A carefully detailed record of the
results of these adjustments shall be furnished to and be subject to the approval of the
EMPLOYER.

12.1 Performance Test

A performance test by keeping the plant running for a period of 72 hrs. Shall be
carried out in peak summer, peak monsoon and peak winter periods. During the tests
all necessary readings shall be taken hourly. From the readings so taken, the
Contractor shall also establish the plant capacity. The computed results shall tally with
the specified capacities furnished with Tender.

The contractor shall install in the system temperature probes, flow meters, pressure
gauges etc., to verify the capacity of the various equipment.

All the test equipment instruments, labour, operating personnel, oil and refrigerant
required for these tests shall be furnished by the Contractor at his own cost.

13
 If the test do not show satisfactory result, the Contractor shall at his own cost, rectify /
replace and defective installation or part thereof as directed by the EMPLOYER within
two months. The decision of the EMPLOYER shall be final and binding in this respect.
Only after all these tests are satisfactorily completed and the defects found during
these are rectified, the plant will be finally accepted.

12.2 Testing Guarantee

All equipment and space conditions shall be tested after carrying out necessary
adjustments and balancing to establish the equipment ratings and indoor space
conditions. At least four sets of readings shall be taken daily for each item tested and
submitted in the form shown separately. Instruments required for testing shall be
furnished by the Contractor.

All equipment shall be guaranteed for the specified ratings with a tolerance of 0% on
the minus (negative) side.

All equipment’s and the entire installation shall be guaranteed against defective
materials and workmanship for a period of 24(twenty four months from the date the
equipment and installation are handed over.

12.3 Reports

Provide 3 copies of the complete balancing and testing reports to the EMPLOYER /
Consulting engineer. Report shall be neatly typed and bound suitable for a permanent
record. Report forms shall contain complete test data and equipment data as specified.

13.0 BALANCED SYSTEM

The Fluid System Balancing Contractor shall leave the system operating in complete
balance with water and air quantities as shown on drawings. Set stops on all balancing
valves and lock all damper quadrants in proper position. Secure all automatic damper
and valve linkages in proper positions to provide correct operating ranges. Proper
damper positions shall be marked on ducts with permanent indication. Notify the
EMPLOYER of any areas of marginal or unacceptable system performance.

All systems to comply with seamless integration on BACNET protocol as a

standardised integration protocol for BMS.

14
14.0 TRAINING

Upon commissioning and final handover of the installation, the Contractor shall
submit (within 4 weeks) 3 copies of operating instructions, maintenance and service
manuals, part lists and all final drawings and diagrams, indexed and bound together in
hard cover ring binder.

The Contractor shall conduct a training programme for designated EMPLOYER’s

personnel. These courses shall be carried out during normal office hours and not be
less than 1 month’s duration. The date of commencement of training shall be mutually
agreed upon and in any case shall be within two weeks of handover of installation.

The training programme shall cover all operating and maintenance aspects of the
system, inclusive of detailed explanation and demonstration of each and every piece of
equipment and an overview of the system network.

The training programme shall consist of both handouts and classroom training at the
job site or at location agreed upon by the EMPLOYER.

All instruction manuals, tools, transportation, etc. association with the training
programme shall be provided by the Contractor. Such cost shall be deemed to have
been included in the CONTRACTOR programme.

15.0 GUARANTEE

The Contractor shall guarantee the inside conditions as stipulated elsewhere. In

addition, the Contractor shall also guarantee that all equipment shall be free from any
defect due to the defective materials and bad workmanship and that the equipment
shall operate satisfactorily and the performance and efficiencies of the equipment
shall be not less than the guarantee values.

The guarantee shall be valid for a period of 24 months after taking over and any parts
found defective shall be replaced free of all costs by Contractor. The services of
successful Contractor’s personnel if requisitioned by the EMPLOYER during this
defects liability period for such work shall be made available free of any cost.

The Contractor shall without any extra cost carry out for a period of 24 (twenty four)
months after the installation is taken over, all routine and special maintenance of the
plant and attends to the defects that may arise in the operations of the plant.

Maintenance will consist of monthly maintenance and necessary adjustment and

lubrication of the equipment by the Contractor’s employee under competent direction
and supervision. In addition to the monthly maintenance, special examination
between regular intervals and emergency minor adjustment, call back services should
be provided during the guarantee period.

15
 Parts that become necessary due to normal wear and tear during the guarantee period
will have to be replaced free of cost.

In case of any defect or malfunctions of the equipment during the period of

maintenance, immediate attention must be ensured without claim to any extra
amount, charges or compensation.

All the maintenance work will be performed during regular hours of regular working
days. However the works in condenser coil and cleaning of cooling coils etc., should be
carried out only during the holidays with prior permission from the EMPLOYER.

One month before the end of the defects liability period, the Contractor shall notify the
EMPLOYER of the required inspections for all equipment and facilities including
specific energy consumption.

16.0 MAINTENANCE IN WARRANTY PERIOD

The CONTRACTOR shall furnish warranty for the entire system for a defect liability
period (DLP) of twenty four (24) months after the final official hand over date of the
installation. This period shall include maintenance replacement of parts, regular
periodic visit by qualified personnel of the CONTRACTOR and attending to emergency
call at short notice.

16.1 CONCLUSION OF 24 MONTH WARRANTY PERIOD

Just before the expiry of the warranty period of the Contract, the Contractor shall carry
out a complete system operability test on all the systems or sub-systems as called for
in the Contract.

The purpose of the test is to verify that the performance of all the systems of sub-
systems in the Contract is in accordance to the specifications.

All tests shall be carried out in the presence of the EMPLOYER or his representative.

The warranty period is deemed to be over if the EMPLOYER or his representative is

completely satisfied with the system performance during the test.

17.0 COMPENSATION FOR SHORTFALL IN CONTRACT RATINGS.

Ratings / Capacities of the Plant

There shall be no credit to the CONTRACTOR if the output of the plant is higher than
the rated capacity. There will be zero percent (0%) tolerance for the rated capacity on
the negative sides.

16
 During performance tests in case of any shortfall in the contracted system /
equipment capacity, the Contractor will be given a chance to make adjustments after
which the Performance test will be conducted again at the Contractors expense. In
case the equipment does not meet the contract rating the equipment will have to be
replaced at the cost of the Contractor within a reasonable period of time as will be
indicated by the EMPLOYER and as per Performance as Guaranteed in the Tender.

17.1 TAKING OVER CERTIFICATE

As soon as the Works have been completed in accordance with the Contract and have
passed the tests on completion, the Consulting ENGINEER will issue a provisional
certificate (hereinafter called the provisional Taking over Certificate) in which he shall
certify the date on which the Works have been successfully commissioned.

18.0 MOCKUPS AND SAMPLES

The Contractor shall construct mock-ups of typical installations of services and

common items of equipment as and when directed by the Consulting engineer. Mock-
ups shall be constructed to ensure proper installation and coordination of all services
on site.

Upon approval, mock-up shall be used as the basis of installation work for similar
areas.

Samples of components, fixtures, etc. shall where required, submitted to the

consulting engineer for approval before commence of the installation work.

18.1 BRAND NAME / MAKE OF EQUIPMENT

For the main air-conditioning plant, CONTRACTORs are required to offer only the
‘Brand’ makes / as indicated elsewhere in the specification of to ensure fair evaluation
of proposal. It is to be noted by the contractor that materials / equipment, for which
brand / make has not been specified, the contractor shall use only reputed makes. The
contractor shall submit a list of such brands / makes to the consulting engineer along
with his offer for approval.

18.2 SITE MANAGER & SITE ENGINEER

The site engineer posted at site shall have adequate experience for handling a job of
this magnitude. The resume of the site engineer shall be submitted to the Consulting
engineer for approval along with the offer.

17
18.3 CONSUMABLE MATERIALS DURING CONSTRUCTION, COMMISSIONING TESTING
AND SUBSEQUENT WARRANTY PERIOD

The Contractor shall supply at his own cost the following consumable materials as and
when required.

(a) (a) Water and electricity for testing & commissioning will be free,
(b) Owner shall not be responsible for water and electricity required for the execution of
project

(c) All oils and greases required for lubrication of compressors, fan bearings, motors
bearings, pivots and other moving parts.

(d) All refrigerant required replacing refrigerant losses in the refrigerant systems.

(e) All consumable, filter elements / rolls.

(f) All Chemicals for the correct chemical treatment of the chilled water system.

(g) All carbon brushes required to replace worn brushers in electric motors.

(h) All electric contact points required to replace worn electric contact points in
switchgears, motor starter gears, electronic control gears and electric relays.

(i) All electric fuses required to replace blown fuses.

(j) All cotton waste, soap detergent and other cleaning materials required for cleaning
purpose.

The cost of these consumable materials shall be included in the contract Price.

After every inspection and service, the Contractor shall submit a written report to the
EMPLOYER with a carbon copy extended to the Architect.
19.0 PAINTING & LABELLING

General

Unless otherwise specified, all exposed surfaces including trunkings and cable tray,
ductwork, equipment, etc., shall be thoroughly cleaned and painted.

All ferrous metal surfaces without protective finishes shall be painted, except surfaces
of moving parts, which shall be thoroughly oiled and greased as required.

18
Non-ferrous surfaces may be left unpainted unless called for in this specification or
required by the Architect for the purposes of colour coding and identification.
Aluminium grilles and diffusers shall be powder coated with colour approved by the
architects.

All bare surfaces requiring painting shall first be given a priming coat followed by an
undercoat and two finishing coats.

Colour Scheme

All services shall be painted in accordance with following colour scheme:-

Service Colour
Chilled water flow Blue
Chilled water return Light Blue
Condenser water flow Grey
Condenser water return Light Grey
Drain Black
Cooling Tower water make up Green
Cooling tower bleed off line Brown
Chemical lines for water treatment Brown
Chillers, Pumps, Switchboard, Local Control Jade Green
Panels
Hangers, Supports, Framework, Valves, To match surrounding
Fittings, etc.
Registers, Diffusers and Grilles To match surrounding
Surface behind Registers, Diffusers and Matt Black
Grilles
Air Handling Unit Fan Coils and Fans Jade Green
Ductwork To match surrounding

Sign Writing

All major items of equipment shall be identified with approved names and / or
numbers of suitable size in proportion to the size of the respective items.

19
 Pipelines shall be painted in contrasting colour directional arrows adjacent
connections, valves and branches and at intervals of not more than 2.5 mm. These
arrows shall be 75 mm long on pipes up to 50 mm diameter and 150 mm long on pipes
over 50 mm diameter.

All stop valves and control valves the function of which is not obvious shall be
provided with a non-corroding metal or laminated plastic identification tag. The tag
shall indicate the service, and the area or items which the valve serves.

20.0 CONTROL OF NOISE & VIBRATION

This section of the specification coves the supply, delivery, installation and testing of
Noise and Vibration Control equipment to be used in the isolation of the various
Mechanical equipment as called for in this specification.

It is the intent of this specification that noise levels due to mechanical equipment and
related services will be controlled to the design objectives stated herein, in all
occupied areas. The requirements specified are considered to be the minimum
precautions necessary to achieve these objectives. The entire installation shall operate
without objectionable noise and vibration as determined by the Architect.

The contractor shall examine all drawings and specifications including architectural
and structural sets of working documents, before commencing any work on the
project and shall immediately bring to the Architect’s attention any characteristics or
properties of the building or any other factors which, in his opinion, would jeopardize
or nullify the attainment of the design objectives.

The contractor shall guarantee that the complete plant and installation when operated
within the design criteria shall acoustically perform to the noise criteria ratings
specified.

The chiller package shall be mounted on steel springs in series with neoprene. Limit
stops are required to limit travel when machine is drained. A steel base frame suitable
for point loading of the Chillers shall be provided as approved by the Architect.

Pumps

(a) All pumps shall be selected for the highest efficiency consistent with the specified
duty and pump impeller diameter shall not exceed 0.9 of the maximum impeller
diameter capability of the pump housing to reduce the possibility of tonal effects.

(b) Pump impellers, shafts, and drive couplings shall be statically and dynamically
balanced to the best commercial standards, and vibration amplitudes shall not
exceed 0.02 mm peak to peak displacement at 1500 rpm when measured on the

20
 machine structure, with the pumps / motors mounted on the inertia blocks
specified.

(c) The pump and motor-assembly shall be mounted on a concrete filled inertia block
and completely isolated. Pump inertia block shall size to support the weight of
elbows, valves and other fittings without creating undue stress on the pump
assembly.

(d) Pump speeds shall not exceed 1500 rpm.

Air Handling Units & Ventilation Fans

All air handling units shall be mounted on steel spring isolators in series with
neoprene pads.

All fans, shall have complete impeller assemblies including drive components,
statically both dynamically balanced to the following maximum allowable vibration
criteria.
Equipment Maximum Allowable Vibration
Peak to Peak Displacements as
measured on equipment (mm)
Ventilation and Air Handling Units
(Centrifugal fans)
Under 600 rpm 0.1
600 – 1000 rpm 0.075
1000 – 2000 rpm 0.05
Over 2000 rpm (impeller speed) 0.025

As part of this Contract, the Contractor shall supply the Sound Power Levels (re 10-12
Watt) of all fans and AHUs offered.

All air-handling units shall be fitted with sound attenuators on the supply main ducts
downstream close of main plenum close to the AHU room. The performance values
(dynamic insertion losses, air quantities, frictional losses) are given as a guide only
and the precise requirements will depend on final fan selections, duct layouts, design
criteria for various areas. In cases where fan and AHU sound power levels exceed the
values lifted in the schedule, additional attenuation may be required.

21
The contractor shall submit, with the proposed shop drawings, his Sound Attenuator
selections based on these factors. Where additional fan attenuation is required on fans
(to meet the noise criteria), this shall be provided by the contractor at no additional
cost to the EMPLOYER.
Acoustic performance of the sound attenuators (net insertion loss) shall meet or
exceed the values listed below.

Octave Band Centre Frequency (Hz)

Insertion loss 63 125 250 500 1K 2k 4k 8k

dB 6 10 18 30 42 34 23 14

Contractor shall submit a test certificate for acoustic and aerodynamic performance of
the attenuators. The insertion loss and self-generated noise for each octave band along
with pressure drop shall be stated.

Miscellaneous Equipment
All equipment located in plant rooms above or under occupied areas and capable of
producing noise or vibration shall be isolated from the structure. Acoustical isolation
by neoprene/fibreglass, cork pads is required for tanks, electrical switchboards, etc.

Testing on Completion

Sound level and vibration measurement shall be made by a testing authority approved
by the consulting ENGINEER. Should the tests show that noise or vibration is in excess
of those specified, or that balancing of equipment is incorrect, or that vibration
transmission through mountings, hangers, etc. is excessive the contractor shall correct
the installation at his own cost. Further tests shall then be carried out at the
contractor’s cost to show that the noise and vibration levels have been reduced to the
limits specified.

Sound level readings shall be taken at times when the building is unoccupied or when
activity in surrounding areas and background noise levels in areas tested, are at a
minimum and relatively free from sudden changes. Readings shall be taken with no
other equipment operating and with all plant, capable of transmitting sound to the
space tested in operation.

All apparatus used for sound and vibration measurements shall be approved by the
consulting ENGINEER.

Noise levels shall be measured with Sound Level meter fitted with an octave band
analyser and conforming to International standards. Overall sound levels shall be read

22
on ‘A’ scale of the meter and octave band sound levels on an octave band analyser
connected to the meter with its C-scale network in use.

23
 SECTION 4.02
STATUTORY REQUIREMENTS

24
1.0 The ACMV system shall meet the requirements of Energy Conservation building code
(ECBC), BCA-GreenMark Platinum requirements, Leadership in Energy and
Environmental Design (LEED) Platinum standards, National Building Code of India
(NBC) and Tariff Advisory Committee (TAC). Contractor shall erect the ACMV system
to comply with the minimum requirements listed below:

1.1 Duct insulation material (thermal as well as acoustic insulation) should have flame
spread rating of not over 25 without evidence of continuous progressive combustion
and with a smoke development rate not higher than 50 (As per ASTM E 84)

1.2 In the installation of the ACMV system ducts it is important to avoid the possibility of
duct being the means of fire spread. Therefore fire dampers must be provided at the
following locations.

At all locations where the ducts penetrate fire walls. The dampers shall be of
motorised type with a rating equivalent to the fire walls in which they are placed.

Where the ducts cross floors. This applies to all ducts located in Steel shafts. The
dampers provided shall be of motorised type with minimum 90 minutes fire rating. At
any other location required by NBC or NFPA 90A. At all locations shown on enclosed
drawings

Holes for the passage of ducts or pipes in walls, floor or roof shall be completely sealed
with fire stopping materials to the full thickness of wall / roof floor.

All shafts utilised for ACMV ducts and pipes shall be properly sealed and fire stopped
at all floor levels.

1.3 Air – conditioning shall conform to the following:

Escape routes like staircases, common corridors, lift lobbies, etc., shall not be used as
return air passage.

The ducting shall be constructed of substantial gauge metal in accordance with good
practice.

The materials used for insulating the duct system (inside or outside) shall be of non-
combustible materials.

Ducts shall not pass through the staircase enclosure.

25
 The air-handing units shall be separate for each floor and air ducts for every floor shall
be separated in no way interconnected with the ducting of any other floor.

The air filters of the air-handling units and fan coil units shall be of non-combustible
materials.

The air-handling unit room shall not be used for storage of any combustible materials.

Inspection panels shall be provided in the main trunking to facilitate the cleaning of
ducts for accumulated dust and to obtain access for maintenance of fire dampers.

All fire dampers shall be UL 555 rated.

GREEN MARK REQUIREMENT

The project aims to achieve Green Mark (Singapore) Platinum statuses under New
Building Category (version4.1) thus the following requirements must be meet as part of
GM compliance. Kindly note that the following refers to Green Mark requirements only for
details kindly refer to respective disciplines tender doc.

PRE – REQUISITE REQUIREMENT:

1. Contractors to performance HEAT BALANCE TEST as per AHRI 550/590 and per BCA
GM requirements.
2. Provide PERMANENT MEASURING INSTRUMENTS for monitoring of water cooled
chilled water system efficiency for the purpose of measurement & verification of
systems. The installed instrument shall have the capability to calculate resultant plant
efficiency within 5% of its true value in accordance with ASHRAE Guide 22, AHRI
550/590 and BCA GM requirements. The permanent instrument shall comprise of
thermistor, flow and power measurement system; each measurement system shall
include the sensor, any signal conditioning, the data acquisition system and the wiring
connecting them.
i) Location and installation of the measuring devices to meet the manufacturer’s
recommendation.

26
ii) Flow meters for chilled and condenser water loop shall be ultrasonic / full bore
magnetic type or equivalent.
iii) All data logging with capability to trend at 1 min sampling time interval.
iv) Data acquisition system i.e., data loggers shall have a min resolution of 16 bit.
v) Dedicated data loggers are to be provided for each of the following groups of
equipment: chiller, chilled water pump, condenser water pump and cooling tower.
vi) Thermistor are to be provided for chilled water and condenser water loop and the
measurement system shall have an end to end uncertainty from the temperature
sensors to the read out devices not exceeding +- 0.05c over the entire
measurement or calibration range. All thermo – wells shall be installed in a manner
that ensures that the sensors can be in direct contact with fluid flow. Provision
shall be made for each temperature measurement location to have two spare
thermo – wells located at both side of the temperature sensor for verification of
measurement accuracy.
3. All major electricity consumption such as ACMV, electrical and receptacle usage must
be sub – metered and linked to BMS for continuous monitoring purpose.

COOLING SYSTEM:

 Water – Side Efficiency: The project aims to achieve an overall chiller plant efficiency
of less than 0.7 kw/RT with water – cooled chilled water plant system.
 Air – Distribution System Efficiency: The ratio of the fan system power to the
supply fan air flow rate (main fan) of each air conditioning system at design conditions
shall not exceed the allowable fan system power as shown in below table. Selection of
fan shall be subject to S.O.'s approval

ALLOWABLE FAN INPUT POWER > 4KW

VARIABLE VOLUME 0.67W/cmh
ALLOWABLE FAN INPUT POWER < 4KW
0.14W/cmh

27
 Mechanical ventilation system Efficiency:

ALLOWABLE FAN INPUT POWER > 4KW

VARIABLE VOLUME 0.294 W/cmh
ALLOWABLE FAN INPUT POWER < 4KW
0.14W/cmh

 VSD Control: All air – side system (>4kw), cooling tower fan and chilled water pump
must be provide with variable speed drive (VSD) by the Contractor
 CO2 Control: all AHU must be provided with CO2 sensors and linked to BMS to
control the fresh air intake.

INDOOR AIR QUALITY PERFORMANCE:

To promote a healthy indoor environment;
 In Occupied areas to provide means to monitor co2 and particular filtration media in
accordance with SS 554 : 2009 code of Practice for indoor air quality for air –
conditioned buildings
 In unoccupied space and server areas to provide means to supply treated ventilation
air on demand.

REFRIGERANTS:

 Use of refrigerants with ozone depletion potential of zero or with global warming
potential of less than 100
 Use of Refrigerant leak detection system in critical areas of plant rooms containing
chillers and other equipment with refrigerants

INDOOR AIR QUALITY PERFORMANCE:

Provision of filtration media and differential pressure monitoring equipment in AHU

in accordance with SS 554 clause 4.3.4.5 and its annex E.

28
THERMAL COMFORT:
All occupied space should comply with SS 553 for thermal comfort in terms of
temperature and RH level , indoor operative temperature between 24 C to 26 C with a
relative humidity <65%.
NOISE COMFORT:

All occupied space should comply with SS 553 for noise comfort (low dbA rating)

29
 SECTION 4.03
SCOPE OF WORK

30
1.0 SCOPE OF WORK

Scope of work under this package covers the supply, installation, inspection and
testing including performance testing at CONTRACTORs works and / or his sub-
contractors’ works, delivery to site, storing and handling at site, erection,
commissioning and carrying out acceptance tests at site of the Air-Conditioning and
Mechanical Ventilation system (ACMV) system. Related electrical works and BMS
works will be executed by the Electrical & BMS contractor. The AC contractor should
co-ordinate with the above contractors for proper installation & commissioning.

It is not the intent to specify completely herein, all the details of design and
construction of the equipment and system. However, the equipment and system shall
conform, in all respects, to high standards of engineering, design and workmanship
and be capable of performing in continuous commercial operation up to the
Contractor’s guarantee in a manner acceptable to the EMPLOYER / Consulting
engineer who will interpret the meaning of drawings and specifications, and shall have
the power to reject any work or materials, which, in his judgement, are not in full
accordance therewith.

The extent of supply under this contract includes all items shown in the bid drawings,
not-withstanding the fact that such items may have been omitted from the
specification or schedules. Similarly, the extent of supply also includes all items
mentioned in the specification or schedules, not-withstanding the fact that such items
may have been omitted in the drawings. Also such of those items not specifically
included in the specifications and drawings, but which are required to complete the
intent of the contract shall also be deemed to be within the scope for supply of the
Contractor.

2.0 ACMV COMMISSIONING REQUIREMENTS

COMMISSIONING TEAM INVOLVEMENT

The commissioning team is responsible for accomplishing the commissioning process
activities and provides leadership for identifying & resolving all commissioning
process issues. Contractor has to submit Commissioning plans to the team. The
commissioning team is composed of following parties
 Architect

 Mechanical design engineer

 Electrical design engineer

 Owner's design representative

31
  Client’s Engineer

 Owner's construction representative

 A representative of the facility's operations staff.

2.1 OPERATIONS & MAINTENANCE DOCUMENTATION

▪ The Commissioning Procedures / Manuals must be prepared by the contractor,
which would be reviewed & approved by the Commissioning Authority (CA). The
draft documents must be submitted before the completion of installation for final
approval from CA.
▪ Supplier must submit the O&M manuals clearly explaining the start-up & safety
checkout procedures along with other operational procedures. The manuals must
contain the detailed daily, monthly, weekly & yearly maintenance procedures &
details.
2.2 INSTALLATION VERIFICATION PROCEDURES

▪ The contractor must submit a detailed Installation & Construction Plan clearly
mentioning the sequence of activities (with checklists) to be performed to achieve
the design intent and maintain the quality protocol as mentioned in the
mechanical design.

2.3 START UP PLAN DEVELOPMENT & IMPLEMENTATION

▪ Pre-functional Checklists for commissioned equipment will be furnished by the

Commissioning Authority (CA). These must be completed and signed by the
Mechanical Contractor.

▪ Supplier will do the commissioning & perform the start-up & safety checkouts of
all individual equipment under the supervision of CA.

2.4 MEASUREMENT AND VERIFICATION

▪ Contractor shall install permanent measuring instruments for monitoring of

water-cooled chilled water plant efficiency. The installed instruments shall have
the capability to calculate resultant chilled water plant efficiency within +/- 5% of
the true value and in accordance with ASHRAE Guide 22 and AHRI 550/590.
Procuring measuring instruments, necessary hardware and software shall be BMS
contractor scope. ACMV contractor shall install all the instruments/ equipment’s
▪

32
 ▪ in supervision of BMS vendor. Also, ACMV contractor shall extend all necessary co-
ordination required to complete the measurement and verification process.

2.5 FUNCTIONAL PERFORMANCE TESTING

▪ Supplier will perform the functional testing of each equipment under the
supervision of CA. Heating equipment would be tested in winter season and air
conditioning equipment would be tested in the summer season.

▪ The testing of chilling machine and /or other equipment whose performance is
linkable to the climatic conditions would be done every month for one year after
installation to verify the performance of the unit at different load & climatic
conditions

▪ Supplier must provide the Performance Characteristics & Curves showing the
equipment performance trends at part loads & full loads & at different climatic
conditions.

▪ Supplier must submit the relevant test certificates / undertakings (ASHRAE /ARI
certification if applicable) for each individual equipment (required for LEED). All
the major instrumentation including CO 2 ventilation control system etc. would be
calibrated & tested by the supplier.

▪ Supplier will assist CA to conduct M & V of the equipment / system after functional
testing.

▪ All the testing & calibration would be done using ASHARE standards & IPMVP
protocols wherever applicable and required.

3.0 TRAINING

▪ Supplier must provide the Training Manuals for the operational staff prior to the
commissioning process. The draft training manuals must be submitted which
would be reviewed by CA. Training manual must clearly mention the training plan
and the scope of training.

▪ Before the start of commissioning, the supplier will conduct detailed training for
the operation staff.

33
4.0 GENERAL NOTES ON EQUIPMENT SELECTION

 Chiller Refrigerant:
Refrigerant should be HFC based (eg R134A)

 Motor & Pump Efficiency:

All the pumps including chilled water pumps & condenser water pumps must be
selected with the highest possible pump efficiencies.
All Motors should be of High Efficiency as per ASHRAE 90.1 Standards.(Or
efficiency class1)

Pump Logic Controller is to be considered for variable primary chilled water

pumping system.

 Cooling towers: with FRP (Fibre-Reinforced Polymer) blades are recommended.

Cooling towers to should be CTI certified.
Cooling tower fan & motor efficiency should be as per ASHRAE 90.1,and the fan
should be provided with VFD.

▪ Air Handling Units:

Fans should be of high efficiency Electronically commutated motors

▪ Variable frequency drives:

Variable frequency drives to be provided for all the AHUs ( need not consider in
the case of EC fans) &fresh air and exhaust fans of Heat recovery unit Primary
chilled water pumps.

▪ BMS compatibility:

Following equipment’s shall have BMS compatibility i.e. necessary hardware

should be supplied with the equipment which will support the communication
protocol used by BMS contractor. BMS compatibility should be preferably on
BACnet.
 Chillers
 Water flow meter for each chiller.
 Variable frequency drives / Pump logic controllers

34
 ▪ Paints & Adhesives:

Paints & Adhesives used for the Air conditioning work should have Low VOC
content as recommended for Greenmark certification.

5.0 CONSTRUCTION IAQ MANAGEMENT:

5.1. DURING CONSTRUCTION:

During Construction Following measures to be taken by ACMV contractor to prevent

indoor air quality problems at a later date.

▪ ACMV ducts and equipment’s (viz. Chillers, AHUS, Fans, Water Pumps, Valves, VFDS)
will be protected from dust entry and moisture.

 Equipment’s mentioned above to be stored in such a place such that it does

not get affected by the dust, debris, water and other contaminants. Covering
should be a good quality Plastic sheet or a Tarpaulin.

 Duct Ends to be covered by plastic sheets which in turn should be tied firmly
with String or Chord and not to be stuck by Cello tape or any other tape
which later on come off defeating the purpose.

▪ All electrical panels will be covered with water proofing covers to protect from
water entry.

▪ All construction workers will be provided with dust control masks to prevent from
health hazards.

▪ Demarking with barricades has been introduced to prevent dust entry from
construction site to finished areas.

▪ All moisture absorbing agents like carpets, furniture, adhesives, sealants, cements
etc. will be stored in moisture proof dry room.

▪ Painting work shall be scheduled to be completed before laying down the carpet.

▪ Photographs to be taken of all the activities at 2 or 3 different stages of

commissioning.

35
 SECTION 4.04
DESIGN CRITERIA & SYSTEM DESCRIPTION

36
1.0 SCOPE OF WORK

The scope of work for proposed office tower phase-1 and clubhouse shall cover design
& detail engineering of air conditioning and mechanical ventilation system. The
project consists of office tower having 2 parking floors, ground plus fourteen floors
and club house having ground plus 3 floors.

The following areas have been considered for ACMV System design.

 Office Tower 1 - Lower parking floor -

Partial exhaust for some portion.
AC for lobby, driver room, BMS room and service provider room

 Office Tower 1 - Upper parking floor -

Mechanical ventilation for chiller plant room, HT room, pump room, garbage room and
Toilet.
AC for lobby, driver room, BMS room and service provider room

 Office Tower 1 - First to Sixteenth Floor –

Mechanical ventilation for staircase, pantry/kitchen and toilet.
AC for remaining areas

 Clubhouse - Basement
Mechanical ventilation for pump room, waste converter room

 Clubhouse - Ground floor

Mechanical ventilation for kitchen, toilet
AC for reception lobby, office

 Clubhouse - First floor

Mechanical ventilation for dry kitchen
AC for restaurant

 Clubhouse - Second floor

Mechanical ventilation toilet
AC for yoga room, squash court and badminton court

37
  Clubhouse - Third floor
Mechanical ventilation toilet
AC for guest room

1.0 CODES AND STANDARDS

1.1 Apart from the specific equipment standards and specifications, the following
boards certifying agency / standards have been considered while designing
ASHRAE – American Society for Heating, Refrigeration and Air-conditioning
Engineers
1.2 ARI – American Refrigeration Institute
1.3 SMACNA – Sheet Manufacturers and Contractors National Association.
1.4 ISHRAE- Indian Society for Heating, Refrigeration and Air-conditioning
Engineers
1.5 ECBC – Energy conservation and building code
1.6 Green Building concepts and CII Guidelines.

2.0 DESIGN CRITERIA

Air Conditioning

Outside design conditions : Summer - 92 F DBT

78 F WBT

Monsoon- 85 F DBT
80 F WBT

Winter - 72 F DBT
65 F WBT

Inside design conditions : 75 F RH – No control

Lighting + computer load for office : 0.75 + 1.2 Watts/SF

38
 0
Glass U factor : 0.283 Btu/ hr.SF F

Glass Shading Co-efficient : 0.32

0
Spandrel U factor : 0.103 Btu/ hr.SF F

0 0
Roof U factor in Btu/hr.SF F : 0.121 Btu/ hr.SF F

Mechanical Ventilation System

Lower parking ventilation : 6 ACH only for one half portions

Kitchen Ventilation : 24 ACH for Fresh Air

30 ACH for Exhaust Air

Toilet Exhaust : 12ACH

Staircase Pressurization : As per ASHRAE Applications 2007

Staircase Ventilation : 4 ACH

Smoke Exhaust : As per ASHRAE Applications 2007

Lift lobby Pressurization : As per ASHRAE Applications 2007

Lift shaft Pressurization : As per ASHRAE Applications 2007

4.0 AIR-CONDITIONING AND MECHANICAL VENTILATION (ACMV) SYSTEM

4.1 The design goal of the air-conditioning system is to provide the designated air-
conditioned space (refer enclosed drawings) within the proposed development with
comfort cooling so as to maintain inside conditions of Dry Bulb Temperature (DBT) of
75 Deg F and not more than 65% Relative Humidity. It is mandatory for the
CONTRACTOR to quote for a system with the following configuration of main
equipment with the list of approved makes specified.

4.3 COOLING TOWERS 720 GPM (FOR OFFICE TOWER)

Approved makes : Refer List of makes

39
 Number required : 3 (2 Working + 1Standby)

Cooling Capacity : 3, 900, 000 BTU/Hr (for 260 TR)

Chilled water flow rate : 720US GPM at 10 Deg F ∆T

Cooling tower water inlet temperature : 100 Deg F

Cooling tower water outlet temperature : 90 Deg F

Entering Air Wet Bulb temp deg F : 83 Deg F

4.4 PRIMARY VARIABLE FLOW CHILLED WATER PUMPS (FOR OFFICE TOWER)

Approved makes : Refer List of makes

Number required : 3 (2 Working + 1Standby)

Pump flow rate : 480 USGPM

Total pump head : 70 Ft

Pump speed : Not more than 1450 RPM

Type of pump : End suction Centrifugal Pumps

4.5 CONDENSER WATER PUMPS (FOR OFFICE TOWER)

Approved makes : Armstrong, Grundfoss, Wilo

Number required : 2 (1 working + 1 standby)

Pump flow rate : 720 USGPM

Total pump head : 70 Ft

Pump speed : Not more than 1450 RPM

Type of pump : End suction Centrifugal Pumps

4.6 AIR HANDLING UNITS (DOUBLE SKIN UNIT)

40
 Approved makes: As per list of approved makes.
For AHU details refer Equipment Schedule & Drawing

4.7 CENTRIFUGAL FANS FOR STARICASE PRESSURIZATION, LIFT LOBBY

PRESSURIZATION, SMOKE VENTILATION

Approved makes: As per list of approved makes.

Refer Equipment Schedule for details

4.8 HEAT RECOVERY UNIT

Approved makes: As per list of approved makes.

Refer Equipment Schedule for details

4.9 The above is a brief outline of the main plant. The contractor shall be responsible for
the supply, erection, testing and commissioning of the chiller plant, chilled water
piping system, AHUs, ACMV electrical works and control system, including BMS
interface and co-ordination etc, to meet specified design conditions. It is important to
note that all ACMV equipment installed shall be equipped with devices which are fully
compatible for connecting to and operable from BMS system. ACMV contractor shall
co-ordinate with BMS contractor and find out exact requirements from BMS specialist
contractor. All electrical works related to ACMV will be executed by main electrical
contractor. ACMV contractor shall provide necessary attendance for final coordination
and connection to his equipment.

4.10 VRV SYSTEM (FOR CLUB HOUSE)

Approved makes: As per list of approved makes.

Refer VRV Schematic drawing / Equipment Schedule for details5.0 DETAILS OF

SYSTEM TO BE PROVIDED

5.1 Central Chilled Water Plant for the Office Air-Conditioning System

The aim of the system for Central Water cooled Chilled Water Air-Conditioning System
is to provide designated air-conditioning space in the proposed comfort cooling at
75Deg.F.

The system shall be integrated, installed and commissioned as a complete operational

package to the complete satisfaction of the EMPLOYER and Consulting ENGINEER.
The Chilled water system is designed to provide the AHUs with chilled water at 46 Deg
F office/comfort applications.

The chillers shall operate to meet the overall office building load requirement

41
 throughout the day. Chiller operation shall be by a combination of chiller optimization
and sequencing.

5.2 Air Handling Units (AHU)

The cooled and dehumidified air supplied by AHUs to the areas served by them shall
ensure the inside conditions of 75 Deg F  1 Deg F Dry Bulb Temperature (DBT) with
RH not more than 60%. The cooled and dehumidified air (supply air) shall be
conveyed to the air-conditioned areas through Galvanized Sheet Steel (GSS) ducting,
and distributed to the air-conditioned areas through supply air diffusers. The GSS
ducting, diffusers, AHU’s and the associated control system shall be designed, erected,
and commissioned by the contractor to ensure that the air-conditioned space is
maintained at the temperature and humidity levels specified above. The return air
from the air-conditioned areas is brought back to the AHU room using the false ceiling
void (space available between the false ceiling and slab above) by means of return air
diffusers or slits. Volume control dampers shall be provided at all branch and sub
branch ducts from individual main and sub main ducts whether shown on drawing or
not to facilitate proper air balancing. The fresh air for Various AHU’s located in the
individual floors is served by Heat Recovery AHUs located at the terrace. Fresh air
damper modulation is directly linked with CO2 sensor located in Return air path of
AHU located at each floor AHU room.

Volume Control Dampers and Fire Dampers shall be provided on duct risers as shown
on air side riser diagram. Fire dampers of proper rating shall be provided whenever
AC duct penetrates a fire wall irrespective of whether shown on drawing or not.

5.3 Heat Recovery System

Fresh Air to individual floor AHU is provided by Heat Recovery Air Handling units
located on Roof. These are double skin weather proof AHU having the following
sections.

Outdoor Air (Fresh Air) Side: Pre Filter, Bag Filter, Heat Recovery Wheel/Thermal
wheel, Supply air fan with VFD controlled by Static pressure transmitter in the fresh
air supply duct.

Exhaust Air Side: Pre Filter, Exhaust fan with VFD, Heat Recovery Wheel

The cold air from air-conditioned areas will pass through the half section of rotating
honey comb cooling the metallic media which is Aluminum or other metal foil. This
continuous rotating cooled media, after coming in other half section of frame, will cool
the hot air coming from outside ambient. Complete unit shall be provided with
necessary controls to recover sensible heat from exhaust air.

42
5.4 Toilet Exhaust System:

All Toilets are Air Conditioned & mechanical exhaust system is provided to all male &
female toilets in all floors. The exhaust from each toilet is taken through a common
duct riser and exhausted out at terrace level though Heat Recovery Unit exhaust air
fan. All interior toilet exhaust ducting shall be under Interior scope.

5.5 Staircase Pressurization:

All staircases are pressurized with fresh air fan located above stair case room,
pumping the air through GSS duct to individual floor lobby area.

5.6 Lift Lobby Pressurization:

Lift Lobby is pressurized with fresh air fan located at terrace level, pumping the air
through GSS duct to individual floor lobby area.

43
 SECTION 4.05
COOLING TOWER

44
6A .0 SINGLE CELL FRP COOLING TOWER

**List of Manufacturers: Marley, Bell, Phaharpur, Baltimore, Advance

6A.1 SCOPE

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at factory works, delivery at site, handling at
site, installation, commissioning and carrying out acceptance test at site of Single Cell
FRP CoolingTowers.

6A.2 CODES AND STANDARDS

The design, manufacture, testing and performance of the cooling tower shall comply
with all currently applicable statutes, regulations and safety codes in the locality
where it is to be installed. The cooling tower shall also conform to the latest applicable
Indian Standards and publications of the Cooling Tower Institute (CTI certified).
Nothing in this specification shall be construed to relieve the CONTRACTOR of this
responsibility.

6A.3 CONSTRUCTION FEATURES

The Cooling Towers shall be of induced draft cross flow design of single cell
construction and shall be low noise type.

The cooling tower shall be guaranteed to perform in accordance with the conditions
specified without any modifications. Cooling towers shall be rectangular in shape
having basin. It shall suitable for the space provided in the drawings.

Each cooling tower shall be complete with motor with VFD, variable speed fan ,
casing, filling, water distribution basin and accessories as described below. Cooling
towers should be fully assembled in factory. This will prevent too many loose parts
from being misplaced or lost besides giving the advantages of perfect assembling thus
maintaining the quality and stability.

The heat rejection capacities shall be based on the following conditions.

Entering Air Wet Bulb Temperature - 84°F

Approach - 6 °F
Entering Condenser Water Temperature - 100°F
Leaving Water Temperature - 90°F

45
Selection details shall be submitted to the Engineer for approval prior to placement of
order.

The type and capacity of the cooling tower shall be as detailed in the schedule and/or
as shown on the drawings.

CASING AND WATERBASIN

The main casing and water basin should be made of FRP (Fiberglass Reinforced
Polyester). The basin sump shall be of 12 gauge thick steel plate, hot dip galvanized to
BS729:1971 standard. The basin shall be self-cleaning with drain fittings.

DISTRIBUTION SYSTEM

The hot water distribution shall be by means of open gravity type basin. It shall be
made of Fiberglass Reinforced Polyester resin. It shall be light –weight and non-
corrosive to maintain stable water sprinkling effect.

INFILL

Infill shall be of ultra-violet rays treated polyvinyl chloride. The PVC infill shall be
durable and highly efficient vacuum-formed type with patented intricate design to
facilitate a good spread of water over the enhanced surface area against a cross-flow of
induced draft of air. The infill shall be incorporated with a ribbed pattern on the
opposite side to act as a drift eliminator. Each PVC infill sheet is bonded with specially
formulated glue in blocks of either 24 sheet or 30 sheets depending on the model.
Apart from the bonding, each block shall be further reinforced with 4 PVC pipes with
retention plates at each of the pipe to ensure a long term use. The entire top layer of
infill shall be supported with galvanized steel pipes to prevent weight of the top layer
infill being imposed on bottom layer. The design shall be such that drift loss does not
exceed 0.2 % of the circulating water quantity.

FAN

The fan shall be axial flow type with FRP blades. The fans shall be designed to provide
the necessary air flow for heat transfer. Fan blades shall be factories balanced and
assembled. Pitch angle should be variable to allow flexibility. Hot-dip galvanized fan
guards shall also be provided over the fan cylinder.

FAN MOTOR

The fan motor shall be a totally enclosed fan cooled weather proof with VFD and an
enclosure for the same which is IP 55 rated. The motor shall be suitable for 415
volts/3/phase/50Hz power supply and shall be located outside the discharge air
stream through a set of V-belts. A belt cover shall be provided to protect the V-belt

46
and shall be of FRP construction. Motor power consumption shall not exceed 9.5 Kw in
order to meet BCA requirements.

V-BELT SYSTEM

The V-belt shall be with fabric impregnated type designed to BS 1400 standard.
Means for adjusting the belt tension shall be provided. Positive means of locking shall
be employed in order to maintain tension during operation.

ACCESS

An inspection door shall be provided to gain entry into the tower to facilitate
inspection and easy maintenance. Access ladder shall be installed on the tower
permanently.

BOLTS & NUTS

All bolts and nuts shall be of stainless steel type or hot dip galvanized.

NOISE LEVEL – CRITERIA

Noise level for cooling towers should be measured in conformed with BS8609.
Measuring power points can be taken from 1m, 2m, 5m, 10m or at 45 degree fan angle
or at opposite drive side. Background noises should be corrected.

Cooling towers shall be guaranteed to operate at low noise and shall not exceed 65dBA
measured 2m from intake face and 75dBA measured at 45degree and 1.5m distance
away from fan.

NOTE: The sub-contractor shall supply and install all ancillary fittings including make
up water supply side from the make-up tank, quick fill and bleed off facilities.

INSTALLATION

Cooling towers shall be assembled rigged and installed in accordance with the
manufacturer’s recommendations and to the satisfaction of the Consultant Engineer.
The supply of auxiliary structural support and vibration isolators where necessary or
recommended as good practice shall be the responsibility of the Sub-Contractor.
Concrete plinth supports for the cooling towers shall be provided by the Sub-
contractor.

PERFORMANCE CERTIFICATION

47
 a. Temperature Curves

The tower manufacturer shall submit curves which show leaving water
temperature from the tower at the design water temperature range at the
design wet bulb.

b. Sound Pressure Levels

Sound testing shall be conducted at the factory of the manufacturer under

controlled conditions. Submit data on cooling tower sound pressure levels
with all fans operating at high speed and with full water flow.

c. Failure to perform at site

Should the tower fail to perform after installation according to the approved
performance curves, the cooling towers shall be replaced at no extra cost to the
Client

6A.4 PAINTING

All exposed steel surfaces shall be given three (3) coats of epoxy paint.

DATA SHEET – A

TECHNICAL REQUIREMENTS

Sl.
Description Requirement
No.
1 System designation : Cooling tower for air-
conditioning system
2 Number required : 3 Nos
3 Operation : Continuous 24 Hrs / day
4 Make up water source : Soft water from basement
5 Analysis : Portable water

7 Hot water inlet temperature : 95 F

8 Cold water outlet temperature : 85F at 80F wet Bulb Temp

48
9 Flow velocity in hot water piping : Maximum 2 m/sec
10 Motor : 415V, 3ph, 50 Hz
11 Casing : FRP
12 Air inlet Louvers : FRP
13 Fill : PVC
14 Internal supporting structure : GRP grids
15 Drift eliminator : PVC
16 Fan deck : FRP
17 Hardware below fan deck : Hot dip galvanized steel
18 Hardware above fan deck : Hot dip galvanized steel
19 Fan blades : Cast aluminum alloy / FRP
20 Cold water basin : FRP
21 Cold water basin foundations : supported on structural steel
sections
22 Drive shaft : Hot dip galvanized steel
23 Orifices / Nozzles / splash cups : Polypropylene
24 Access ladder : Hot dip galvanized steel
25 Foundations : Yes

Sl.
Description Requirement
No.
26 Anchor bolts : Yes
27 Cold water basin : Yes
28 Fan guard : Yes
29 Access ladder : Yes
30 Two speed motors : Yes
31 Motor starters : Yes
32 Hot water piping : Yes
33 Cold water outlet, overflow, drain, : Yes
quick – fill, make-up water pipes,
dosing piping & valves
34 Temperature gauge at inlet : Yes

49
 35 Temperature gauge at outlet : Yes
36 Level switch and associated controls : Yes
(*)
37 Vibration limit switch : Yes
38 Vibration isolators : Yes
39 Commissioning and performance test : Yes
40 Fan and fan motor handling : Yes
arrangement to be made available near
each coiling tower.

DATA SHEET – B
DATA TO BE FURNISHED BY TENDERER ALONG WITH OFFER
Sl.
Item Description Options / Unit Contractor’s Input
No.
1 System description
2 Number offered
2.1 Model number
3 Tag nos.
Counter flow / cross
4 Type of tower
flow
Single flow / double
5 Type of inlet
flow
6 Overall size of tower M - (L) x (B) x (H)
7 Volume of water in basin M3
8 Type of fill Splash / film
9 Type of drift eliminator
10 Cooling water flow Kg/hr
11 Dry air flow Kg/hr
12 Ratio (L/G)
13 Inlet air enthalpy above 0 deg C Kcal/kg
14 Exit air temperature Deg C
15 Exit air enthalpy above 0 deg C Kcal/kg
16 Markup water required m3 / hr
17 Fan SUB-CONTRACTOR
18 Blade diameter M

50
 DATA SHEET – B
DATA TO BE FURNISHED BY TENDERER ALONG WITH OFFER
Sl.
Item Description Options / Unit Contractor’s Input
No.
19 Fan speed RPM
m
20 Fan static pressure
WC
21 Fan static efficiency %
22 Fan BKW KW
23 Fan drive Direct / Gear
24 Type of coupling
SUB-CONTRACTOR of reduction
25
gear
26 Type of reduction gear
27 Gear ratio
28 Service factor
Guaranteed power input to fan
29 KW
motor
30 Motor rating / speed
31 Total weight of tower only – dry Kg
32 Total weight of tower only – wet Kg
33 Total weight of basin – empty Kg
34 Total weight of basis with water Kg
Dimensioned general
arrangement drawing : Plan &
35 To be furnished
section of cooling tower to be
enclosed
Type of fan and fan handling
36 arrangement near each cooling
tower

DATA SHEET - C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER AWARD OF CONTRACT AND

BEFORE INSTALLATION

1. List of drawings and documents to be submitted for review, approval and information
with scheduled submission dates.

51
 2. Quality Assurance Plan (QAP)

3. Dimensioned to scale drawing of cooling tower with plan and elevation. All data
furnished in data sheets A and B shall be included in this drawing or other relevant
drawings or documents.

4. Cross-section drawing of cooling tower with complete part list and materials of
construction.

5. Dimensioned to-scale general arrangement drawing for foundation with loading data.

6. Dimensioned to-scale layout drawing for all equipment

7. Hot water piping drawing with details of supports and flange details.

8. Motor data sheet, drawing and torque-speed curve

9. Instrument data sheet and drawings.

10. Procedure for performance testing

11. Thermal Performance curves and Fan characteristic curves.

12. Installation, operation and maintenance manual along with lubrication schedule.

DATA SHEET - D

CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION

Tim Remar
No Description Unit Date
e ks
10.0 12.0 14.0 16.0 18.0 20.0
0 0 0 0 0 0
Entering Air
1. ºC
temperature WB
Entering water
2. ºC
temperature
3. Leaving water pump ºC
4. Motor current Amp
5. Noise level dB

52
 Make up water quality
6.
and treatment test
Is cooling tower sump
7.
clean
8. No Leaks, No Overflows
Drift Eliminators
9. working, No water
carryover
10. No slime or Algae
Biocide treatment
11.
working
Is make up water
12.
consumption normal

MODE OF MEASUREMENT:

1.0 Representatives from the Contractor and Engineer shall conduct a joint inspection of the
Equipments. All the discrepancies observed either incomplete works or defective work
shall be clearly indicated in the joint inspection report. The mode of measurements given
below is for the purpose of measurement and payment and the scope of works shall be as
specified elsewhere in the specification.

2.0 Induced Draft cooling tower

Each cooling tower including fan with 2 speed motor and accessories as specified in
tender document shall be regarded as one unit for the purpose of measurement and
payment.

53
SECTION 4.06
PUMPS

54
1.0 SCOPE

This specification covers the supply, installation, co-ordination, testing including factory
and field testing, start-up supervision, training, necessary documentation and
commissioning of Flexible coupled base mounted End suction pumps. Pumps shall
be base mounted, single stage, end suction back pull out design with a foot
mounted volute to allow removal and service of the entire rotating assembly
without disturbing the pump casing, piping, electrical motor connections or pump
to motor alignment.

Chilled water pumps shall be Primary-Coil Secondary (P-CS) variable flow type distribution
type. Primary chilled water pumps shall be variable flow type complete with factory supplied
VFD to circulate chilled water in primary loop and high energy efficient, integrated drives and
permanent magnetic (IE5 type) motor with controller inbuilt type circulator at each AHU. The
circulator shall be capable of doing balancing of flow to individual AHU without any external
balancing valve, the circulator shall modulate flow by accepting Differential temperature
feedback across AHU through analog input without any external 2-way modulating valve. The
entire system shall be of self-balancing type with temperature-based control on both primary
and AHU side. The variable primary pump shall have “Distributed pumping Controller” with
necessary VFD, temperature transmitter etc. Condenser pumps shall be of constant flow type.
2.0 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection and performance testing of

end suction pumps shall comply with all currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. Nothing in this
specification shall be construed to relieve the CONTRACTOR of this responsibility. The
equipment supplied shall comply with the latest applicable Indian, American, British or
equivalent standards.

3.0 DESIGN REQUIREMENTS

The total head capacity curve shall preferably be continuously rising towards the shut
off. In case of unstable (drooping) characteristic the duty point shall be well away from
the unstable region. The shut off head shall be at least 110% of the total head.

The required NPSH at duty point shall be at least 1.0 M less than the available NPSH.

Pumps shall run smooth without undue noise and vibration. The noise level shall be
limited to 70 dBA at a distance of 1.8 M for primary pumps and 40 dBA at a distance of 1.8 M
for coil pumps .. Vibration shall limited to class IIC of BS 4675 Part –I.
The power consumption of individual chilled water pump shall not exceed 7.5Kw and
that of condenser pumps shall not exceed 15Kw to meet the BCA requirements.
The power rating of the pump motor shall be the larger of the following:

a) The maximum power required by the pump from zero discharge to zero head.

55
 b) 115% of the power required at the duty point.

Pumps of a particular category shall be identical and shall be suitable for parallel
operation with equal load division. Components of identical pumps shall be
interchangeable.

4.0 FEATURES OF CONSTRUCTION

Pump volute:

Pump volute shall be EN-GJL-250 Grey Cast Iron with integrally cast pedestal
support feet

Impeller:

The impeller shall be lead free cast Bronze (CuSn10 which is according to EN
1982) enclosed single suction type with smooth surface finish for
minimum frictional loss, balanced to ISO 1940-
1:2003 / ANSI/HI 1.1-1.5-1994, section 1.4.6.1.3.1, balance grade G6.3 and keyed to
theShaft and secured by a locking cap screw.

Shaft:

Shaft shall be provided with or without sleeves under packing / seal and shall be
locked to the shaft. The pump shaft shall be of 300 series Stainless steel equal to AISI
SS420, precision ground to provide a true running rotating element.

Shaft sleeve design shall prevent corrosion and wear to the shaft. Material grade of
shaft sleeve shall be ASTM I836, C89833.

Wear rings:

Unless otherwise specified, renewable wear ring of bronze shall be furnished at least
on the casing. Pumps shall be fitted with lead-free bronze renewable case wear rings
indexed with a dowel pin for fixed positioning. Material grade of wear rings shall be
ASTMB148, C95400 or equal.

56
Seals:

The liquid cavity shall be sealed off at the pump shaft by an internally-
flushed mechanical seal with carbon seal seat and Silicon carbide seal ring, suitable for
continuous operation at 284 Deg F (140 Deg C).

Bearings:

Antifriction bearings shall be of standard type and shall meet minimum L-10 rating life
of 25000 hrs.

Bearings shall be ball type, grease lubricated and locked to the shaft with positive
locks of ample size to withstand any axial thrust loads. Bearing shall provide a
minimum life of 10 years when calculated at 50% of Best-Efficiency-Point for the
scheduled pumps.

Working pressure:

Maximum allowable working pressure (MAWP) for all the pressure containing parts
shall in no case be less than the maximum discharge pressure produced by the pump
at shut off (including tolerances), at the max suction pressure, for the maximum
impeller diameter and the maximum continuous speed.

Note: MAWP shall not be less than 10 kg/cm² for pumps with 125# flanges & 16
kg/cm²
For pumps with 150# flanges.

Pump shall be rated for minimum of 175 psi (12bar) working pressure.Volute shall
have gauge tapping at the suction and discharge nozzles and vent and drain
Tapping at the top and bottom.

Vibration:

The pump(s) vibration limits shall conform to Hydraulic Institute ANSI/HI 1.1-1.5-
1994; Section 1.4.6.1.1 or ISO 10816 for recommend acceptable unfiltered field
vibration limits (as measured per HI 1.4.6.5.2) for pumps with rolling contact bearings.
.

Each pump set on the inertial block shall be mounted on vibration isolators with static
spring ribbed neoprene vibration isolators with static deflection of 25 mm minimum.
Vibration isolator efficiency shall not be less than 95%.

Brackets for vibration isolators shall be either welded or bolted to four sides of the
concrete inertia block.

57
Vibration isolators shall be equipped with levelling bolts and not less than 6 mm thick
ribbed neoprene sound pad on the bottom. The ratio of spring diameter to its height at
the rated deflection shall not be less than 0.8.

Sound Level:

The maximum permissible sound pressure level of the pump shall not exceed 70 dbA
Measured at 1m from pump surface for the recommended range of operation.

Base plates:

Base plate shall be of structural steel or fabricated steel channel with fully enclosed
sides and ends, and securely welded cross members. Grouting area shall be fully open.
The combined pump and motor base plate shall be sufficiently stiff as to limit the
susceptibility of vibration. The minimum base plate stiffness shall conform to
ANSI/HI 1.3.4-1997 for Horizontal Base plate Design standards.

The seismic capability of the pump shall allow it to withstand a horizontal load of 0.5g,
excluding piping and/or fasteners used to anchor the pump to mounting pads or to the
floor, without adversely affecting pump operation.

The base plate should be provided with lifting lugs for at least a four-point lift.

Coupling:

A flexible type, Standard pin& bush type or center drop-out (Spacer) design coupler,
capable of absorbing tensional vibration, shall be employed between the pump and
motor.

Pumps for variable speed application shall be provided with a suitable coupler sleeve.
The coupling shall be shielded by a dual rated ANSI B15.1, Section 8 & OSHA 1910.219
compliant coupling guard.

Motors:

.
Motor shall be a horizontal, foot mounted, totally enclosed fan-cooled,
standard squirrel cage induction motors with main dimensions
according to IEC standards. Electrical tolerances are to IEC 60034. Motor
shall be energy efficient type minimum of IE3 standard.

58
Motor shall be to with IP 55 enclosure. The class of insulation shall be F with
temperature rise limited to Class B.
Motor shall be suitable for operation on a 415 V (± 10% variation), 50Hz ± 5%,
3phase, or 240V-1phase AC supply. Motor shall be suitable for both DOL and / or
STAR/DELTA starting.

Pump Selection:

The pump(s) selected shall conform to ANSI/HI 9.6.3.1 standards for Preferred
Operating Region (POR) unless otherwise approved by the engineer. The pump NPSH
shall conform to the ANSI/HI9.6.1-1997 standards for Centrifugal and Vertical Pumps
for NPSH Margin

Pump with constant speed drives shall be capable of at least 5 % head increase at
rated condition and at rated speed by replacing with a new impeller. Offered impeller
shall in no case be less than the minimum diameter impeller.
The pumps for parallel operation shall have characteristics suitable for capacity
sharing. The shut off head in such cases shall not be less than 110 % of the rated head
and no more than 120 % rated head.

Pumps with variable speed drives shall be capable of operating continuously up to

105% of rated speed as well as operating briefly up to driver trip speed.

Each pump shall be hydrostatically tested at factory as per Hydraulic Institute

standards.
It shall then be thoroughly cleaned and painted with at least one coat of high-grade
paint prior to shipment.

The pumps shall be factory manufactured, assembled and tested in an ISO 9001
approved facility.

Casing vent and Drain as per manufacturer standard shall be provided. As an option
casing drain with an isolation valve and flanged piping terminated at the skid edge
shall be provided. Base plate shall also provide with flanged drain connection.

Motor Selection:

Motor should be of variable frequency drive compatible.

The motor selection for mains operated pumps will be as given below:-

Motor name plate rating : % of pump rated BKW

59
 : 140 % of rated pump BKW / Max BKW of the
Less than 4 kW pump. Whichever is higher.

: 125 % of rated pump BKW / Max BKW of the

Less than 22 kW pump. Whichever is higher.

22 kW – 55 kW : 115 % of rated BKW

Higher that 55 kW : 110 % of rated BKW

Note: The motor nameplate rating for pumps under parallel operation shall not be less
than the max BKW indicated on the pump data sheet (the power at the END of the
curve for the rated impeller) or shall have the specified margin as per this clause
whichever is greater.
The pump motors shall also be suitable for Start-up under open discharge valve
condition.

5.0 FEATURES OF CONSTRUCTION (AHU COIL PUMPS)

Scope:
This specification covers the design, materials of construction, features,
performance and testing of inline, single stage, inbuilt VFD centrifugal
pumps. Pump shall be suitable for the purpose they are intended.

General:
The pumps shall be canned-rotor type (i.e. pump and motor form an
integral unit without shaft seal and with only two gaskets for sealing),
single stage, in-line suction and discharge ports of identical diameter with
integrated differential pressure sensor at casing.
The pumped liquid shall be used to lubricate bearings and cool the motor.
The impeller, rotor and pumped liquid shall be separated from the stator
by a rotor can.

Pump shall be fitted with a 1-phase, permanent magnet, synchronous

motor. Motor shall include a frequency converter and PI controller in the
motor terminal box.
The circulator pump shall be energy-optimised and comply with the EuP
Directive (Commission Regulation (EC) No 641/2009), the average energy

60
efficiency index (EEI) shall less than or equal to 0.18. EEI to be obtained
according to EN 16297.

Construction:
Pump Housing:
Pump spiral volute casing shall be of in-line robust construction with
integrated differential pressure and temperature sensor.
Pump Casing shall be EN 1561 EN-GJL-250 Grey Cast Iron and capable of
withstanding to the maximum pressure developed by the pump.
Impeller:
The impeller shall be polyether sulfone composite (PES) to obtain the
optimum hydraulic efficiency and energy efficiency.
Seal ring shall be of EN 1.4301 placed on pump housing should be of
primary seal.
Neck ring shall be of EN 1.4301 to guide the leakage flow back into the
impeller.

Shaft:
Shaft shall be EN 1.4404 stainless steel and shall be adequately sized to
withstand all stresses, hydraulic loads, vibrations and torques coming in
during operation.
Shaft shall be fitted with rotor based on canned rotor technology and
characterised by the absence of a stuffing box or shaft seal.
Rotor Assembly:
Rotor shall be of neodymium permanent magnet welded, balanced, & leak
tested for high-performance.
Rotor-can shall be of composite material (PPS) to reduce the loss between
the rotor and stator and to increase the efficiency of the pump.
Stator with housing:
Stator with housing shall be of pressure-die-cast aluminium for high
efficiency and to minimize energy losses.
Stator should incorporate thermal winding protections to protect the
windings against too high temperatures.
Motors and electronic controller:

61
The circulator shall incorporate a 4-pole synchronous, permanent-magnet
motor (PM motor). This motor type shall be characterised by higher
efficiency than a conventional asynchronous squirrel-cage motor. The
pump speed shall be controlled by an integrated frequency converter.
Motor shall be with IP 44 enclosure.
Motor shall be suitable for operation on 200-240 V (± 10% variation),
50Hz ± 5%, 1 phase AC supply.
Motor shall require no external motor protection and shall incorporate
thermal protection against steady overload and stalled condition (IEC 34-
11)
Frequency convertors:
Pumps shall have an integrated frequency convertor and a PI controller
incorporated within the motor terminal box. Integrated controller shall be
supplied with TFT (Thin Film Transistor) interface for controlling and
display of pump info.
Motor terminal box shall provide the following connections either with
basic terminals or with additional function modules provided as required
o one dedicated digital input
o one analog inputs, 0(4)-20 mA / 0-10 V
o 5 V voltage supply to potentiometer and sensor
o one configurable digital input or open- Collector output
24 V voltage supply for sensors
o two signal relay outputs (potential-free contacts)
o interface options for various fieldbus module like Modbus, Profibus,
LON, Bacnet MSTP / IP, etc.
Motor terminal box shall have a control panel to set the pump to
“Minimum” or “Maximum” operation or to “Stop”. An indicator on the
control panel shall provide visual indication of the pump status:
o "Power on": Motor is running (rotating green indicator lights)
or not running (permanently green indicator lights)
o "Warning": Motor is still running (rotating yellow indicator
lights) or has stopped (permanently yellow indicator lights)
o "Alarm": Motor has stopped (flashing red indicator lights).
Control Features:
Pump integrated controller should perform the following control modes.

62
. AUTOADAPT Feature.
. FLOWADAPT Feature.
. Proportional- pressure control.
. Constant- pressure control.
. Constant-temperature control.
. Differential-temperature control.
. Constant-curve duty.
. Max. or min. curve duty.
. Automatic night setback.

Data Communication:
Communication with the pump is possible by means of a remote-
controlled device supplied as an accessory. The remote control shall
enable enhanced settings as well as reading out of a number of
parameters such as "Actual value", "Speed", "Power input" and total
"Power consumption".
Pump shall have provision to accept data communication interface
module for transmission between pump and external system, for
example a BMS (building management system) or SCADA system.
Interface options for various fieldbus module like Modbus, Profibus, LON,
Bacnet MSTP / IP, etc should be available
Painting:
The pump housing and pump head should be electrocoated to improve
corrosion resistance.
The electrocoating process should be of alkaline cleaning, pre-treatment
with Zinc phosphate coating, Cathodic electrocoating (epoxy).
The pump housing with normal painting is not acceptable.
Name plates:
Each pump shall be provided with a nameplate indicating the following
details:
1. Pump type designation
2. Pump Model
3. Rated flow
4. Rated head

63
 5. Rated speed
6. Power P2
7. Pressure rating/max temperature
8. Voltage
9. Frequency

Tender Drawings:
The Contractor / Vendor along with their Bids shall submit the following
drawings.
. Preliminary outline dimensional drawing of pump and motor.
. Performance.
. Technical Data sheet for pumps

TESTS AND INSPECTION

A standard hydrostatic test shall be conducted on the pump casing with water at 1.5
times the maximum discharge head or twice the rated discharge head. whichever is
higher. While arriving at the above pressure, the maximum suction head shall be taken
into account.
The hydrostatic tests on the casing shall be conducted for a minimum duration of 30
minutes.

6.0 INSTALLATION

While loading/unloading the Contractor shall ensure no damage to equipment. The

Contractor shall rectify any damage done. The decision of Engineer-in-charge is final.

The Engineer-in-charge shall see that the equipment is properly installed and
connected, if not, the Contractor shall redo the work without any extra cost.

Any re shifting/relocating of equipment within the room shall not be paid extra.

The equipment shall be located as per drawing and the Contractor shall counter-
check with the Engineer-in-charge before installation.

The Contractor should visually inspect the equipment along with the Engineer-in-
charge and prepare a joint record of missing parts, or mountings or gauges or visual

64
 damages. The pump shall be carefully transported to the place of installation and
installed on a foundation made for the equipment.

The equipment shall be leveled with leveling bolts or shims to the tolerances set by
the Engineer-in-charge and equipment manufacturing recommendations and all
foundations bolts shall be grouted. The Contractor shall supply necessary foundation
bolts and Nuts or isolation pads, isolation mounts.

The Contractor’s scope shall also include mounting of gauges, and instruments. The
installation, testing and commissioning of equipment shall be carried out in
accordance with manufacturer’s installation manual and/or the instructions of
the Engineer-in-charge.

7.0 PERFORMANCE TEST

a. Standard Running Test

The pumps shall be tested as per ISO 9906 Annexure 3B, at rated speed at SUB-
CONTRACTOR’s works to measure capacity, total head, efficiency and power The
pumps shall be tested over the range covering from shut-off head to the maximum flow.
The duration of the test shall be minimum one hour. Minimum five readings
approximately equidistant shall be taken for plotting the performance curves.

b. NPSH Tests

NPSH tests shall be conducted with water as the medium.

c. Mechanical Balancing

In addition to static balancing, impeller and balancing drum shall be balanced

dynamically at or near the operating speed.

d. Field Testing

After installation, the pumps shall be subjected to testing at site also. If the field
performance is found not to meet the requirements regarding vibration and noise as
specified, the equipment shall be rectified or replaced by the CONTRACTOR, at no extra
cost to the EMPLOYER.

8.0 TENDER DRAWINGS

The following drawings shall be submitted by the CONTRACTOR along with their Bids.

65
 Preliminary outline dimensional drawing of pump and motor. (Suction and discharge
connections and foundation details shall also be indicated).

Performance curves (capacity vs. total head, efficiency, NPSH and KW requirement)
ranging from zero to maximum capacity.

Pump Catalogues.

9.0 PAINTING

The equipment shall be thoroughly cleaned and greased. All rust sharp
edges and scales shall be removed. All external and exposed cast iron
parts of pumps have an epoxy-based coating made in a cathodic electro-
deposition (CED) process which is high-quality dip-painting process and
which would prevent rusting and corrosion. The colour code for the
finished product is NCS 9000/RAL 9005.
The pump shaft shall not be painted.

10.0 PUMP HEAD CALCULATION

It is very important that contractor shall submit actual pump head calculation based on
site installation conditions taking into account pressure drop in installed (to be
installed) chillers, piping and fitting. This actual pump head calculation shall be
submitted for engineers’ approval before ordering equipment and motor. Required
pump motor capacity will be provided based on actual head calculation without any
extra cost.

11.0 PART 1 – GENERAL- VFD AND PLC SPECIFICATIONS FOR DISTRIBUTED PUMPING
SCHEME

11.1 SECTION INCLUDES:

11.2 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

66
 F. CSA - Canadian Standards Association
G. NEC - National Electrical Code
H. ISO - International Standards Organization
I. IEC - International Electro technical Commission

11.3 SUBMITTALS:

A. Submittals shall include the following:

1. System summary sheet

2. Sequence of operation
3. Shop drawing indicating dimensions, required clearances and location and size of
each field connection
4. Power and control wiring diagrams
5. 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.
6. Pump data sheets

B. Submittals must be specific to this project. Generic submittals will not be accepted.

11.4 QUALITY ASSURANCE

A. 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.

B. The manufacturer shall have a minimum of 20 years experience in the design and
construction of variable speed pumping systems.

C. The local supplier of Chilled Water Variable Speed Pumping System (VSPS)
Must have relevant expertise in all aspects of design, application engineering,
Installation, programming, interfacing, commissioning and after sales service.
Supplier must have, as a minimum, commissioned 75 projects of secondary chilled
water VSPS in India.

D. 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.

67
 E. The manufacturer shall carry a minimum product liability insurance of
$5,000,000.00 per occurrence.

F. Manufacturer shall be listed by Underwriters Laboratories as a manufacturer of

packaged pumping systems.

G. 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.

PART 2 - PRODUCTS

11.5 ACCEPTABLE MANUFACTURERS

A. Subject to compliance with these specifications, the following manufacturers shall

be acceptable:
- Grundfos
- Armstrong
- WILO

11.6 MANUFACTURED UNITS

A. Furnish and install as shown on the plans a Power save Variable Speed Pumping
System as manufactured by Manufacturer.

B. The control system shall include as, a minimum, the programmable logic pump
controller, adjustable frequency drive(s) and temperature transmitters as indicated
on the plans. Provide additional items as specified or as required to properly
execute the sequence of operation.

C. The variable speed pump logic controller, adjustable frequency drive(s) and
temperature transmitters shall ship as assembled components to the jobsite.

Pump logic controller, adjustable frequency drives, sensor/transmitters and related

equipment shall be factory assembled.
D. Line voltage power wiring shall be installed by the electrical contractor as shown
on the field connection drawings and wiring diagrams supplied with the pumping
package.

68
 F. Low voltage (24 VDC and 115 VAC) wiring shall be installed by the controls
contractor as shown on the field connection drawings and wiring diagrams supplied
with the pumping package

11.7 COMPONENTS

Pump Logic Controller Package

a) Approved Manufacturers

As per recommended make list.

b) Components of Pump Logic Control Panel

a) To supply and install Minimum Viable System (MVS) Controller as per

the design
b) The control system should include the Pump logic controller, Variable
frequency drive(s), Temperature transmitter(s) and Differential
pressure transmitter(s) as indicated in the design
c) Pump logic control panel should house dedicated Pump Logic Controller,
Variable frequency drive(s) and associated switchgears
d) Pump logic controller, Variable frequency drive(s), Differential pressure
transmitters, Flow transmitters, Temperature transmitters and related
equipment shall be installed by the mechanical contractor as shown in
the design
e) Input power wiring to the pump logic control panel and the output
wiring to the motors shall be the scope of electrical contractor and to be
done as indicated in the electrical drawings submitted for the specific
project
f) Low voltage wiring for the Building Management System to be done by
the BMS contractor from the pump logic control panel to the IBMS
system

c) Specifications

Minimum Viable System Controller

a) Minimum Viable System Controller shall be listed by and bear the label
of Underwriter’s Laboratory Inc (UL). The controller shall be specifically
designed for Distributed Pumping System applications

69
b) Minimum Viable System controller in built in Variable frequency drives
are not accepted. Logic controller should be external to the drives used
in the system

c) Minimum Viable System Controller shall be capable of receiving multiple

analog input signals from temperature transmitters (T1, T2, T3 & T4)
installed in the plant room as indicated in the design. Pump Logic
Controller would control the speed of the primary variable pump based
on this temperature signals & minimum flow signal from the differential
pressure transmitters placed across the chillers

d) Minimum Viable System Controller shall be capable of controlling up to

six pumps in parallel

e) The hydraulic stabilization program shall utilize a proportional-integral

control function. The proportional-integral values shall be user
adjustable in the Minimum Viable System Controller over a finite range

f) Minimum Viable System Controller shall be self-prompting and all alarm

messages shall be displayed in plain English. The operator panel shall
have the following features:

Multi fault memory and recall of faults with time stamping

Red fault light with related alarm message on default screen Touch
display

g) Minimum Viable System Controller shall have a display screen size of

minimum 4.3” graphical touch display with backlight. Current status of
settings and measured values are to be displayed in the default screen

h) Minimum Viable System Controller shall have optional password

protection to safeguard the settings against unwanted / unauthorized
changes

i) Display should have functional keys / touch screen for the operation
easiness

j) The following communication features shall be provided to the BMS

Remote start/stop of the VSPS through potential free contact

from BMS

Individual pump start/stop/trip status from Minimum Viable

System Controller through potential free contact to BMS

70
 k) The following communication features shall be provided to BMS system
via RS-485 port utilizing Modbus protocol

Individual analog input

Individual pump/VFD on/off status
System percent reference
System start/stop command
System operating mode
Individual pump kW consumption via VFD
Individual pump operating hours
Individual pump running speed in Hz/percentage reference
System flow, when optional flow sensor is provided

l) Minimum Viable System controller shall be of approved equal

Variable Frequency Drive:

a) The variable frequency drive(s) shall be pulse width modulation (PWM)

type, microprocessor controlled design

b) VFD, including all factory-installed options, is tested to UL standard 508.

VFD shall also meet C-UL and be CE marked and built to ISO 9001:2000
standards

c) VFD shall comply EMC directives as per IEC 61800-3:2004, category C1

with 50-meter motor cable (for power less than or equal to 90 Kw) &
category C2 with 50 meter motor cable (for power more than 90 Kw)

d) VFD shall be housed in IP21 enclosures for indoor applications. Wall

mounted/VFDs with plastic enclosures shall not be acceptable. For out
door applications, VFDs shall be housed in IP 54 enclosure.

e) VFD shall employ an advanced sine wave approximation and voltage

vector control to allow operation at rated motor shaft output speed with
no derating. This voltage vector control shall minimize harmonics to the
motor to increase motor efficiency and life. Power factor shall be near
unity regardless of speed or load.

f) VFD shall have balanced DC link chokes to minimize power line

harmonics. VFDs without a DC link choke shall provide a 3% impedance
line reactor

71
 g) Automatic motor adaptation (AMA) algorithm shall be available in the
VFD. This feature shall allow for automatic adaptation of drive to meet
the characteristics of the motor to have increased efficiency leading to
additional energy savings. AMA feature should be able to configure
without disconnecting the motor from the VFD

h) Output power switching shall be done without interlocks or damage to

VFD

i) The following user adjustable parameters shall be provided in the VFD

Acceleration time
Deceleration time
Minimum frequency
Maximum frequency

j) VFD shall be compatible for ModBUS protocol as standard

k) VFD shall have Automatic Energy Optimization (AEO) function. This

feature shall reduce voltages when the drive is lightly loaded to provide
a 3% to 10% additional energy savings
l) VFD shall be suitable for elevations to 1000 meters above sea level
without derating. Maximum operating ambient temperature shall not be
less than 40 deg Celsius. VFD shall be suitable for operation in
environments up to 95% non-condensing relative humidity

m) VFD shall be capable of displaying the following data in plain English via
40 character alphanumeric display:

Frequency
Voltage
Current
Kw per hour consumption
Running hours
Run mode (remote/local)
Active power
RPM

n) VFD(s) shall be warranted for a period of 12 / 18 months

Differential Pressure Transmitters

72
Differential pressure transmitters shall be field mounted and shall transmit an isolated 4-
20mA DC signal indicative of process variable to the pump logic controller via standard three
wire 24 DC system with Emission/Immunity confirming to EN61000-6-2/3.

Unit shall have stainless steel wetted parts with two 7/16” process connections. It shall be
protected against radio frequency interference and shall have water tight, IP 55 electrical
enclosure.
Sensor should be capable of withstanding a burst pressure of 25 bar. Accuracy shall be within
2.5% BFSL (Best Fit Straight Line)

Differential pressure transmitters shall be of approved make or approved equivalent

3. Sequence of operation

The system shall consist of Minimum Viable System Controller, multiple pump/VFD sets, with
manual and automatic alternation and pump staging
The pumping system shall start upon the start command from the BMS when the Minimum
Viable System is configured in “Remote” mode
If the Minimum Viable System Controller is configured in “Local” mode, the system is started
via the “Control Unit” at the panel
System starts in auto mode, with one pump running in minimum rpm as per the sequence:

First instance,
 Duty pump modulates its speed based on the Chilled Water Supply Temperature (T2)
& chiller evaporator leaving temperature (T1)
 If the above temperature levels could not be satisfied by duty pump at its 100% speed,
Minimum Viable System controller sends a request to Chiller plant manager (CPM) /
Building automation system (BAS) for next chiller to stage in
 On receiving the next chiller stage in signal from CPM/BAS, corresponding chiller
isolation valve is opened
 On receiving the valve open feedback signal from the dry contact of the valve, next
standby pump is started after a preset (programmable) time delay in Minimum Viable
System controller
 In parallel, Chiller plant manager/BAS commands the active chiller to unload, to take
care of transient flow during pump switching, to avoid evaporator tubes from freezing

 Second duty pump starts with minimum speed and both the duty pumps
 modulate equally at same speed based on the temperature set point (T2=T1)

Second Instance,
 When the temperature transmitter at chilled water return side (T3) exceeds the
temperature transmitter chilled water return side after bypass line (T4), duty pumps
modulate its speed further down

73
  Upon reaching the safe minimum flow condition, pumps speed is limited by safe flow
level
 After a delay as set in Minimum Viable System controller, a request signal to Chiller
plant manager/BAS to destage a chiller in the plant is sent
 Upon receiving the destage signal from the CPM / BAS, Minimum Viable System
Controller closes isolation valve of the corresponding chiller
 Upon receiving the valve close feedback command, one of the duty pump is switched
off after a delay

Third Instance,
 During plant minimum load with one chiller under operation, if the temperature
transmitter at chilled water return side (T3) exceeds the temperature transmitter
chilled water return side after bypass line (T4) and the flow at the active chiller is at
the minimum safe flow level (DP value), Minimum Viable System controller maintains
the duty pump speed
 This condition is reset once the flow through the active chiller crosses the safe
minimum flow level when chilled water supply temperature (T2) exceeds the
evaporator leaving temperature as set Minimum Viable System controller

 Pump logic controller should be equipped with PID algorithms to take care of tuning of
the system in order to counter, rate of flow change issues at the chillers
 Differential pressure transmitters shall be provided as indicated in the design
 Each DPT shall send a 4-20 mA signal to the pump logic controller, indicative of the
field condition
 Pump logic Controller shall compare each field DPT signal against the set point and
consider the most deviated signal for engineering the VFD/Pumps speed
 Pump logic Controller shall continuously scan the field Temperature Transmitter
signals and compare with the set point to control the duty pumps
 Minimum Viable System controller will monitor flow through chiller evaporator coils
either through flow transmitter installed inline with the evaporator coils of chillers or
DP measurement with a DPT fixed across the chiller evaporator coil tube
 Chiller evaporator coil isolation valve has to be controlled by the Minimum Viable
System controller based on the plant requirement
 In the event of duty pump/VFD fault, Pump logic Controller automatically initiates a
timed sequence to start the standby pump/VFD set in the variable speed mode. The
standby variable speed pump shall be controlled by the Minimum Viable System
controller
 VFD fault indication shall be continuously displayed on the display screen graphically
until the fault is rectified and the controller has been manually reset
 In case of differential pressure / temperature transmitter failure a plain English
warning message shall be displayed on the Minimum Viable System controller screen
 In the event of failure to receive temperature transmitter signals, a user selectable
number of VFD/Pump sets shall run at a user adjustable speed. Same shall be reset
upon correction of the zone failure

74
 Installation

a) To install the equipment supplied as per manufacturers operating & installation

manuals
b) Concrete pedestal, expansion joints at pipelines, anti vibration pads/mounts as
required to be provided by the mechanical contractor as per the drawings
provided by the supplier
c) Power wiring as required, shall be provided at site by the electrical contractor as
per the electrical drawings submitted
d) Control wiring of the field instruments like DP transmitters, flow transmitters,
temperature transmitters shall be responsibility of the contractor. It has to be done
as per the instructions/recommendations given by the equipment supplier

4. Commissioning

a) System manufacturer or trained representative shall provide the commissioning

support for the Distributed Pumping System at site, once installed
b) Commissioning support to include verification of installation, including pumps &
field instrumentation
c) Commissioning is termed to be incomplete until the system manufacturer or
trained representative demonstrates to the owner / end user / their
representative the sequence of operation as stated above
d) Same should be signed off in writing by all the parties concerned vide system
handing over document
e) System manufacturer or their trained representative shall provide on-site training
for operators on the operation & maintenance aspect of the system.

DATA SHEET - A
TECHNICAL REQUIREMENTS FOR CHILLED WATER PUMPS FOR OFFICE

1.0 DESIGN FEATURES

1.1 Pump designation Chilled water variable
primary pumps
1.2 Minimum design capacity US GPM 480 ( 2 GPM/TR)
1.3 Total head (Primary) Ft 70
14. Location Indoor
1.5 Maximum rated speed (at 50 Hz.) RPM 1450

75
1.6 Liquid handled Water
1.7 Number required Nos 3 ( 2 Working + 1 Standby)

2.0 FEATURES OF CONSTRUCTION

2.1 Type of pump End suction
2.2 Impeller Enclosed
2.3 Volute Single
2.4 Shaft Coupled
2.5 Drive Transmission Direct
2.6 Seal Mechanical seal
2.7 Coupling Flexible
2.9 Prime Mover AC Electric motor
3.0 MATERIALS OF CONSTRUCTION
3.1 Impeller Bronze/ Stainless steel
3.2 Casing Cast Iron GR FG 200*
3.3 Shaft EN – 8 Steel *

1.0 DESIGN FEATURES

1.1 Pump designation Chilled water variable
primary pumps
1.2 Minimum design capacity US GPM 480 (2GPM/TR)
1.3 Total head (Primary) Ft 70
14. Location Indoor
1.5 Maximum rated speed (at 50 Hz.) RPM 1450
1.6 Liquid handled Water
1.7 Number required Nos 3 ( 2 Working + 1 Standby)

2.0 FEATURES OF CONSTRUCTION

2.1 Type of pump End suction
2.2 Impeller Enclosed
2.3 Volute Single
2.4 Shaft Coupled

76
2.5 Drive Transmission Direct
2.6 Seal Mechanical seal
2.7 Coupling Flexible
2.9 Prime Mover AC Electric motor
3.0 MATERIALS OF CONSTRUCTION
3.1 Impeller Bronze/ Stainless steel
3.2 Casing Cast Iron GR FG 200*
3.3 Shaft EN – 8 Steel *
3.4 Shaft Sleeve EN-8 Steel *
3.5 Impeller Ring SS 304 *
3.6 Casing Ring Cast Iron GR FG 200*
3.7 Stuffing Box Packing Graphite Asbestos*
3.8 Base Plate Fabricated Steel / Cast Iron*
Note : For components marked *
material test certificates shall be
furnished
4.0 ACCESSORIES
4.1 Companion Flanges Yes
4.2 Foundation Bolts Yes
4.3 Base Plate Yes
5.0 TESTING
5.1 Hydrostatic Test Casing Witnessed
Jackets / Cooling Passage
5.2 Performance Test Std. Running Witnessed
Test
NPSH Test

DATA SHEET – B
TECHNICAL REQUIREMENTS FOR CONDENSER WATER PUMPS FOR OFFICE

1 DESIGN FEATURES

77
1.1 Pump designation Condenser water pumps
1.2 Minimum design capacity US GPM 720(3 GPM/TR)
1.3 Total head Ft 70
14. Location Indoor
1.5 Maximum rated speed (at 50 Hz.) RPM 1450
1.6 Liquid handled Water
1.7 Number required Nos 3 (2 Working + 1 standby)
2.0 FEATURES OF CONSTRUCTION
2.1 Type of pump End suction
2.2 Impeller Enclosed
2.3 Volute Single
2.4 Shaft Coupled

2.5 Drive Transmission Direct

2.6 Seal Mechanical seal
2.7 Coupling Flexible
2.9 Prime Mover AC Electric motor
3.0 MATERIALS OF CONSTRUCTION
3.1 Impeller Bronze/ Stainless steel
3.2 Casing Cast Iron GR FG 200*
3.3 Shaft EN – 8 Steel *
3.4 Shaft Sleeve EN-8 Steel *
3.5 Impeller Ring SS 304 *
3.6 Casing Ring Cast Iron GR FG 200*
3.7 Stuffing Box Packing Graphited Asbestos*
3.8 Base Plate Fabricated Steel / Cast Iron*
Note : For components marked *
material test certificates shall be
furnished

4.0 ACCESSORIES

78
 4.1 Companion Flanges Yes
4.2 Foundation Bolts Yes
4.3 Base Plate Yes
5.0 TESTING
5.1 Hydrostatic Test Witnessed
Casing
Jackets / Cooling Passage
5.2 Performance Test Witnessed
Std. Running Test
NPSH Test

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER AWARD OF CONTRACT AND

BEFORE’ INSTALLATION

1. Quality Assurance Plan (QAP)

2. Detailed dimensioned general arrangement drawing of pump and driver.

3. Foundation drawing of pump and driver with static and dynamic loads, details of fixing,
grouting and all relevant data required for design of foundation

4. Cross-section drawing of the pump with complete part list, materials of construction and
relevant standards for each part

5. Pump performance curves flow rate Vs head, BKW, efficiency, NPSHR from zero flow to
maximum flow and torque-speed curve

6. Scheme for pump sealing, lubrication and cooling

7. Driver dimensional drawing

8. Surface preparation and painting procedures

9. Catalogues, data sheets and drawings for instruments

10. Installation, operation and maintenance manual

11. Isolation pads and SS or Hot dip galvanised foundation bolts provided by the Contractor.

79
12. Cork -rubber make metallic bellows shall be provided at suction and discharge.

13. Pressure gauges with needle valve provided at suction and discharge lines.

14. All accessories provided to complete the pump installation.

CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION

Remark
No Description Unit Time Date
s
14.0 16.0 18.0 20.0
10.00 12.00
0 0 0 0
Kg/cm
13. Suction pressure 2

Kg/cm
14. Discharge pressure 2

15. Water flow rate FT3/hr

16. Current Amps
Bed plate levels and
17.
alignment checks
Hydraulic test for
18. casing at 1.5 times
design pressure
Noise level from
19. 6 F dB
pump
20. Discharge Vs head F
Discharge Vs
21.
efficiency
22. Discharge Vs BkW

Run Test shall be conducted on the following Pumps.

1. Chilled Water pumps

2. Condenser Water pumps

12.0 MODE OF MEASUREMENT

A. Representatives from the Contractor and Engineer shall conduct a joint inspection of
the Equipment. All the discrepancies observed either incomplete works or defective
work shall be clearly indicated in the joint inspection report. The mode of

80
 measurements given below is for the purpose of measurement and payment and the
scope of works shall be as specified elsewhere in the specification.

B. Centrifugal pumps

Each pump set including motors, flexible connection at inlet and outlet, vibration
isolators and accessories as specified in tender document shall be regarded as one
unit for the purpose of measurement and payment.

SECTION 4.07
AIR HANDLING UNITS

81
DOUBLE SKIN AIR HANDLING UNITS (AHU)

1.0 SCOPE

This specification covers the general design, materials, and construction features,
manufacture shop inspection and testing at manufacturer’s works, delivery at site,
handling at site, installation, testing, commissioning and carrying out performance test
at site of variable air volume type double skin air handling units.

2.0 CODES AND STANDARDS

The design, materials, manufacture, inspection, testing and performance of AHUs shall
comply with all currently applicable statues, regulations, codes and standards in the
locality where the equipment is to be installed. Nothing in this specification shall be
construed to relieve the ACMV Contractor of this responsibility. In particular, the
AHUs shall conform to the latest edition of following standards:

Methods of Testing Panel type Air Filters for Air Conditioning and
IS 7613
Ventilation purposes.
Methods of Testing – Forced Circulation Air Cooling and Air
ASHRAE 33
Heating Coils.

82
 ARI 410 Forced circulation Air-Cooling and Air-Heating Coils.
ARI 430 Central-Station Air-Handling Units.
AMCA 210 Laboratory methods of Testing Fans for rating
Clean room and Work Station requirements, controlled
FED STD 209E
environment.
NFPA 90A Installation of Air-conditioning and ventilating systems.

3.0 CONSTRUCTION FEATURES

3.1 TYPE

The AHUs shall be draw through type Horizontal floor mounted as specified. The unit
shall comprise of various sections such as pre-filters of MERV rating 8,Fine filters of
MERV rating 13, cooling coil and fan, etc. The Contractor shall check the dimension of
AHU room as indicated in the drawing and on site and select AHU model to suit the
room dimensions. The Contractor shall calculate and ensure that the AHU selected can
be installed within the AHU space as indicated in the drawings and must provide
allowance of space for maintenance of AHU to the satisfaction of the superintending
officer.

3.2 CASING / CABINET

A. The Casing shall have a pentapost perimeter frame with a modular system based
on standardised sandwich thermal break panels. The sandwiched thermal break
panel shall be double-sided skin type with injected polyurethane insulation foam
being totally encased by high grade and appropriate gauge galvanized sheets. Non
thermal break panel and open profile panel are not acceptable. Removal of the side
panels must not affect the structural integrity of the unit. The frame works shall be
made from non-corrosive recyclable extruded aluminium channels fitted together
with non-metal corner pieces to prevent thermal bridging and condensation.

B. The floor panels including fan section shall have double wall construction to allow
maintenance personnel access without damage to the insulation

C. The sheet metal gauge shall be not less than 0.7mm (internal and external). The
base of casing shall be capable to withstand the weight of people without
deflection. The panel shall provide high noise damping characteristic of 30 dB
reduction. The insulation of the panels shall be injected polyurethane with thermal
conductivity (k value) of no more than 0.02 W/ (m◦K). The minimal thickness and
density of the insulation shall be 50 mm and 48 kg/CUM The insulation shall not
absorb moisture and must be rust-resistant. The panels shall be held in place by
"access" clips and Allen key arrangement for easy removal. The fixing of each

83
 panel to the pentapost perimeter frame shall be from outside the unit. The panels
shall be flush mounted. There shall be no sharp edges or corners on the unit which
might cause accident/ Injury.

D. The outer wall shall be galvanised steel, chemically treated, pre-coated with
primer and finished with oven-baked polyester based powder paint of at least 50
microns thickness to resist nicks and scratches to galvanised panels and to allow
easy cleaning of exterior. The coating shall not be affected by detergent cleaning.
The inner wall shall be galvanised steel.

E. Access door or service panel shall be supplied with a hinged access door with latch
or with removable panel with handles and panel block. Door shall swing outward
for unit sections under negative pressure. An access door of minimum 600mm x
900mm size shall be provided on the casing for easy access to the internal
components for maintenance and cleaning.

F. For the best minimization of heat loss through AHU, thermal break aluminium
profile shall be used.

G. The units shall be equipped with supply air and fresh air volume control damper
(VCD) of required size to match the air volume and velocity as mentioned in the
equipment schedule. All VCD shall be of the opposed blade type. The damper
casing shall be constructed with 2mm thick corrosion resistant galvanized steel.
Blades shall be constructed of double skinned 2 mm thick, aerofoil shaped
corrosion resistant galvanized steel. The blade is externally mounted on the shaft,
out of air stream. Each damper shall be equipped with heavy gauge steel gear
action type operator that provides precise control of airflow. The damper shall be
suitable to mount motorized actuator.

H. The complete unit shall be mounted on a fabricated GI base frame, height of 100
mm for ease of shipment and handling.
I. The casing shall to provide inbuilt I/O points before and after the cooling coil section(2
each). Also the prefilter section to provide the I/O points to measure the differential
pressure across the filters to meet the BCA requirements.
J.

3.3 FAN AND MOTOR

The complete EC Centrifugal Fan unit shall be of rugged bolted construction made of
sheet steel, statically and dynamically balanced.
Impeller:

84
The Fan shall be Single Inlet Centrifugal Impeller with High Efficiency Backward
curved blades and external rotor EC (Electronically Commutated) motor, energy
optimized for operation without spiral housing for high efficiency and favourable
acoustic behaviour. The impeller shall have an odd number of 5 or 7 backward curved
blades with 3-dimensional blade geometry for achieving low noise.

The high efficiency backward curved impeller with rotating diffuser, made of high
performance composite material, with external rotor motor shall be statically and
dynamically balanced according to DIN ISO 1940 Part 1.

The ECblue fan should be capable of being fitted in horizontal or vertical position in
the AHU, depending on the application.

Galvanised Inlet cone shall be provided with a nozzle for volume flow measurement of
the fan.

Motor:

The minimum efficiency class of the motor shall be IE4. The motor shall be external
rotor motor construction with integrated electronics and suitable for continuous
operation. The speed of the motor shall be variable depending on an external control
signal. The fans shall be Modbus RTU compatible for communication with BMS
(Building Management System). The fan in totality shall be of most efficient type so
that the power consumption and noise level is minimal. The EC motor shall have a
wide voltage input range: 3~380…480V, 50/60 Hz.

The motor shall be minimum IP54 protection class, with Thermal class 155 (Insulation
class F). The EC motor shall be provided with suitable protection from moisture & hot
climate. The ball bearing shall be provided with long time lubrication for maintenance
free operation.
The power consumption shall be limited to 0.6 W/cfm to meet the BCA requirements.

Integrated Electronics:

The device electronics shall be protected from overload by the Active Temperature
Management, so that if the ambient operating temperature exceeds the design limit
then the fan is not switched off immediately. In such a condition the fan should be
operational at lower speeds, till the time the operating ambient temperature drops
down.

85
 The EC fan shall meet all necessary EMC (Electromagnetic Compatibility) directives.
The EC fan should comply to applicable EMC standards: Interference Emission
Standard EN 61000-6-3 / 2.

External VSD (Variable Speed Drive) is not required for speed modulation of EC fans.

Fan characteristic curves shall be related to measurements a re-circulating chamber

test rig in accordance with DIN 24163 Part 2 or ISO 5801.

The performance data of the fan shall comply with Precision Class AN2 according to
ISO 13348.

The fan(s) must comply with AMCA Publication 211 and be licensed to bear the AMCA
Certified Rating Program seal for sound and air performance, FEG and FEI. The fans
shall be tested for air performance — flow rate, fan pressure, power, air density, speed
of rotation and fan efficiency — according to ANSI/AMCA Standard 210/ASHRAE
Standard 51. Fan sound ratings shall be certified in compliance with AMCA Publication
311 and shall comply with ANSI/AMCA Standard 301. The fans shall be tested
according to ANSI/AMCA Standard 300.

Fan shall be certified with AMCA Fan Energy Index (FEI) as per the calculation method
for the new metric, which is defined in ANSI/AMCA Standard 208.

The EC Fan shall have the following protective features already integrated in the
controller:

• Overvoltage protection

• Short Circuit protection

• Under voltage/ Over voltage detection

• Locked rotor protection

• Line fault detection

• Active Temperature Management for thermal protection of motor and electronics

• Alarm relay 250V/2A

• Over temperature protection of electronic and motor

• External LED display shall be provided for indication of the status of the fan

The rated cfm should be achievable at 50 Hz. Or below.Fan motor power shall not exceed
0.6W/cfm, for systems which motor name plate power greater than 4Kw.

86
3.4 COOLING COIL SECTION

A. Coil shall be installed such that unit encloses headers and returns bend. Drain and
vent connections shall be provided exterior to unit casing. Coil connections should
be sealed with rubber grommets to minimize air leakage and condensation inside
panel assembly.

B. Coils shall be removable through side panels of unit without the need to remove
and disassemble the entire section from the unit. Capacity, water pressure drop
and selection procedure shall be designed in accordance with ARI Standard 410.

C. Standard Aluminium fins are maximum 12 FPI (fin per inch).

D. Standard coil frame shall be 1.5mm thick galvanized steel (GI).

E. Standard working pressure of the coil is 250 psig (17 bars).

F. Cooling coils shall be selected for maximum face velocity of 2.5 m/s (500 FPM).
Coil row shall be selected as per the sensible and latent load specified in the
equipment schedule using coil selection software. Header and collar is constructed
of steel. Piping connection is only one sided, either “left” or “right”, viewing from
return air side.

G. The connection for steel header is by Male Pitch Threaded (MPT) joint.
H. The row depth of the coil and also the coil contact area shall be selected in accordance
with the design delta T of 12.7 Deg.F. All these documents and selection shall be submitted
to the consultant and take approval before purchase.
I.

J. UV emitters shall be provided to prevent the spread of infectious bacteria and

airborne microorganism.

3.5 UVC Emitters

UVC Emitters shall be provided for all AHUs. They shall be installed at the off-coil
sections of all AHUs, just after the cooling coils, to improve indoor air quality and to
keep the cooling coils clean. Emitters shall have high UVC energy output and be
effective in destroying pathogens (viruses, bacteria and fungi), allergens (bacteria and
mould) and toxins (endotoxins and cotoxins) under cold moving air conditions. .

UVC intensity of 253.7 nanometres shall be determined in accordance with the general
provisions of IES Lighting Handbook, 1981 Applications Volume, under 45 F moving

87
 air stream of not less than 400 fpm. Intensity shall not be less than 10 µW/cm 2, at 1
metre, per inch of Emitter arc length, as measured from filament. The UVC Emitters
must be suitable for high airflow and low temperature operation. As such, they must
provide a UVC output of at least 122 µW/cm 2 at 1 metre and 45F at 400 fpm and a
UVC output of at least 158 µW/cm2 at 1 metre and 68F at 400 fpm. All UVC Emitters
shall be UL and CSA listed for damp conditions. Technical literature/test data sheets
must be submitted to confirm compliance.

Power supplies for the UVC Emitters shall be of Class P2, rapid start type with a power
factor of 0.95 and a power conversion of not less than 70%. They should be designed
to maximize photon production, radiance and reliability in cold, moving air streams
and be able to operate at 100 % RH.

Emitters and fixtures are to be installed in sufficient quantity and in such an

arrangement so as to provide and equal distribution of UVC energy on the coil and in
the drain pan. The minimum UVC energy striking the leading edge of all the coil fins
shall not be less than 716 µW/cm2 at the closest point. The through placement shall be
not less than 60 % of that value at the farthest point which therefore sets the
minimum quantity of fixtures installed. Additionally, equal amounts are to strike the
drain, either directly or indirectly.

Emitters and fixtures shall be installed at right angles to the conforming lines of the
coil fins, such that through incident angle reflection, UVC energy bathes all surfaces of
the coil and drain pan as well as all of the available line of sight airstream.

The UVC Emitters shall be fitted with a radiometer at each AHU to measure the UVC
energy output and determine the remaining life of the UVC lamps. Each radiometer
must be provided with a large direct readout LCD display, a 0-0.5 Vdc analog output
with adjustable minimum set-point, internal SPDT relay outputs with adjustable
minimum set- point for triggering alarms, lights or system shutdown and adjustable
gain for long-run input correction. The radiometer shall be interfaced to the Building
Management System (BMS) for monitoring of UVC energy output at each AHU and to
indicate when the UVC lamps are due for replacement. The radiometer shall be from
the same manufacturer as the UVC Emitters.

The power supply for the UVC emitters shall be tapped from the AHU control panel.

3.6 DRAIN PAN

An insulated condensate drain pan shall be provided in each AHU which shall extend
under the entire coil and fan section. The drain pan shall be of double-wall
construction with 25 mm thick foam insulation cemented between stainless steel
sheet (grade 304) of 18 gauge outer pan and inner pan. The inner pan shall be finished
with a coating of water – proof and corrosion – resistant material. Drain connection

88
 shall be provided on both sides of the casing. The drain pan shall be sloped ¼ inch per
ft and constructed to allow complete pan drainage.

3.7 FILTER SECTION

General

The Contractor shall supply, install, test and commission pre-filters/primary filters of
MERV 8 rating and fine filters of MERV 13, to all AHU’s and all treated fresh air intakes.

The Contractor shall provide (minimum) the following filter changes including all pre-
filters and accessories;
 one complete set (of temporary air filters) for initial start-up for testing
and commissioning
 one complete set after testing and commissioning and before handover
to employer
 one complete set halfway during the Defects Liability Period
 one complete set at the end of Defects Liability Period

The Contractor shall nevertheless replace any filters discovered to be worn out or
clogged during the course of the free servicing and maintenance period. The filters
replaced are not considered as part of the above mentioned sets.

Air filters shall comply with the requirements of ASHRAE 52-76 or an approved
equivalent standard. Reference shall be made to ASHRAE 52-76 or to the relevant
approved equivalent standard for definition of terms employed. Air filter tests shall be
performed by an independent Testing Laboratory. Test certificates shall be produced
on request.

The filters shall be installed complete with all accessories and other minor necessary
for their satisfactory installation and performance whether individually specified or
not.

a. Pre-Filter

Each unit shall be provided with a factory assembled filter section with minimum
MERV 8 rating, containing 48mm thick washable synthetic type air filters having GSS
frame. The media shall be supported with High Density polyethylene (HDPE) mesh on
one side and aluminium on the other side. Filter banks shall be easily accessible and

89
 designed for easy withdrawal and replacement of filter cells. Filter bank framework
shall be fully sealed and constructed from GSS. The efficiency of the filters shall be
90%down to particle size of 10 microns as per IS 7613, and ASHRAE 52.1.

b. BAG Filter

Flanged microvee filters 600mm thick with HDPE filter media shall be provided to suit
MERV 13 rating. The filter frame and filter bank framework shall be GSS construction
with neoprene rubber gasket. The efficiency of the filters shall be 99% down to
particle size of 5 microns as per IS 7613 and ASHRAE 52.1.

c. Filters - Codes and Standards.

a. ASHRAE 52.1 Gravimetric and Dust spot procedures for testing Air
cleaning devices.
b. IS 7613 Methods of testing panel type Air filters for ACMV

3.8 AHU TOTAL (INTERNAL AND EXTERNAL) PRESSURE CALCULATION

The AHU external static head indicated on the equipment schedule is indicative only,
contractor shall submit calculations for the internal and external pressure loss of each
air handling unit based on the proposed equipment and ducting system, so that the fan
is capable of providing the necessary output of the designated head. Detailed
calculations of fan external static head and fan curves with all relevant documents
shall be submitted to the consultant’s approval prior to the placing order of the AHU.
Required motor HP based on actual calculated static pressure shall be provided
without extra cost.

3.9 NOISE LEVEL

The noise level from the air handling unit should be less than 62 dBA when measured
from 1m from the unit.

3.10 FLEXIBLE CONNECTION

Heavy duct flexible (Fire retardant) double layer canvas connection shall be provided
at the outlet of AHU fan. Additional double layer canvas connection shall be provided
between the GSS ducting and AHU. This canvas connection shall contain a provision
(zip) for measuring the DBT and WBT of the cooled and dehumidified air.

90
 The AHU shall be provided with the following accessories, mixing box bulk head lamp,
inspection windows, limit switch, extended grease lines and belt and motor guard.

TECHNICAL REQUIREMENTS

91
Sl.
Description Requirements
no.
1 Numbers and minimum capacity Refer equipment schedule
2 Cooled and Dehumidified air flow Refer schedule
rate –
3 Cooling coil face area Air velocity across cooling coil face
area to be less than 500 FPM (2.5
m/s)
4 Number of rows for cooling coil As per computer coil selection OR
equipment schedule whichever is
higher.
5 Entering chilled water 46 F
temperature – deg C
6 Leaving chilled water 58.5 F
temperature – deg C
7 Chilled water flow rate – m3/hr Refer schedule
8 Drain connection on both sides of 1 Inch dia socket connection
AHU
9 Coil tube dia 1 Inch (13 mm)
10 No. of Fins Not more than 12 FPI
11 Type of fan motor 415 V, 3 PH, 50 Hz TEFC Sq. Cage,
with variable speed drive.
12
13 Pre-Filters (cleanable type) Minimum MERV 8 Pre filters (panel
type) of 90% efficiency down to 10
microns, Maximum face velocity 350
FPM (1.75 m/s)
14 Fine filters (BAG Filter) cleanable Minimum MERV 13 Fine flirters
type (pleated media panel type) of 99%
efficiency down to 5 microns.
Maximum face velocity 350 FPM
(1.75 m/s).

92
 DATA SHEET - B
DATA TO BE FURNISHED BY TENDERER
( for each size / capacity of AHU separately)
Sl.
DESCRIPTION REQUIREMENT
No.
1. Air Handling Unit No.
2. Type
3. Model / Make
4. Grand Total Heat (TR)
5. Total Sensible Heat (TR)
6. Minimum Supply Air Quantity (S/A – CFM)
7. Minimum Outside Air Quantity (O/A – CFM)
8. Air entering coil temperature (TE-DB deg F)
9. Air entering coil temperature (TE – WB deg F)
10. Air leaving coil temperature (TL – DB deg F)
11. Air leaving coil temperature (TL – WB deg F)
12. Maximum Air Face Velocity (m/sec) across coil
13. Maximum Air side pressure drop across coil in inches
14. Total Fan Static Pressure in inches
15. External Static Pressure in inches
16. Chilled Water Entering Coil Temperature (deg F)
17. Chilled Water Leaving Coil Temperature (deg F)
18. Chilled Water Velocity – Maximum (FPS)
19. Coil Rows
20. Coil Fins / Cm.
21. Chilled Water Flow Rate GPM
Maximum Chilled Water Pressure Drop (Feet)
22.
through coil
22.1 Type of Fan FC / BC / Aerofoil
22.2 Type of Fan Control
22.3 Maximum fan rpm
22.4 Maximum outlet velocity FPM
23. Type of Filters
24. Pre-Filters

93
 DATA SHEET - B
DATA TO BE FURNISHED BY TENDERER
( for each size / capacity of AHU separately)
Sl.
DESCRIPTION REQUIREMENT
No.
Numbers
Dimension
Efficiency
Face velocity
Maximum Air side pressure drop across filter
25.
(Pascals)
26. Type of Starter
27. Motor Voltage
28. Type of Vibration isolator
29. Interlock with smoke detector and fire alarm system
30. Supply and return air noise treatment
31. Controls
32. Dimensions L x B x H
33. Operating weight kg
34. AHU motor kW rating BKW / KW

DATA SHEET - C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACTOR

AND BEFORE INSTALLATION

1. Schedule of drawings and documents to be submitted for review, approval and

information with submission dates.

2. Quality Assurance Plan (QAP).

3. Detailed P & I diagram showing clearly the scope of supply of equipment, piping with
line sizes and material specifications, valves, specialities, instrumentation and control
and all accessories. This drawing or documents mentioned under following clauses
shall include all design data and information furnished in data sheets A and B. The
makes of all major components and controls shall be indicated.

94
4. Dimensioned general arrangement drawing showing all equipment with accessories,
mounting details, nozzle locations, etc.

5. Overall space and head room requirement with details of handling during erection,
operation and maintenance.

6. Foundation drawing with static and dynamic loading data, pocket details, foundation
outline, Anti vibration mounts (AVM)/ spring vibration isolators.

7. Cross-sectional drawings of all items with part list and materials of construction.

8. Performance curves and selection charts for fan, filters, etc. Selection charts and
calculation for cooling coil.

9. Operation and maintenance manual with lubrication schedule.

10. Catalogues furnishing detailed technical data for fan, coils, filters, etc.

DATA SHEET - D
CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION
Air Handling Unit Number: -

Sl.
Description Unit Remarks
No.
1. Entering Air temp DB (deg F)
2. Entering Air temp WB (deg F)
3. Leaving Air temp DB (deg F)
4. Leaving Air temp WB (deg F)
5. Entering Water temp (deg F)
6. Leaving Water temp (deg F)
7. Coil / Filter area (SFT)
8. Face Velocity (FPM)
9. Air Flow (CFM)
10. Fan Speed (RPM)
11. Voltage
12. Current (A) = R- Phase
= Y- Phase
= B- Phase
13. Over load relay range A

95
 Sl.
Description Unit Remarks
No.
14. Over load relay setting A
15. Inlet Water pressure (Kg / cm²)
16. Outlet water pressure (Kg / cm²)
17. Noise level AHU room (dBA)
Vibration level
18. = X - axis
(Microns)
= Y - axis
= Z - axis
19. Fresh air velocity (FPM)
20. Fresh air filter area (SFT)
21. Fresh air flow (CFM)
22. Designed CFM

DATA SHEET - D
CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION
Air Handling Unit Number: -

Sl. Needs Not

Description OK
No. Attention Applicable Remarks
Outside Air Intake
1. Location
2. Open during occupied hours?
3. Unobstructed
Odours from outdoors?
4.
(describe)
5. Cooling tower within 25 feet?
6. Exhaust outlet within 25 feet
Bird Screen
7. Unobstructed?
8. General condition?
Outside Air Dampers

96
Sl. Needs Not
Description OK
No. Attention Applicable Remarks
9. Operation acceptable?
10. Seal when closed?
11. Actuators operational?
12. Minimum % O.A
Measured % O.A
13. Note day, time, ACMV operating
mode under “Comments”
14. Maximum % O.A
Is minimum O.A. a separate
15.
damper?
For VAV systems: is O.A.
16. increased as total system air-flow
is reduced?
Mixing Plenum
17. Clean?
18. Floor drain trapped?
19. Air tightness
20.  of outside air dampers
21.  of return air dampers
22.  of exhaust air dampers
23. All damper motors connected?
24. All damper motors operational?

1. Air mixers or opposed blades?

Mixed air temperature control
2.
setting -------------- oF
Is mixing plenum under negative
pressure?
3. Note: If it is under positive
pressure, outdoor air may not be
entering.
Filters
4. Type
Complete coverage?
5.
(i.e., no bypassing)
Correct pressure drop?
6.
(Compare to manufacturer’s

97
 recommendations.)
7. Contaminants visible?
8. Odour noticeable?
Cooling Coil
9. Inspection access?
10. Clean?
11. Supply water temp.--------- oF
12. Water carryover?
Any indication of condensation
13.
problems?
Condensate Drip Pans
14. Accessible to inspect and clean?
15. Clean, no residue?
16. No standing water, no leaks?
17. Noticeable odour?
18. Visible growth (e.g., slime)?
19. Drains and traps clear, working?
20. Trapped to air gap?
21. Water overflow?
Supply Fan Chambers
22. Clean?
23. No trash or storage?
Floor drain traps are wet or
24.
sealed?
25. No air leaks?

Doors close tightly?

Supply Fans
Location
Excess vibration?
Corrosion problems?
Controls operational, calibrated?
Control sequence conforms to
design / specifications?
(describe changes)

98
 No pneumatic leaks?

4.0 MODE OF MEASUREMENT:

A. Representatives from the Contractor and Engineer shall conduct a joint inspection of
the Equipment. All the discrepancies observed either incomplete works or defective
work shall be clearly indicated in the joint inspection report. The mode of
measurements given below is for the purpose of measurement and payment and the
scope of works shall be as specified elsewhere in the specification.

B. AIR HANDLING UNIT

Air handling unit of cabinet type along with flexible connection at fan outlet, flexible
connection at chilled water pipe inlet and outlet of AHU, filter, fan, motor, outlet
damper etc., as specified in tender document shall form one unit for the purpose of
measurement and payment.

C. SUPPLY AIR FAN UNIT

Supply air fan unit consisting of fan, fan motor, louvers, filters, vibration isolators,
sound attenuators, outlet dampers, flexible connection at fan outlet, weather proof
enclosure of GSS cabinet type construction and accessories will be regarded as one
unit for the purpose of measurement and payment.

D. PRE-FILTERS & BAG FILTERS

Pre-filters/Bag-filters complete with support, frame etc., shall be measured from the
approved drawings I as built drawing on the basis of core area (excluding margin
flanges) and paid per unit area. Pre filters and final filters in supply air fan units are
part of fan units and no separate payment will be made for the same.

99
 FAN COIL UNITS

Scope:

Scope of work under this section comprises the supply, installation, testing and
commissioning of Fan Coil Units conforming to these specifications and of the sizes and
capacities given in the Schedule of Equipment.
Materials and Construction:

100
 Fan Coil Unit shall consist of water coil section, fan deck, motor and blow assembly,
side, top and bottom sheets of corrosion resistant galvanised steel formed to provide
air-discharge flanges, insulated drain pan attached to the unit without metal to metal
contact. Four slots shall be provided in the top flange to accommodate mounting
hangers. Overall height from the bottom of drain pan to the top of mounting flanges
shall not exceed 250mm for horizontal type units.
Casing shall be of sheet steel not thinner than 18 Gauge suitably stiffened to minimise
drumming and vibration and shall be protected against corrosion and powder coated.
All corners shall be without sharp edges. Casing shall include space for pipe
connections and valves and there shall be access to the fan, motor, filter, damper, drain
pan, pipe connections and valves, for maintenance purpose. Wing nut arrangement
shall be provided for the flanged joints of the FCUs so as to avoid contact of the sheet
metal body with the threading in order to avoid damage.
Coil shall be of tube and fin design. Bends and joints shall be silver-alloy brazed. The
coil shall be suitable for 10.2 kg/sq.Cm (150 PSI) working pressure. Automatic air vent
shall be located on the return header and drain plug in the supply header. Supply and
return connections shall be 16mm (5/8”) O.D. copper. Tubes shall be 16mm (5/8”) or
12mm (1/2”) or 10mm (3/8”) O.D. as per manufacturer’s standards and with 5
fins/cm (12FPI) for cooling.Copper tubes shall be of 27 gauge thickness and
aluminium fins shall be of 34 gauge thickness. Coils shall be used for chilled water
circulation.
Slow speed centrifugal fans and direct drive, resiliently mounted two-bearing
motor shall be on a single vertical mounting plate. Fans be of the forward curved
centrifugal or tangential flow type and may be of mild steel, aluminium, reinforced
glass fibre or rigid plastics material. Motors shall be quiet running and shall have
sleeve bearings factory lubricated for life. Motor windings and electrical components
shall be oil impregnated or protected to avoid trouble from condensation. Motor shall
be BLDC/Equivalent type and have built-in thermal overload protection. The fan
power consumption shall not exceed 0.25 W/cfm to meet the BCA requirements. The
entire assembly shall be easily removable after taking out two screws, which are to be
readily accessible.
Drain pan shall be extended type to cover the pipe / valve assembly and shall be
fabricated of 18 Gauge corrosion resistant galvanised steel and shall be watertight.
Minimum of 50mm (2”) thick insulation shall be sandwiched between the galvanised
sheets. Interior surface of the pan shall be finished with 2 coats of red oxide and
properly bituminised so as to provide a smooth surface for positive condensate drain.
Drain connection from the pan shall be 40mm (1/2”) O.D, PVC to M.S. Connection shall
be located at the rear of the pan at the same side as the coil connections. The drain pan
shall be isolated from the balance of the assembly with no metal to metal contact for
maximum protection against 'sweating'. Pan shall be large enough and shall extend
under the tube ends to accommodate the installation of shutoff valves and controls.
Unit shall be complete with all interconnecting copper tubing between M.S. piping and
motorised valve. Ball valve with strainer on the chilled water inlet connection and ball valve
without strainer on the chilled water outlet connection shall be provided.

101
 Air filters may be of nylon fibre, glass fibre or cellular plastic material and shall have a
minimum efficiency of 40% down to 20 microns when tested in accordance with IS
7613 - 1975 using test dust No. 3.
Controls:
Fan coil units shall be provided with controls as given in Section - ‘Controls and
Instrumentation’.
Noise Level:
Casings shall be lined with material to act as both thermal and acoustic insulation. Fan and
Motor assemblies shall be complete with anti-vibration mountings. Noise data shall be
provided by the Contractor and shall be based on the tests in accordance with the
appropriate ASHRAE and British Standard specifications. Full details of the testing technique
and procedure shall be given. The data shall include an octave band analysis of the sound
power level of the unit when operating at its design speed.
Installation:
The installation of fan coil unit shall include all ancillary material like suspenders with
vibration isolators, making chilled water connections with the M.S to copper pipes and valves
to coil, making all electrical connections, sloping drain pan towards drain outlet, testing,
balancing, etc. as required at site.
Testing:
Fan Coil Units shall be tested for their design performance and test results shall be furnished
in accordance with section - 'Test Readings'.
Painting:
Units shall be with epoxy powder coated finish.

102
 SECTION 4.08
HEAT RECOVERY UNITS

103
1.0 SCOPE

This specification covers the general design, materials, and construction features,
manufacture shop inspection and testing at manufacturer’s works, delivery at site,
handling at site, installation, testing, commissioning and carrying out performance test
at site of Double skin Heat recovery unit (HRU). The units shall be capable of handling
variable air volume.

2.0 CODES AND STANDARDS

The design, materials, manufacture, inspection, testing and performance of Heat

recovery unit shall comply with all currently applicable statues, regulations, codes and
standards in the locality where the equipment is to be installed. Nothing in this
specification shall be construed to relieve the ACMV Contractor of this responsibility.
In particular, the Heat recovery unit shall conform to the latest edition of following
standards:

Methods of Testing Panel type Air Filters for Air Conditioning and
IS 7613
Ventilation purposes.

104
 Methods of Testing – Forced Circulation Air Cooling and Air
ASHRAE 33
Heating Coils.
ARI 410 Forced circulation Air-Cooling and Air-Heating Coils.
ARI 430 Central-Station Air-Handling Units.
AMCA 210 Laboratory methods of Testing Fans for rating
Clean room and Work Station requirements, controlled
FED STD 209E
environment.
NFPA 90A Installation of Air-conditioning and ventilating systems.

3.0 CONSTRUCTION FEATURES

3.1 TYPE

The Heat recovery unit shall be draw through type Horizontal floor mounted as
specified. The unit shall comprise of various sections such as Bag filter, Pre-filter, Heat
Recovery wheel, supply fan & exhaust fan etc. All units shall be suitable for outdoor
mounting.

3.2 CASING

A. The Casing shall have a pentapost perimeter frame with a modular system based
on standardised sandwich thermal break panels. The sandwiched thermal break
panel shall be double-sided skin type with injected polyurethane insulation foam
being totally encased by high grade and appropriate gauge galvanized sheets. Non
thermal break panel and open profile panel are not acceptable. Removal of the side
panels must not affect the structural integrity of the unit. The frame works shall be
made from non-corrosive recyclable extruded aluminium channels fitted together
with non-metal corner pieces to prevent thermal bridging and condensation.

B. The floor panels including fan section shall have double wall construction to allow
maintenance personnel access without damage to the insulation

C The sheet metal gauge shall be not less than 0.7mm (internal and external). The
base of casing shall be capable to withstand the weight of people without
deflection. The panel shall provide high noise damping characteristic of 30 dB
reduction. The insulation of the panels shall be injected polyurethane with thermal
conductivity (k value) of no more than 0.02 W/ (m◦K). The minimal thickness and
density of the insulation shall be 50 mm and 48 kg/CUM The insulation shall not
absorb moisture and must be rust-resistant. The panels shall be held in place by
"access" clips and Allen key arrangement for easy removal. The fixing of each
panel to the pentapost perimeter frame shall be from outside the unit. The panels
shall be flush mounted. There shall be no sharp edges or corners on the unit which
might cause accident/ Injury.

105
 D The outer wall shall be galvanised steel, chemically treated, pre-coated with primer
and finished with oven-baked polyester based powder paint of at least 50 microns
thickness to resist nicks and scratches to galvanised panels and to allow easy
cleaning of exterior. The coating shall be ultra violet resistant, outdoor weather
resistant, and shall not be affected by detergent cleaning. The inner wall shall be
galvanised steel.

E Access door or service panel shall be supplied with a hinged access door with latch
or with removable panel with handles and panel block. Door shall swing outward
for unit sections under negative pressure. An access door of minimum 600mm x
900mm size shall be provided on the casing for easy access to the internal
components for maintenance and cleaning.

F For the best minimization of heat loss through HRU, thermal break aluminium
profile shall be used.

G The units shall be equipped with supply air, fresh air volume control damper
(VCD) of required size to match the air volume and velocity as mentioned in the
equipment schedule. All VCD shall be of the opposed blade type. The damper
casing shall be constructed with 2mm thick corrosion resistant galvanized steel.
Blades shall be constructed of double skinned 2 mm thick, aerofoil shaped
corrosion resistant galvanized steel. The blade is externally mounted on the shaft,
out of air stream. Each damper shall be equipped with heavy gauge steel gear
action type operator that provides precise control of airflow. The damper shall be
suitable to mount motorized actuator.

3.3 HEAT RECOVERY WHEEL

The Heat Recovery section shall have minimum recovery effectiveness of 75 % of total
heat, i.e. both sensible and latent. Necessary computerized selection of the wheel
should be provided along with the bid to justify the same. The wheel shall be made of
pure aluminum foil coated with molecular sieve desiccant. The cross contamination
between the two air streams shall be nil and leakage less than 0.04%. The vendor shall
submit a testimonial that the cross contamination won’t exceed this value. The vertical
and radial run of the wheel shall be less than 1 mm per meter of diameter. The wheels
shall have non-contact labyrinth seals for effective sealing between the two air
streams.

The substrate: The substrate or wheel matrix should be only of pure aluminum foil so
as to allow.
a) Quick and efficient uptake of thermal energy.
b) Sufficient mass for optimum heat transfer
c) Maximum sensible heat recovery at a relatively low rotational speed of 20 to 25 rpm

106
Nonmetallic substrates made from paper, plastic, synthetic or glass fibre media, will
not be acceptable.

The substrate shall not be made from any material which is combustible or supports
combustion like synthetic fibrous media. The wheel has to be certified as per DIN EN
ISO 846 or Equivalent standard with 0% fungal and bacterial growth at 95% Relative
humidity and above.

Fire rating:
NFPA - 90A certification with 0% for Flame spread classification should be confirmed
by manufacturer.

Pressure drop:
The pressure drop across the rotary heat exchanger shall not exceed 0.1 inch for every
100 FPM face velocity, or part thereof, for the minimum stated / required latent
recoveries / efficiencies Necessary software selection of the wheel has to be enclosed
to justify the pressure drop and efficiency calculations.

The Desiccant:

The desiccant should be water molecule selective and non-migratory. The desiccant
should be molecular sieve 3Å so as to keep the cross contamination to absolute
minimum and also ensure the exclusion of contaminants from the air streams, while
transferring the water vapor molecules.

The desiccant, of sufficient mass which should not be less than 5 kg per 1000 CFM of
air, should be coated with non-masking porous binder adhesive on the aluminum
substrate so as to allow quick and easy uptake and release of water vapor. A
confirmation has to be provided by manufacturer of wheel to this effect. A matrix with
desiccants impregnated in nonmetallic substrates, such as synthetic fiber, glass fiber,
etc. will not be accepted.

Rotor:
With optimum heat and mass through matrix formed by desiccant, of sufficient mass,
coated on an aluminum foil, the rotor should rotate at lower than 20 to 25 RPM,
thereby also ensuring long life of belts and reduced wear and tear of seals. The rotor
shall be made of alternate flat and corrugated aluminum foil of uniform width. The
rotor honeycomb matrix foil should be so wound and adhered as to make a
structurally very strong and rigid media which shall not get cracked, deformed etc. due
to change of temperature or humidity.

107
 The rotor having a diameter up to 3000 mm shall have spokes to reinforce the matrix.
From 2000 mm diameter upwards, a special wing structure, to prevent the rotors from
wobbling or deforming due to the successive pressure differentials, will be provided.
Sectioned wheels, with pie segments, capable of being assembled in the field, shall be
available as an option, above 2000 mm in diameter.
The surface of the wheel/rotor should be highly polished to ensure that the vertical
run out does not exceed +/- 1 mm for every 1 meter diameter, thereby ensuring,
negligible leakage, if labyrinth non-contact seals are provided, and minimal drag, if
contact wiper seals are provided. The radial run out also shall not exceed +/- 1 mm for
every 1 meter diameter, thereby minimizing the leakage/drag on the radial seals, and
minimize the fluctuation in the tension of the drive belt.

The rotor shall be a non-clogging aluminum media, having a multitude of narrow

aluminum foil channels, thus ensuring a laminar flow, and will allow particles up to
800 microns to pass through it.

The media shall be cleanable with compressed air, or low pressure steam or light
detergent, without degrading the latent recovery.

Casing: The recovery wheel casing shall be manufactured from epoxy coated tubular
structure to provide a self-supporting rigid structure, complete with access panels,
purge sector, rotor, bearings, seals, drive mechanism complete with belt.

The rotor/wheel should have a field adjustable purge mechanism to provide definite
separation of airflow minimizing the carryover of bacteria, dust and other pollutants,
from the exhaust air to the supply air. It shall be possible, with proper adjustment, to
limit cross contamination to less than 0.04% of that of the exhaust air concentration.

The face and radial seals shall be four (4) pass non-contact labyrinth seals for effective
sealing between the two air streams, and also for a minimum wear and tear ensuring
infinite life of the seals.

3.4 FAN AND MOTOR

The fan section of Heat recovery unit shall be direct driven centrifugal DIDW fans
supplied as a complete fan unit with IEC standards, foot mounted motor mounted on a
stable base frame. Fan impeller with backward curved blades shall be made of steel
sheet, welded and painted with a 60 µm thick coat of epoxy powder. The impellers
shall be dynamically balanced to accuracy in accordance with ISO 1940- 1973 G 2.5
(sizes 0.35 – 140) or G6.3 (size 022-031) at the maximum speed.

108
 Standard motors of well-known brands with IP55 protection, thermal class F, shall be
used.
Fan motor shall be suitable for 415V / 3 Phase / 50 Hz equipped with PTC
resistors/temperature sensors and suitable for integrating with variable frequency
drives (VFD).During commissioning and maintenance the detailed instructions
provided by the motor manufacturer (type plate/motor operating instructions) must
be followed, this also applies to the motor protection devices required onsite.

The fan shall be supplied with built in air flow sensor for air flow measurement. For
pressure measurement a pressure tapping at a pre-determined position on the inlet
cone shall be provided whereby the decrease in the pressure created by the cone can
be measured. It is required to measure the differential pressure between the static
pressure in the plenum on the suction side and the pressure at the inlet cone. Detailed
description measurement and connection diagram and calibration factors shall be
shared for consultant’s approval before procurement.
Anti-vibration mounts (AVM) shall be designed to prevent noise and vibration being
transmitted through the base of the frame. AVMs should be mounted beneath the fan
base frame so the weight and spring deflections are evenly distributed. They should
not be mounted symmetrically around the center of gravity of the system when idle,
because a counter force is induced into the system by the pressure created by the
working fan. Vibration and noise insulation shall be minimized by ensuring that the
fan is connected to its external environment by flexible coupling. The AVM shall be
supplied with the suitable mounting material for the base frame (CC or U profiles).

3.5 FILTER SECTION

General

The Contractor shall supply, install, test and commission pre-filters/primary filters,
Bag filters/secondary filters.

The Contractor shall provide (minimum) the following filter changes including all pre-
filters, secondary filters:
 one complete set (of temporary air filters) for initial start-up for testing
and commissioning
 one complete set after testing and commissioning and before handover
to employer
 one complete set halfway during the Defects Liability Period

109
  one complete set at the end of Defects Liability Period

The Contractor shall nevertheless replace any filters discovered to be worn out or
clogged during the course of the free servicing and maintenance period. The filters
replaced are not considered as part of the above mentioned sets.

Air filters shall comply with the requirements of ASHRAE 52-76 or an approved
equivalent standard. Reference shall be made to ASHRAE 52-76 or to the relevant
approved equivalent standard for definition of terms employed. Air filter tests shall be
performed by an independent Testing Laboratory. Test certificates shall be produced
on request.

The filters shall be installed complete with all accessories and other minor necessary
for their satisfactory installation and performance whether individually specified or
not.

A Pre-Filter

Each unit shall be provided with a factory assembled filter section with minimum
MERV 8 rating, containing 48mm thick washable synthetic type air filters having GSS
frame. The media shall be supported with High Density polyethylene (HDPE) mesh on
one side and aluminium on the other side. Filter banks shall be easily accessible and
designed for easy withdrawal and replacement of filter cells. Filter bank framework
shall be fully sealed and constructed from GSS. The efficiency of the filters shall be
90%down to particle size of 10 microns as per IS 7613, and ASHRAE 52.1.

B BAG Filter

Flanged microvee filters 600mm thick with HDPE filter media shall be provided to suit
MERV 13 rating. The filter frame and filter bank framework shall be GSS construction
with neoprene rubber gasket. The efficiency of the filters shall be 99% down to
particle size of 5 microns as per IS 7613 and ASHRAE 52.1.

C Filters - Codes and Standards.

a. ASHRAE 52.1 Gravimetric and Dust spot procedures for testing Air
cleaning devices.
b. IS 7613 Methods of testing panel type Air filters for ACMV

110
3.6 HEAT RECOVERY UNIT TOTAL (INTERNAL AND EXTERNAL) PRESSURE
CALCULATION FOR SUPPLY FAN AND EXHAUST FAN

The heat recovery unit external static head indicated on the equipment schedule is
indicative only, contractor shall submit calculations for the internal and external
pressure loss of fresh air fan & exhaust air fan based on the proposed equipment and
ducting system, so that the fan is capable of providing the necessary output of the
designated head. Detailed calculations of fan external static head and fan curves with
all relevant documents shall be submitted to the consultant’s approval prior to the
placing order of the unit. Required motor HP based on actual calculated static pressure
shall be provided without extra cost.

3.7 NOISE LEVEL

The noise level from the heat recovery unit should be less than 70 dBA when
measured from 1m from the unit.

3.8 FLEXIBLE CONNECTION

Heavy duct flexible (Fire retardant) double layer canvas connection shall be provided
at the inlet & outlet of HRU fans. Additional double layer canvas connection shall be
provided between the GSS ducting and HRU. This canvas connection shall contain a
provision (zip) for measuring the DBT and WBT of the cooled and dehumidified air.
The HRU shall be provided with the following accessories, mixing box, bulk head lamp,
inspection windows, limit switch, extended grease lines and belt and motor guard.

TECHNICAL REQUIREMENTS

Sl.
Description Requirements
no.
1 Numbers and capacity Refer equipment schedule
2 Fresh and Exhaust air flow rate & Refer schedule
Temperatures –
Recovery Effectiveness-Total
3 Min 75 %
Sensible
Min 75 %

111
 Latent Min 75 %
4 Substrate type Aluminum
5 Desiccant type Molecular sieve 3OA
6 Seals Non-contact, Labyrinth
7 Type of fan motor 415 V, 3 PH, 50 Hz TEFC Sq. Cage with
VFD drive
Face velocity-fpm Not more than 900 fpm
8
9 Drain connection on both sides of 1 Inch dia socket connection
heat recovery unit
10 Type of starter VFD
11 Pre-Filters (cleanable type) Minimum MERV 8 Pre filters (panel
type) of 90% efficiency down to 10
microns, Maximum face velocity 350
FPM (1.75 m/s).
12 Fine filters (BAG Filter) cleanable Minimum MERV 13 Fine flirters
type (Where applicable for Heat (pleated media panel type) of 99%
Recovery Unit on this Project) efficiency down to 5 microns.
Maximum face velocity 350 FPM
(1.75 m/s).

DATA SHEET - B
DATA TO BE FURNISHED BY TENDERER
( for each size / capacity of HRU separately)

Sl.
DESCRIPTION REQUIREMENT
No.
1. Heat Recovery unit No.
2. Type
3. Model / Make
4. Grand Total Heat (TR)
5. Total Sensible Heat (TR)
6. Recovery Effectiveness-Total Min ---- %

112
 DATA SHEET - B
DATA TO BE FURNISHED BY TENDERER
( for each size / capacity of HRU separately)

Sl.
DESCRIPTION REQUIREMENT
No.
Sensible Min --- %
Latent Min ---- %
7. Substrate type
8. Desiccant type
9. Seals
10. Minimum Supply Air Quantity (S/A – CFM)
11. Minimum Outside Air Quantity (O/A – CFM)
12. Air entering coil temperature (TE-DB deg F)
13. Air entering coil temperature (TE – WB deg F)
14. Air entering Relative Humidity (%)
15. Air leaving coil temperature (TL – DB deg F)
16. Air leaving coil temperature (TL – WB deg F)
17. Air leaving Relative Humidity (%)
18. Total Fan Static Pressure in inches
19. External Static Pressure in inches
22.1 Type of Fan FC / BC / Aerofoil
22.2 Type of Fan Control
22.3 Maximum fan rpm
22.4 Maximum outlet velocity FPM
20. Type of Filters
Pre/ Bag Filters
Numbers
21. Dimension
Efficiency
Face velocity
Maximum Air side pressure drop across filter
22.
(Pascals)

113
 DATA SHEET - B
DATA TO BE FURNISHED BY TENDERER
( for each size / capacity of HRU separately)

Sl.
DESCRIPTION REQUIREMENT
No.
23. Type of Starter
24. Motor Voltage
25. Type of Vibration isolator
26. Interlock with smoke detector and fire alarm system
27. Supply and return air noise treatment
28. Controls
29. Dimensions L x B x H
30. Operating weight kg
31. AHU motor kW rating BKW / KW

DATA SHEET - C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF CONTRACTOR

AND BEFORE INSTALLATION

1. Schedule of drawings and documents to be submitted for review, approval and

information with submission dates.

2. Quality Assurance Plan (QAP).

3. Detailed P & I diagram showing clearly the scope of supply of equipment, piping with
line sizes and material specifications, valves, specialities, instrumentation and control
and all accessories. This drawing or documents mentioned under following clauses
shall include all design data and information furnished in data sheets A and B. The
makes of all major components and controls shall be indicated.

4. Dimensioned general arrangement drawing showing all equipment with accessories,

mounting details, nozzle locations, etc.

114
5. Overall space and head room requirement with details of handling during erection,
operation and maintenance.

6. Foundation drawing with static and dynamic loading data, pocket details, foundation
outline, Anti vibration mounts (AVM)/ spring vibration isolators.

7. Cross-sectional drawings of all items with part list and materials of construction.

8. Performance curves and selection charts for fan, filters, etc.

9. Operation and maintenance manual with lubrication schedule.

10. Catalogues furnishing detailed technical data for fan, filters, etc.

Sl.
Description Unit Remarks
No.
1. Entering Air temp DB (deg F)
2. Entering Air temp WB (deg F)
Entering Air Relative Humidity
3.
(%)
4. Leaving Air temp DB (deg F)
5. Leaving Air temp WB (deg F)
6. Leaving Air Relative Humidity (%)
7. Air Flow (CFM)
8. Fan Speed (RPM)
9. Voltage
10. Current (A) = R- Phase
= Y- Phase
= B- Phase
11. Over load relay range A
12. Over load relay setting A
13. Inlet Water pressure (Kg / cm²)
14. Outlet water pressure (Kg / cm²)
15. Noise level AHU room (dBA)
Vibration level
16. = X - axis
(Microns)
= Y - axis
= Z - axis
17. Fresh air velocity (FPM)

115
Sl.
Description Unit Remarks
No.
18. Fresh air filter area (SFT)
19. Fresh air flow (CFM)
20. Designed CFM

DATA SHEET - D
CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION
Heat Recovery Unit Number: -

Sl. Needs Not

Description OK
No. Attention Applicable Remarks
Outside Air Intake
25. Location
26. Open during occupied hours?
27. Unobstructed
Odours from outdoors?
28.
(describe)
29. Cooling tower within 25 feet?
30. Exhaust outlet within 25 feet
Bird Screen
31. Unobstructed?
32. General condition?
Outside Air Dampers
33. Operation acceptable?
34. Seal when closed?
35. Actuators operational?
36. Minimum % O.A
Measured % O.A
37. Note day, time, ACMV operating
mode under “Comments”
38. Maximum % O.A
Is minimum O.A. a separate
39.
damper?
40. For VAV systems: is O.A.

116
Sl. Needs Not
Description OK
No. Attention Applicable Remarks
increased as total system air-flow
is reduced?
Mixing Plenum
41. Clean?
42. Floor drain trapped?
43. Air tightness
44.  of outside air dampers
45.  of return air dampers
46.  of exhaust air dampers
47. All damper motors connected?
48. All damper motors operational?
1. Air mixers or opposed blades?
Mixed air temperature control
2.
setting -------------- oF
Is mixing plenum under negative
pressure?
3. Note: If it is under positive
pressure, outdoor air may not be
entering.
Filters
4. Type
Complete coverage?
5.
(i.e., no bypassing)
Correct pressure drop?
6. (Compare to manufacturer’s
recommendations.)
7. Contaminants visible?
8. Odour noticeable?
Supply Fan Chambers
9. Clean?
10. No trash or storage?
Floor drain traps are wet or
11.
sealed?
12. No air leaks?
13. Doors close tightly?

117
 Sl. Needs Not
Description OK
No. Attention Applicable Remarks
Supply Fans
14. Location
15. Excess vibration?
16. Corrosion problems?
17. Controls operational, calibrated?
Control sequence conforms to
18. design / specifications?
(describe changes)
19. No pneumatic leaks?

4.0 MODE OF MEASUREMENT:

A Representatives from the Contractor and Engineer shall conduct a joint inspection of
the Equipment. All the discrepancies observed either incomplete works or defective
work shall be clearly indicated in the joint inspection report. The mode of
measurements given below is for the purpose of measurement and payment and the
scope of works shall be as specified elsewhere in the specification.

B AIR HANDLING UNIT

Air handling unit of cabinet type along with flexible connection at fan outlet, flexible
connection at chilled water pipe inlet and outlet of AHU, filter, fan, motor, outlet
damper etc., as specified in tender document shall form one unit for the purpose of
measurement and payment.

C SUPPLY AIR FAN UNIT

Supply air fan unit consisting of fan, fan motor, louvers, filters, vibration isolators,
sound attenuators, outlet dampers, flexible connection at fan outlet, weather proof
enclosure of GSS cabinet type construction and accessories will be regarded as one
unit for the purpose of measurement and payment.

D EXHAUST AIR FAN UNIT

Exhaust air fan unit consisting of fan, fan motor, louvers, filters, vibration isolators,
outlet dampers, weather proof enclosure of GSS cabinet type construction and
accessories will be regarded as one unit for the purpose of measurement and payment.

E PRE-FILTERS AND BAG FILTERS

118
Pre/ bag filters complete with support, frame etc., shall be measured from the
approved drawings I as built drawing on the basis of core area (excluding margin
flanges) and paid per unit area. Pre filters and bag filters in supply air fan units are
part of fan units and no separate payment will be made for the same.

119
 SECTION 4.09
VENTILATION FANS

120
1.0 SCOPE

This specification covers the design, materials, construction features, manufacture,

shop inspection and testing at Manufacturer’s works, delivery at site, handling at site,
installation, testing, commissioning of Ventilation Fans covered in this section.

2.0 GENERAL

All emergency fans such as Sprinkler pump room, Fire Command Centre (FCC),
Staircase pressurization fans, Lift Lobby pressurization fans and Smoke extraction
fans, etc shall be installed with 0-30 seconds timer for sequential starts. During power
blackout, all emergency fans shall able to run in sequence so that not to overload the
emergency Generator. The timing of the sequence shall be determined on site during
commissioning.

All fans including motors, electrical wiring, control panels, etc. serving Kitchen
Exhaust, Smoke Control System, Smoke Free Lobby/Fire Fighting Lobby, Smoke
purging system serving Sprinkler pump room etc shall be rated at 2500C, 2 hrs to
comply with the requirements of the Local Authorities.

All fans including motors, electrical wiring, control panels, etc. serving the Kitchen
Exhaust, electrical switch rooms, shall be flame proof and explosion proof type C to
comply with the requirements of the Local Authorities.

2.1 VIBRATION AND NOISE CONTROL

The following vibration isolation shall be provided for all fans except propeller
fans.

a) Less than 1500 CFM

All isolators shall be sized to have minimum 12mm static deflection when loaded.
The isolators shall be complete with double-neoprene-in-shear isolators for
supports or hangers.

b) More than 1500 CFM but less than 5000 CFM

All isolators shall be sized to have minimum 25mm static deflection when loaded.
The isolators shall be complete with un-housed spring-neoprene in series
isolators for supports or hangers. Floor mounted units shall have isolators with 2
layers of 8mm non- skid neoprene pads separated by 2mm steel shim.

121
 c) More than 5000 CFM

All isolators shall be sized to have minimum 50mm static deflection when loaded.
The isolators shall be complete with un-housed spring-neoprene in series
isolators for supports or hangers. Floor mounted units shall have isolators with 2
layers of 8mm non- skid neoprene pads separated by 2mm steel shim.

The contractor shall supply the sound power levels (re 10-12 watts) of all fans
offered (from 63Hz to 8 kHz center band frequencies). The contractor shall allow
for appropriate sound attenuation to achieve the space criteria and indicate in the
specification drawings based on actual fan power levels of the fan to be used.

3.0 CODES AND STANDARDS

The design, manufacture and performance of Ventilation fans shall comply with all
currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. Nothing in this specification shall be construed to relieve
the CONTRACTOR of this responsibility. The equipment supplied shall comply with the
latest applicable Indian or equivalent standards. In particular, the equipment shall
conform to the latest editions of the following standards.

3.1 IS: 2074 Ready mixed paint, air drying, red oxide-zinc chrome
Primer

3.2 IS: 4894 Centrifugal fans

3.3 AMCA 210 Laboratory methods of testing fans for rating

3.4 ISO: 1940-1 Mechanical vibration – Balance quality requirements of

rigid bodies
Part 1 : Determination of permissible residual unbalance

3.5 Fans shall be licensed to bear the AMCA Air and Sound Certified ratings seal.

3.6 Fan wheel and housing shall be statically and dynamically balanced in
accordance with ISO 1940 AMCA 204-G2.5 Standards.

3.7 AMCA 210, Laboratory methods of testing fans for rating

3.8 Smoke and heat exhaust fans are required to be in compliance with the
requirements of Class B performance, as defined in BS 7346 Part 2:1990. This

122
 requires the fan to be subjected to a rated temperature of 250 Deg C for a rated
duration of 2 hrs.

3.9 The fan is required to satisfy the performance criteria specified in BS 7346:
Part 2:1990 relating to structural performance, electrical performance and
aerodynamic performance throughout the rated duration
For toilet and kitchen exhaust system the maximum power consumption
allowable is 0.5W/cfm to meet the BCA requirements.

4.0 CENTRIFUGAL FANS

CONSTRUCTION FEATURES

4.1 HOUSING

The housing shall be constructed using 14-gauge sheet steel and all parts shall be
bonded and then coated with primer finish of approved colour. The fan scroll shall be
attached to the side plate by means of continuous lock seam or welded seam. 18 gauge
galvanized wire mesh inlet screens of 5 cm with sleeves shall be provided on both
inlets. Housing shall be provided with standard cleanout & door with quick locking
tension handless and neoprene gasket. Rotation arrow shall be clearly marked on the
housing.

4.2 FAN WHEEL

The Fan wheel shall be a forward curve type. Fan wheel and housing shall be statically
and dynamically balanced in accordance with ISO 1940 AMCA 204-G2.5 Standards.
Fan outlet velocity shall not exceed 9 meters per second and maximum fan speed shall
be 1500 RPM. The wheel made of cold rolled sheet steel.

4.3 SHAFT

The shaft shall be constructed of SAE 1040 steel, turned, ground and polished. Shaft
shall be statically and dynamically balanced and shall provide excellent shaft-to-race
fit for increased bearing life. Shaft shall not pass first critical speed through the full
range or specified fan speeds.

4.4 BEARINGS

The Bearing shall be of the sleeve / ball-bearing type mounted directly on the fan
housing. Bearing shall be designed especially for quiet operation and shall be of the
self-aligning, greasing pack pillow block type. Bearings shall be maintenance free.

123
4.5 MOTOR

Fan motor shall be suitable for 415 ± 10% volts, 50 cycles 3 phase power supply,
squirrel cage, totally enclosed motor, provided with class “B” insulation. Motor
nameplate horsepower shall exceed brake horsepower by a minimum of 10%. Motor
speed shall not exceed 900 RPM. The fan and motor combination selected for the
particular required performance shall be of the most efficient (Smallest horsepower),
fan so that sound level is lowest. Motor position should be in accordance with AMCA
Std 99-2407-66. Fans shall be suitable for operations up to 250 °C for 2 hours running
condition. Fans Shall be suitable for outdoor applications.

4.6 DRIVE

The fan wheel shall be mounted directly on the motor shaft.

DATA SHEET - A

TECHNICAL REQUIREMENTS (REFER EQUIPMENT SCHEDULE)

Sl. Options /
ITEM Design Requirement
No. Unit
1 Fan No.
2 Make of place of manufacture
3 Model number
4 Capacity (Air) FT3/hr
5 Outlet velocity FPM
6 Total pressure Pascals
7 Speed RPM
8 Class of construction
9 Volumetric efficiency %
10 POWER REQUIREMENT
10.1 Brake power KW
10.2 Limit load power KW
10.3 Motor rating KW
Input power at motor terminal at
10.4 KW
design conditions

124
11 WEIGHT
11.1 Fan Kg
11.2 Motor Kg
Fan motor assembly including base
11.3 Kg
frame and V-belt drive
12 Total dynamic load Kg
13 Whether all accessories included Yes / No
14 Performance curves enclosed Yes / No
15 Noise level at 1.8m dBA 65

DATA SHEET - B

DATA TO BE FURNISHED BY TENDERER ALONG WITH OFFER

Sl. Options /
ITEM Contractor’s Input
No. Unit
1 Fan No. CF
2 Make of place of manufacture
3 Model number
4 Capacity (Air) FT3/hr
5 Outlet velocity FPM
6 Total pressure Pascals
7 Speed RPM
8 Class of construction
9 Volumetric efficiency %
10 POWER REQUIREMENT
10.1 Brake power KW
10.2 Limit load power KW
10.3 Motor rating KW

125
 Input power at motor terminal at
10.4 KW
design conditions
11 WEIGHT
11.1 Fan Kg
11.2 Motor Kg
Fan motor assembly including base
11.3 Kg
frame and V-belt drive
12 Total dynamic load Kg
13 Whether all accessories included
14 Performance curves enclosed
15 Noise level at 1.8m dBA

DATA SHEET - C

DATA TO BE FURNISHED BY THE CONTRACTOR AFTER AWARD OF CONTRACT AND

BEFORE INSTALLATION

1. Schedule of drawings and documents to be submitted for review, approval and

information with submission dates.

2. Quality Assurance Plan (QAP).

3. General arrangement and section drawing with all dimensions and complete part list
with codes and materials of construction. This drawings shall include all data
indicated in Data sheets A and B.

4. Foundation drawing with static and dynamic loads, unbalanced forces and moments, if
any, pocket details, etc.

5. Drawing showing fabrication and construction details of the fan.

6. Fan rating charts or tables with selection marked.

7. Characteristics curves for fans with duty point marked.

8. Torque-speed curve for fans.

9. Operation and maintenance manual with lubrication schedule.

126
 DATA SHEET - D
CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION

Sl.
Description Remarks
No

23. Location, Tag No.

24. Fan blades clean
25. Belt guards installed
26. Proper belt tension
27. Excess vibration
28. Fan working
29. Register open
30. Volume, Cubic Mtr / hr
31. Negative pressure maintained
32. Fans, Controls, Dampers all operate
33. Test witnessed and certified
34. Back draft Dampers closing
35. Motor Amperage
36. Motor Voltage
37. Fan Rotation

127
MODE OF MEASUREMENT:

A. Representatives from the Contractor and Engineer shall conduct a joint inspection of
the Equipment’s. All the discrepancies observed either incomplete works or defective
work shall be clearly indicated in the joint inspection report. The mode of
measurements given below is for the purpose of measurement and payment and the
scope of works shall be as specified elsewhere in the specification.

B. Centrifugal fan

Each centrifugal fan (except fan part of fan units) including fan motor, vibration
isolators, outlet dampers, common base frame, flexible connection at inlet and outlet
of fan and accessories as specified in the tender document will be regarded as one unit
for the purpose of measurement and payment.

128
 SECTION 04.10
WATER TREATMENT

129
1.0 SCOPE

This specification covers the general design, materials, manufacture, supply,

installation, testing and commissioning of Water Treatment System equipped with
control panel and monitoring devices for closed chilled water circuit and open
condenser water circuit. Electronic type Chemical dosing system with tank & first
charge of chemicals for both chilled water & condenser water system. The water
treatment includes with control & monitoring system shall include all piping, valves,
controls, software's, wiring etc.

Contractor shall submit all relevant technical specification/ documents and get prior
approval from project consultant before procuring the system.

Water treatment (Chemical Dosing) is proposed to treat the soft water required for
the air conditioning purpose both chilled water circuit & condenser circuit. Water
treatment control & monitoring is proposed only to open condenser water circuit.

2.0 SYSTEM DESCRIPTION

Water treatment control & monitoring system continuously measures key system
parameters (Scaling potential, Corrosion trends) detects upsets, takes appropriate
corrective action and communicates with system users.
System shall be similar to NALCO or equivalent approved make
.
Electronic type Chemical dosing system with tank & first charge of chemicals for both
Chilled water & Condenser Water system .

2.1 FEED AND CONTROL

Cycles of Concentration - On/Off based on the scale control or conductivity set point
ranges from 200 to 10,000 microsiemens, non fouling.

Chemical feed inhibitor - On/Off based on Scale Control with manual, timer or slave
options.

Chemical Feed - Oxidizing Biocide - On/Off based on Bio-Control with manual, timer or
slug-based options.

Chemical Feed – Non-oxidizing Biocide On/Off based on Timer or manual based feed
with pre-bleed and lockout capability.

130
 pH - Acid or caustic on/off, based on flat surface, double junction 2-wire pH probe
input, range 0-14 pH.

2.2 MONITORING FUNCTIONS

Corrosion Monitoring - Continuous on-line measurement of mild steel and copper.

Other metallurgies available.

Additional Monitored Variables -

a. Cell Fouling
b. Turbidity
c. Temperature
d. Background Fluorescence
e. Relay Status
f. Pulse counter with water meter

Additional Calculated Variables-

a. Blow down Rate
b. Heat Rejection
c. Makeup Water Rate
d. Recirculation Rate
e. Pump Duty
f. Chemical Usage
g. System Volume

The vendor should ensure that the treatment system can achieve 7 or better cylces of
concentration. Also he should submit the details showing how it is going to achieve 7 or better
COC.
This system shall be monitored, remotely overridden and controlled by a Building
Management System (BMS). Hence, any software protocol involved shall be made open
to the awarded BMS manufacturer.

131
 SECTION 04.11
SIDE STREAM FILTRATION SYSTEM

132
Scope
Furnish and install the liquid-solids separation system as specified herein.
Primary Purpose – The system will remove unwanted solids from a cooling tower sump or
remote basin or condenser line using a centrifugal-action vortex separator. The liquid-solids
separation system will help prevent particle fouling of the cooling system's components
reduce maintenance and servicing routines, maintain optimum energy efficiency of the heat
exchange process, limit blow down & chemical use practices and control harmful bacteria
growth in the basin/sump. Fluid viscosity must be 100 SSU or less.
For Side Stream Installations -- Control of solids in the re circulated cooling water system
shall be accomplished via a side-stream flow of not less than 10-30% of the full-stream
system flow through a completely assembled separation/filtration package. The package's
pump shall provide sufficient pressure for the re-introduction of side-stream fluid back into
system flow.

133
System Performance Requirements
Testing Requirements – Each unit must be tested by the manufacturer prior to shipment to
ensure it conforms to stated operating specifications.
Independent Testing Laboratory – Performance of said products must be verified by
published results from an independent and identified testing laboratory. Standard test
protocol of upstream injection, downstream capture, and separator purge recovery is allowed
with 50-200 mesh particles to enable effective, repeatable results. Single pass test
performance must not be less than 95% removal. Model tested must be of same flow-design
as specified unit.
Performance
Flow Capacity - Unit shall have a flow capacity of 280 US GPM or 64 m 3/hr
Pressure Loss - Shall be between 3-12 psi (0.2 to 0.8 bar) remaining constant, varying only
when the flow rate changes.
Solids Removal Effectiveness All Systems – In a single pass through the separator, given solids
with a specific gravity of 2.6 and water at 1.0, performance is expected to be 98% of 74
microns and larger. Additionally, particles finer in size, heavier by specific gravity and some
lighter by specific gravity will also be removed, resulting in an appreciable aggregate removal
of particles (up to 75%) as fine as 5 microns.
In Recirculating Systems - 98% performance is predictable to as fine as 40 microns (given
solids with a specific gravity of 2.6), with correspondingly higher aggregate performance
percentages (up to 90%) of solids as fine as 5 microns

Maximum working pressure: 150 psi (10.3 bar).

Maximum operating temperature: 100º F (38º C).

Construction

The separator package - Shall provide for initial pre-straining prior to pump suction (except
for side-stream applications), followed by direct pumping through a specific
centrifugal-action solids-from-liquid separator. Separated solids shall be
continuously bled from the separator's collection chamber into the package's integral
solids recovery vessel and solids collection bag. Excess liquid shall pass through the
bag and return to system flow via piping connected to the package's pump suction
line. Alternatively, the separated solids may be purged periodically to desired
disposal with an automatic purge valve.

Pump - End-suction, single stage; TEFC motor; cast iron housing; iron / Bronze impeller;
bronze shaft sleeve; silicon carbide mechanical shaft seal; flooded suction required.

134
 Separator - Centrifugal-action design, incorporating a true tangential inlet and mutually
tangential Swirlex internal accelerating slots, employed to promote the proper
velocity necessary for the removal of the separable solids. The internal accelerating
slots shall be spiral-cut for optimum flow transfer, laminar action and particle
influence into the separation barrel. The separator's internal vortex shall allow this
process to occur without wear to the accelerating slots. Separated particle matter
shall spiral downward along the perimeter of the inner separation barrel, in a
manner which does not promote wear of the separation barrel, and into the solids
collection chamber, located below the vortex deflector plate. The separator shall be
of unishell construction with SA-36, SA-53B or equivalent quality carbon steel,
minimum thickness of .25 inches (6.35 mm)

Vortube - To ensure maximum particle removal characteristics at flow rates of 400 U.S. gpm
(90 m3/hr) or greater, the separator shall incorporate a vortex-induced pressure
relief line (Vortube), drawing specific pressure and fluid from the separator's
extended solids collection chamber via the outlet flow's vortex/venturi effect,
thereby efficiently encouraging solids into the collection chamber. System fluid shall
exit the separator by following the center vortex in the separation barrel and spiral
upward to the separator outlet.

Solids Collection Vessel - Housing shall be 304 stainless steel with stainless steel basket and
coated carbon steel lid with air pressure relief valve; 25- micron fiber felt solids
collection bag. Flow control orifice included. Solids capacity: 360 cubic inches (6
liters).

Indicator Package – Shall identify when the internal bag requires cleaning/replacement by
sensing pressure differential through the solids recovery vessel.
Option: Indicator gauge may be supplemented with a dry electric contact in order to
operate a light or audible signal when bag servicing is required.
Inlet and Outlet – Shall be grooved/flanged couplings
Purge Outlet – Shall be threaded with a screw-on flange
Piping - Schedule 40 galvanized carbon/ mild steel; reinforced rubber hose to solids recovery
vessel.
Electrical Control - IEC starter with overload module; HOA selector switch; re-
set/disconnect/trip switch; 120 volt. Power requirement: 380/415 volt, 3 phase.
Valve - Ball valves on purge line for isolation of solids-handling/purging equipment. Optional
inlet/outlet valve kit is available.
Skid Plate -- Stainless steel, 3/16-inch (5 mm) minimum thickness
Paint Coating - Shall be oil-based enamel

135
 SECTION 4.12
PIPING AND VALVES

136
1. SCOPE
This section lays down the general requirements for Supply, Installation and testing of
all Piping works like Chilled Water, Condenser water, Condensate drain piping and
Refrigerant piping and related valves and accessories.

2. CODES AND STANDARDS

The material construction, manufacture, inspection, testing and commissioning of
water piping shall comply with all currently applicable statutes, regulations and safety
codes in the locality where the Equipment will be installed. Nothing in these
specifications shall construed to relieve the CONTRACTOR of his responsibility. The
equipment supplied shall comply with the latest applicable Indian and / or British
Standards. Other National Standards are acceptable, if they are established to be equal
or superior.

Grooved coupling shall be as per below mentioned codes/standards,

1. American Society for Testing Materials (ASTM)

a. ASTM A-53 – Pipe, Steel, Black and Hot-Dipped Zinc Coated, Welded
and Seamless.
b. ASTM A-183 – Carbon Steel Track Bolts and Nuts
c. ASTM A-234 – Standard Specification For Piping Fittings or Wrought
Carbon Steel and Alloy Steel.
d. ASTM A-449 – Quenched and Tempered Steel Bolts and Studs
e. ASTM A-536 – Ductile Iron Castings
f. ASTM F-1476 - Standard Specification for Performance of Gasketed
Mechanical Couplings for Use in Piping Applications

2. American Society of Mechanical Engineers

a. ASME B16.9 – Factory Made Wrought Butt Welded Fittings
b. ASME B31.1 – Chemical Plant and Petroleum Refining Piping
c. ASME B31.9 – Building Services Piping

3. American Water Works Association

a. AWWA C-606 – Grooved and Shouldered Joints

3. SCOPE OF SUPPLY AND ERECTION

3.1 The CONTRACTOR shall supply all piping material like pipes, fittings, flanges and
other items as required.

3.2 Scope of erection to be performed by the CONTRACTOR is outlined below:

137
a) The CONTRACTOR shall unload from carriers at plant site, handle, check,
receive, transport, store, erect and test all materials furnished by him and
others in accordance with this specification and General Conditions of Contract.
The EMPLOYER shall be informed of any loss of damage within seven days of
receipt of material.

b) The CONTRACTOR shall also install small accessory piping and any specialties
furnished for equipment such as relief valves, built-in bypass and other
equipment of this type.

c) The CONTRACTOR shall install primary elements for flow measurements,

control valves and on-line metering equipment.

d) The CONTRACTOR shall hydrostatically test the entire piping system including
valves and specialties.

e) All piping shall be internally cleaned and flushed by the CONTRACTOR before
and after erection in a manner suited to the service as directed by the
EMPLOYER.

f) For hydrostatic testing and water flushing, the CONTRACTOR shall furnish
necessary pumps, equipment and instruments, piping etc. The EMPLOYER will
provide water at available points of supply to which the CONTRACTOR’s
temporary piping will be connected.

g) The CONTRACTOR’s scope under this includes the following:

i) All materials required for Grooved Coupling joints

ii) Jointing material as required for all screwed joints. Fasteners (bolts, nuts,
studs washers etc.) and gaskets are required for all flanged joints.

iii) Services of erection superintendents, erection superiors, fitters, riggers,

other skilled and unskilled labour.

iv) Erection tools, tackles and other required materials.

h) Wall cutouts & sealing the wall cutouts using fire retardant material after
installation of pipes shall be part of HVAC work.

138
4. MATERIAL SPECIFICATION

4.1 The material specification for piping, valves & specialities shall be as explained in later
sections.

4.2 Colour code shall be used to identify pipe material. The CONTRACTOR shall be able to
identify on request all random piping prior to any field fabrication.

4.3 The CONTRACTOR shall furnish six (6) copies of certificates for piping for –

a) Dimensions and
b) Hydrostatic test

5. CLEANING OF PIPING
All piping shall be wire brushed and purged with air blast to remove all rust and mill
scale from inner surface. The method of cleaning shall be such that no material is left
on the inner or outer surfaces, which will affect the serviceability of the pipe.

6. PROTECTION DURING TRANSIT

Effective precautions such as capping and sealing shall be taken to protect all pipe
ends against ingress of dirt and damage during transit or storage. The outside of the
carbon steel pipe (black) shall receive two coats of red lead paint.

7. SHOP AND FIELD HYDROSTRATIC TESTS

All pipes and fittings shall be tested hydrostatically at the ships where manufactured
to test pressures which are given in the applicable codes mentioned. All piping
systems shall be tested hydrostatically by the CONTRACTOR after erection.

8. The chilled water and condensate drain piping shall be suitably insulated as per
specification.

9. Automatic air vents shall be installed at all high sections of piping as well as in the
AHU room piping. The discharge from these air vents shall be piped via copper tubes
of appropriate size to the nearest waste drain pipe.

139
10. GUARANTEE

The CONTRACTOR shall guarantee all material, fabrication and workmanship,

erection, installation and proper functioning of all the piping and also tightness of all
joints, for a period of one year from the date of commissioning.

10.1 The Contractor shall employ both in shop and field, qualified personnel.

10.2 If any shop fabrication part fails to meet the field tests in such a manner that the
EMPLOYER’s Inspection believes that the defect is minor, it will be remedied in the
field by the CONTRACTOR at no cost to the EMPLOYER. In the event the EMPLOYER
rejects defective part as not being capable of remedy in the field, the CONTRACTOR
may at the EMPLOYER’s discretion be required to transport new parts, from his
shop at his own expense.

11. WATER PIPING

11.1 All chilled water and condenser piping up to 150 mm dia shall be of medium class
mild steel conforming to IS: 1239.. Pipe flanges shall conform to IS: 1536 whereas
the threads shall conform to IS:554.
11.2 Pipes above 150 mm shall be factory rolled and fabricated using MS Plates of
minimum thickness 6mm for pipes upto 350 mm dia and from 7mm thick M.S sheet
for pipes of 400 mm dia and above.

11.3 Whenever GI pipe is cut, it shall be painted with 2 coats of zinc paint both internally
and externally over a coat of zinc chromate primer.

11.4 The Grooved coupling shall be as explained in later sections.

12. PRESSURE GUAGES & THERMOMETERS

Bourdon type pressure gauges with aluminium casing with a minimum 100 mm dial
and appropriate range complete with needle valves shall be provided at the inlet and
outlets of heat exchangers, and pump sets.

Thermometers shall be of dial type mounted on a board with separable copper well.
The case shall be of cast aluminium, weather & water proof type. Thermowell shall be
provided at the inlet and outlet of all heat exchangers.

140
13. TESTING

13.1 All piping shall be tested to hydrostatic test pressure of at least 1 ½ times the
maximum operating pressure but not less than 7 KSC for a period of not less than 24
hours. All leaks and defects in joints and piping during the test shall be rectified and
approval shall be taken. No pipe shall be welded with water inside the pipes. Piping
repaired subsequent to the above pressure shall be retested in the same manner.
Systems may be tested in sections and such sections shall be capped securely.
Entire system shall then be retested. Noiseless circulation of water in the circuit
should be achieved. If improper circulation due to air lock is found, it is the
responsibility of the air-conditioning contractor to carry out all the rectification
including opening and refinishing of floor, wall etc., and Pressure gauges should be
valved off during pressure testing. The air-conditioning contractor shall provide all
materials, tools and instruments, services and labour required to perform the test
and to remove the water resulting from cleaning and after testing.

13.2 The consultants shall be informed well in advance by the air-conditioning

contractor of his intention to test a section or sections of piping and all such tests
shall be witnessed by the consultants or their authorized representatives. Test
certificates duly signed by the contractor and the consultant shall be submitted by
the contractor after completing the tests.

13.3 No insulation shall be applied to pipes unless the pressure testing is completed to
the satisfaction of the consultants. Insulation shall be done as per the tender
specifications.

13.4 After completion of the installation, the pipe lines are to be flushed thoroughly to
blow out the entire dirt and muck. Commissioning strainers shall be used before all
equipment. The system then shall be balanced to deliver the water quantities as
specified. Balancing report after certification shall be submitted with completion
drawings and documents.

13.5 Pipelines shall be provided with one coat of primer and 2 coats of paint of colour
and quality as specified. Insulated piping and valves shall also be provided with
painting in a similar manner. Direction of flow shall be marked on pipelines in bold
markings.

13.6 Provide automatic air vents at highest points. The body shall be of cast iron and the
float and leverage shall be of stainless steel. The operating pressure shall be 150
psig. Air vents, purge and drain valves are considered to be a part of the piping and
no extra cost will be paid for the same.

141
 13.7 Provide expansion joints to prevent bending, bowing of pipes resulting in unusual
stresses. The expansion joint shall be complete with anchor bases, inner liners, tie
rods, outer jackets and flanges. The expansion joints shall be of stainless steel.

13.8 Provide flanged rubber bellows at pump, chiller inlets and outlets that are assumed
to be a part of the equipment.

14. STANDARD GROOVED AND ADVANCED GROOVED (AGS) PIPING SYSTEM

FOR IPS STEEL 2” (DN 50) THROUGH 60”(DN1500)

I. Quality Assurance

To assure uniformity and compatibility of piping components in grooved end

piping systems, Grooving tools shall be supplied by the same manufacturer as the
grooved components.

II. Materials:

A. Pipe/Grooved (Standard/Lightwall): Carbon Steel, A-53B/A-106B - Roll or cut

grooved-ends as appropriate to pipe material, wall thickness, pressures, size and
method of joining. Pipe ends to be grooved in accordance with current listed
standards conforming to ANSI/AWWA C-606.

B. Mechanical Couplings for Joining Carbon Steel Pipe

1. Standard Mechanical Couplings, 2 inch (DN50) through 12 inch (DN300):

Manufactured in two segments of cast ductile iron, conforming to ASTM A-
536, Grade 65-45-12. Gaskets shall be pressure-responsive synthetic rubber,
grade to suit the intended service, conforming to ASTM D-2000. (Gaskets used
for potable water applications shall be UL classified in accordance with
ANSI/NSF-61 for potable water service.) Mechanical Coupling bolts shall be
zinc plated (ASTM B-633) heat treated carbon steel track head conforming to
ASTM A-449 and ASTM A-183, minimum tensile strength 110,000 psi (758450
kPa) as provided standard.

a. Rigid Type: Coupling housings with offsetting, angle-pattern bolt pads

shall be used to provide system rigidity and support and hanging in
accordance with ANSI B31.1, B31.9, and NFPA 13.

a. 2” (DN50) through 8” (DN200): Installation ready rigid coupling for

direct stab installation without field disassembly. Gasket shall be
Grade “EHP” EPDM compound with red color code designed for

142
 operating temperatures from -30 deg F (-34 deg C) to +250 deg F
(+120 deg C).
b. 10” (DN250) through 12” (DN300): Style 07 (Zero-Flex®). Standard
rigid coupling. Gasket shall be Grade “E” EPDM compound with green
color code designed for operating temperatures from -30 deg F (-34
deg C) to +230 deg F (+110 deg C).

b. Flexible Type: Use in locations where vibration attenuation and stress

relief are required. Flexible couplings may be used in lieu of flexible
connectors at equipment connections. Three couplings, for each connector,
shall be placed in close proximity to the vibration source.
a. 2” (DN50) through 8” (DN0200): Installation ready flexible coupling
for direct stab installation without field disassembly. Gasket shall be
Grade “EHP” EPDM compound with red color code designed for
operating temperatures from -30 deg F (-34 deg C) to +250 deg F
(+120 deg C).
b. 10” (DN250) through 12” (DN300): Gasket shall be Grade “E” EPDM
compound with green color code designed for operating
temperatures from -30 deg F (-34 deg C) to +230 deg F (+110 deg C).

2. Flange Adapters: For use with grooved end pipe and fittings, flat faced, for
mating to ANSI Class 125 / 150 flanges

3. Grooved couplings shall meet the requirements of ASTM F-1476.

4. Gasket: Synthetic rubber conforming to steel pipe outside diameter and

coupling housing, manufactured of elastomers as designated in ASTM D-2000.

a. Reference shall always be made to the latest published Selection Guide for
Gaskets for proper gasket selection for the intended service.

5. AGS Mechanical Couplings, 14 inch (DN350) through 60 inch (DN1500):

Couplings shall consist of two ASTM A-536 ductile iron housing segments, a
wide elastomer pressure responsive gasket, and zinc electroplated carbon
steel track head bolts and nuts conforming to the physical and chemical
requirements of ASTM A-449 and the physical requirements of ASTM A-183.

a. Coupling housings designed with the wedge-shaped AGS key profile to

engage the mating pipe(s)/component(s) wedge-shaped AGS grooves.
Housings include lead-in chamfer to accommodate a wider acceptable
range of initial pipe positions. Housings shall be coated with orange enamel
or galvanized.

143
 b. Gasket: Wide width, pressure-responsive, synthetic rubber of a Flush Seal®
design, conforming to steel pipe outside diameter and coupling housing,
manufactured of elastomers as designated in ASTM D-2000.

1) Grade “E” EPDM with green color code designed for operating
temperatures from -30 deg F (-34 deg C) to +230 deg F (+110 deg C).
2) Grade “T” Nitrile with orange color code designed for operating
temperatures from -20 deg F (-29 deg C) to +180 deg F (+82 deg C).
3) Grade “L” Silicone with red color code designed for operating
temperatures of -30 deg F (-34 deg C) to +350 deg F (+177 deg C);
recommended for dry heat service (air without hydrocarbons).
4) Reference shall always be made to the latest published Selection Guide
for Gaskets for proper gasket selection for the intended service.

c. Coupling Types:

1) Rigid Coupling: Coupling key shall be designed to fill the wedge shaped
AGS groove to provide a rigid joint that corresponds with support
spacings as defined by ASME B31.1 and B31.9. Systems incorporating
rigid couplings require the calculated thermal growth/contraction of the
piping system to be fully compensated for in the design of the piping
system through use of adequate flexible components.

2) Flexible Coupling: Coupling key shall be designed to fit into the wedge
shaped AGS groove and allow for linear and angular movement,
vibration attenuation, and stress relief. Support requirements defined by
Design Data Submittal 26.01.

3) Flange Adapter 14 inch (DN350) to 24 inch (DN600): For use with

AGS grooved end pipe and fittings, flat faced, for mating to ANSI Class
125 / 150 flanges.

C. Grooved End Fittings:

1. Standard fittings shall be cast of ductile iron conforming to ASTM A-536,

Grade 65-45-12, forged steel conforming to ASTM A-234, Grade WPB 0.375"
wall (9,53 mm wall), or fabricated from Std. Wt. Carbon Steel pipe conforming
to ASTM A-53, Type F, E or S, Grade B. Fittings provided with an alkyd enamel
finish or hot dip galvanized to ASTM A-153. Zinc electroplated fittings and
couplings conform to ASTM B633.

2. AGS Fittings shall be supplied with factory AGS grooved ends. Fittings shall be
manufactured of ductile iron conforming to ASTM A-536, forged carbon steel
conforming to ASTM A-234, or factory fabricated from carbon steel pipe

144
 conforming to ASTM A-53. Fittings shall be manufactured to the dimensional
standards ASME B16.9. Orange enamel coated or galvanized.

3. Hole-Cut Branch Outlets:

a. Bolted Branch Outlet: Branch reductions on 2"(DN50) through 8"(DN200)

header piping. Bolted branch outlets shall be manufactured from ductile
iron conforming to ASTM A-536, Grade 65-45-12, with synthetic rubber
gasket, and heat treated carbon steel zinc plated bolts and nuts conforming
to physical properties of ASTM A-183.

b. Strapless Outlet: 1/2"(DN15) or 3/4"(DN20) NPT outlet on 4" (DN100)

and larger header sizes rated for 300 PSI (2065 kPa). .

b. Strapless Thermometer Outlet: To accommodate industrial glass

bulb thermometers with standard 1-1/4"-18 NEF 2B extra fine
thread and 6" (152mm) nominal bulb length on 4" (DN100) and
larger header sizes rated for 300 PSI (2065 kPa).

D. Grooved End Specialties

1. Expansion Joints:

a. 2”(DN50) through 6”(DN150) Sizes: Packless, gasketed, type with

grooved end telescoping body, suitable for axial end movement to 3”. 350
psi (2410 kPa).

b. 3/4"(DN20) and Larger Sizes: Expansion joint consisting of a series of

grooved end nipples joined with flexible-type couplings. Joint movement
and expansion capabilities determined by number of couplings / nipples
used in the joint.

2. Dielectric Waterways: 1”(DN25) through 8”(DN200) sizes, grooved, plain

end, or threaded end, ASTM A-53 carbon steel or ASTM A-536 ductile iron
body, zinc electroplated, with LTHS high temperature stabilized polyolefin
polymer liner.

3. Suction Diffuser – Flanged outlet with grooved inlet connections, rated to

300 psi (2065 kPa). Ductile iron (ASTM A-536) body, 304 stainless steel
frame and perforated sheet diffuser with 5/32" (4,0mm) diameter holes.
Removable 20 mesh 304 stainless steel start-up pre-filter, outlets for
pressure/temperature drain connections, and base support boss. Series 731-
G and W731-G.

145
 E. Tooling:

1. Use roll sets or cut groovers compatible with the pipe material and wall
thickness per installation instructions.

2. Common wedge shaped AGS groove for pipe sizes 14” (DN350) through
24”(DN600) requiring one (1) common AGS roll set per tool, for use with
approved grooving tools.

III. Execution:

A. Installation:

1. Pipe ends shall be clean and free from indentations, projections and roll
marks in the area from pipe end to groove for proper gasket sealing.

2. The gasket style and elastomeric material (grade) shall be verified as

suitable for the intended service as specified.

3. Install the AGS piping system in accordance with the latest installation
instructions.
4. AGS products shall not be installed with standard grooved end pipe or
components. (Installing AGS products in combination with standard
grooved end products could result in joint separation and/or leakage.)

5. Use grooving tools with AGS roll sets to groove the pipe. Follow
guidelines for tool selection and operation.

6. Couplings installation shall be complete when visual metal-to-metal

contact is reached.
B. Training:

1. A trained representative from grooved coupling supplier shall provide

on-site training for contractor’s field personnel in the use of grooving
tools, application of groove, and product installation.

C. Application:

1. A representative from grooved coupling supplier shall periodically visit

the job site and review installation. Contractor shall remove and replace
any improperly installed products.

146
 2. Grooved mechanical pipe couplings, fittings, valves and other grooved
components may be used as an option to welding, threading or flanged
methods.

3. All grooved components shall conform to local code approval and/or as

listed by ANSI-B-31.1, B-31.3, B-31.9, ASME, UL/ULC, FM, IAPMO or
BOCA.

4. Grooved end product manufacturer to be ISO-9001 certified.

15. VALVES
All butterfly valves shall be PN 16 rated. All valves shall be preferably with GROOVED
ENDS. If not provided with grooved ends, suitable flange adaptors shall be used for
connections.

a. Gate and Globe valves

Gate and globe valves up to 50 mm size shall be gun metal construction. Valves above
50 mm dia shall have cast iron body and bronze/gun metal spindle valve seat. The
valves shall have non rising spindle.

b. Butterfly valves

The butterfly valve shall be supplied along with flow control lever. The valves shall be
compact in size and shall conform to BS 5155, MSS SP 67 and API 609. The valves shall
be light in weight and easy to install. The body shall of close grain cast iron conforming
to IS:210 and the seating shall be of Resilient black, Nitrile rubber / EPDM moulded on
to the body. The disk shall be of SG iron nylon coated, whereas the shaft shall be of
stainless steel A ISI 431 treated permanently for lubrication. The shaft seals shall be of
Nitrile ‘O’ rings and rubber seals. Valves shall be suitable for a working pressure of 150
psig. Care should be taken during installation to see that the disk is not damaged
during installation due to the flanges being incorrectly spaced. Provide gear operated
valves for sizes having 300 mm and above. For smaller sizes such as 40 mm and below
diaphragm type valves are acceptable.

c. Ball valves

Ball Valves shall have body of carbon steel. The ball and the shaft shall be of stainless
steel. The seat shall be of PTFE. The valve shall be complete with socket weld ends.

d. Check valves

147
 Check valves for smaller sizes shall be of swing type of gun metal construction. Lift
type check valves shall be used for horizontal lines. Wafer type plate check valves shall
be used for bigger sizes as shown in the specifications. The check valves shall be
suitable for 10.5 KSC test pressure.

e. Strainers

Strainers shall be preferably of approved ‘Y’ type or pot type as specified in the tender
schedule with GI or fabricated steel bodies. Strainers upto 50 mm shall be of gun metal
type. Strainers shall have a removable bronze screen with 3 mm perforations and
permanent magnet. Strainers shall be provided with flanges. They shall be designed so
as to enable blowing out accumulated dirt and facilitate removal and replacement of
all screens without disconnection from the main pipe. Strainers shall be provided with
isolating valves so that they may be cleaned without draining the entire system.

F Manual balancing valves

Manual balancing valves shall be provided at inlet pipe to each branch header or riser
pipe and at location as shown on the drawing

G Pressure Independent Dynamic Balancing cum Control valve

The Self balancing flow control valves that are pressure independent, two-way,
modulating to accept Input signals from the control system.

Each Air Handling Unit / Fan Coil Unit shall be provided with 2Way Pressure
Independent Balancing Cum Control Valve integrated in a single Body with Globe Type
in Construction.
FCU Valves Should be Provided with Spring Return Function Actuators Only.
Regarding Control - Valve should be equipped with electronic modulating actuator
which can accept either “4(0)-20 mA / 2(0)-10 V DC signals. Operating voltage for
actuator shall be 24V AC.Delta p controller should ensure 100% valve authority at all
loads (part load Actuator shall be able to work against maximum closing pressure of 6
Bar at full load). With feedback signal to Control system.
Regarding Balancing – Each Valve should have steeples adjustable maximum flow
limitation as per the designed flow rate of coils. Balancing should be done only in Valve
not in actuator so that at any given condition of failure balancing is not lost and easily
accessible.
All Valve actuator are microprocessor based with self calibrating feature.
Valve should be of linear control characteristics with stepless Characteristics.

148
I. Valve Body and Characteristics:

 Pressure Controller Device should maintain the Pressure irrespective of

Fluctuation with the help of Diaphragm self adjusting type and should not be in
contact with each other.
 Valve should be Globe Type in Construction and not with cylinder type
cartridge. Globe construction valves are accepted as the most accurate
characteristics valves. (i.e. they very closely follow the graphs made for valve
opening and flow characteristics.)
 Control valve shall accurately control the flow, with help of Modulating
Actuator
 All Valve Sizes should have a Testing Port Device for verifying accuracy of flow
performance with respective of Differential Pressure.
 Flow regulation unit shall consist of stainless steel Material 316.

II. Valve Actuator and Housing:

 The Valve + Actuator must have ability to undertake both Logarithmic Control
Characteristics and Linear Control Characteristics. This ensures compatibility
for both Water/Air and Water/Water Heat Exchange.
 Valve Actuator housing shall made of non Corrosive (Aluminum) Material.
Valve actuator housing shall be IP Protection (Weather Proof: Dust & Water
Protected). Valve actuator housing shall be acceptable to IP 42 Till 40MM and
above should be IP54.
 Control/Dip Switch Setting should be easy to Manual Access to avoid Manual
Contact to directly with Integrated IC Circuit of the system.
 Actuator should not play a part in balancing process. This will ensure that even
an operational issue in the actuator will not lead to loss of Balancing.
 Only Liner characteristics should not be acceptable as with this valve + actuator
characteristic, the resultant energy characteristic will not remain linear and
this shall lead to improper control leading to overflow/underflow
phenomenon.

III. Valve Flow Balancing:

 Balancing & Control: Balancing should be accomplished by the Diaphragm and

Control should be taken care by Actuator receiving signals from Room
Thermostats or BMS.
 Manual Override Flow Balancing should only be done in Valve , not in actuator
and should not involve opening of actuator Body.
 Flow Setting Balancing (Commissioning) for the Valves should be simple and
fool proof.
 Should not involve opening of the actuator.

149
  Should not need compulsory involvement of high end technicians.
 Should avoid direct Manual Contact with Integrated Circuit (IC) of the
actuators.

IV. PIDBCV valve specifications

Description For 15 to 32 mm For 40 to 150 mm

Diff Pressure (P1-P3) 16 To 400 kPa 30 To 400 kPa
Media Temperature -10 ° to 120 °C, -… ° to 248 °F -10 ° to 120 °C, -… ° to 248 °F
Ambient
10 ° to 54 °C, 14 ° to 131 °F 10 ° to 54 °C, 14 ° to 131 °F
Temperature
Body Material Brass (CuZn40Pb2 - CW 617N) Grey iron EN-GJL-250(GG25)
Internal Components 316 Stainless Steel 316 Stainless Steel
Test Ports Needle measuring nipple Needle measuring nipple
Leakage acc. to
No visible leakage (at 100N) max.0,01 - 0.05% of kv at 650N
standard IEC 534
Stem Seals EPDM - CuZn40Pb2 - CW 617N EPDM –NBR
Maximum Close Off
600 kPaD, … psi 600 kPaD, … psi
Pr
Maximum
400 kPaD, … psi 400 kPaD, … psid
Operational Pr
Control Range Standard IEC 534 Since CV Characteristic is Linear Control Range is
Infinity
Control Valve Linear Characteristic with the help of Actuator in equal Ratio
Character Percentage

ACTUATOR SPECIFICATIONS FOR ALL SIZES

Supply Voltage : 24V AC

Power Consumption : 10V AC
Frequency : 50 HZ
Control Input : 2-10V DC, 4-20mA, 3-point Selection.
Position Output : 2-10V DC 4-20mA
Body Housing Insulation : Non Corrosive - IP 42 Till DN 40 & IP 54 Till DN
50 To 150.
Imp Note :- Aluminium Housing for Actuator in Chilled Water is not Allowed.

c. Sufficient number of flanges and unions shall be provided as required to facilities

maintenance work once the piping is installed. Piping shall be properly supported on
or suspended from stands, clamps, roller hangers, etc., as required. The contractor

150
 shall adequately design all brackets, saddles, clamps and hangers and shall be
responsible for their structural integrity. Each support shall be isolated from the
support by means of anti-vibration springs or durable liner of neoprene rubber. Pipe
supports shall be of steel and shall be painted with rust preventive paint and finish
coated with synthetic enamel paint of approved colour. Only factory made supports
with Galvanized fully threaded rods with bands are acceptable. The chilled water pipes
shall be isolated from the bands by a rubber sheet. Pipe supports on the terrace
exposed to weather shall be hot dip galvanized.

d. The spacing of pipe supports shall not be more than that as specified below:

NOMINAL PIPE SIZE IN MM SPACING IN M

Up to 25 mm 1.5 m
32 to 150 mm 2.5 m
Above 150 mm 3.0 m

The GI support rods shall be 8 mm thick for pipes up to 50 mm dia, 10 mm for pipes
from 65 mm to 125 mm dia and 12 mm for pipes 150 mm dia and above.

e. Extra supports shall be provided at bends and heavy fittings like valves to avoid undue
stresses on the pipes.

f. Suitably designed blocks shall used for resting the pipe on the supports wherever
required.

g. Vertical risers shall be parallel to walls and column lines and shall be straight and
plumb. Risers passing from floor to floor shall be supported at each floor by clamps or
collars attached to pipe with a 12 mm thick rubber pad. Risers shall also have a
suitable concrete pipe support at the lowest point.

h. Pipe sleeves of 50 mm larger diameter than the pipe shall be provided wherever pipes
pass through the walls and the annular space filled with felt and finished with
retaining rings. Insulated piping shall be supported in such a manner as not to put
undue pressure on the insulation. 14 gauge sheet shall be provided between the
insulation and clamps, saddle extending at least 10 mm on both sides of the clamps,
saddles.

i. All bends shall be of 5 piece construction for pipe sizes 200 mm dia and for larger
pipes at least 7 piece construction shall be provided.

j. Where pipes are laid underground, the top of the insulated pipes shall not be less than
750 mm from the ground. Pipes shall be placed over RCC / PCC sleepers as shown in
the drawing. Buried pipes shall be covered by river sand cushion for a height not less
than 150 mm from the top of the pipe. After pipes have been laid and top sand

151
 cushion provided, the trench shall be refilled with excavated soil and any extra soil
shall be removed from the site of work by the contractor. RCC / PCC sleepers are in
the scope of the air-conditioning contractor.

k. All piping work shall be carried out in a workman like manner causing minimum
disturbance to the existing services. Piping installation shall be carried out with
vibration elimination fittings wherever required. While installing the pipes, adequate
clearance shall be provided for insulation wherever insulation is called for.

l. Drains shall be provided at all low points in the piping system and shall be of the
following sizes:

MAIN LINE SIZE IN MM DRAIN SIZE IN MM

Upto 300 25
Over 300 40
Drain shall be provided with gate valves of equal size but with rising spindle.
Alternatively, ball valves shall be provided. Drain shall be piped through G.I medium
class pipe to the nearest floor drain. Piping shall be pitched towards the drain points.
Wherever specified, drain pipes for the ceiling suspended units and fan coil units shall
be provided with water grade blue HDPE/PVC pipe with screwed joints. The joints
shall be proper so that no water leaks over the false ceiling. The pipes shall be tested
for leaks to a minimum pressure of 1 KSC before the false ceiling sheets are fixed.

m. Air vents shall be provided at all high points in the piping system for venting. Air
vents shall be of gun metal construction and of automatic type. Similarly drain valves
shall be provided at all dirty legs. The size of the valves shall be 25 mm size for pipes
upto 100 mm and 40 mm for sizes larger than 100 mm. Drain shall be closed with
dummy caps to prevent accidental opening.

CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER INSTALLATION

Sl.
Description Unit Remarks
No.
Hydrostatic pressure conducted as
23.
per specification
24. Any leaks
25. Any defects in joints
26. Tested after rectifying defects
27. Test witnessed and certified
28. Any noise in piping system
29. Any water noise in coils

152
Sl.
Description Unit Remarks
No.
30. Any water noise in equipment
Proper flow achieved through
31.
AHU, FCU
32. Piping insulation checked
33. All valves open
34. All motorized valves close / open
Expansion joints provided and
35.
checked
36. Pipe work cleaned
Water condition after pipe
37.
cleaning checked
Expansion tank Ball valve
38.
functional
39. All strainers clean
40. Pressure gauges working
41. Thermometers working
Drain points provided at Low
42.
points
43. Air vents provided at High points
44. Pipe support and spacing checked
1. Pipe material checked

16. METHOD STATEMENT FOR CHEMICAL FLUSHING OF PIPING SYSTEM

16.1 Introduction

1.1 This method statement has been prepared as a guideline for the site testing and
commissioning (chemical flushing) of piping system.

1.2 This procedure will be adopted for all Chilled Water and Condenser water Piping
System.

1.3 For newly installed system it is essential that the system is thoroughly flushed
with water to dislodge any sand, silt, mud or welding butts left in the system. It is
also necessary to pre-clean the system with specific chemicals and dispersants to
remove the factory contaminants such as cutting oils, mill scale and other
contaminants likely to exist in the piping network and other equipments and heat
exchangers. Once the system is thoroughly cleaned, it should be chemically treated
to afford protection to the system against corrosion, deposit formation and fouling

153
 etc. The chemical treatment affords an excellent protection to the system when it
is applied on clean and passivated metallic surfaces. The chemical treatment
introduced in un-cleaned and dirty system does not afford adequate protection
and therefore thorough pre-cleaning and flushing of the system is very essential.

16.2 Requirements

The following chemicals and ingredients required to carry out the flushing:

 Ample Quantity of Fresh water with following quality.

Turbidity Appearance Conductivity PH Total Calcium Chloride Iron

NTU M.Mho/cm Hardness Hardness as Cl as
as CaCO3 as CaCO3 ppm Fe
ppm ppm ppm
< 10 Clear < 200 7.0- < 50 < 30 < 50 <
8.0 0.3

 AQB – 406 for Alkaline Cleaning.

 AQB – 333 for Organic Cleaning.
 AQB – 12000 and AQB – 1527 – For passivation.

16.3 Mechanical Checks – Preliminary checks

Perform the following mechanical checks and record the on the Pre-Commissioning
Check List:

a. System is thoroughly tested and watertight.

b. All strainers have been cleaned and placed.

c. All strainers have been cleaned and placed.

d. Chillers need to be By-Passed by joining supply and Return.

e. Identifying and making the quick drain arrangement at lower most point in the
system.

16.4 Start Up -

A. Initial cleaning:

a. Fill the system with Fresh water and Circulate for at least 6-8 hours and heavily
drain out from the lowest available drain points.

154
 b. Again fill the system with fresh water and repeat the above procedure for
another one – two times and proceed with the following chemical flushing
procedure involving 02 stages – Stage A and Stage B.

B. Stage- a cleaning :

a. Add the AQB-406 (Alkaline Chemical) to each circuit and circulate for about 8-12
hours and then heavily drain the system from the lowest possible drain point.
This stage is called as ALKALINE Cleaning for the loosening of sand, Silt and oily
contaminants expected to be present in the newly installed system.

b. After the chemical is circulated for 08-12 hours, the system is heavily drained
and flushed 02-03 times with the water, until the appearance of water and
circulating water TDS is near to the source water.

C. Stage- b cleaning:

a. Add the AQB 333 (Organic Chemical) to each circuit and circulate for about 8-12
hours and then heavily drain out from lowest possible drain points. This stage is
called as Organic Cleaning and required for the loosing of contaminants such as
mill scale and corrosion product (Rust) Etc.
b. After the chemical is circulated for 08-12 hours, the system is heavily drain and
flushed 02-03 times with the water, until the appearance of water and circulating
water TDS is near to the source water.

D. Passivation:

a. Finally the system be refilled with fresh water (Source water) and be subjected
to passivation cum preventive treatment (chilled Water) and passivation
(Condenser water) with following chemicals. AQB-12000 and AQB- 1527.

b. Add the above two chemicals to each circuits and circulate for about 6-10 hours
and then heavily drain the system. This stage called as Passivation that allows
the conditioning of active and cleaned metallic surface against corrosive attack
(AQB-12000) and also the Biocide (AQB-1527) against immediate microbial
fouling.

c. After these chemicals are circulated then only the condenser water system is
heavily drained out and properly flushed source water and be left for operation.
It is not required to drain the chilled water circuit as these chemicals added to
this circuit also serve as the preventive treatment.

155
17. MODE OF MEASUREMENT:

17.1 Representatives from the Contractor and Engineer shall conduct a joint inspection
of the Equipment. All the discrepancies observed either incomplete works or
defective work shall be clearly indicated in the joint inspection report. The mode
of measurements given below is for the purpose of measurement and payment
and the scope of works shall be as specified elsewhere in the specification.

17.2 Piping and Pipe insulation

All water pipes and other pipes be measured nett length and measured linear over
all fittings such as bends junction etc., and given in running metres. The length
shall be taken along -With centre lines of the pipes and fittings. The unit rate shall
include fittings (Elbows, Tees, bends, Mitres, Reducers, flanges, Gaskets, Bolts,
Nuts, CAPS, Blind flanges and end closures). The measurements will be based on
the approved drawing I as built drawing and paid per unit running metre. Length
of other fittings (valves and strainers), which are paid under appropriate item,
shall not be re-measured under linear measurement. The bill of quantities
specified does not include any wastages during fabrication and erection. These
shall be included by the tenderer in the unit rate.

17.3 Valves

Each Valve including accessories shall be regarded as one unit. The quantity of
valves will be based on the approved drawing I as built drawing for the purpose of
measurement and payment. Also the unit rate quoted shall include valve
insulation for valves in chilled water piping, no separate payment will be made for
valve insulation. The unit rate quoted for motorized valves shall include cost of
actuators, no separate payment will be made for valve actuators.

17.4 Strainers

Each strainer including accessories shall be regarded as one unit. The quantity of
strainer will be based on the approved drawing I as built drawing for the purpose
of measurement and payment. Also the unit rate quoted shall include strainer
insulation for strainers in chilled water piping, no separate payment will be made
for strainer insulation.

156
 SECTION 4.13
AIR DISTRIBUTION SYSTEM
(SHEET METAL DUCT WORK)

157
1. SCOPE

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at manufacturer’s works, delivery at site,
installation, testing, commissioning and carrying out performance test at site of Air
Distribution system.

2. CODES and STANDARDS

The design, materials, construction features, manufacturer, inspection, testing and

performance of air distribution system shall comply with all currently applicable
statues, regulations, codes and standards in the locality where the system is to be
installed. Nothing in this specification shall be construed to relieve the Contractor of
this responsibility. In particular, the air distribution system shall conform to the latest
edition of following standards.

IS 277 Galvanized Steel Sheet (Plain and corrugated).

IS 655 Metal Air Ducts.
IS 737 Wrought Aluminum and Aluminum Alloy sheet and strip for general
engineering purposes
SMACNA HVAC Duct construction standards – Metal and Flexible.
SMACNA HVAC Air duct leakage test manual.
SMACNA HVAC systems – Testing, adjusting and balancing.
UL 181 Factory – Made Air ducts and connectors.
UL 555 Fire Dampers.
ASHRAE 70 Method of testing for rating the performance of Air Outlets and inlets.

3. MATERIAL REQUIREMENT

Ducting shall be fabricated from Galvanized steel sheet (GSS).

a. GSS duct shall be of lock forming grade, zinc coated conforming to IS 277 coating grade
120 or better.

b. AL sheets shall be of grade 31000 as per IS 737.

c. SS duct shall be of SS 304 as per ASTM A 167.

158
4. CONTRUCTION FEATURES

Fabrication details shall be generally in accordance with the details given here under.
Wall cutouts & sealing the wall cutouts using fire retardant material after installation
of ducts shall be part of HVAC work.

4.1 RECTANGULAR DUCT

a. For Low Pressure System (upto Fan external static pressure of ± 75mm WC).

THICKNESS OF
LARGER SIDE TYPE OF TYPE OF
SHEET mm/G
OF DUCT mm TRANSVERSE JOINT REINFORCEMENT
GSS / SS AL
25x25x3mm MS angle
Upto 250 0.63 / 24 0.80 / 22 --
flanged joint
25x25x3mm MS angle 25x25x3mm MS angle
251 to 750 0.63 / 24 0.80 / 22
flanged joint @1250 mm c/c.
25x25x3mm MS angle 40x40x3mm MS angle @
751 to 1000 0.80 / 22 1.00 / 20
flanged joint 1250 mm c/c.
40x40x3mm MS angle 40x40x3mm MS angle @
1001 to 1500 0.80 / 22 1.00 / 20
flanged joint 750 to 800 mm c/c.
40x40x3mm MS angle 50x50x6mm MS angle @
1501 to 2100 1.00 / 20 1.25 / 18
flanged joint 750 to 800 mm c/c.
65x65x6mm MS angle 65x65x6mm MS angle @
2101 to 2400 1.25 / 18 1.50 / 16
flanged joint 750 to 800 mm c/c.
50x50x3mm MS angle @
750 to 800 mm c/c with
50x50x3mm MS angle the rod(s) of 10mm dia,
Greater than
1.25 / 18 1.50 / 16 flanged joint with tie evenly spaced along
2401
rod(s) of 10 mm dia. reinforcing angle,
spacing not exceeding
1500 mm.

b. For High pressure system duct (Fan external static pressure of +76 to +250mm
WC)

THICKNESS OF
LARGER SIDE TYPE OF TYPE OF
SHEET mm/G
OF DUCT mm TRANSVERSE JOINT REINFORCEMENT
GSS / SS AL
40x40x3mm MS angle 40x40x3mm MS angle @
Upto 600 0.80 / 22 1.00 / 20
flanged joint 750 to 800 mm c/c.

159
 50x50x3mm MS angle 50x50x3mm MS angle @
601 to 1200 1.00 / 20 1.25 / 18
flanged joint 600 mm c/c
50x50x3mm MS angle 50x50x3mm MS angle @
1201 to 1500 1.25 / 18 1.50 / 16
flanged joint 600 mm c/c
65x65x6mm MS angle 50x50x3mm MS angle @
1501 to 2000 1.50/16 1.80 / 14
flanged joint 600 mm c/c
50x50x3mm MS angle @
600 mm c/c with tie
50x50x3mm MS angle
rod(s) of 10mm
Greater than flanged joint with tie
1.50 / 16 1.80 / 14 diameter, evenly spaced
2001 rod(s) of 10 mm
along reinforcing angle,
diameter.
spacing not exceeding
1500 mm.

c. Longitudinal seams shall be Pittsburgh lock type at corners as shown on sheet.

Longitudinal joints shall not be provided for rectangular ducting at locations other
than corners, except where larger side of duct exceeds 2500mm. Longitudinal joints of
ducting having side larger than 2500mm other than corner shall be grooved or
standing seam as shown.
If specified, sealing of the longitudinal seams shall be accomplished using Dow corning
RTV 732 Silastic or equivalent.

d. All circumferential joints shall be MS angle flanged joints.

e. Flanges used for transverse joints shall be joined with each other with Galvanised
Steel (GS) bolts, washers and nuts. The bolts shall be of minimum M8 size and the
spacing between bolts shall be maximum 150 mm for low pressure system and 100
mm for high pressure system.

f. For transverse angle flanged joints, neoprene gasket (3mm uncompressed thickness
and width equal to flange face) adhered to the flange face shall be used. The bolt holes
in gasket shall be the same as bolt diameter and shall be punched prior to insertion of
gaskets.

g. All flanges shall be applied with two coats of zinc-chromate, silver or zinc paint. (Red
oxide is prohibited)

h. Angles shall have welded corners and shall be riveted to the ducts at 300mm centres.
(maximum).

i. For SS ducts all related appurtenances such as transverse joint angles, reinforcement
angles, fasteners, turning vanes, access doors, etc. shall be of the same material as of
duct.

160
j. Ducts shall be fabricated using lock forming machine.

4.2 DUCT SUPPORTS AND HANGERS

a. Rectangular duct shall be supported from ceiling using trapeze hangers. Ducts shall
rest on supporting angle or channel and this supporting angle or channel shall be
supported by CS rods or angles or channels on both sides of ducts with weld or bolts.

Supporting details for low-pressure system shall be as given below.

MAXIMUM SPACING
LARGER SIDE SUPPORTING VERTICAL ROD
BETWEEN
OF DUCT mm ANGLE mm DIAMETER mm
SUPPORTS mm
Upto 900 40x40x6 10 3000
901 to 1500 50x50x6 10 3000
1501 to 2400 50x50x6 10 2400
2401 and above 65x65x6 12 2400

Supporting details for high pressure system shall be as given below:

MAXIMUM SPACING
LARGER SIDE SUPPORTING VERTICAL ROD
BETWEEN
OF DUCT mm ANGLE mm DIAMETER mm
SUPPORTS mm
Upto 1250 50x50x6 15 2400
1251 to 2100 65x65x6 15 2400
2101 and above Mc 75x6 15 2400

b. Round duct shall be supported using single or two hanger straps or rods. Straps and
rods shall be of GSS.

Supporting details for round duct shall be as given below.

DUCT STRAP ROD

161
 DIAMETER WIDTH THICKNESS DIAMETER
Nos. Nos.
mm mm G mm
Upto 600 1 25 22 1 7
601 to 900 1 25 20 1 10
901 to 1250 2 25 20 2 10
1251 t o1500 2 25 18 2 10
1501 to 2100 2 25 16 2 10

c. Zinc coated anchor fasteners or embedded plates shall be provided for upper
attachments to the building. Anchor fasteners shall be provided by Contractor.
Embedded plates shall be provided by Contractor. Contractor shall provide duct
supports from angle cleats welded to the embedded plates. Anchor fasteners shall be
loaded to maximum 20% of the maximum rated capacity specified by the
manufacturer. Site Engineer shall approve all anchor fasteners used for supporting
duct.

d. In case of insulated duct, anchor fasteners shall be selected based on actual total load.

e. Duct supports shall be qualified and sized for seismic forces, if specified in Data Sheet
– A.

4.3 FLEXIBLE CONNECTIONS (Metal Duct connections to Supply / Exhaust Fan)

Where sheet metal duct connects to the intake or discharge of fan units, a flexible of
fire retarding double layer heavy duty canvas of atleast 150mm width shall be
provided. The material shall be attached to angle frames by means of steel and over
the end of the flexible connection. The material shall be secured between the band and
the angle frame by bolting. Sleeve shall be made smooth and the connecting duct work
rigidly held by independent supports on both ends. The flexible connection shall be
suitable for fan intake and outlet pressures.

4.4 TRANSFORMATION

Duct transformation shall be used to change the shape of duct and shall be made for
easy and noiseless flow of air. Maximum slope of transformation shall be 1:4

4.5 BENDS, OFFSETS and BRANCH CONNECTIONS

All bends, offsets and branch connections shall be made for smooth and noise less flow
of air and minimum pressure drop. In case of full radius elbow optimum ratio of
centerline radius of elbow to duct dimension of 1.25 shall be considered. However,
due to space constraint shorter radius constraint shorter radius elbow or square

162
 elbow with guide vanes may be provided. Contractor shall furnish the details of guide
vanes i.e. number of vanes, location etc. in the drawing. The flow of air to the branch
duct shall be regulated by a splitter damper or volume control damper.

4.6 SPLITTER DAMPERS and VOLUME CONTROL DAMPERS (VCDs)

a. Splitter dampers shall be fabricated of minimum 18G GSS and shall be of robust
construction. The position of splitter damper shall be adjusted by use of the splitter
rod.

b. VCD shall be fabricated of minimum 18G GSS and shall be of robust construction. VCD
shall be single blade type for round duct and opposed blade type for rectangular duct.
VCD shall have a locking device mounted outside the duct to hold the VCD in a fixed
position without vibration. Fully open and fully closed position shall be marked for
easier operation of VCD.

c. Motor operated VCD shall be provided, if specified. Actuator for dampers shall develop
sufficient torque for easy operation of VCD.

d. VCD shall be provided with Teflon or brass bushing for blade shaft as specified in Data
Sheet – A. Motor operated VCD shall be provided with Teflon bushing or sealed ball
bearing for blade shaft as specified in Data Sheet – A. (Optional)

e. For SS duct, all splitter dampers and VCDs shall be fabricated from SS 304 sheet.

f. Volume control dampers shall be provided in every branch duct from individual main
ducts. Volume control dampers shall also be provided in branch duct from main
connecting to individual supply / exhaust air outlets, and inlets, fresh air intake duct,
etc.

4.7 Fire dampers

a. All supply and return air ducts crossings full height wallin any floor shall be provided
with fire dampers of at least 90 minute fire rating. These shall be multi leaf dampers.

b. Fire dampers blades and outer frames shall be of 16G GSS construction. The damper
blades shall be provided on both ends using chrome plated spindles in self lubricated
bronze bushes. Stop shall be provided on top and bottom of damper housing made of
16G GSS. For preventing smoke leakage, side metallic compression seals shall be
provided. The approved make Caryaire or equivalent.

c. Fire damper shall be provided with factory fitted sleeves. Access doors shall be
provided within the duct in accordance with the manufacturer’s recommendation.

163
 d. For SS duct, all fire dampers shall be fabricated from SS 304 sheet. Outdoor air
grills shall be of the single louver type with opposed blade volume control dampers
adjustable from the face of the grilles.

e. Fire isolating dampers complete with outer frame, damper blades, motorized or
fusible link actuator, linkages and sleeves, shall be installed in all locations as may be
required by the relevant Authorities. In particulars, fire dampers shall be installed in
ducts where they pass through compartmentation walls, fire walls and concrete floors
except in the case where the duct itself is in a fire isolated shaft.
Fire dampers shall be motorised smoke & fire dampers type. It shall be
supplied with spring loaded UL stamped fusible link to close fire
damper in the event of rise in duct temperature. Fire damper shall also
close on receipt of fire alarm signal to cut off air supply instantaneously.
An electric limit switch shall also be operated by the closing of fire
damper, which in turn shall switch off power supply to AHU blower
motor as well as strip heaters.

Fire dampers shall be CBRI tested & certified for 90 minutes rating
against collapse & flame penetration as per UL 555-1995.(Under
writers laboratories)

Fire dampers shall be compatible with the fire detection system of

building & shall be capable of operating automatically through an
electric motor on receiving signal from fire alarm panel.

a. .

All fire dampers shall be approved by the relevant Authorities. Inspection door shall
be provided for fire dampers. Fire dampers shall be UL 555 rated and certified by UL.
All fire dampers shall be complete with factory fabricated and fitted duct sleeve. The
joints at the sleeve end shall be slip on type.

b. Fire Rated Ductwork

All Fire Rated Ductwork shall have a minimum of 2 hours fire rating and to the
approval of the local authorities.

c. Flexible ducts

Insulated flexible ducts shall be provided to connect the supply air ducts to all air
delivery devices such as grilles and diffusers. The length of the flexible duct shall not
exceed 1.5 m. The airflow velocity through the flexible duct shall not be more than 3.0
m/s.

Flexible ducts should be internally insulated with ½ “thick 1bls.cuft density fiberglass

164
 blanket enclosed in a polystyrene sleeves finished with factory made aluminum foil.
Clamps should be used for fixing of flexible ducts on both ends and wrapped with good
quality duct tapes equivalent to that of Birla 3M make. No packing and silver duct tape
will be acceptable.
. The fire rating of the flexible duct shall conform to BS 476 Parts 5, 6 and 7.

i. Very branch duct shall have test plugs.

j. Every duct tap-off from supply and return air duct shall be complete with opposed
blade volume contract damper.

l. The duct leakage rate shall not exceed 1% of full flow and 25% of the ducts shall be
tested at site for duct leakage.
m. Caulking and drain

Wherever duct passes through wall or slab, all the openings between masonry and
duct work shall be neatly caulked or sealed by the Contractor to prevent movement of
air from one space to the adjoining space. Where duct passes through the floor, a drain
trap of 100mm width across the width of the duct and 50mm depth shall be provided
with a suitable plug at the lowest point in the elbow.

4.8 Accessdoor

Access door shall be provided in duct before and after equipment installed in duct and
at all fire damper locations. All access doors shall be fabricated of the same material as
the duct work and shall have minimum two hinges. Hinges shall be zinc plated and pins
shall be of brass. Access doors shall be of minimum of 305 mm x 305 mm size. At least
two heavy solid brass fasteners and a brass handle are required for each door. A
continuous neoprene rubber gasket shall be adhered to the opening frame with
adhesive.

4.9 Diffusers and grilles (air diffusion equipment)

a. The type and quantity of diffusers and grilles shall be provided, as specified in the
drawing. The contractor shall ensure that the diffusers and grilles offered are of
requisite capacity, throw and terminal velocity. Diffusers and grilles shall be fabricated
from CS, factory coated with rust resistant primer or extruded aluminium section with
powder coating, as specified in the drawing.

Whenever VCD is provided with diffusers or grilles it shall be located within the duct
collar. Diffusers and grilles shall be of flush pattern,

Ceiling diffuser shall be equipped with fixed air distribution grids, removable key
operated volume control dampers and anti-smudge rings. The extruded aluminium

165
 diffusers shall be provided with removable central core and concealed key operation
for volume control damper.

b. Linear diffusers shall be of extruded aluminum construction.

c. Slot diffuser shall be of extruded aluminum construction multi-slot type with air
pattern controller provided in each slot. Supply air slot diffusers shall be provided
with hit and Miss VCDs in each slot.

d. Grilles with VCD shall be single acting or double acting, as specified in the drawing.
Grilles without VCD shall have fixed blades or adjustable blades, as specified in the
drawing.

e. All diffusers, grilles and registers shall be of extruded aluminum construction, and
aluminum powder coated. Aluminum registers, diffusers and grilles shall be approved
by Architect. The shade of aluminum powder coating for grilles, registers and diffusers
shall be approved by Architect.

All ceiling diffusers shall be of the louver face type with removable core complete with
opposed blade volume control dampers. The diffuser surface shall be completely flush
with the false ceiling.

Supply registers shall be of the rectangular universal type with adjustable horizontal
and vertical vanes complete with opposed blade volume control dampers. Dampers
shall be adjustable by a removable key or screwdriver from the face of the registers.

Fresh air and discharge air grilles shall be of the fixed single louver type with opposed
blade volume control dampers adjustable from the face of the grilles. All diffusers,
registers and grilles shall be selected to account for the noise levels as specified for
various area.

For areas where square ceiling diffusers are used, they shall be of the louver face type
with removable core complete with opposed blade volume control damper.

Supply air register shall be of the rectangular universal type with adjustable
horizontal and vertical vanes complete with opposed blade volume control dampers.
Dampers shall be adjustable by a removable key or screw driver from the face of the
register.

Outdoor air grilles shall be of the fixed single louver type with opposed blade volume
control dampers adjustable from the face of the grilles.

4.10 Plenums

Plenums shall be factory fabricated of 18G GSS for low-pressure system and 16G GSS

166
 for high-pressure system. Type of reinforcement and supporting details shall be as per
clause 4.1 and 4.3. Plenums shall be constructed to withstand 133% of rated plenum
pressure without structural failure. Wall and roof deflection at rates pressure shall not
exceed 10mm per meter of width.

5. INSPECTION AND TESTING

a. The ducts, branches, elbows etc. shall be inspected and the joints and connection shall
be checked before these are assembled in position. After assembly the system shall be
checked for tightness, vibration and noise.

b. Changes in direction shall be made with elbows with an inside radius equal to the
width of the duct, where possible, but where space does not permit this radius,
sharper or right – angle bends within inside radius not less than 1 of the duct width
which may be used with double thickness aerofoil turning vanes. The turning vanes
shall have a flange covering the whole base and they shall be rivetted to the duct at not
more than 75 mm intervals. Insecurely fitted turning vanes shall be rejected. All
changes in dimensions and shape of ducts shall be done in a gradual manner and to
approval.

c. Ductwork shall be free from waves or buckles and the sheet metal is to be machine –
bent to ensure neat and accurate fabrication. If double thickness aerofoil shape
internal stiffeners are fitted, the original ‘cross sectional area of duct shall be
maintained.

d. Full sized standard sheets of the gauges specified are to be used and any patched or
made-up pieces of duct work are liable to be rejected. Joints between flanged
connections shall be fitted with neoprene rubber gaskets of 5 mm thick.

e. All duct work not insulated shall be painted externally with one coat of primer and
two coats of anticorrosive paint.

f. All duct surfaces behind diffusers, registers and grilles shall be painted Matt black.

g. All toiler riser ductwork shall be of soldered or welded seams and joints throughout.

h. Duct joints and seams shall be made air tight by use of sealants acceptable to local
authority. Test points shall be provide at the discharge of each air handling unit and
at each individual zone of the duct work system. Test points shall consist of 25 mm
diameter sockets fitted with sealing plugs which can be removed for the fitting of
measuring devices. Test points shall be insulated as for the ductwork and shall be
provided with identification labels.

i. Duct dimensions and drawings.

167
 The contractor shall furnish duct layout drawings showing clear internal sizes for all
air-conditioned as well as areas covered by MV.

J Rectangular risers should be supported by angles or channels secured to the sides of

the ducts with welds, bolts sheet metal screws or blind rivets. Riser support intervals
should be one or two storey height.

K In case embedded plates are provided contractor shall provide support from angle
cleats welded to embedded plates.

L Ducts shall have support on either side of elbow within two feet and for branch
connection it shall be within four feet.

M Turning Vanes

All curved elbows shall be provided with air turning vanes consists of curved metal
blades or vanes arranged so as to permit the air to make abrupt turns without
appreciable turbulence.

All right angle elbows shall be provided with double thickness aerofoil turning vanes
extending over at least 50 percent of the while curvature of the elbow. The turning
vanes shall have a flange covering the whole base be rivetted to the duct at not more
than 60 mm centres.

N Sound Attenuators (Dissipative Type) to be provided on all AHU fan supply main ducts
from plenum.

O Sound attenuators shall consist of an outer casing, sound absorbing material and
internal baffles, splitters and supports. Casings shall be of galvanized steel of not less
than 20 g. thickness. Casings shall be tested to 150 mm wg. and shall show no leakage,
or distortion in this condition. Duct sealing compound shall be furnished by the
supplier for sealing all silencers on site, where necessary, as determined by the
ENGINEER.

P Sound absorbing material shall be high-density fiberglass held in place with at least
5% compression to prevent voids due to settling. Absorption material density shall be
minimum 48 kg / cu.m fiberglass faced with minimum 26 g. perforated galvanized
sheet metal of minimum 40% open area. Combustion rating for the silencer acoustic
infill shall not be less than the following, when tested in accordance with ASTM E84:

Flame spread classification - 25

Smoke development rating - 0
Fuel contribution - 20

168
 j. The supplier shall supply certified test data on dynamic insertion loss and self-noise
with airflow of at least 7.62 m/sec. (1500 ft / min) face velocity. Ratings shall be
determined in a duct-to-reverberant room test facility, which provide for airflow
through the test silencers during rating.

6. BALANCING

a. The air distribution system shall be tested and balanced so that the requisite
temperature and air flow are maintained throughout the space to be air-conditioned
or ventilated.

b. During start-up phase, Contractor shall make all arrangement for drilling or plugging
of all test opening or holes, adjustment of VCDs, adjusting of fan speed to obtain
specified flows, obtaining actual motor ampere readings, and all related functions to
ensure the proper operation of all systems.

c. Test holes for system commissioning shall be minimum 20mm diameter to accept a
standard pitot tube of 8mm diameter and each hole shall be fitted with an effective
removable type seal. Location of test holes shall be decided by Contractor in
consultation with Contractor / Engineer.

d. All instruments required for testing and balancing of air distribution system shall be
provided by the Contractor.

e. Complete air balance report shall be submitted for scrutiny and approval. Four copies
of the approved balance report shall be provided with completion documents.

f. Splitter damper and VCD adjustments shall be permanently marked after air balancing
is complete so that these can be restored to their correct position if disturbed at any
time.

169
 FIG.1-LOW PRESSURE-LOW VELOCITY SHEET METAL
DUCTWORK CONSTRUCTION DETAILS

H
PLAIN 'S'
SLIP(B)
H

~
~

~
~
~

~
GASKET REINFORCING ANGLE SIZE
AIR FLOW AIR FLOW AIR FLOW AND MAXIMUM
COMPANION LONGITUDINAL SPACING
HEMMED ANGLE SLIP(H) ANGLES(M)
BETWEEN TRANSVERSE
'S' SLIP(C) JOINT AND/OR
INTERMEDIATE
REINFORCING

H
H 1/8 H H
H
~

~
~

~
~
~
~

~
ALTERNATE
DIMENSION GALVANISED IRON POCKET LOCK(K) BAR SLIP(E) AIR FLOW BAR SLIP(F)
OF LONGEST SHEETMETAL
SIDE OF DUCT THICKNESS REINFORCED
IN mm IN mm BAR SLIP(G) *

H 1/8
H H

DRIVE SLIP(A) STANDING ANGLE RFD ANGLE RFD

SEAM(I) POCKET(L) STANDING
SEAM(J)

THRU 300 0.71 A-B - - - - -

K

301 THRU 460 0.71 A-B - - - - -

K

461 THRU 760

0.71 K C-E - - - 25x25x3 AT 1.5m cc

761 THRU 1070 0.86 K E-C-I - - - 25x25x3 AT 1.5m cc

1071 THRU 1370 0.86 K E G - - 35x35x3 AT 1.5m cc

1371 THRU 1520 1.02 K E G - - 35x35x3 AT 0.8m cc

H
1521 THRU 2130 1.02 - - G F J 35x35x3 AT 0.8m cc
L
H M
2131 THRU 2440 1.32 - - - L J 35x35x3 AT 0.8m cc

H M
OVER 2440 1.32 - - - L J 50x50x6 AT 0.8m cc

NOTES:
H : (HEIGHT DIMENSION) UPTO 1070=25
H : (HEIGHT DIMENSION) 1090 TO 2440=40
H : (HEIGHT DIMENSION) OVER 2440=50
* : ROLLED FORMED SLIP SHALL BE 400
MAXIMUM AND 50 REINFORCING ANGLE
ANGLE FASTENED TO SLIP WHEN "H"
DIMENSION REQUIRES 50 HEIGHT

170
 CHECKLIST AND PERFORMANCE TEST DATA TO BE PROVIDED AFTER
INSTALLATION

Needs Not
No Description O.K Remarks
Attention Applicable
38. Duct Work clean ?
Sealed, No leaks, Tight
39.
connection ?.
40. Fire Dampers open ?
41. Access doors closed ?
42. Lined ducts ?
Flexible duct connected,
43.
No Tears ?
44. System balanced
Short circuiting or other
45.
Air Distribution problems
a
?
b Note locations.
VCD provided as per
46.
specification ?
VCD all open and adjusted
47.
?
Supply / Return / Exhaust
48.
outlets / Inlets balanced ?
49. Noticeable flow of Air
Air balance report
50.
submitted with details ?
VAV Box
51. a. Minimum stops - %
b. Maximum opening - %
52. Controls working ?
53. Thermostats
a. Type
b. Properly located
c. Working
d. Set point - °C
e. Space temperature - °C

171
 54. Duct insulation checked
Duct supports and hangers
55.
checked including spacing
Turning valnes provided
56.
in elbows.
Test witnessed and
57.
certified

7.0 MODE OF MEASUREMENT

Representatives from the Contractor and Engineer shall conduct a joint inspection of
the Equipment. All the discrepancies observed either incomplete works or defective
work shall be clearly indicated in the joint inspection report. The mode of
measurements given below is for the purpose of measurement and payment and the
scope of works shall be as specified elsewhere in the specification.

7.1 Air-distribution system

a. Ducting

The following procedure for measurement shall be followed for purpose of billing
in case of items subject to variation in quantities.

Payment for ducting shall be on the basis of the external surface area of the
ducting.

The rate per square meter of the external surface shall include flanges, gaskets for
joints, bolts and nuts, duct supports and hangers. Vibration isolation pads or
suspenders; flexible connections, inspection doors, dampers, turning vanes,
straightening vanes and any other item which will be required to complete the
duct installation except external insulation and finish thereon.

The external area shall be calculated by measuring the over-all width and depth
(including the corner joints) in the center of the duct section and over-all length of
each duct section from flange face to flange face in case of duct lengths with
uniform cross section. Total area will be arrived at by adding up the areas of all
duct sections.

In case of taper pieces average width and depth will be worked out as follows:

W1 = Width of small cross section

W2 = Width of large cross section
D1 = Depth of small cross section
D2 = Depth of large cross section

172
 Average Width = W1 + W2
2
Average Depth = D1 + D2
2

Width and depth in the case of taper pieces shall be measured at the edge of the
collar of the flange for duct / sections fitted with angle iron flanges; otherwise at
the bottom of the flange where the flanges are of GSS. Face to face length for taper
piece shall be the mean of the lengths measured face to face from the centre of
width and depth flanges.

For special pieces like bends, branches, and tees, etc, the same principal of area
measurement as for linear lengths shall be adopted, except for bends and elbows,
the length of which shall be the average, of the lengths of inner and outer
periphery along the curvature of angle of the piece.
Duct measurements for calculation of area shall be taken before application of
insulation.
b. Fire Dampers

Fire dampers shall be measured by their cross-sectional area perpendicular to air

flow based on the approved drawing I as built drawing and paid. Quoted rates
shall include necessary accessories and flanges for mounting, access door etc.

c. Fusible link and solenoid for operation of Fire Dampers

Each Solenoid and associated accessories will be regarded as one unit for the
purpose of measurement and payment. Each Fusible link and associated
accessories will be regarded as one unit for the purpose of measurement and
payment. The measurements will be based on the approved drawing I as built
drawing and paid per unit.

d. Supply and return air Grilles

Supply and Return air grille area shall be calculated by measuring width by height,
excluding flanges. In case of supply air grilles, volume control dampers shall form
part of supply air grilles and the unit rates quoted for supply air grilles shall
include the cost of volume control dampers. Frame work for grilles shall be
included in unit rates quoted. The measurements will be based on the approved
drawing I as built drawing and paid per unit area.

e. Volume control damper (VCD) in Duct

VCD (manual or motorized) shall be measured by their cross-sectional area

perpendicular to air flow based on the approved drawing I as built drawing and

173
 paid per unit area. Quoted rates shall include necessary collars and flanges for
mounting etc. No special allowance shall be payable for extension of cross-section
outside the air stream. Volume control dampers in supply and exhaust fan units
are part of fan units and no separate payment will be made for the same.

f. Back draft damper

Back draft damper shall be measured by their cross-sectional area perpendicular

to air flow based on the approved drawing I as built drawing and paid per unit
area. Quoted rates shall include necessary collars and flanges for mounting etc. No
special allowance shall be payable for extension of cross-section outside the air
stream.

g. Sound Attenuators

Each Sound attenuator with accessories will be regarded as one unit for the
purpose of measurement and payment. The measurements will be based on the
approved drawing I as built drawing and paid per unit. Sound attenuators in
supply and exhaust fan units are part of fan units and no separate payment will be
made for the same.

h. Flexible Connection

Flexible Connections other than at equipment inlet and outlet shall be measured
by their cross-sectional area perpendicular to air flow. Quoted rates shall include
necessary mounting arrangement, flanges, nuts and bolts and treated for fire
requisite length of canvas cloth. The measurements will be based on the approved
drawing I as built drawing and paid per unit area.

174
SECTION 4.14
INSULATION

175
1. SCOPE
This specification covers the technical requirements and essential particulars for the
supply, application and finishing of the composite thermal insulation for cold
equipment, piping systems, air-conditioning ducts etc. The scope of supply of the
contractor shall include, but not be limited to, the following items:
a) Insulation material as specified
b) Finishing material as specified
c) Auxiliary materials such as binding and lacing wires, wire netting, bands, screws,
pop-rivets, etc. as required
d) Angles, clamps, lugs, etc, for supporting insulation
e) Weather hoods
f) Any material as may be required for making the insulation complete

2. CODES AND STANDARDS

The following are some of the codes and standards relevant to this specification:
IS 277 Galvanized Steel Sheets (Plain and Corrugated)
IS 737 Wrought Aluminum and Aluminum alloy Sheet and Strip for General
Engineering purposes
IS 14164 Industrial Application and finishing of Thermal Insulation Materials at
Temperatures above (-)800 C and up to (+) 7000 C
BS 5970 Thermal Insulation of Pipe work and Equipment (in the Temperature
Range (-) 100 0 C to (+) 8700 C
BS 476 Closed cell polyolefin foam insulation
ASTM E84 Closed cell polyolefin foam insulation
ASTM E96 Closed cell polyolefin foam insulation

176
3. INSULATION WORK
1) The scope of this section comprises supply and application of insulation to sheet
metal ducting, chilled water piping, condensate drain piping, insulation for walls
and ceiling and floor.

2) Closed cell Poly vinyl nitrile foam insulation shall have a density of 55 Kg/cum and
a thermal conductivity of not greater than 0.032W/m K 20deg C. Closed cell Poly
vinyl nitrile foam insulation shall have factory laminated reinforced aluminum foil
facing of 9micron thickness and self adhesive backing. Closed cell Poly vinyl nitrile
foam insulation shall be used for duct insulation.

3) Poly vinyl nitrile foam insulation of density 50 kg/m3 and of Class O fire retardant
grade shall be used for duct acoustic insulation.

4) For pipe inside the building in the plant room and shafts, insulation should be
Expande Polystyrene (T.F quality) of thickness 75 mm and density 24Kg/Cum
suitably protected with glass cloth and 2 coats of vapour barrier upto 65 mm
diameter of chilled water pipe. Less than this diameter same material of thickness
50 mm and having the same density shall be used.
5) For insulation of refrigerant piping closed cell elastomeric material shall be used.

6) All insulation on equipment and piping shall be applied only after the system has
been pressure tested satisfactorily.

7) The consultants/ owners or their authorized representatives reserve the right to

peruse the weights, dimensions etc., of the insulation material supplied. Samples of
all insulation material specified, in various forms shall be submitted by the
successful contractor. The customers/ consultants shall have the right to reject all

177
supplies which do not conform to the specifications and to the samples so
approved.

External (Thermal) Insulation of Air-Conditioning Ducts:

Supply air ducting (as shown in the drawing) for air conditioning from AHU fan
outlet to the terminal device (diffuser or grille) shall be insulated with Closed cell
Poly vinyl nitrile foam insulation having a density of 55 Kg/cum The thermal
conductivity (K) value shall not be more than 0.032 W/m. k at 20 deg C. The
material shall be Class 0 as per BS 476 part 6 & 7 and NFPA 90A & 90B compliant.
The duct insulation shall be anti microbial in nature and pass ASTM G21 for fungal
growth. The material shall have permeability resistance factor of >20000 as per
ASTM E96. The material shall be of low VOC and green building compliant.
Internal (Acoustic) Insulation Of Air-Conditioning Ducts And AHU Room Wall
Acoustic Insulation:
Acoustic insulation shall be provided for the following:

a) All supply air plenums.

b) The first eight (8) meters of air-conditioning duct from AHU outlet.
c) The return air transfer ducts in the AHU room wall, connecting the AHU room
with the air-conditioned area.

The portion of supply air duct which is acoustically (internal) insulated need not
be insulated thermally (external).

Insulation material shall be Open cell Poly vinyl nitrile foam insulationof density
50 kg/ m3 and fire retardant in nature. The thermal conductivity (K) value shall not
be more than 0.035 W/m K . Thickness shall be 12 mm for Duct Acoustic
Insulation. Manufacturer recommended adhesive shall be used to ensure
adherence of duct insulation to surface of the ducts.

178
 External fire retardant insulation of air-conditioning ducts
All ducts crossing the kitchen areas shall be insulated with fire retardant material.

Chilled water piping for AHU and FCU

All chilled water piping, condensate drain piping shall be insulated as indicated
herein. Prior to application of insulation, all pipe work shall be cleaned on the
surface with wire brush to remove dirt and dust.
The insulation for chilled water piping shall be carried out from Expande
Polystyrene (T.F quality)having a minimum ‘K’ value of 0.035 W/m k at mean
temperature of 200 C and a density of 25 Kg/cum.
For chilled water pipes in the chiller plant room and air handling unit rooms and as
well as shaft risers and exposed roof, insulation shall be with factory laminated
ultra tough foil of 15microsn thickness. This basically includes entire chilled water
piping network. The joints shall be formed with proper grooves and overlaps and
secured in position using sheets of same grade.
Arrows indicating direction of flow shall be clearly marked.

4. DRAIN PIPE INSULATION

If PVC/HDPE pipe is used for drain piping, no insulation is necessary. If steel pipes are
used, the material for insulation of drain pipes shall be pipe sections of flexible closed
cell physically cross linked closed polyolefin foam having a ‘K’ valve of 0.032 W/mK at
a mean temperature of 200 C and a density of 25 Kg./cum.
The thickness of insulation shall be 15 mm thickness.

5. GENERAL REQUIREMENTS
5.1 The application of insulation shall be made in a workmanlike manner. The
insulation shall be applied to all surfaces when these are at ambient temperature.
Ample provision shall be made for the maximum possible thermal movement and

179
 the insulation shall be applied in a manner which shall avoid breaking or
telescoping due to alternate periods of contraction and expansion.
5.2 Insulation shall be applied after all leak tests on equipment and piping are over and
the section of the plant has been specifically released by the EMPLOYER for such
work.
5.3 All surfaces to be insulated shall be clean and dry before the insulation is applied.
The surface shall be cleaned of all foreign material such as scale, dirt, rust and paint,
by the use of steel wire brushes and steel scrapers, where necessary. One coat of
primer paint shall be applied and allowed to dry before application of insulation.
5.4 After cleaning and application of one coat of primer paint on the surface to be
insulated, the insulation adhesive shall be applied. The insulation adhesive shall be
of rubber based adhesive grade as recommended by the manufacturer of insulation
material. A similar layer of adhesive shall be applied on the inside surface of the
insulation. Insulation material of required thickness shall be stuck to the surface
with joints staggered. The adjoining sections shall be tightly pressed together. All
the joints shall be sealed with adhesive material and sealed 72mm wide reinforced
aluminum foil tape. Voids shall be completely avoided. Vapour barrier and
insulation finish shall be applied as specified.
5.5 Where multi layer insulation is provided, insulation adhesive shall be used between
two layers.
5.6 For aluminum sheet finishing material provided, all joints shall be sealed with
bitumastic paint and made effectively weather and waterproof.
5.7 Approval of the Engineer shall be obtained for samples of materials. Necessary test
certificates shall be furnished to Engineer, before dispatching any material to site.
5.8 The following information shall be furnished by contractor after award of contract.
a. Detailed insulation application procedure with drawings
b. Test Certificates for insulation materials

180
6. MODE OF MEASUREMENT:
Representatives from the Contractor and Engineer shall conduct a joint inspection of
the Equipments. All the discrepancies observed either incomplete works or defective
work shall be clearly indicated in the joint inspection report. The mode of
measurements given below is for the purpose of measurement and payment and the
scope of works shall be as specified elsewhere in the specification.

6.1 Thermal Insulation for Duct

Area of duct insulation finished as per specification shall be calculated on the basis
of finished duct area before insulation based on the approved drawing/ as built
drawing and paid per unit area.

6.2 Acoustic Insulation for Duct

Area of acoustic insulation finished as per specification shall be calculated on the
basis of finished duct area before insulation based on the approved drawing/ as
built drawing and paid per unit area.

181
 SECTION 04.15
TESTING AND BALANCING

182
1.0 GENERAL

1.1 All testing and balancing shall be made in the presence of the Consulting Engineer or
his representative or other inspecting authority. Give not less than 5 days prior notice,
in writing, to these parties before making any tests. Check list format has been
furnished in every section for all air conditioning & ventilation equipment. The duly
filled check list has to be submitted to the consulting engineer before starting the
testing & balancing.

1.3 Supply all necessary skilled labour, helpers, equipment and materials for tests,
operating and adjusting the systems and for fully instructing the Employer or his
representatives in the operation of the system.

1.4 Protect valves and equipment from damage during tests. Include connection to
previously tested sections, if the systems are tested in sections.

1.5 Prior to the balancing procedure, operate all systems for at least 16 consecutive hours,
or longer if required, to prove satisfactory automatic operation. If systems shutdown is
experienced for any reason, repeat and test until 16 consecutive hours are achieved.
Operate equipment as recommended by the equipment manufacturers and in such a
manner as to avoid damage to the work of other trades. Submit to the Consulting
Engineers for review a log of all tests made which shall include time, temperature,
pressure and other readings necessary to indicate that the systems have been
operated and tested as required by the Specification.

1.6 Upon completion of testing and balancing submit six (6) copies of the recorded test
data for the Consulting Engineers evaluation and approval.

1.7 Flow quantities for Air side and Chilled water systems shall be verified by the
Consulting Engineers and Clients representatives before the report is submitted.

2.0 TESTING OF MEDIUM & LOW PRESSURE DUCTS

2.1 The Medium and Low Pressure ducts shall be tested for air leaks.

3.0 TESTING OF PIPES

3.1 All pressure systems specified to be tested using water as the test medium shall be
first checked by pre-testing the test section, or system, with compressed air at 34.5 pig
for a period of 3 minutes. Correct all leaks disclosed by the pre-set before proceeding
with the specified testing using water as the test medium.

183
3.2 Test all piping as noted below with no leaks or no loss of pressure. Repair or replace
Defective piping until tests is accomplished successfully.

SYSTEM TEST PRESSURE TEST MEDIUM TEST DURATION

Chilled water 1724 kPa Water 24 hours
piping
Condensate drains 3m hd Water 24 hours
Refrigerant piping 2070 kPa Dry Nitrogen 4 hours

4.0 PRE BALANCE CHECKS AND START UP

4.1 The Air and Water Systems will be checked out at specified below, and started up
prior to balancing.

a) Complete "'water pressure and duct pressure testing for leakage.

b) Complete all 'Punch List' check items.

c) Install all dampers and other balancing devices as called for in the construction
documents and verify the same are properly installed, indexed and in good
working order.

d) Check all motor starters and verify that the sizing is correct, taking length of
electrical feeders into consideration. Record amp readings on all motors.

e) Check out and align all equipment drives.

f) Set all fan sheaves to provide the indicated capacities at specified static
pressures (RPM as specified).

g) Set all manual balancing dampers, valves and balancing valves at 100% open
position. Verify that all fire dampers are open.

h) All adjustable pitch pulleys shall be removed from the motor shaft. The shaft
and pulley threads shall be cleaned, lightly oiled, and pulley remounted, aligned
and properly adjusted.

i) Clean interior of all plenums, casings and ducts and install all filters before
starting systems.

j) Make sure all controls systems are calibrated and functioning properly.

k) Place all systems in automatic operation.

184
 I) Operate systems for 16 consecutive hours without shutdown with all
equipment in perfect working order. Manufacturer’s representative must be
present at initial start- up all equipment.

m) Check fan and pump bearings for grease.

n) Install clean prefilters and install high efficiency filters in all systems prior
To starting air balance.

0) Provide availability of personnel from all the related mechanical and

Controls contractors during balancing.

5 TEST REPORTING FORMS

5.1 General

Test forms used for testing and balancing shall be set up to include the following
information. Each sheet shall have job name and address, name of air conditioning
sub-contractor, architect and engineer instruments used to perform tests, and name of
test technician or test engineer. All forms shall be submitted in typewritten form. A
minimum of 6 copies shall submit.

5.2 Supply & Return air Grilles -Test Sheets

a) Fan Systems and/or zone number

b) Room number or area designation

c) Outlet code number, which shall correspond to code number of outlet on air
balance code drawing.

d) Size of Outlet -.

e) Type of Outlet -.

f) Manufacturer of Outlet

g) Manufacturer's effective area for each size

h) Required FPM and required CFM of each outlet

Available FPM and CFM of each outlet

185
5.3 Air Handling Equipment Test Sheets .

The test sheets shall provide details of the following items: (Refer Checklist in section
4.13)

System Fan Number Fan RPM

Fan Manufacturer Size of Sheave Driver
Total CFM Size of Sheave Driven
Return Air CFM Motor Manufacturer
Outside Air CFM Motor Size, Voltage
Total Static Pressure Phase & RPM KW
Suction Static Pressure Amperage Nameplate Rating
Discharge Static Pressure Final Operating Amperage
Coil Pressure Drop Overload Setting
Filter Pressure Drop

5.4 Exhaust Fans, Fresh Air Fans and Pressurization Fans Test Sheets

The test sheets shall provide details of the following items:.

System Fan Number Amperage Nameplate Rating

Fan Manufacturer Final Operating Amperage
Size and Model Fan RPM
Motor HP, Voltage & Phase Total Static Pressure,
Overload Setting

5.5 Test, Code Drawings

Each Report shall contain a single line drawing of air distribution system with fan
system and zone number indicated. Each and every outlet, supply, and return shall be
indicated on this drawing by a number corresponding to the number on the outlet test
sheet, enabling the Engineer to locate each outlet for this drawing.

Drawing shall be clear and neat and shall list name of job and location of same.

5.6 Temperature Test Sheets

Temperature test sheets shall list both specified and test conditions in opposite
columns.

Items listed on this sheet shall be as follows:

186
 a) Entering Air D.B. & W.B. Temperature

b) Leaving Air D.B. & W.B. Temperature

c) Entering Coil Water Temperature

d) Leaving Coil Water Temperature

e) Outside Air -D.B. & W.B. Temperature

f) Room temperature reading to be checked against thermostat setting

6.0 AIR SIDE TESTING AND BALANCING

6.1 The Air System shall be tested and balanced as under:

a) Test and adjust fan RPM to design requirements

b) Test and record motor full load amperes.

c) Make Pitot tube traverse of main supply ducts and obtain design CFM at fans

d) Test and record system static pressures, suction discharge and total.

e) Test and adjust system for design recirculated air.

f) Test and adjust system for design outside air.

g) Test and record entering air temperatures DB/WB.

h) Test and record leaving air temperature DB/WB

i) Adjust all main supply and return air ducts to proper design CFM.

j) Adjust all zones to proper design CFM (supply and return).

k) Test and adjust each diffuser, grille and register to within 10% of design
Requirements:

I) each grille, register shall be identified as to location and area.

187
 m) Size, type and manufacturer of diffusers, grilles, registers, and all tested
equipment shall be identified and listed. Manufacturer's ratings on all
equipment shall be used to make required calculations.

n) Readings and tests of diffusers, grilles, and registers shall include required
velocity and test resultant velocity. Required CFM and test resultant CFM after
adjustments.

0) In co-operation with control manufacturer's representative, set adjustments of

Automatically operated dampers to operate as specified, indicated and/or noted.

q) As part of the work of this contract, the Contractor shall make any changes in
the pulleys and belts for correct balance as required.

7.0 WATER SYSTEMS TESTING AND BALANCING

HVAC contractor shall engage the services of balancing valve supplier to provide
complete water side balancing.

7.1 Pre Balancing Checks

The Air Balancing should have been completed before the Water balancing begins. The
Contractor is to ensure that the following works are completed prior to
commencement of water balancing.

a) Open all valves to full open position, including coil stop valves, bypass valves,
and return line balancing cocks.

b) Remove all strainers and clean the same and replace in system.

c) Examine water in system and ensure water has been treated and is cleaned.
This is to be verified by Owner's representative.

d) Check pump rotation

e) Check expansion tanks to determine they are not air bound and the system is
completely full of water.

f) Check all air vents at high points of water systems and determine all are
installed and operated freely. Bleed any air out of systems.

g) Set all temperature controls so all coils are calling for full cooling.

188
 h) Check operation of all automatic valves.

i) Check and set operating temperatures of chillers to design requirements.

7.2 Initial Balancing

a) Set Chilled Water Pumps to proper gallons per minute delivery .

b) Adjust water now of chilled water through chiller.

c) Check leaving water temperatures and return water temperatures through

chiller.
Reset to correct design temperatures.

d) Check water temperature at inlet side of Cooling coils. Note rise or drop of
temperatures from source.

e) Proceed to balance each chilled water coil.

f) Upon completion of flow readings and adjustments at coils, set all

Memory stops and records all data.

7.3 Final Balancing

Upon completion of the above, the final balancing shall be completed as follows:

a) After adjustments to coils are made, recheck settings at the pumps and chillers
and read just if required.

b) Install pressure gauges on coil, read pressure drop through coil at set flow rate
on call for full cooling. Set Pressure drop across bypass valve to match coil full
pressure drop. This prevents unbalanced flow conditions when coils are on full
bypass.

c) Set Chilled Water bypass to pressure differential specified on drawings

d) Record and check the following items at each cooling elements:

Flow Rate
Inlet Water Temperature

189
 Leaving Water Temperature
Pressure drop of each coil
Pressure drop across by pass valve
Pump operating suction and discharge pressures and final total
discharge head.
List of all mechanical specifications of pumps
Rated and actual running amperage and KW of Pump Motor

7.4 Upon completion of final balancing, all information shall be inserted of a sheet listing
all items required by specifications and be included in complete test and balance
report. All sheets shall be neatly typed.

7.5 Submit sample forms to the M & E Engineer for approval prior to starting balancing.

190
 SECTION 04.16
DATA/INFORMATION TO BE FURNISHED WITH THE BID

191
 1. Contractor shall furnish complete information called for in the Data Sheets failing
which the Bid will be considered as incomplete and the Employer reserves the right to
reject the Bid.

2. Contractor should furnish pressure drop calculations. The pressure drop calculations
for the air distribution system to be furnished in support of the AHU's and pump head
calculation in detail for all pumps.

3. Drawings indicating overall dimensions and weights of chilling unit, pumps, cooling
towers, AHU’s supply air fans & exhaust fans and their mounting arrangement.

4. Capacity rating charts for AHU fans, supply fans, exhaust fans, pumps giving air flow,
static pressure, speed and power consumption.

5. Resume of Site Manager and Site Engineers

6. Schedule of Submission of Major Drawings by the CONTRACTOR after the award of

contract.

7. The Contractor shall submit the following key drawings / data showing Engineering
information for Employer’s approval / information as a minimum.

8. Air Conditioning System -

a) Chiller Plant room layout

b) AHU room layout drawings

c) Terrace floor Cooling Tower plant

d) Chilled water piping layout

e) Duct lining & insulation details

f) HRU assembly details

g) All other details required

9. Block interlock diagram for sequential operation and safety interlocks and write up on
control system for complete air-conditioning / mechanical ventilation system.

10. Operation and maintenance manuals for various equipment / system offered

192
11. Performance curve for supply fans, exhaust fans, roof extractors and pumps.

SCHEDULE – 1

This Schedule is to ensure that adequate space allocation is made to accommodate the
equipment selected. CONTRACTOR is required to check the space allowed for them in the
drawings with the space required by the equipment selected. The space should include space
required for the maintenance of the equipment.

The CONTRACTOR is required to confirm their space requirements as follows:-

Sl. Equipment Space Is Space If No, State

No. Allocated Allocated Size Required
Adequate?
(Yes or No?
1 Chiller Refer
Drawings for
2 Pumps details

3 Cooling tower

4 AHUs

5 Riser shafts for piping

6 Riser shafts for ducts

7 Fans located on terrace

8 Electrical Control Panel

9 Others

COMPANY SEAL

SIGNATURE

NAME

DESIGNATION

193
 COMPANY

DATE
SCHEDULE – 2

Schedule of Makes offered by Contractor -

Sl. No. Item Make / Brand

1 Chillers
2 Pumps
3 Cooling Towers
4 Air handling units
5 Air handling unit fans
6 GSS sheets
7 Aluminum Grilles / Diffusers
8 Fire dampers and fire cum smoke dampers
9 Damper actuator
10 Volume control dampers
11 Pipes
12 Non Return Valve
13 Check valves
14 Ball valves
15 Pot / Y strainer
16 Pressure gauge
17 Thermometer with thermo well
18 Manual Balancing Valves
19 Motorized ON/OFF valve
20 Pre-filter
21 Bag –filter
22 Insulation
23 Thermal (external) duct insulation
24 Acoustic (internal) duct insulation
25 Piping insulation

194
26 Pressure Independent Balancing cum Flow
modulating valve for AHU’s.

Sl. No. Item Make / Brand

27 Flow meters
28 Centrifugal fans
29 Roof Top fans

COMPANY SEAL SIGNATURE

NAME

DESIGNATION

COMPANY

DATE

195
 SCHEDULE – 3

This Schedule is for the guaranteed power consumption of the following equipments.

The CONTRACTOR is required to confirm their requirements as follows:-

Sl. No. Equipment Electrical Power

consumption in KW

1 Chillers

2 AHUs

3 Pumps

4 Cooling tower

COMPANY SEAL SIGNATURE

NAME

DESIGNATION

COMPANY

DATE

Note: Penalty shall be imposed for increase in power consumption.

196
SECTION 4.17
VFD

197
1. SCOPE

This specification covers the supply, delivery, installation, connections, testing and
commissioning of Variable Frequency Drives and associated accessories of required type
and capacity as shown in equipment schedule.

2. GENERAL REQUIREMENTS

This section provides general requirements for pulse-width modulated (PWM)

Adjustable Frequency Drives, herein referred to as AC Drives, for use with NEMA design
AC motors, or standard IEC motors.

The AC Drive is a system for controlling the rotational speed of an AC motor and
providing on demand the right torque to the pump & fan application.

The drive must be able to manage asynchronous motor.

Shortening the downtime increases the operational performance of any facility and
reduces the operating expenditures. Maintenance and monitoring tools such as fault
history, parameters upload/download, scope and keypad emulation are built-in in the
drive and used for trouble shooting. Moreover additional user-friendly PC software must
encompass the configuration management and commissioning functionalities without
additional investment.

The VFDs shall be fully compatible with third party Building Automation System. The
BMS shall accept all necessary inputs and outputs including remote start / stop, speed
command input, safety shutdown input, drive trip output, speed indication output, and
energy consumption. The VFDs shall incorporate necessary harmonic filters to limit the
injection of harmonics to 5% . The VFDs shall be built to confirm to all relevant IEC
Standards.

198
3. APPLICABLE STANDARDS

The VSD is qualified to address all the major economic area standards.
The AC Drives shall be:
- CE marked, conforming to European Low Voltage (2006/95/EC modified from
73/23/EEC and 93/68/EEC and EMC (2004/108/EC modified from 89/336/EEC)
Directives, and Machinery directive N0 98/37/EC modified by 98/79/EC.
- UL marked according to UL 508C,
- CSA marked according to CSA 22.2 N14-05.
- GOST marked (Baltic and Russian area)
- C-Tick marked to comply with Australasian Communication Authorities.

Moreover it shall comply with National and International standards and the
recommendations for electrical industrial control devices (IEC, EN, UL, NFC, VDE) listed
below-

Standard Title
IEC 60068- Environmental testing; Part 2-3: Tests - Test Ca: Damp heat,
2-3 steady state
IEC 60068- Part 2-6: Tests - Test Fc: Vibration (sinusoidal)
2-6 Part 2-27: Tests - Test Ea and guidance: Shock
IEC 60068-
2-27
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 61800-3 Adjustable speed Electrical Power Drive Systems; Part 3: EMC
requirements and specific test methods
IEC 61800- Part 5-1: Safety requirements - Electrical, thermal and energy
5-1

199
4 SPECIFIC REQUIREMENTS

4.1 PROTECTION

The following function shall be available to prevent the risks of equipment destruction
from component’s failures.

The AC Drive shall be protected against short circuits, between output phases and to
ground.

The AC Drive shall have under-voltage power-loss ride through performance.

The AC Drive shall integrate a protection against IGBT chips over temperature in
addition to the heat sink overheat protection.

The output frequency shall be software enabled to fold back when the motor is
overloaded.

Upon loss of the analog process follower reference signal, the AC Drive shall be
programmable to display a fault.

Three skip frequency ranges that can be programmed to a bandwidth of 30Hz.

4.2 COMMISSIONING

A keypad display interface shall offer the modification of AC Drive adjustments

through a touch keypad. All electrical values, configuration parameters, I/O
assignments, faults, local control, and adjustment storage, and diagnostics shall be
accessible The built-in graphic keypad display interface must have the Run/Stop
command buttons for quick local running feature.For security reasons the keypad
must not be removable from the drive.

200
 The optional remote display is mandatory and must have the three following press
keys:

- LOC/REM to switch the drive command locally or remotely via a graphic Keypad

- RUN to run the drive

- STOP to stop the drive.

A red led will lit on the front panel to indicate the energizing status of the drive DC bus.

The hereafter parameters Speed reference, Motor current, Drive rated current, Drive
thermal state; Output power must be displayed on the graphic terminal.

The motor should be able to operate after the wiring without any parameter settings.
Thus allows short lead-time for connection checking to speed up the commissioning.

4.3 HARMONICS MANAGEMENT

Increasing the product life expectancy will improve the ROI of any facility. The DC
power link capacitor technology must be compliant to a life expectancy of 14 years as
minimum duration.

To mitigate the over sizing of the transformer and power cables the rectifier bridge
technology must guarantee a VSD THDI (Total Harmonic Current Distortion IEC/EN
61000-3-12 standard) below 35% without additional parts such as fixed or swinging
DC chokes, line inductances,.

While the Drive operates An HVAC regulation sequence in between 30Hz and 50Hz the
THDI must not go over 45%THDI to be energy efficient.

The whole drive must be highly efficient energy and volume wise thus the use of line
filters is not a reasonable solution

201
4.4 CONTROL CONNECTIONS

The control power for the digital inputs and outputs shall be 24Vdc. The input logic
type (positive logic) or sink (negative logic) is configured by a hardware switch.

The internal power supply shall incorporate automatic current fold-back that protects
the internal power supply if incorrectly connected or shorted. The transistor logic
outputs will be current limited and will not be damaged if shorted.

Removable terminal strips shall be used on all logic and analog signal connections in
the power converter

Two voltage-free relay output contacts will be provided. One of the contacts will
indicate AC Drive fault status. The other contact shall indicate a drive run status. These
relays shall be configurable for other status indicators.

4.5 SERIAL COMMUNICATION

The AC drive shall have a dual port communication:

One RJ45 port for Modbus.

One Screw cage plug style for the following protocols: Modbus, METASYS N2, APOGEE
FLN, BACnet

The Lon Works protocol shall be available as an optional plug-in board.

Low time response solution such as Gateway solution cannot be used.

202
5 OPERATION

5.1 RATINGS

The AC Drive is an unique product which is designed to operate at the input line
voltage and power rating range indicated in the table below. This uniqueness provides
a consistent system interface for the whole solution.

Voltage Phases Power rating

200V -15% to 240V +10% three-phase 0.75 kW to 30 kW

380V -15% to 480V +10% three-phase 0.75 kW to 75 kW

The AC Drive shall operate from an input frequency range of 50Hz - 5% to 60Hz + 5%.

The efficiency of the AC Drive at 100% speed, 100% load, and 35% THDI shall not
be less than 97%.

The requested AC Drive over torque capacity is 120% of the nominal torque for one
minute.

5.2 ENVIRONMENTAL RATINGS

Operating ambient -10°C up to 50 °C without derating in side by

Temperature side mounting.
-up to 60 °C with derating
Storage ambient -25°C up to 70 °C
Temperature
Maximum operating 1000 m without derating
altitude 1000…3000m: current derating of 1% per
additional 100 m.
Max. Relative Humidity 5…95 %, without condensation and dripping
(IEC 60068-2-3) water

203
The AC drive must operate with a switching frequency of 12 kHz for Drives below 18,5
kW (8 kHz for Drives above 15 kW) to die down the motor noise at 40°C without
derating.

The AC Drive shall be able to give a 100 % output current continuously in the above
specified conditions. The de-rating factor must not have an impact on the lifetime of
the AC Drive, the unit’s performance, overload capability included, and the reliability
of the AC Drive.

The EMC Plate must be included in the standard drive in order to conform to EMC best
practices.

The top of the standard drive must comply with IP21 or IP41 to prevent from any
objects dropping in the drive and damage it.

The product must have both versions IP21 and IP55.When using IP54 class B EMC
filter must embedded in the enclosure.

Class B EMC (EN55011) filter built-in the IP55 enclosure is a requested option and
Class A EMC (EN55011) filter must be embedded in the standard IP21 and IP55 drive.

An accessory must be proposed to achieve UL type 1 compliancy. The Type 1 products

shall additionally be recognized as plenum rated and comply with the applicable
requirements for installation in a compartment handling conditioned air.

204
6 MAINTENANCE

6.1 BUILT-IN FUNCTIONALITY

Upon power-up, the AC Drive shall automatically test for valid operation of memory,
loss of analog reference input, loss of communication, DC-to-DC power supply, control
power and pre-charge circuit.

An user-friendly PC software workshop is used as a commissioning, configuration set-

up and troubleshooting tool.

6.2 MANUFACTURER

The AC Drive Manufacturer must have a minimum of 40 years experience in world-

class drive design and manufacturing. The installed base product quantity must be
large enough to be credible in its capability to be an edge company continuously
enhancing its product management process.

6.3 LOCAL SUPPORT

The Supplier shall have a permanent representative office with a trained and skilled
support staff, in the country where the goods are delivered. The support team must be
able to attend to site problems on site within 24 to 48 hours with fair notice from
customer.

The most critical spare parts like fuses, IGBTs, cooling fans as well as main control-
and I/O-boards shall be available on site or within 8-12 hours after the positive
identification was made of the spare part that is required to repair the drive.

The more rarely used spare parts should be available in maximum 11 days on site.

205
 6.4 WARRANTY and AFTER-SALES

A factory test report shall be delivered by the AC Drive Manufacturer on request.

A 24-month parts warranty shall be provided on materials and workmanship from the
date of purchase.

Services are provided (spare part and repairing) for 5 years after the end of
commercialization.

7 SUSTAINABLE DEVELOPMENT

The manufacturer of the AC Drive shall be a qualified ISO 14001 facility.

The materials used in the AC Drive shall be recyclable, non-toxic and flame retardant.
The AC Drive shall comply with the European directive RoHS (Restriction Of
Hazardous Substances) 2002/95/EC.

The Product Environmental Profile (PEP) analysis must be performed in conformity

with standard ISO 14040 “Environmental management: life cycle assessment,
principle and framework”.

As any worldwide leading sustainability-driven companies, the supplier must be listed

in the Dow Jones Sustainability World Index, Dow Jones STOXX World Index, ASPI
Euro zone (Advanced Sustainable Performance Index), Ethibel Sustainability Index
(ESI) Excellence Europe, Ethibel Sustainability Index (ESI) Excellence Global.

206
 SECTION 04.18
ACMV RELATED ELECTRICAL WORKS

207
1. SCOPE

The scope of this section comprises of supply, errection, testing and commissioning of
VFD, power distribution covering power cabling, conduits, cable laying from Electrical
Panel to ACMV equipment and end termination. All equipments shall be suitable for 3
Phase /single 415/230 volts, 50 cycles’ power supply system with solidly earthed
Neutral.

2. CONDUITS

Conduits and Accessories shall conform to relevant Indian Standards. Wall

thickness shall be 16 gauge upto 32 mm dia and 14 gauge above 32 mm dia
conduit. Screwed G.I.conduits shall be used. Joints between conduits and
accessories shall be securely made, to ensure earth continuity. All conduit
accessories shall be threaded type only. All raw metal shall be painted with
bitumastic paint.

Only approved make of conduits and accessories shall be used.

Conduits shall be delivered to the site of construction in original bundles and

each length of conduit shall bear the label of the manufacturer.

Maximum permissible number of 650/1100 volt grade PVC insulated wires that may
be drawn into rigid non metallic or MS Conduits are given below :

Size of wires Nominal Maximum number of wires within conduit

Cross size(mm)
section Area (Sq. mm.) 20 25 32 40 50
1.5 5 10 14 -- --
2.5 5 8 12 -- --
4 3 7 10 -- --
6 2 5 8 -- --
10 -- 3 5 6 --
16 -- 2 3 -- 6
25 -- -- 2 4 6
35 -- -- -- 3 5

208
3. CABLES

M.V. Cables shall be PVC insulated aluminium conductor and armoured cables
conforming to IS Codes. Cables shall be armoured and suitable for laying in
trenches, ducts, and on cable trays as required. M.V. Cables shall be termite
resistant. Cable glands shall be double compression glands. Control cables and
indicating panel cables shall be multi core PVC insulated copper conductor and
armoured cables.

4. CABLE LAYING

Cable shall be laid in accordance with IS code of Practice. Cables shall

be laid on 14 gage factory fabricated perforated galvanized sheet steel cable trays,
and cable drops / risers shall be fixed to ladder type cable trays factory fabricated
out of galvanized steel angle. Access to all cables shall be provided to allow
cable withdrawal / replacement in the future. Where more than one cable is
running on a cable tray, one dia spacing shall be provided between cables to
minimise the loss in current carrying capacity. Cables shall be suitably
supported with Galvanized saddles when run on walls / trays. When buried,
they shall be laid in 350 mm wide and 750 mm deep trench and shall be covered
with 250 mm thick layer of soft sifted sand & protected with bricks/tiles. Special
care shall be taken to ensure that the cables are not damaged at bends. The
radius of bend of the cables when installed shall not be less than 12 times the
diameter of cable
.

5. WIRE AND WIRE SIZES

1100 volts grade PVC insulted copper conductor wires in conduit shall be used.

For all single phase/ 3 phase wiring, 1100 volts grade PVC insulated copper conductor
wires shall be used. The equipment inside plant room and AHU room shall be
connected to the control panel by means of insulated copper conductor wires of
adequate size in exposed conduits. Final connections to the equipment shall be
through wiring enclosed in galvanized flexible conduits rigidly clamped at both ends
and at regular intervals. An isolator shall be provided near each motor/equipment
wherever the motor/equipment is separated from the supply panel through a
partition barrier or through ceiling construction. PVC insulated copper conductor
wires shall be used inside the control panel for connecting different components and
all the wires inside the control panel shall be neatly dressed and plastic beads shall be
provided at both the ends for easy identification of control wiring.

209
The minimum size of control wiring shall be 1.5 sq. mm PVC insulated stranded soft
drawn copper conductor wires drawn through conduit to be provided for connecting
equipment and control panels.

Power wiring, cabling shall be of the following sizes:

i. Upto 5 HP motors/ 5 KW heaters 3 x 4 sq. mm copper conductor.

ii. From 6 HP to 10 HP motors 3 x 6 sq. mm copper

6 KW to 7.5 KW heaters conductor.

iii. From 12.5 HP to 15 HP 2 Nos. 3 x 6 sq. mm

motors with star delta starters copper conductor.
iv.From 20 HP to 25 HP motors 2 Nos. 3 x 10 sq. mm
with star delta starters copper conductor
v. From 30 HP to 35 HP 2 nos. 3 x 16 sq. mm
motors with star delta starters copper conductor
armoured cable.

vi. From 40 HP to 50 HP 2 Nos. 3 x 25 sq. mm.

motors with star delta starters aluminium conductor
armoured cable.

vii. From 60 HP to 75 HP motors 2 Nos. 3 x 35 sq. mm

with star delta starters aluminium conductor
armoured cable.

viii 100 HP Motors 1 No. 3 x 150 Sq.mm

with soft starters alumniumconductor
armoured Cable.

ix 150 HP Motors 1 No. 3 x 240 Sq.mm

with soft starters alumniumconductor
armoured Cable.

x 250 HP Motors 2 Nos. 3 x 240 Sq.mm

with soft starters alumniumconductor
armoured Cable.

210
6. CABLE TRAYS

The cable tray shall be fabricated out of 2 mm thick pregalvanized sheet steel using
proper jigs and fixtures.

All accessories such as bends, tees etc., shall also be manufactured at the tray
manufacturer’s works. These shall not be fabricated at site
Perforated cable trays shall be of similar material with 1.6 mm thick G.I cover on top
retained in position by screws.
Cable tray sections shall be joined by fish plates.
The accessories like bends, reducers, etc., of similar material with galvanized
hardware shall be supplied.

7. PUSH BUTTON STATIONS

Push button stations shall be provided for manual starting and stopping of
equipment Green and Red colour push buttons shall be provided for ‘Starting’
and ‘Stopping’ operations. ‘Start’ or ‘Stop’ indicating flaps shall be provided for
push buttons. Push Buttons shall be suitable for panel mounting and accessible
from front without opening door, Lock lever shall be provided for ‘Stop’ push
buttons. The push button contacts shall be suitable for 6 amps current capacity.

8. DRAWINGS

Shop drawings for wiring of equipment showing the route of conduit & cable shall be
submitted by the contractor for approval of Architect/Consultant before starting the
work. On completion, four sets of complete “As-installed” drawings incorporating all
details like, conduits routes, number of wires in conduit, location of panels, switches,
junction/pull boxes and cables route etc. shall be furnished by the Contractor.

9.0 DEMARCATION

ACMV contractor shall refer to electrical specification for details of different items,
schematic drawing prepared by electrical division under electrical works bid and
understand his exact scope of works.ACMV contractor shall discuss with consultant
and building main electrical works contractor, fully understand the demarcation
before submitting the offer. ACMV contractor shall also liason and engage main
electrical contractor of this project to supply and execute ACMV related electrical
works.

211
 SECTION 4.19
SCHEDULE OF MAINTENANCE CONTRACT

212
SERVICING AND MAINTENANCE CONTRACT FOR
AIR-CONDITIONING AND MECHANICAL VENTILATION SYSTEMS
We offer to the Corporation the following maintenance services for the future maintenance of
the whole Air-conditioning and Mechanical Ventilation including Building Management
System (BMS) installation works covered under this tender, commencing after the expiration
of the Defects Liability Period. The price entered shall stay firm till the end of the Defects
Liability Period of this Contract and shall be based on the maintenance responsibilities as
specified for the warranty period. In addition, it shall cover all standard servicing and
maintenance works as recommended by the equipment supplier/manufacturer which is not
specified in this Specification. Also, it shall cover all trips by the Contractor to attend to any
complaint calls in between routine servicing.The Corporation does not bind itself to award
the Maintenance and Servicing Contract after the warranty and maintenance period to the
successful Tenderer.We are prepared to enter into maintenance and servicing contract with
the Corporation in order to provide such maintenance services. After the expiry of the
Maintenance and Warranty Period of the installation, we offer our comprehensive service and
maintenance for a period of three (3) years for the sum per annum as stated below.

System Cost Per Annum (S$)

1st Yr. 2nd Yr. 3rd Yr.

1. Air-Conditioning System

2. Mechanical Ventilation System

3. Other Systems (please specify)

…………………………………………
…………………………………………
…………………………………………

Total INR

________________________________ ____________________
Company’s Stamp and Signature Date

213
 SECTION-04.20
SCHEDULE OF DEVIATION

214
DEVIATION FROM SPECIFICATION

The Tenderer shall list below or on separate sheets all deviations from the specification
requirements.
Failure to comply with this condition and any deliberate attempts to conceal deviations from
these requirements will invalidate the tender.
Tenders complying with basic requirements but with minor details not identical with those
specified will not necessarily be rejected.
Explanation of these deviations shall however be furnished with the tender.

If no details are given the tender will be assumed to comply with the Specification
requirements in all respects.

1.

2.

3.

4.

5.

6.

7.

__________________________ ____________________
Company’s Stamp and Signature Date

215
SECTION 4.21
VRV SYSTEM

216
1. SCOPE

The scope of this section comprises the supply, installation, testing and commissioning
of Variable Refrigerant Volume System conforming to these specifications and in
accordance with the Equipment schedule & design drawings

2. TYPE

Units shall be air cooled, variable refrigerant volume air conditioner consisting of one
outdoor unit and multiple indoor units, each indoor unit having capability to cool
independently for the requirement of the rooms.

It shall be possible to connect multiple indoor units on one refrigerant circuit. The v
indoor units on any circuit can be of different type and also controlled individually. following
type of indoor units shall be connected to the system

 Ceiling mounted cassette type (Round flow )

 Slim Ceiling mounted duct type
 Ceiling mounted built-in type
 Ceiling mounted duct type
 Ceiling suspended type
 Wall mounted type

Compressor installed in outdoor unit shall be equipped with at least one inverter
compressor up to 18HP, two inverter compressors up to 36 HP and above this, three
inverter compressors. The system shall be capable of changing the rotating speed of
inverter compressor by inverter controller in proportion to variations in cooling load.

Outdoor unit shall be suitable for mix match connection of all type of indoor units.

The refrigerant piping between indoor units and outdoor unit shall be extended up to
165m with maximum 50m level difference without any oil traps.

Both indoor units and outdoor unit shall be factory assembled, tested and outdoor
units filled with first charge of refrigerant before delivering at site.

3. OUTDOOR UNIT

The outdoor unit shall be factory assembled, weather proof casing, constructed from
heavy gauge mild steel panels and coated with baked enamel finish. The unit should be
completely factory wired tested with all necessary controls and switch gears:

217
  All outdoor units above 8HP shall have minimum two scroll compressors and be
able to operate even in case one of compressor is out of order.
 In case of outdoor units above 18HP, the outdoor unit shall have at least 2 inverter
compressors so that the operation is not disrupted with failure of any compressor.
 It should also be provided with duty cycling for automatically switching starting
sequence of multiple outdoor units/compressors.
 The noise level shall not be more than 60-65 dB (A) at normal operation measured
horizontally 1m away and 1.5m above ground level.
 The outdoor unit shall be modular in design and should be allowed for side by side
installation
 The unit shall be provided with its own microprocessor control panel.

The outdoor unit should be fitted with low noise, aero spiral design fan with large
airflow and should be designed to operate compressor-linking technology. The
outdoor unit fan should also be capable to deliver 70 Pa or external static pressure to
meet long exhaust duct connection requirement.

The condensing unit shall be designed to operate safely when connected to multiple
fan coil units, which have a combined operating nominal capacity up to 130 % of
indoor units.

4. COMPRESSOR

The compressor shall be highly efficient scroll type operating on R410a environmental
friendly refrigerant and capable of inverter control. It shall change the speed in
accordance to the variation in cooling load requirement:

 The inverter shall be Insulated Gate Bipolar Transistor (IGBT) type for efficient
and quiet operation.
 All outdoor units shall be designed for automatic capacity control to meet load
fluctuation and indoor unit individual control. All parts of compressor shall be
sufficiently lubricated stock. Forced lubrication may also be employed.
 Oil heater shall be provided in the compressor casing.

5. HEAT EXCHANGER

The e-Pass heat exchanger shall be constructed with copper tubes mechanically bonded to
aluminum fins to form a cross fin coil.

 The aluminum fins shall be provided with special coating.

218
  The unit shall be provided with necessary number of direct driven low noise level
propeller type Aero spiral fans with DC motor arranged for vertical discharge.
Each fan shall have a Aero fitting grille resulting in reduced pressure loss.

6. REFRIGERANT CIRCUIT

The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid valves at
condenser end. All necessary safety devices shall be provided to ensure the safely
operation of the system.

The new Sce-bridge Circuit (sub-cool) feature prevents the flash gas from long piping and
reducing the refrigerant volume required and there by reduction in piping size.

7. REFRIGERANT

R410A is a new mixed refrigerant that exhibits superior safety characteristics .Even with
zero coefficient of ozone layer depletion, R410A offers a better performance to than
conventional R22.

Further lead free PC Boards making its use even more environmentally conscious.
Galbarium a material that requires no coating is used for the bottom plate for easy
recycling.

8. REFRIGERANT PIPING

All refrigerant piping for the air conditioning system shall be constructed from soft
seamless up to 19.1mm and hard drawn copper refrigerant pipes for above 19.1mm with
copper fittings and silver-soldered joints. The refrigerant piping arrangements shall be in
accordance with good practice within the air conditioning industry, and are to include
charging connections, suction line insulation and all other items normally forming part of
proper refrigerant circuits.

All joints in copper piping shall be sweat joints using low temperature brazing and or
silver solder. Before joining any copper pipe or fittings, its interiors shall be thoroughly
cleaned by passing a clean cloth via wire or cable through its entire length. The piping
shall be continuously kept clean of dirt etc. while constructing the joints through nitrogen
bleeding at 1.0kg/sqcm and subsequently, it shall be thoroughly blown out using nitrogen.

After the refrigerant piping installation has been completed, the refrigerant piping system
shall be pressure tested using nitrogen at pressure of 30Kg per sq. cm. Pressure shall be

219
maintained in the system for 24 hours. The system shall then be evacuated to minimum
vacuum if 700mm hg.

The air-conditioning system supplier shall be design sizes and erect proper
interconnections of the complete refrigerant circuit.

The thickness of copper piping shall not be less than 20gauge for pipes up to 19.1mm and
18guage for bigger sizes

The suction line pipe size and the liquid line pipe size shall be selected according to the
manufacturers specified outside diameter. All refrigerant pipes shall be properly
supported and anchored to the building structure using steel hangers, anchors, brackets
and supports which shall be fixed to the building structure by means of inserts or
expansion shields of adequate size and number to support the load imposed thereon.
To protect nitrile rubber insulation of exposed copper piping from degrading due ultra
violet rays & atmospheric condition, it shall be covered with M.S Type / G.I. Type
protection tray.

9. SAFETY DEVICES

All necessary safety devices shall be provided to ensure safe operation of the system.

Following safety devices shall be part of outdoor unit; high pressure switch, fuse,
crankcase heater, fusible plug, over load relay, protection for inverter, and short recycling
guard timer.

10. OIL RECOVERY SYSTEM

Unit shall be equipped with an oil recovery system to ensure stable operation with long
refrigeration piping lengths.

11. INDOOR UNIT

This section deals with supply, installation, testing, commissioning of various type of
indoor units confirming to general specification and suitable for the duty selected. The
type, capacity and size of indoor units shall be as specified in Equipment schedule.

Indoor units shall be either ceiling mounted cassette type, or ceiling mounted ductable
type or floor standing type or wall mounted type or other as specified in BOQ. These units
shall have electronic control valve to control refrigerant flow rate respond to lead
variations of the room.

220
 a) The address of the indoor unit shall be set automatically in case of individual and
group control

b) In case of centralized control, it shall be set by liquid crystal remote controller

The fan shall be dual suction, aerodynamically designed turbo, multi blade type, statically
& dynamically balanced to ensure low noise and vibration free operation of the system.
The fan shall be direct driven type, mounted directly on motor shaft having supported
from housing.

The cooling coil shall be made out of seamless copper tubes and have continuous
aluminum fins. The fins shall be spaced by collars forming an integral part. The tubes shall
be staggered in the direction of airflow. The tubes shall be hydraulically/ mechanically
expanded for minimum thermal contact resistance with fins. Each coil shall be factory
tested at 21kg/sqm air pressure under water.

Unit shall have cleanable type filter fixed to an integrally molded plastic frame. The filter
shall be slide away type and neatly inserted.

Each indoor unit shall have computerized PID control for maintaining design room
temperature. Each unit shall be provided with electronic expansion valve & should have
microprocessor thermostat for cooling.

Each unit shall be with wired LCD type remote controller. The remote controller shall
memorize the latest malfunction code for easy maintenance. The controller shall have
self-diagnostic features for easy and quick maintenance and service. The controller
shall be able to change fan speed and angle of swing flat individually as per
requirement.

12. CEILING MOUNTED CASSETTE TYPE UNIT (MULTI FLOW TYPE)

The unit shall be ceiling mounted type. The unit shall include pre-filter, fan section and
DX-coil section. The housing of the unit shall be powder coated.

Galvanized steel. The body shall be light in weight and shall be able to suspend from
four corners.

Unit shall have an external attractive panel for supply and return air. Unit shall have
four way supply air grilles on sides and return air grille in center.

Each unit shall have high lift drain pump, fresh air intake provision (if specified)
Low gas detection system and very low operating sound.

221
 All the indoor units regardless of their difference in capacity should have same
decorative panel size for harmonious aesthetic point of view. It should have provision
of connecting branch ducts.

13. CEILING MOUNTED DUCTABLE TYPE UNIT

Unit shall be suitable for ceiling mounted type. The unit shall include pre filter, fan
section & DX coil section .The housing of unit shall be light weight powder coated
galvanized steel. The unit shall have high static fan for Ductable arrangement.

14. CEILING SUSPENDED TYPE

Unit shall be suitable for ceiling suspended arrangement below false ceiling.
The unit include pre filter, fan section & DX coil section. The housing of unit shall be
light weight powder coated galvanized steel.

15. HIGH WALL MOUNTED UNITS

The units shall be wall-mounted type. The unit includes pre filter, fan section & DX coil
section. The housing of unit shall be light weight powder coated galvanized steel.
Unit shall have an attractive external casing with sophisticated design and compact
casing harmonized in any interior décor.

16. CEILING MOUNTED BUILT-IN TYPE

Unit shall be suitable for Highly flexible for various arrangement with complete line-
up of optional kits to satisfy various needs such as design concept ,interior decoration
and so on. The unit includes pre filter, fan section & DX coil section. The housing of
unit shall be light weight powder coated galvanized steel. Each unit shall have optional
high lift drain pump.

17. CENTRALIZED TYPE REMOTE (TOUCH SCREEN TYPE) CONTROLLER

A multifunctional compact centralized controller shall be provided with the system.

The Graphic Controller must act as an advanced air-conditioning management system

to give complete control of VRV air-conditioning Equipment, It should have ease of use
for the user through its touch screen, icon display and color LCD display.

It shall be able to control up to 64 groups of indoor units with the following

Functions:-

222
 a) Starting/stopping of Air conditioners as a zone or group or individual unit.

b) Temperature settling for each indoor unit or zone.

c) Switching between temperature control modes, switching of fan speed and

direction of airflow, enabling/disabling of individual remote controller
operation.

d) Monitoring of operation status such as operation mode & temperature setting

of individual indoor units, maintenance information, trouble shooting
information.

e) Display of air conditioner operation history.

f) Daily management automation through yearly schedule function with

possibility of various schedules.

The controller shall have wide screen user friendly color LCD display and can be wired
by a non polar 2 wire transmission cable to a distance of 1 km. away from indoor unit.

18. SCHEDULE TIMER

A schedule timer shall be supplied as an optional accessory.

a) The timer shall be able to set operation schedule for all indoor units.
b) The timer shall be able to set 8 pattern of schedule combined with centralized
controller.

19. PIPE INSULATION

a. Refrigerant Pipe Insulation

The whole of the liquid and suction refrigerant lines including all fittings, valves
and strainer bodies, etc. shall be insulated with 19mm /13 mm thick
elastomeric nitrile rubber as specified in BOQ.

b. PVC Drain Pipe Insulation

Drain pipes carrying condensate water shall be insulated with 6 mm thick

elastomeric nitrile rubber insulation.

223
 For proper drainage of condensate, U Trap shall be provided in the drain piping
(wherever required). All pipe supports shall be of pre fabricated & pre painted
slotted angle supports, properly installed with clamps etc.

TECHNICAL DATA SHEET

(DATA TO BE FURNISHED BY TENDERER)

VRV UNIT SPECIFACTION

Make of machine

Model No

Origin of Machine

Nominal Capacity-TR

Overall dimensions (LXWXH) mm

Overall weight – Kg

Number of compressors

Capacity at 40.0 deg.C out door design temp

Noise level at 1m along perimeter dBA

Material & thickness of casing

No of Constant speed compressors

Speed of Compressor

VRV UNIT SPECIFACTION

Make of machine

Model No

Origin of Machine

Nominal Capacity-TR

224
Overall dimensions (LXWXH) mm

Overall weight – Kg

Number of compressors

Capacity at 40.0 deg.C out door design temp

Noise level at 1m along perimeter dBA

Material & thickness of casing

No of Constant speed compressors

Speed of Compressor

No of Variable speed compressors

Range of speed

ikW per TR per compressor

Refrigerant

Type of Compressor

TR, KW, IKW/TR and COP at below

conditions for part load operations
25%
50%
75%
(enclose performance chart)

Starting current of first compressor Amps

Starting current of the last compressor

together with other compressors at full load
– Amps

Full load current (Amps)

Type of starter

225
 SECTION 4.22
LIST OF APPROVED MAKES

226
1.0 LIST OF APPROVED MAKES FOR AIR CONDITIONING & MECHANICAL VENTIALTION

Sl. Description Approved Make

No.
1 VRV Units Daikin, Mitsubishi, Toshiba, LG, Hitachi/Bluestar
2 Cooling Towers Marley, Baltimore, Paharpur, Bell, Advance

3 Pumps Armstrong,Grundfos,Wilo, xylem

AHU /CSU/FCU/ Fresh air / Trane /Carrier/ / Caryaire / Bluestar / ETA-

4 Exhaust Fans Novair/ /HPS/Clivet/ Edgetech, EUROCLIMA

Bryair/DRI / / Flakt Woods / /

5 Heat Recovery Unit Greenheck/Swegon

Kitchen exhaust bifurcated

Centrifugal Fans. Suitable for Kruger / Nicotra / Flakt Woods/Humidin
6 grease and high temp exhaust air. /Comferi /Greenheck

Kruger / Nicotra / Flakt Woods/Humidin

7 Plug Fans /Comferi

Kruger / Flakt Woods/greenheck/system

8 Duct inline Fans air/Humidin

Waterloo / Air master / Caryaire / Ravi Star/

9 Supply / Return Diffusers & Grilles Dynacraft/system sir/cosmos

Honeywell / Siemens / Trane / Sauter/

10 Modulating Motors Johnson Controls

11 Filters Aerosol / Erofil / John Fowler / EMW/ Dyna craft

12 Motors ABB / Siemens/ Kirloskar

13 Galvanized/MS Sheet Steel SAIL / Jindal/ TATA

227
 14 MS Pipes JINDAL / TATA

Sl. No. Description Approved Make

TAHydronics
15 Manual Balancing Valve /Hattesley/Obentrop/Energy/Honeywell/siemens

Audco / Advance/
16 Butterfly Valve Leader/Shakti/Honeywell/KITZ

17 Check Valve Advance/ Leader/ Shakti(Bonami)/Honeywell

Eps insulation Beardcell, Quality thermopack, L’loyd

18 Y-Strainers & Pot Strainers Sant / Adavnce/KITZ

19 Globe Valve Neta / Leader/Honeywell/Siemens

20 Thermal & Acoustic Insulation Thermobreak, Aramflex, K flex, Aeroflex

21 Thermostats and Humidistats Honeywell / Siemens / Trane / Sauter

Pressure Independent Dynamic

22 cum Balancing Valves Honeywell / Danfoss / Flowcon

23 Vibration isolators Dunlop/Cori/Kanwal

24 Measuring Instruments Toshiniwal / Meco

25 Cables Asian/Nicco/Finolex

26 Welding Rods Advani orlikon / Esab

27 Flexible Ducts ATCO / Supaflex / Polyaire/seven star/caryaire

28 Pressure Gauges Waree / H guru/Baumer

29 Thermometers Waree / Artherm / Italy

30 Test Points Anergy

31 Automatic Air Vent Anergy/ITAP/SANT

228
 32 Fire Dampers Ravistar/Air Master/Airflow/Caryaire/systemair
33 Volume Control Damper Ravistar/Air Master/Airflow/Caryaire/systemair

Sl. No. Description Approved Make

34 Motorized Dampers Ravistar/Air Master/Duct Master/systemair

35 Exhaust Fans Kruger/Comferi/Nicotra/Kanalflakt

Saveaire, , Caryaire, Blue Star, Green heck,

36 Smoke Ventilation Fans systemair

37 Flexible Couplings Kanwal/Cori/Dunlop/Resistoflex/Easy flex

38 Air Intake Louvers Ravistar/Air Master/Air Flow/Systemair

39 Variable Frequency Drives ABB/Danfoss/Honeywell

40 Rubber bellows Kanwal/Cori/Dunlop

Pressurised Expansion Tank with

41 vacuum degasser , Armstrong,Flamco, Reflex,spirotech

43 Chilled water Coil UV emitter STERIL-AIRE

Coil secondary pumps Grundfos, Xylem, Armstrong
Water Treatment plant & Chemical
44 Dosing System NALCO / Kimberlite/THERMAX
45 Sidestream filtration system Lakos, Grisworld, Wingert

229