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List of Major Equipments / Materials for District cooling project Mechanical 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15)

Chillers Cooling Towers Primary chilled water pumps Secondary chilled water pumps Non Return valves Strainers Isolating valves Thermal Energy Storage tank Chemical dosing system Side stream filtration system Energy transfer stations Make up water tanks Expansion vessels Air seperators Pipes (GRP and MS pipes) a) Pipe from cooling tower to chiller b) Inter connection Pipe between chillers c) Reticulation pipe Pipe supports 5 Ton / 7 Ton Overhead crane Insulation for chilled water lines

16) 17) 17)

Estimated Man hrs for the district cooling projects A) Chillers (with upstream and downstream) 1) Erection of chillers- 650 hrs 2) Installation of vibration inertia base- 50 hrs 3) Piping between upstream and downstream chillers- Refer to pipes and valves hrs 4)Flexible connectors- 20 hrs B) Cooling Towers 1) Erection of cooling towers- 1500 hrs (Size of cooling tower depends on the approach) 2) Installation of vibration inertia base- 100 hrs 3) Flexible connectors- 20 hrs 4) Installation of cooling tower basin C) Primary / Secondary chilled water & Cooling tower pumps 1) Erection of pumps- 300 hrs 2) Installation of vibration isolators- 30 3) Flexible connectors- 20 hrs 4) Installation of valves such as PRV / BFV and NRV- Refer to pipes and valves hrs 5) Installation of strainers (Basket / Wye)- Refer to pipe and valves hrs D) Thermal Energy Storage Tanks 1) Supply and installation of TES- Subcontractor 2) Co-ordinating the activities of TES- 1500 hrs E) Chemical dosing system 1) Installation of chemical dosing system- 100 hrs 2) Installation of valves and pipings from the main stream to chemical dosing system (Refer to pipe and valves hrs) F) Side stream filtration system / Sweeper system 1) Installation of side stream filtration system- 100 hrs 2)Installation of valves and pipings from the main stream to side stream filtration system G) Energy Transfer Stations ( upto 2500 TR) 1) Installation of ETS- 200 hrs 2) Connection of valves and pipings from the main stream to side stream filtration system H) Make-up water tanks 1) Installation of make-up water tanks- Subcontractor 2) Co-ordinating the activities of tank- 300 hrs

I) Air seperators 1) Installation of air seperators- 100 hrs 2) Connection of all valves and piping from the main stream to air seperators J) Chemical for cleaning, flushing and initial filling of chilled water line- 200 hrs k) Chemical for cleaning, flushing and initial filling of cooling tower water line- 200 hrs L) Air compressors 1) Installation of air compressors- 70 hrs 2) Installation of all valves and pipng to the compressor M) Installation of 5 Ton / 7 Ton crane with support- 300 hrs

Welding material quantities- Steel Type of weld : Butt Pipe size (mm) 6 8 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 550 welding rod Kg 0.04 0.05 0.06 0.09 0.14 0.18 0.2 0.23 0.27 0.29 0.32 0.41 0.54 0.68 0.88 1.1 1.32 1.54 1.76 1.98 2.2 2.42 consumption of Acetelene m
3

consumption of O2 m
3

0.03 0.05 0.06 0.08 0.11 0.14 0.17 0.2 0.23 0.25 0.3 0.34 0.4 0.48 0.69 0.86 1.04 1.21 1.38 1.55 1.73 1.9

0.03 0.05 0.06 0.08 0.14 0.17 0.2 0.24 0.25 0.28 0.31 0.45 0.54 0.62 0.88 1.1 1.32 1.54 1.76 1.98 2.2 2.42

600 700 800 900 1000 1200 1400 1600

2.64 3.08 3.52 3.96 4.4 5.28 6.16 7.04

2.07 2.41 2.75 3.09 3.43 4.11 4.79 5.47

2.64 3.08 3.52 3.96 4.4 5.28 6.16 7.04

Note : All pipe size considered for schedule 40

Welding material quantities- Steel Type of weld : Flange Pipe Size (mm) 6 8 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 550 Welding rod Kg 0.05 0.07 0.08 0.11 0.16 0.2 0.25 0.32 0.41 0.43 0.45 0.56 0.79 0.9 1.26 1.57 1.88 2.2 2.51 2.83 3.14 3.45 Consumption of Acetelene m
3

Consumption of O2 m
3

0.04 0.06 0.07 0.1 0.13 0.14 0.17 0.21 0.28 0.31 0.37 0.48 0.57 0.65 0.94 1.18 1.41 1.65 1.88 2.12 2.36 2.59

0.05 0.07 0.08 0.11 0.16 0.17 0.2 0.25 0.35 0.4 0.45 0.62 0.76 0.82 1.26 1.57 1.88 2.2 2.51 2.83 3.14 3.45

600 700 800 900 1000 1200 1400 1600

3.77 4.41 5.05 5.69 6.33 6.97 7.61 8.25

2.83 3.31 3.79 4.27 4.75 5.71 6.67 7.63

3.77 4.41 5.05 5.69 6.33 6.97 7.61 8.25

Note : All pipe sizes considered for schedule 40

Welding material quantities : Steel Type of weld : Square branch Pipe Size (mm) 6 8 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 550 Welding rod Kg 0.05 0.06 0.08 0.11 0.16 0.2 0.23 0.29 0.34 0.36 0.4 0.51 0.68 0.85 1.1 1.38 1.65 1.93 2.2 2.48 2.75 3.03 Consumption of Acetelene m
3

Consumption of O2 m
3

0.06 0.08 0.09 0.1 0.14 0.18 0.21 0.25 0.29 0.33 0.38 0.43 0.5 0.6 0.86 1.08 1.3 1.51 1.73 1.94 2.16 2.38

0.07 0.08 0.09 0.1 0.18 0.21 0.25 0.3 0.35 0.42 0.5 0.56 0.68 0.78 1.1 1.38 1.65 1.93 2.2 2.45 2.75 3.03

600 700 800 900 1000 1200 1400 1600

3.3 3.84 4.38 4.92 5.46 6.54 7.62 8.7

2.59 3.03 3.47 3.91 4.35 5.23 6.11 6.99

3.3 3.9 4.5 5.1 5.7 6.9 8.1 9.3

Note : All pipe sizes considered for schedule 40

Welds and welded fittings Type of weld : Butt Pipe Size (mm) 8 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 550 600 Man hrs

Type of weld : Bend or Elbow Man hrs

0.22 0.27 0.37 0.43 0.48 0.6 0.71 0.85 1.07 1.28 1.55 1.96 2.24 3.28 4.15 5.1 5.88 7.72 9.35 10.54 12.17 13.8

0.51 0.6 0.85 0.95 1.09 1.26 1.5 1.7 2.21 2.6 3.23 3.91 4.54 6.29 8.28 10.46 11.25 13.6 17 19.89 22.78 25.67

700 800 900 1000 1200 1400 1600

16.4 21.5 27.8 36.8 68.1 99 130

30.8 41 53.6 71.6 135 195 255

Note : 1) All pipe sizes are considered for schedule 40 2) No mitre joints are considered for elbows.

Man hrs for pre-heating of Carbon steel Butt welds and any type of flange welds Pipe size (mm) 50 65 80 100 125 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1200 1400 Man hrs

0.2 0.3 0.5 0.6 0.7 0.8 0.9 1.3 1.9 2.2 3 4.1 5.2 6.4 7.6 9.2 10.3 11.8 13.5 17.6 20.1

1600

22.6

Note : All pipe sizes are considered for schedule 40

1) Chillers Packaged single compressor chillers are available upto 2500 Tons and packaged dual compressors upto 5000 Tons The compressors can be either open or hermetic The three common forms of capacity control for centrifugal compressors are by using inlet guide vanes, variable speed drive and hot-gas by pass (not applicable to the DCP in middle east) VSD on chillers are advantageous in DCP, but life cycle costs must be evaluated Performance of water chillers can be measured on Integrated Part Load Value (IPLV) IPLV or NPLV = 1 (0.01/A) +(0.42/B) + (0.45/C) + (0.12/D) A = Kw/ Ton @ 100% Load B = Kw/ Ton @ 75% Load C = Kw/ Ton @ 50% Load D = Kw/ Ton @ 25% Load Equation between flow and TR gpm = TR X 24 1.8 Xt gpm is the chilled water flow in gallons / minute t is the temperature difference in 0C 1 TR = 12000 BTU/Hr 1 TR = 3.517 KW 1 Kg/Sec = 3.6m /Hr 1 gpm = 6.3 X 10-5 m3/ Sec Cooling load in KW/Ton KW/Ton is the ratio of energy consumption in KW to the rate of heat removal in Tons at the rated conditions Lower the KW/Ton , more efficient is the system Coefficient of performance of chiller (COP) cop is the ratio of cooling capacity in TR to the energy consumed by the chiller in KW (COP= Ton/KW)
3

Installation of 36" and 42" dia pipes Type of welding : Arc welding No. of people for fit-up of 1 joint - 1 Fab + 2 Fitter +2 Helper + 1 Tack welder (for 8 hrs = 8 X 6 = 48 hrs) Welding for 1 joint (Root + Fill + Cap) - 2 Welders + 2 Helpers - (Each 4 hrs = 4 X 4 = 16 hrs) Total man-hrs required for 1 joint preperation & weld - 64 hrs ( 48+16 ) Total man power required Fab - 1 No Fitter - 2 Nos Helpers - 4 Nos Tack welder - 1 No Welders - 2 Nos Consumables Welding rod for root (6010) - 25 nos Welding rod for fill (7018) - 100 nos Welding rod for cap (7018) - 100 nos Total oxygen cylinders used for 1600 mm reticulation line - 60 nos Total acetelene cylinders used for 1600 mm reticulation line - 20 nos (oxy-acetelene cylinders are using for edge preperation)

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