GUIDELINES

FOR
HVAC & CIVIL WORKS.

INDEX
SR.
NO.

DESCRIPTION

PAGE

SECTION I
PARTICULAR TECHNICAL GUIDELINES
SECTION II
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0

TECHNICAL GUIDELINES
GENERAL DESCRIPTION
LIQUID CHILLING MACHINE WATER COOLED
DOUBLE SKIN AIR HANDLING UNITS
VENTILATION FANS
PUMPS
PIPING
PIPE CLEANING AND CHEMICAL WATER TREATMENT
SHEET METAL WORKS
INSULATION
PAINTING
ELECTRICAL WORKS
PREVENTIVE MAINTENANCE CONTRACT
MAKE OF EQUIPMENT AND APPROVED MANUFACTURES
PRECISION AIR CONDITIONING SYSTEM FOR DISASER
RECOVERY CENTRE
MISCELLANEOUS CIVIL WORK FOR PLACING CHILLERS AND
COOLING TOWER FOR DATA CENTER

7-8
8-21
21
21-25
25-34
34-40
41-44
44-50
51-55
56
57-60
60-61
61-63
63-66
66

SECTION I
1.0

PARTICULAR TECHNICAL GUIDELINES:

1.1

FOUNDATION:

1.1.1

All concrete foundations/structural steel frame work required by the agency can be
provided in the HVAC scope. The agency can furnish detailed particulars and drawings
showing exact location and dimensions of required foundations in such time as to obtain
structural approval. All required anchor bolts, nuts, washers, vibrator isolators, etc., can
also be furnished by the agency. Necessary approval from base building structural
consultant can be obtained by the agency.

1.2

EQUIPMENT SUPPORTS:

1.2.1

Provide supports for all apparatus as specifically detailed and as required by manufacturers
of specific equipment.

1.3

EQUIPMENT PROTECTION:

1.3.1

Keep all pipe openings closed by means of plugs or caps to prevent entrance of foreign
matter. Protect all piping duct work, equipment or apparatus.

1.3.2

Protect all bright finished shafts; bearing housings and similar items, units in services no
rust will be permitted.

1.3.3

Equipment and materials stored on the job site can be covered or otherwise suitably
protected at the direction of and to the satisfaction. Motor control centers, etc., can be
completely covered against moisture, dust and foreign materials. In case of damaged
coverings can be replaced until the equipment is connected and operated.

1.4

ADJUSTMENTS AND INSTRUCTIONS:

1.4.1

Make necessary adjustments for each system and piece of apparatus installed, using
factory trained and employed personnel for such systems as temperature controls and
whenever practicable for other equipment and instruct the operator and his staff thoroughly
in proper operation of the apparatus.

1.5

ACCESSIBILITY:

1.5.1

The installation of valves thermometers, clean out fitting and other indication equipment or
specialists requiring frequent reading, adjustments, inspection, repairs and removal or
replacement, can be conveniently and accessibly located with reference to the finished
building. Thermometers and gauges can be installed so as to be easily read from the floor
level.

1.6

ACCESS PANELS:

1.6.1

Furnish access panels, where indicated and where required to provide access to valves
and other appurtenances. Panels can be of type required for the wall or ceiling construction.
Doors can be of appropriate size and design.

1.7

INSERTS & SLEEVES:

1.7.1

Layout work in advance of placing of concrete slabs or construction of walls, furnish and set
inserts and sleeves necessary to complete the work.

1.8.

PIPE SLEEVES:
1.

2.

Wall Sleeves:
a.

Interior wall sleeves can be 22 gauge galvanized steel, flush with wall on both
sides. Sleeves can be large enough in diameter to provide 6mm clearance around
pipe or insulation. All sleeves in Fire wall can be sealed using 3 M fire proof sealant.

b.

Exterior wall sleeves can be PVC, flush with wall on both sides. Sleeves can be
large enough to allow for caulking from outside using 3M weather proof sealant.

Floor Sleeves:
a.

b.
1.8.1

Interior floor sleeves for general areas can be 22 gauges galvanized steel
extending 25mm above finished floor. All pipes passing through sleeves can be
caulked with 3 M Sealant. Insulated pipes can have insulation butted to floor sleeve
and sealed with 3 M insulating cement on both sides. Exception: chilled water or
refrigerant suction piping insulation can be run continuous through the sleeve and
caulked.
Interior floor sleeves for kitchen areas can be galvanized steel pipe extending
25mm above finished floor. Caulked can be the same for general areas.

DUCT SLEEVES;
1.

Wall Sleeves:
Same as interior wall pipe sleeves except minimum 18 gauges and properly blocked to
prevent collapse during construction.

1.9

CLEANING:

1.9.1

Mechanical equipment, piping and duct work can be free of rust and other foreign materials.

1.9.2

Air system can be blown clear.

1.9.3

Electrical contacts and motor starters can be vacuumed clean of dust and debris.

1.10

OPERATION:

1.10.1

Entire mechanical and electrical apparatus can operate at full capacity without
objectionable noise or vibration.

1.11

TRAINING FOR PERSONNEL:

1.11.1

The agency can associate trainings for required personnel during the erection of equipment.

1.12

ALTERNATE PROPOSALS:

1.12.1

The system schematic can be adhered to for developing the detailed system design.

1.13

DESIGN CONFIRMATION:

1.13.1

Agency to confirm that the scheme on which this enquiry for offer is prepared has been
verified by us and that it meets with the requirements of all Government, semi-Government,
Municipal Local and other Authorities, whose permission would become necessary for the
completion of the project.

1.14

SYSTEM DESIGN and EQUIPMENT/MATERIAL GUIDELINES:

The agency can detail design the system based on schematic which is part of this
document and guarantee the required environmental conditions as specified. Agency
should seek all clarifications before submission of technical & commercial offer.
Submission of offers would imply that agency has clearly understood the requirements and
obtained clarifications, if any, in regard to all the queries.
Equipment-set/system and materials in the scope of manufacture, supply and installation
can comply with the appropriate/relevant codes of practice and standard guidelines.
References to standards, codes, guidelines, recommendations can mean the latest edition
of such publications adopted and published as on the date of invitation to submit the offers.
Any deviation whatsoever from the standards can be only after express confirmation by us
in writing before release of purchase order.
Agency can provide, whenever required, samples of material/s. The samples can be
submitted for approval well before the commencement of a particular job.
Agency can provide all items whether specifically mentioned or not but which are usual or
required to make the equipment-set/system operational. The equipment-set/system and
associated materials can be in accordance with the intent or purpose of these guidelines
and can be considered to be in the scope of work of the contract to be furnished without
extra charge, as if fully described and called for in these guidelines.

1.15

BILL OF MATERIAL:
The agency should submit bill of material in detail with quantities. The agency should
indicate the manufacturer name/ brand names and model nos. of various items being
proposed meeting the specs.

1.16

DOCUMENTATION:
Before proceeding with the work, agency can submit the general layout and assembly
drawings and such additional assembly and subassembly detail drawings as may be
necessary to demonstrate fully that all parts of the equipment-set/system to be furnished
will conform to guidelines. Agency can also submit catalogues and selections of the
individual items in the equipment-set/system proposed. Further, the equipment-set/system
and material delivered to the site can conform strictly to the approved make and selection
as given in purchase order.
No modification whatsoever should be made in drawings once it has been approved,
without prior consent in writing. Agency can also arrange to furnish complete set of
drawings for assembly, erection, maintenance, repair and operation of the equipmentset/system. All parts in the drawings can be suitably numbered for identification and
ordering as spares. One set of relevant drawing, general layout/arrangement drawing of A0
size to be laminated and kept at site for reference.
Approval of the drawings cannot relieve agency of obligation to meet all requirements of the
contract and the correctness of the drawings. Agency can be wholly responsible for all
alterations in the work due to discrepancies or omissions in the drawings (or other
particulars) supplied by agency whether such drawings have been approved or not. No
amount can be payable towards such alterations.
After execution of the project, agency can furnish a set of A0 size laminated original of "as
built" drawings along with soft copies.
Agency can furnish and install in the plant room a neatly typed set of operating instructions
securely framed and glazed.

1.17

TESTING:

The equipment-set/system can be tested as per offer guidelines. Routine and type tests for
the various items of equipment-set/system can be performed at the work site and agency
can furnish test certificates for the same. Agency can permit purchasers representative to
be present during any or all the tests. After agency notifying that the installation has been
completed, agency can make under direction and in purchasers presence any such tests
and inspections that are considered necessary to determine whether or not full intent of the
guidelines has been fulfilled.
In case the work does not meet the full intent of the guidelines and further tests are
considered necessary, agency can carry out the same at their own cost.
All calibrated instruments required for tests can be of the required accuracy and can be
furnished by agency at no extra cost. Generally ARI/Euro vent Code can be followed.
Agency can carry out site performance tests takes over the Air conditioning systems.
TENDERER to submit test certificates along with software selection sketch of equipment
proposed.
Test procedure can be as per the Method Statement for On-Site Commissioning &
Testing.
1.18

HANDING OVER DOCUMENTS (HOD):

After successful testing and commissioning of the equipment along with accessories in total
should submit Handing over Documents neatly bound to corporate standards along with
copies in CD.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

The following are to be included in the HOD:

Brief Design Concept
List of supplier
As built Drawings
Approvals/Documents
Escalation Matrix
Test Readings/ Reports. (Full testing and commissioning record)
Installation and commissioning Reports.
Warranties/ Guarantees.
Snag list status.
Operating manuals.
Tools/ Tackles/ Spares.
Emergency operation derails.
Log book/ Service record.
Emergency contact of list with Phone/ Mobile/ Pager/ Fax/ E-mail/ Etc.
***** ***** *******

SECTION II
TECHNICAL GUIDELINES
1.0

GENERAL DESCRIPTION

1.1

SCOPE:
These guidelines together with system schematic cover design, supply, erection, testing
and commissioning of Air Conditioning system for the project.

1.2

Building:

1.2.1

For details of building construction, refer Architectural and Structural drawings.

1.3

Schedule of Requirements:

1.3.1

Air conditioning, requirements as per the schematic drawings.

1.4

Design Data (Leading practices)

The summer, Monsoon and winter design and indoor condition shall be as per Latest ASHRAE
2011 guidelines
For DC Precision AC areas
(supply air temp. 22 C 2 C) and Relative
Humidity (RH) shall be as per Latest 2011 Thermal guidelines of ASHRAE.
For UPS,
For Battery room
For BMS
Communication Room

30C 2C
25C 2C
26C 2C
24C 2C

Height

As per Arch drg

Lighting

16 W/ Sq.mtr (1.5 W/Sq.ft)

Ventilation Air

10 cfm/person

Exposed Glass

Refer base building data

1.5

Performance Guarantee:

1.5.1

The agency can guarantee the HVAC system to maintain conditions as per guidelines and
drawings.

1.5.2

The agency can also guarantee that the performance of the various equipments individually
cannot be less than the specified ratings when working under the operating conditions
given for the respective items in the finally accepted Schedule of Equipment.

1.5.3

The agency can guarantee the power input to the Air conditioning Units at the specified
condition.

1.5.4

The agency can achieve the desired ambient noise level in the occupied space.

1.6

System schematic Drawing:

1.6.1

System schematic drawings have been enclosed for developing detailed design.
7

1.7

Technical Data:

1.7.1

Technical data of equipment can be furnished as required under section Schedule of

Technical Data.

1.8

Test Data:

1.8.1

All equipment can be tested as required by the various articles of the guidelines and Test
Data, as required under Article Test Readings can be furnished.

1.8.2

Test readings can be furnished for peak summer, winter and monsoon outside condition.

1.9

Work At Site:

1.9.1

The agency can inspect the site and ascertain for himself the nature, character and extent
of work to be executed and can include all items and services necessary whether
specifically mentioned or not in the guidelines. Drawings or schedule of equipment to make
a complete working plant to meet with the intent and purpose of these guidelines.

1.10

Electrical Equipment:

1.10.1

All electrical equipment can be suitable for 230V 10%, 1 phase, 50 cycles/415V 10%, 3
phase, 50 cycles, 4 wire AC supply unless otherwise stated.

***** ***** *****

2.0

LIQUID CHILLING MACHINE WATER COOLED

2.1

SCOPE:

2.1.1

The scope of this consists of but is not necessarily limited to the following
a)
c)
d)
e)
f)

Manufacture and supply of screw/scroll liquid chillers with associated motors, soft
starters and accessories.
b)
All associated items herein to be supplied delivered and installed.
Assembly of chillers components including connection of coolers, condensers,
motors, compressors, etc. into complete refrigeration machines.
Provide manufacturers factory representatives services including co-ordination and
start-up and testing supervision.
Testing (factory & field), start-up supervision, training and providing necessary
documentation and tools for operation.
Carry out performance test run.

2.2

QUALITY ASSURANCE:

2.2.1

Each chiller cannot be of capacity higher than 150 TR. The performance can be certified in
accordance with ARI-550-98 / Euro vent standards.
Pressure vessels can be designed, constructed, tested, stamped and complete with
devices in accordance with ANSI/ASHRAE 15 - 1989 Safety Code and ASME Code.

2.2.2

Chillers can be the product of a manufacturer normally supplying this type of equipment
and who can show evidence having completed at least five installations of approximately
the same capacity, that have been in successful operation for the last five years.

2.2.3

The chiller can be factory performance tested under full load conditions in an ARI certified
test facility or equivalent Euro vent certified test facility. The manufacturer can supply a
certified test report to confirm the performance as specified.
The chiller can be designed/manufactured and tested in accordance with the
Applicable portions of the latest revisions of the recognized Standards and Codes.
ARI / Euro vent Standards

2.3

CAPACITY:

2.3.1

Actual refrigeration capacity of each chilling machine cannot exceed 150 TR.
Maximum Power Consumed: Not greater than 0.67 in kW/TR

2.4

GENERAL:

2.4.1

The chiller can be completely factory assembled including all interconnecting refrigerant
piping and internal wiring of controls, mounted on a steel base frame which accommodates
the water cooled condenser, compressors and coolers. Operating test can include
operation with water flowing through the cooler and condenser. The unit structure can be
heavy gauged galvanized steel and can be painted with baked on enamel and shipped with
a full operating charge of refrigerant gas. Each unit can contain 2 or more refrigerant
circuits, each with a single compressor of appropriate capacity. The unit can be designed
and constructed in accordance with the applicable sections of the codes given above.

2.5

COMPRESSORS:

2.5.1

2.5.2

The compressor can be either rotary screw type or scroll type. Compressor can be semihermetic, field re-buildable and utilize horizontal rotors. Vertical rotor compressors are not
acceptable. The chiller should be able to unload to 10% of design tonnage with constant
entering condenser water temperature. The compressors can be driven by electric motor via.
A speed increase gear or direct drive. Manufacturers with speed increasing transmission can
annually inspect the gears and the bearings. The compressor parts and profiles should be
designed specifically for chilled water applications. The compressor can be mounted on
isolators. The compressor can incorporate a complete anti-friction bearing design to reduce
power and increase reliability; four separate cylindrical roller bearings to handle radial loads;
and two 4-point angular contact ball bearings to handle axial loads. The compressor can
have an internal oil reservoir to assure a constant supply of oil to the bearings at all times.
The compressor can have internal muffler. A spring actuated positive seating check valve
can be incorporated in the compressor housing to prevent rotor backspin during shutdown.
Each compressor can be equipped with discharge shut off valve. The compressor housing
can be of cast iron, precision machined towards minimal clearance for rotors. The rotors can
be of high steel alloy. The compressors can also contain a 500 W (115-1-50) temperature
actuated immersion heater to prevent refrigerant condensation during shut down. Power
wiring to control center can be contained and protected within a liquid tight conduit.
All chiller plant should come with multiple compressors. (Min 2 compressors per chiller.)
Capacity Control:
The control system can modulate capacity from 100% to 20% of chiller full load with
constant entering condenser water temperature by use of a slide valve in the rotor section
9

of the compressor. The slide valve is driven by a piston and cylinder actuated by oil
pressure controlled external solenoid valve via. The microprocessor control center. The
capacity control may also be provided by use of pilot operated solenoid valve. The
compressor can start in unloaded condition. The unit can be capable of operating with
lower temperature of cooling tower water during part load operation in accordance with ARI
Std. 550-98/Euro vent Std.
2.5.3

Compressor Motor:
The motor can be hermetic and liquid refrigerant cooled and operated at approx. 2900 rpm
(50 Hz).
The motor stator can have U. L. Class H Insulation. The terminal boxes can be rain tight.
The hermetic motor can be high torque, soft start and equipped with six internal heat
sensing thermistors. The motor can have 3 RTDs in the motor windings, one per phase to
protect high motor temperature at start-up.

2.5.4

Oil Separator and Lubrication:

An external oil separator of horizontal design located at the discharge end of the
compressor with no moving parts can be provided to minimise the carryover before
refrigerant enters the heat exchangers. The oil separator can consist of a perforated
cylinder that surrounds a helical passage. Oil separation can be achieved by means of
centrifugal force through the helical passage way which forces the oil to collect on the
exterior walls of cylinder. Oil separator can be designed for a maximum working pressure
of 450 psig and can be UL and CSL listed. The oil separator can include a sight glass.
The compressor can also have oil reservoirs to lubricate the bearings, during start-up,
coast-down and in case of power failure. This could also be achieved by pre-lube or postlube oil pump operation. During operation, oil can be delivered by positive system pressure
differential or a full time operation of an oil pump.
An immersion oil heater [500 Watt (230-1-50)] can be provided, temperature actuated to
effectively remove refrigerant from the oil. An external replaceable cartridge, 3 micron oil
filter can be provided along with manual isolation stop valves for ease of servicing. An oil
educator can be provided to automatically remove the oil which may have migrated to the
evaporator and return it to the compressor.
Oil cooling can be provided by liquid injection to maintain proper oil and discharge
temperatures for all conditions. A temperature blending solenoid valve controlled via the
Control Center can provide consistent oil temperature at all times to assure proper oil
viscosity independent of system conditions.

2.6
2.6.1

ECONOMIZER:
An economizer can be included in each circuit to enhance the overall system performance.
The refrigerant to refrigerant, plate type economizer can be constructed of acid resistant
stainless steel. The compact and pressure resistant heat exchanger package can be
formed, brazed and the entire material can be utilized for heat transfer. The heat
exchangers can be OSA listed and designed for 450 psig. The temperature limits can be
320 F minimum to 365 F maximum.

2.7

COOLER AND CONDENSER:

2.7.1

The cooler and condenser can be of the shell and tube type designed for 300 psig
working pressure on refrigerant side and be tested at 450 psig. Flooded type design for
cooler can also be acceptable. Shell can be fabricated from rolled carbon steel plate with
fusion welded seams, have carbon steel tube sheets, drilled and reamed to accommodate
the tubes, and intermediate tube supports spaced no more than four feet apart. The shell
10

can be built in accordance with ANSI/ASHRAE-15-1992 Safety code for Mechanical

Refrigeration. The refrigerant side can be designed tested and stamped in accordance
with the ASME Boiler and Pressure Vessel Code Section VIII, Div I. The tubes of the
cooler and the condenser should be individually replaceable.
Water boxes can be flanged and gasketed for easy removal and access to the tubes. The
water boxes can have flanged water connections/ grooved connections for easy field chilled
water and condenser water connections. Cooler and Condenser tubes can be internally
enhanced seamless copper and externally finned to achieve maximum efficiency. The
nominal tube wall thickness can be 0.028 for both cooler and condenser tubes. Cooler
tubes can be 1 dia. Condenser tubes 3/4 dia. Tubes can be mechanically expanded with
tube sheets. Liquid level sight glasses can be located on the side of the shell in
determining proper refrigerant charge. The condenser can have a baffle arrangement to
prevent direct impingement of compressor discharge gas upon the tubes. Also a
refrigerant sub- cooler can be provided for improved cycle efficiency.
The waterside should be hydrostatically tested at 1 1/2 times the design working pressure
but not less than 225 psig. Vent and drain arrangements/connections can be provided on
each water box.
Cooler and condensers can be manufactured as per European directive 97/93/EC as
An option to ANSI Standard. Cooler and condensers can be mechanically pinable
shell and tube type with removable head.
All water connection can have Victaulic couplings. Chiller can be insulated with 19mm
closed cell polyvinyl chloride foam with a maximum K factor of 0.28. Chiller insulation
can have aluminium cladding. Chiller shell can have drain and vent.
2.8

REFRIGERANT CIRCUIT:

2.8.1

The refrigerant circuit can be constructed of copper tubing with brazed joints. Refrigerant
circuit can include oil separators, high and low side pressure relief devices, discharge and
liquid line shut off valves. The refrigerant flow to the cooler can be metered by a single
fixed orifice with no moving parts. The liquid line can include a shut off valve with a
charging port, sight glass with moisture indicator, thermal expansion valves, solenoid valve
and filter drier. Additional valves can be provided to facilitate removal of refrigerant charge.
Factory insulation can be 19mm closed cell polyvinyl chloride foam with a maximum K
factor of 0.28 and cover all low temperature surfaces to include the evaporator and water
flanges, suction elbow, economizer, motor housing and motor cooling lines. Insulation
can have aluminium cladding.

2.8.2

The refrigerant should be for zero ODP.

2.9

POWER PANELS:

2.9.1

The machine should include a unit starter/power panel. The power panel can contain the
following:
Compressor power terminal, compressor motor starting contactors, current transformer
sensing for each compressor phase for protection against under current, over current,
unbalanced current, single phasing compressor stall, phase reversal protection and voltage
spikes and control power supply terminal strip for 115-1-50.

2.9.2

Power will be supplied at a single point.

Necessary enclosures, terminal block,
interconnecting wiring from power panel to compressors to be included by manufacturers.

11

2.9.3

Manufacturers to also provide a factory mounted disconnect switch with internal fusing and
an external lockable handle (in compliance with N.E.C. Article 440-14) to isolate the power,
voltage for servicing.

2.9.4

Each refrigerant system can contain a factory mounted circuit breaker with external handle
(in compliance with N.E.C. Article 440-14) to isolate the system for servicing fusing to be
included by the manufacturer.

2.9.5

Starters:
Motor Starters:
The starter can be factory installed and wired on the chillers. The starter enclosure can be
IP-44 with a hinged access door with lock and key. The following specific requirements for
motor starters must comply with these guidelines.
a) Starter can be of the Wye-delta closed transition type/soft starter. The Wye contactor
capable of handling 33% of the delta locked rotor current and equipped with resistors
properly sized to provide a smooth transition. The resistors can be protected with a
transition resistor protector to prevent damage to the resistors. This device must trip in a
maximum of 2 seconds, locking out the starter, and can be of the manual reset type. The
starter can be equipped with a transition timer adjustable from 0 to 30 seconds. Transfer
time from Wye to delta cannot exceed 90 milliseconds.
b) Starter can be free-standing NEMA-1 enclosure designed for top and bottom cable
entry and can have front access with adequate working clearance for line and load
wiring below 650 amperes and, where possible, sized to be compact. Adequate
separation of high and low voltage sections and proper mechanical and electrical
interlocks will be provided to meet all applicable safety and operating codes.
c) Starter can have a permanent nameplate mounted inside the cabinet showing
manufacturers identifying numbers, order number, voltage, rated load amps and
locked rotor amps, and overload trip settings. Starter can have affixed to the inside of
the door a complete, as built, wiring schematic showing all accessory items provide.
d) Starters can be equipped with solder less line and load side connectors to handle wire
sizes indicated by standard electrical industry practice and the National Electrical Code.
Lug sizes and types are for copper conductors only. Starter line (L1, L2, L3) and load (T1,
T2, T3, T4, T5, T6) terminals must be identified by suitable markers. The starter can also
be equipped with a clearly marked control terminal strip. Wire markers are required at each
end of each wire lead; both control and power, and can correlate with schematic and/or
wiring connection diagrams.
e) The starter can be equipped with redundant motor control relays with coils in
parallel and contacts. The MCR relays interlock the starter with the screw control
centre and directly operate the motor contactors (start and run). They can constitute
the only means of energizing the motor contactors and no other devices - manual and
automatic, factory installed or remote can be wired so as to energize the starter. The
relays can have 115 VAC coils with a maximum combined inrush of 500 VA and a
maximum combined sealed rating of 50 VA.
f) The main contactor that completes the starting sequence can contain two sets of
auxiliary contacts, one normally open and one normally closed with ratings of not less than
125 VA at 115 VAC. An additional set of normally open contacts rated at 125 VA pilor duty
at 115 VAC can be provided on both MCR relays.
g) Overload relays can be microprocessor motor controller. There can be an overload in
each phase set at 107% of the rated load amps of the connected motor. Overloads can be
manual reset and can de-energize the main contactor when over current occurs. Overload
12

can be adjustable and selected for mid-range. Overload can be adjusted for locked rotor
trip time of 8 seconds at full voltage and must trip in 60 seconds or less at reduced voltage.
h) Starter can be equipped with a line to 110 volt/50 Hertz control transformer, fused in
both primary and secondary, to supply power to the screw unit control box and oil pump
motor. The transformer can be rated at 2 KVA minimum in addition to any starter
requirements and can additionally have an inrush rating of 12.5 KVA minimum at 80%
power factor and 95% secondary voltage. The secondary can be furnished with 10%
voltage taps for all international orders. The secondary fusing can be a dual element rated
20 amp, 250V. CP-2 terminal can be grounded at the starter.
I) Starter can include an advance motor protection system incorporating 3 phase overloads
and current transformers. This electronic protection system can monitor and protect against
following conditions:
-

Three current transformers and 3-phase digital ammeter (1% accuracy).

Motor current as a percent of full load amps for each phase.
Phase failure/reversal protection.
Ground fault protection.
Stall protection.
High/low line voltage protection.

j) Space can be left available for possible future relays and contacts to be specified later
for wiring to the supervisory data center.
k) Permanent wiring diagram to be affixed to the inside of the panel load. Drawings to be of
plasticised finish.
l) Provide power transformer in each chiller starter to enable remote KW readings by
building automation system.
2.10

CONTROLS:

2.10.1

The unit can be equipped with a complete microprocessor control system. This system can
consist of temperature and pressure sensors, input/output boards, power supply board,
main processor board with display and keypad. Boards can be individually replaceable for
each of service. All devices and sensors can be factory mounted and wired.

2.10.2

The display can be a minimum of 160-character liquid crystal display (LCD) providing all
messages in plain English. Two or three digit displays are not acceptable. The display can
be light emitting diode (LED) backlit for easy viewing in all light conditions.

2.10.3

The interface device can be equipped with 18 individual touch-sensitive membrane key
switches. These switches can be divided into four separate sections and be multi-level
password protected from changes by unauthorized personnel.

2.10.4

End user interaction with the display section of the interface can provide the following
information on the 160-character LCD. In addition, all of the operation data can be
accessible by pressing one of the Quick Access keys.
1.
2.
3.
4.
5.
6.
7.
8.

Entering chilled water temperature

Leaving chilled water temperature
Entering condenser water temperature
Leaving condenser water temperature
Evaporator temperature
Suction temperature
Suction superheat temperature
Discharge temperature
13

9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.

Discharge superheat temperature

outside air temperature
Motor amps (1 amp resolution) & Motor KW
Oil feed temperature
Oil sump temperature
Oil pressure
Condensing temperature
Liquid line temperature
Liquid sub-cooling
Condenser approach
Evaporator approach
Evaporator pressure
Condensing pressure
Lift pressure
Motor amps at % of RLA
Oil differential pressure
Total hours of operation
Number of starts
Hours since last start
Time of last start
Time of last stop
High discharge temperature
Low evaporator temperature
Soft load
Maximum pull down
Remote amp limit
Manual amp limit
Network amp limit
Manual load
Maximum amp load
Minimum amp load
Leaving evaporator set point
Reset leaving set point
Remote reset signal
Fault history (last 8) with time/date stamp
Critical sensor values at time of faults
Unit status
- Start-up sequence status
- Shutdown status
- Operational status
For Motor KW an external KW meter to be provided.

2.10.5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

The microprocessor can sense any abnormal condition and take the necessary
anticipatory action to either unload or shut down the compressor. As a minimum
the following safeties can be incorporated in the control system and can be
indicated on the display:
Low discharge set point
High discharge set point
Low evaporator pressure - no load
Low evaporator pressure - unload
High discharge T - load
Condenser pressure low
Evaporator pressure low - freeze
Evaporator pump failure
Condenser pump failure
Low evaporator pressure - SD
Low oil delta pressure
14

12.
Low oil feed temperature
13.
High oil feed temperature
14.
Low motor current
15.
Failed stop - high amps
16.
High discharge line temperature
17.
High condenser pressure
18.
Mechanical high pressure switch
19.
High motor temperature
20.
No starter transition
21.
No evaporator water flow
22.
No condenser water flow
23.
Starter fault
24.
Sensor failure
- Liquid line temperature
- Discharge temperature
- Suction temperature
- Entering evaporator temperature
- Entering condenser temperature
- Leaving evaporator temperature
- Leaving condenser temperature
- Evaporator pressure
- Condenser pressure
- Oil feed temperature
- Oil sump temperature
- Oil pressure
2.10.6

Leaving chilled water temperature can be controlled to within 0.2 F of set point. The
microprocessor can employ PI (proportional plus integral) control algorithms to insure
precise control without hunting, droop or overshooting of the set point. End user can input
leaving chiller water temperature set point by interaction with the keypad and display.

2.10.7

The end user can be capable of changing set points by entering the correct
password, touching the desired function key, pressing the increase/decrease key to change
set point, then ENTER or CANCEL.

2.10.8

The microprocessor can limit the amp draw of the compressor to the rated load amps (RLA)
or at a user selected value from 30 to 100% of RLA (1% increments) as protection from
exceeding maximum allowable amp draw. The microprocessor can anticipate any trends
above the set point and automatically unload the compressor until the amp draw is below
the set point. The display can indicate any override amperage condition if the above
occurs.

2.10.9

The microprocessor can be capable of resetting the chilled water temperature either based
on return chilled water temperature or a remote 4-20mA DC signal from an energy
management system. The amount of reset can be programmable by inputting the amount
of reset based on the signal (if remote) or the desired entering chilled water temperature (if
local). The microprocessor can also be capable of being demand limited locally from 30%
to 100% RLA (1% increments) or from a remote 4-20mA DC signal from an energy
management system.

2.10.10

the microprocessor can incorporate a soft load function to prevent the compressor from
operating at full load during the chilled water temperature pull down period. This function
can be accessed by the keypad and can incorporate the following adjustable set points: (a)
percent load at which ramp function begins, and (b) length of time in minutes that the
compressor will be allowed to reach maximum amp limit. Microprocessor can display
current soft load limit value in % of rated load amps during the ramp-up function.

15

2.10.11

the microprocessor can be equipped with a time clock to allow the end user to program a
yearly schedule during the week, weekend, and holidays. This Clock Schedule can allow
for two discrete, 7-day repeatable schedules to be programmed for one automatic
START/STOP per day. A 1-year programmable Holiday Schedule can override the weekly
Clock Schedule and restrict the chiller from operating on the holiday selected. The
operator can have the ability to input an override time period (0 to 50 hours) that will allow
chiller operation during scheduled OFF periods due to Clock or Holiday scheduling.

2.10.12

The control system can have auto-restart after power failure and not require battery
back-up or auxiliary power supply for maintaining program memory. The microprocessor
can have a battery backed-up time clock to insure correct time of day input after power
failure. The time clock function can allow for time changes.

2.10.13

for ease of service and enhanced system reliability, the microprocessor can be capable of
storing the current and previous eight safety shutdowns with a time/date stamp and
recording a sensor data at the time of alarm.

2.10.14

the microprocessor can be capable of starting the unit form a local or remote station. The
station selection can be programmable by simple end user input via the keypad and display.
Multiple machine installation applications can be capable of non-simultaneous starting to
prevent overloads on the distribution systems.

2.10.15

the microprocessor can incorporate two short cycle time functions: (1) Start-to-Start, and (2)
Stop-to-Start function. These can be specially programmed to provide the least amount of
time off line while providing the maximum in compressor motor protection. The Start-toStart function can be set at 40 minutes but can be capable of being programmed from 20 to
60 minutes. The Stop-to-Start function can be set at 5 minutes but can be capable of being
programmed from 3 to 20 minutes. Both conditions must be met prior to machine start.
The auto-restart after power failure function can provide a restart within 2 minutes,
assuming both short cycle time functions have been satisfied.

2.10.16

the microprocessor can incorporate the following automatic START and STOP set points
and each can be individually programmable via the keypad and display:
a) Start-up Differential Temperature: Adjustable temperature above chilled water set point
that will activate the normal start-up sequence. The Start-up Differential value can be
adjustable from 1.0 to 10.0 F.
b) Shutdown Differential Temperature: Adjustable temperature below chilled water set
point that will cycle the unit OFF after satisfying chiller system load. The Shutdown
Differential value can be adjustable from 1.0 to 3.0 F.

2.10.17

For initial unit start-ups (Local request, Remote Start/Stop, or Automatic Time Schedule
Start-up), there can be a Load Delay Timer (adjustable be end user) that will postpone the
initial temperature measurement of the leaving evaporator water for an adjustable time
period in order to sample the true chilled water loop temperature and eliminate
unnecessary nuisance start-ups.

2.10.18

Unit microprocessor can be capable of controlling the chilled water and condenser water
pumps through the use of factory supplied optically isolated output contacts.

2.10.19

the microprocessor can be capable of starting and stopping cooling tower fans through the
use of four optically isolated digital output contacts. The end user can be capable of start
and stop temperature differential set points to provide the optimum energy savings of the
compressor motor and tower fan motors.

2.10.20

the chiller control panel can provide a condenser/chiller water pump output relay that closes
when the chiller is given a signal to start.
16

2.10.21

the microprocessor can be non-volatile requiring no additional battery backup while

maintaining all data even during an extended shutdown or power failure.

2.10.22

as a standard feature, the microprocessor can be capable of communicating to other units

or a personal computer with the use of a twisted pair wire communication interface of RS232 (100 feet) or RS-422/485 (5000 feet). Communication interface can be RS-232 or RS422/485.

2.10.23

the microprocessor can have an auto-logging feature that will automatically log chiller
functions at time of daily peak load or at a preset time and store up to six weeks of
accumulated data.

2.10.24

the unit can have Service Test mode for troubleshooting hardware.

2.10.25

the unit can be factory configured in either English or SI units.

2.10.26

the unit can include keypad programmable alarm contacts. The contacts may be set up as
normally open, normally closed, or as an optional pulse output for pre-alarm conditions.

2.10.27

The unit can include analog inputs for chilled water reset, demand limiting, heat recovery
sensors, evaporator flow gpm, and condenser flow gpm.

2.10.28

the microprocessor can possess pre-alarm logic to high and low pressure controls logic to
take corrective action to avoid an alarm trip.

2.10.29

the unit can display pre-alarm warnings for low and high superheat, low oil temperature,
and high oil temperature.

2.10.30

the microprocessor can display complete warning and alarm diagnostics in plain English.
All warnings, problems and faults can be time/date stamped. In addition, operating
conditions prior to shutdown can be retained in memory.

2.10.31

the microprocessor can incorporate oil cooler valve control.

2.10.32

the unit can be capable of pre-emptive control of low evaporator pressure

Conditions - inhibit loading or unload.

2.10.33

the unit can possess multilevel password protection capabilities to prevent unauthorized
access to set points and to the Service Test mode.

2.10.34

the pull down rate can be adjustable (0.1/min. to 5.0min.) by using only the keypad.

2.10.35

as a standard feature, the lead-lag and load balance functions for dual and two-compressor
units can be contained within the unit controller code. Wiring can consist of a single
shielded twisted pair cable connecting each unit controller.
a) The unit controller can have the capability to automatically dedicate the machine with the
fewest operating hours as Lead. The operator can also have the ability to override the
Auto-Lead feature and manually dedicate either machine as Lead.
b) Lag unit operation can only occur when sufficient system load exists beyond the
capability of the Lead unit. Lag unit operating can be assured by first loading the Lead unit
to its full capacity (user programmable based on % RLA) for a specific time period (user
programmable) before starting the Lag unit. The stopping of the Lag unit can be based
upon both units operating a minimum of two unit condition where one unit is capable of
handling system capacity (user programmable based on % RLA) for a specific time period
before stopping the Lag unit (unit with the highest number of elapsed hours).
17

c) Machine sequencing with a return water thermostat cannot be allowed due to the inability
to change the thermostat set point.
d) The unit controllers can automatically start the Lag unit or maintain operation of running
machine should either unit stop during normal operating due to a safety shutdown.
e) During two-compressor operation, the Load Balance feature can equally divide the
cooling capacity and power consumption between the two units. This can be done by
maintaining equal % RLA on each unit.
f) The unit compressor can have the capability to reset the leaving chilled water demand
limit of both units.
2.10.36

the unit can be provided with an Open Protocol Communications Module providiseamless
integration and comprehensive monitoring, control and data exchange with other building
automation systems.

2.11

WATER CONNECTIONS:

2.11.1

Provide Victaulic water connection with water connection kit for both chiller and condensers.

2.12

FLOW SWITCH:

2.12.1

Provide vapour proof SPDT, NEMA 4X switch (150 psig DWP), -20 F to 250 F with 1
NPT connection for upright mounting in horizontal pipe. This flow switch for condenser &
evaporator or its equivalent must be furnished with each unit.

2.13

VIBRATION ISOLATORS:

2.13.1

Provide vibration isolators level adjusting, spring type, 1 deflection for mounting under unit
base rails. Agency must guarantee vibration isolation and if required provide prong type
isolators.

2.14
2.14.1

2.15
2.15.1

2.16

SEQUENCE CONTROL KIT:

For 2, 3 or 4 units with chilled water circuits connected in series or parallel, consists
of a return water thermostat, lead lag selection switches for sequence starting and time
delay relay with NEMA-1 enclosures, 115-1-50 service.
INSTALLATION:
The chilling machine can be installed over a cement concrete platform and can be
adequately isolated as per manufacturers recommendations against transmission of
vibrations to the building structure.
PAINTING:

2.16.1

Water chilling machine can be finished with durable enamel paint. Shop coats of paint that
have become marred during shipment or erection can be cleaned off with mineral spirits,
wire brushed and spot primed over the affected areas then coated with enamel paint to
match the finish over the adjoining shop painted surface.

2.17

PERFORMANCE TESTING & SUBMITTALS:

2.17.1

Submittals:
a) The manufacturers can submit drawings indicating components, assembly, dimensions,
weights and loading required clearances and location and size of field connections.
18

b) The manufacturer can submit product data indicating rated capacities, weights,
specialties and accessories, electrical requirements and wiring diagram.
c) The manufacturer can also submit their installation instructions.
d) The manufacturer can also submit reading of compressor speed, suction gas
temperature and pressure, condensing gas temperature and pressure and water
velocity through evaporator tubes and condenser tubes.
2.17.2

Testing:
a) The manufacturer can supply a certified test report to confirm performance as specified.
Proper ARI / Euro vent certification documents for the test loop can be made available
upon request from the manufacturer for inspection. The performance test can be
conducted in accordance with ARI standard 550-98 procedures and tolerances.
Following shall be the criterion for type test at factory :b) The performance test can be run with clean tubes in accordance with ARI 550-98 to
include the following:
1. A downward temperature adjustment can be made to the design leaving evaporator
water temperature to adjust from the design fouling to the clean tube condition.
2. An upward temperature adjustment can be made to the design entering condenser
water temperature to adjust from the design fouling to the clean tube condition.
c) The factory test instrumentation can be as per ARI Standard 550, and the calibration of
all instrumentation can be traceable to the National Institute of Standards and Technology
(formerly NBS).
d) A certified test report of all data can be submitted to the owner prior to shipment of
chillers. The factory certified test report can be signed by an office of the manufacturers
company. Pre-printed certification will not be acceptable; certification can be in the original.
e) The equipment will be accepted if the test procedures and results are in
conformance with ARI Standard 550-98. If the equipment fails to perform within allowable
tolerances, the manufacturer will be allowed to make necessary revisions to his equipment
and retest as required.
f) Equivalent Euro vent test is acceptable.

2.18 CHILLER SOUND PERFORMANCES:

2.18.1

The chillers can have a factory installed sound attenuator that will lower the
manufacturers published A weighted sound data at least 3 dBA (operating at maximum
capacity at ARI conditions). Provide compressor acoustic enclosure.

2.19

Remote Shut down Control Switch:

Furnished and turnover to the electrical agency two Push Button operated remote Shut
Down Switches, break glass type, red painted, to shut down all electric power to the
chillers

2.20

Intelligent free-cooling
The proposed units should equipped with free-cooling options. The system should operate
on chilled water mode & also should be capable of producing chilled water using external
air if it permits. When the external air temperature is low enough, the microprocessor
control system activates the free cooling mode: water is circulated by the free-cooling pump
inside special heat exchange coils and cooled by external air forced in by the fans, which,
together with the pump, are the only components which absorb energy. The water is then
conveyed back into the circuit and supplied to the equipment.
19

Units should be equipped with free-cooling devices allow operation even when the external
temperature is able to guarantee only partial rather than complete dissipation of the thermal
load.
2.21

MAINTENANCE SERVICE:

2.21.1

Preventive maintenance procedures must be adhered to including periodic inspections.

2.22 INTERFACES TO BUILDING AUTOMATION SYSTEM:

2.22.1

For the integration of chiller microprocessor panel to the Building Automation System an
Interface Control Document can be developed by BAS Agency. It can be responsibility of
HVAC Agency to provide following to BAS Agency for preparing the interface.
a) Hardware Protocol of Chiller Microprocessor Panel.
b) Software Protocol of Chiller Microprocessor Panel.
c) Communication structure relating to collection of message/event information.
d) Description of the formatted packets/blocks of data which construct controller
commands/response.
e) Complete overview of the system.
f) All information described above to be available at one point.
g) Written permission to BAS agency to develop the interface without any financial
application.

2.22.2

The unit controller can be capable of Open Protocol communications providing seamless
integration and comprehensive monitoring, control and data exchange with other building
automation systems. The Open Protocol Planner & Integrator including all necessary
hardware required to integrate with the BMS should be provided by the Chiller
Manufacturer.

2.23

START-UP AND INSTALLATION:

2.23.1

Manufacturer can furnish a factory trained service technician without additional charge for
installation and start up of units. Start-up of the system can proceed once the consulting
engineer has approved the installation. Manufacturer can provide instruction of the owners
personnel on the operation and maintenance of the unit. Manufacturer can provide
operating instructions and part lists.
A satisfactory operation test can be conducted in the presence of the construction manager.
Power and water required for operation and testing will be furnished without cost to the
works agency. Any damage to the units during shipment and installation can be made
good by supplier at no extra cost.
Manufacturers should provide a spare part list (including compressors) which they intend to
stock in Delhi. In addition manufacturer must indicate exact time required for them to refill
refrigerant and oil in case of leakage.
Manufacturer should support above schedule by providing parts in their stock in Mumbai.
***** ***** *****

20

3.0

DOUBLE SKIN AIR HANDLING UNITS

As supplied by base building.

..
***** ***** *****

4.0

VENTILATION FANS:

4.1

CABINET TYPE EXHAUST FANS

4.1.1

Units can be complete factory-assembled and tested of approved manufacture.

4.1.2

Casing can be of 16 gauge galvanized sheets, ribbed and reinforced with access provided
by hand holes in casing panels. Supply air units can have fan section, and filter section with
independent base frame with levelling screws and joined together with foam rubber gasket.

4.1.3

Fans can be driven by an electric motor as specified in the schedule of equipment. Motor
ratings are only tentative and where a fan requires a higher capacity motor, the agency can
clearly point out the requirement and make his offers accordingly. Motor ratings can be at
least 20% over limit lead plus transmission losses but not less than the specified ratings.

4.1.4

Fans to be given 2 coats of epoxy paint after fabrication and mounted on common base
frame with spring type vibration mounts and having a minimum of 25mm static deflection.
Fans should be statically and dynamically balanced.

4.2

Filters:

4.2.1

Fresh air fans can be provided with non combustible fibrous cleanable filters. The filter
media can be of non woven type synthetic fibres.

4.3

Installation:

4.3.1

The MS frame work required for the fans will be prepared by the air conditioning agency as
per the requirement. The agency can supply foundation bolts, base plate wherever required,
vibration eliminators etc. and he can be also ensure that all the above accessories are
placed securely in proper position. All necessary hardware can by GI. The frame work can
be given 2 coats of epoxy paint.

4.3.2

Spring Vibration eliminators can be provided with an efficiency of not less than 80%.

4.3.3

Fan inlet and outlet connections can be by means of double flexible connections of the nonflammable type.

4.3.4

Fan belt drive can be complete with bolts, belt sheaves and suitable belt guard.

4.3.5

After completion of installation the Vendor can give final paint to the fans. Two coats of
epoxy paint can be given.

21

4.4

Testing:

4.4.1

Inspect fan and remove objects or debris. Inspect and flush coils and remove debris or
obstructions. Verify that all fire dampers are open and control dampers are to their proper
position.

4.4.2

Record the following design requirements for fans and fan motors from the design drawings
and reviewed shop drawings:

4.4.3

a.

Manufacturer, model and size.

b.

Air quantities - cubic feet per minute.

c.

Approximate fan speed - revolutions per minute.

d.

Fan static pressure (total or external) inches of water.

e.

Outlet velocity - feet per minute.

f.

Fan brake horsepower.

g.

Motor horsepower

h.

Volts, hertz, amperes and service factor at design conditions.

Record the following data from fans and fan motors installed at the project
a.
Manufacturer, model and size.
b.

Motor horsepower, service factor and revolutions per minute.

c.

Volts, hertz, full load ampere and service factor.

d.

Motor starter and heater size.

e.

Equipment location.

4.4.4

Completely adjust fans and duct systems by the adjustment of sheaves, dampers, and
other volume and diverting control devices, to obtain the air quantities indicated in the
Contract Documents. Integral dampers in terminal outlets and inlets are not to be used for
adjustment of duct branches. Adjust outside air and return air modulating dampers to admit
the specified quantities of air under all cycles of operation. Adjust final air quantities within
5% of the design requirements. Balance air outlets, with air pattern as shown on the
Drawings.

4.4.5

Record the following test data for fans and fan motors installed at the project at final
balanced conditions:
a.
Fan speed - revolutions per minute.
b.

Fan suction, discharge and total static pressure (external or total) - inches of water.

c.

Static pressure drops across filters, dampers in the fan casings in inches of water.

d.

Motor operating amperes and voltage per phase at operating conditions.

e.

Fan cubic feet per minute as required above.

f.

Calculated brake horsepower.

4.5

Motors:

4.5.1

Operating Conditions:
Ambient Design temperature for motors can be 45 deg C
22

4.5.2

Motors can be of the squirrel cage induction motor type having the following features.
a.

Frequency

50 Hz 3%

b.

Standards

Latest editions of relevant Indian or

International Standards.

c.

Type of enclosure

Totally enclosed for fan cooled (TEFC)

d.

Degrees of Protection

e.

Type of Motor

f.

Direction of Rotation

g.

Treatment of Winding

Can be chemically treated to withstand

atmosphere laden with chemical fumes/dust.

h.

Additional Features

Thermistors can be provided for

motor of rating 55 KW and above.
Thermistor can be one per phase.

i.

Terminal box

a. Six terminals with shorting stripes to be

provided.

IP 55 for all motors with class F insulation

continuous duty
Three phase squirrel cage induction motor
with single bare shaft extension with keyway and key.
Shaft to be drilled and tapped with standard diameter hole.
Suitable for bi-directional rotation, or as
specified in equipment guideline.
the

b. To be preferably located on right hand

side when facing the driving end or on top.
c. To be rotatable in four insulated armoured
cables.
k.

Earthing

Two external and one internal earthing

terminal.

l.

Starting duty

Motor up to 5.5kw suitable for DOL starting

& above 5.5 kw for star delta starting / Auto
Transformer starting.

m.

Name plate

n.

Painting

Synthetic Enamel manufacturers standard

paint.

o.

Inspection/testing

Will be inspected. Tests to be witnessed by

Clients representatives at vendors works.

p.

Statutory approval

q.

No. of starts/hour

r.

Residual Voltage

Starting Suitable for restarting against a residual

voltage of 40% in opposition to the supply
voltage.

Standard. It can indicate equipment number

besides technical data of Motors.

Motors can be acceptable to local statutory

authorities.

23

s.

Bearing

t.

Cables Entries

Grease Lubricating ball or roller bearing.

Vertical motors can have thrust bearings
designed to carry the maximum axial thrust.
For LT motors, refer schedule

Any provision required for cable entry to the motor can be provided i.e. separate junction
box, if required.
4.6

PROPELLER TYPE WALL EXHAUST FANS:

4.6.1

Propeller type fans can be G.E.C or Crompton. Fan can be of blade type, ring or diaphragm
mounted and of the capacity shown in the schedule of equipment. Fans can be provided
with gravity type louvers unless otherwise stated.

4.6.2

Fan drive can be single phase or three phase motors as indicated in the schedule of
equipment and can be complete with starter unless otherwise stated. All motors can be of
class F insulation.

4.6.3

Fan can be provided with speed regulators. Provide rain protection louver and bird screen
for each fan.

4.7

Installation:

4.7.1

The wooden frame required for the fans will be prepared by the owner to the drawings
supplied by the agency. All necessary hardware can by GI. Base frame can be give 2 coats
of epoxy paint.

4.7.2

After completion of installation the Vendor can give final paint to the fans. Two coats of
epoxy paint can be given.
INLINE FANS:

4.8
4.8.1

Inline fan can incorporate SISW direct driven centrifugal fan with TEFC (IP-44) motor. The
fan assembly can be encased in sheet metal housing of 22G GSS and with necessary
inspection cover with proper gasket assembly. The fan material can be of galvanized sheet.
Flanges can be provided on both side of the inline fan to facilitate easy connection. Flexible
anti-vibration joints can be provided to arrest vibration being transformed to other
equipment connected to inline fan. Motor can be single phase/3 phase can be mentioned in
technical guideline attached in tender.

4.8.2

All single phase can be provided with speed regulator while all three phase fans can be
provided with opposed blade dampers in GSS construction at fan outlet for air balancing.
***** ***** *****

5.0

PUMPS:

5.1

Scope:

5.1.1

The scope of work under this article comprises the supply, installation (including civil work),
testing, commissioning and erection of pumps of the type and capacities specified in the
schedule of equipment. Pumps can be suitable for the purpose they are intended. Pumps
can be imported. If necessary the agency can provide temporary pumps to meet the
completion schedule.

5.2

Description:
24

5.2.1

Provide pumps in accordance with the Contract Documents.

5.3

Work Included:

5.3.1

End Suction Horizontal Back pull out type Base Mounted Pumps.

5.4

Submittals:

5.4.1

Submit manufacturers latest data.

5.4.2

Shop drawing submittals to indicate certified pump curves BPSH, pump performance
characteristics with pump and system operating point plotted.

5.5

Quality Assurance:

5.5.1

Select pumps to operate at or near their point of peak efficiency, allowing for operation at
capacities of approximately 25% beyond design capacity.
In addition, select the design impeller diameter so that the design capacity of each pump
(GPM and TDH) does not exceed 85% of the capacity obtainable with maximum impeller
diameter at the design speed for that model.

5.5.2

In order to ensures table operation and to prevent any possibility of hunting, the pump
curve must be continuously rising from maximum capacity up to the shutoff point.

5.5.3

Make the entire pump assembly including, but not limited to, the casing or enclosure,
suction and discharge flanges, and seals, suitable for operation with the Pump Working
Pressure and temperatures indicated on the drawings. For the purpose of this guideline,
the pump working pressure is defined as the sum of the scheduled maximum suction
pressure and the maximum dynamic head at shutoff developed by the pump for pumping
duty specified. Test each entire pump assembly hydraulically at the factory at least 50 psig
pressure above the pump working pressure.

5.5.4

Perform a complete factory electric operating and sequence test, capacity performance test,
and hydrostatic test for each factory assembled pumping system prior to shipment. Include
a system operating flow test from zero to 100% of design flow for the pumping unit with
guideline suction and net discharge pressure conditions specified on the drawings. Verity
the accuracy of the system flow with an independent calibrated test flow meter. The factory
operating and performance test may be witnessed by the Engineer and Owner. Notify the
Owner in writing at least 3 weeks prior to the factory performance test. Before the pumping
assembly is shipped from the factory, transmit certified factory performance test data for
factory testing including flow, head, and horsepower at all flow rates on a plot of the system
flow test. Certify that the pumps have been satisfactorily tested as specified herein before
and are in compliance with the requirements of the Contract Documents. Do not install the
pumping system before the test data has been reviewed by the Engineer.

5.5.5

Provide flanged connections on suction and discharge drilled to ANSI standards.

5.5.6

Comply with local codes.

5.6

Construction:

5.6.1

Pumps can be as per IS 1520-1960 and can be of the following construction.

5.6.2

Pump casing to be cast iron with smooth water passages and fitted with a bronze
replaceable bearing ring.
25

5.6.3

The impeller supplied for the specified conditions is to be one piece bronze. Diameter not to
exceed 85% of the casing cut water diameter. Impeller should be statically and
dynamically balanced.

5.6.4

Pump shaft to be stainless steel of a size and design to limit shaft deflection at shaft seal
box to not more than 0.002 inches.

5.6.5

Seal the pump liquid cavity with a face type mechanical seal with NI-Resist stationary seat,
carbon washer, ethylene propylene flexible members, brass metal parts and 18-8 stainless
steel spring. Seal to be mounted over a bronze shaft sleeve.

5.6.6

Couple the pump flexibly to a TEFC IP55 electric motor. Motor and pump bearing to be
grease lubricated and sized for a minimum of 100,000 hours average bearing life. Motor
and pump to be aligned and mounted on a steel base. Provide a coupling guard.

5.6.7

Mount pump and motor on a common fabricated structural steel base furnished by the
pump manufacturer. Provide in the base provisions for grouting and anchor bolts. Machine
surfaces for the motor and pump mounting. Motor mounting to permit horizontal adjustment.
Provide the base of sufficient strength to prevent vibration, wrapping or misalignment of the
pump and motor when installed without grouting.
N.B. Ensure that the pump is vibration isolated from the structure and that no resonance
occurs with structural elements.

5.6.8

General guidelines:
Pumps

End suction back pull out

Casing

Cast Iron/Cast Steel

Impeller

Bronze conforming to BS
1400

Shaft

Stainless Steel

Shaft Sleeve

Bronze

Seal

Mechanical Seal

Bearing

Ball / Roller

5.6.9

Driver ratings shown are only tentative and Tenderers can select their drivers at least 15%
in excess of the maximum B.H.P. of the pump plus transmission losses, if any. (But not less
than specified ratings)

5.6.10

Pump and driver can be mounted on a single bed plate and directly driven through flexible
coupling.

5.7

Accessories and fittings:

5.7.1

The following accessories can be provided with each pump among other standard
accessories required.
a.

Coupling guard

b.

Lubrication fittings and seal piping.

c.

Test or air vent cocks

26

d.

Mechanical sealing

The following fittings can be provided with each pump along among other standard fittings
required:
a.

25mm GI gland drain.

5.8

Installation:

5.8.1

Pumps can be installed as per manufacturer recommendations. Pumps set to be mounted

on concrete inertia block which in turn is mounted on vibration isolation springs. The
concrete foundation will be made by the owner to the agencys requirement. The inertia
block, spring isolators and foundation bolts, isolation pad etc. can be supplied by the
agency. The agency can, ensure that the foundation bolts are correctly embedded.

5.8.2

Pump sets can preferably be factory aligned. Whenever necessary site alignment can be
done by competent persons. Before the foundation bolts are grouted and the couplings
bolted, the bed plate levels and alignment results can be submitted to the engineer.

5.9

Motors:

5.9.1

Operating Conditions:
Ambient Design temperature for motors can be 40 deg C

5.9.2

Motors can be of the squirrel cage induction motor type having the following features.
a.

Frequency

50 Hz 3%

b.

Standards

Latest editions of relevant Indian or

International Standards.

c.

Type of enclosure

Totally enclosed for fan cooled (TEFC)

d.

Degrees of Protection

IP 55 for all motors with class F insulation

continuous duty

e.

Type of Motor

Three phase squirrel cage induction motor

with single bare shaft extension with keyway
and key. Shaft to be drilled and tapped with
standard diameter hole.

f.

Winding connection

g.

Direction of Rotation

h.

Treatment of Winding

i.

Additional Features

Delta Connected Motor above 2.2 KW

Star connected box of cast iron 2.2 KW
Suitable for bi-directional rotation, or as
specified in equipment guideline.
Can be chemically treated to withstand the
atmosphere laden with chemical fumes/dust.
a. Thermistors can be provided for
motor of rating 55 KW and above.
Thermistor can be one per phase.

27

j.

Terminal box

a. Six terminals with shorting stripes to be

provided.
b. To be preferably located on right hand
side when facing the driving end or on top.
c. To be rotatable in four insulated armoured
cables.

k.

Earthing

Two external and one internal earthing

terminal.

l.

Starting duty

Motor up to 5.5kw suitable for DOL starting

& above 5.5 kw for star delta starting / Auto
Transformer starting.

m.

Name plate

n.

Painting

o.

Inspection/testing

p.

Statutory approval

Motors can be acceptable to local statutory

authorities.

q.

No. of starts/hour

Unless otherwise specified 3 equally voltage

of 40% in 2 cold starts and one hot restart.

r.

Residual Voltage Starting

s.

Bearing

Grease Lubricating ball or roller bearing.

Vertical motors can have thrust bearings
designed to carry the maximum axial thrust.

t.

Cables Entries

For LT motors, refer schedule

Standard. It can indicate equipment number

besides technical data of Motors.
Synthetic Enamel manufacturers standard
paint.
Will be inspected. Tests to be witnessed by
Clients representatives at vendors works.

Suitable for restarting against a residual

voltage of 40% in opposition to the supply
voltage.

Any provision required for cable entry to the motor can be provided i.e. separate junction
box, if required.
5.10

Testing:

5.10.1

Tenderer can submit the performance curves of the pumps supplied by them. They can
also check the capacity and total head requirements of each pump to match his own piping
and equipment layout.

5.10.2

On completion of the entire installation, pumps can be tested for their discharge head, flow
and BHP test results can correspond to the performance curves.

5.10.3

Tenderers can furnish the required testing instrument and arrange for their connection
required without any additional cost.

5.11

Painting:

28

5.11.1

After complete installation and testing, pumps, accessories and fittings can be given two
coats, three mills each of approved finishing paint.

5.12

Mode of Measurement:

5.12.1

The pump together with drive motor, (starter wherever mentioned) coupling, coupling guard,
base plate, vibration mounts, will be one unit for measurement.

5.13

Execution:

5.13.1

Rigidly bolt the pump base to the vibration isolation base and fill with concrete or grout after
installation on the isolation base. After final alignment, dowel all pumps and motors 25
horsepower and over to the base.

5.13.2

The pump manufacture to be responsible for aligning in the field prior to start-up of flexibly
coupled pumps. Alignment to be with dial indicator with accuracy of plus or minus 0.002
inch. The pump manufacturer must submit a written report certifying that the alignment
work has been performed by his personnel and that the pumps are ready for operation.

5.13.3

Pumps to be levelled up on tapered steel wedges in such manner to permit a minimum of

inch of grout between the pump base and the top of the concrete base.

5.13.4

Pump motors are to be covered during construction period if the motor has to be run the
Mechanical Agency will be responsible to make sure that the area in which the motor is
running is clean.

5.13.5

Mechanical Agency to provide lifting eye ring above each vertical inline pump to facilitate
removal of motor for repair.

5.13.6

Paint the entire assembly of each pump with two coats of enamel after shop testing.

5.13.7

All operating controls and safety devices must be demonstrated after each system has
been installed and put into operation at the project site.

5.13.8

Provide drains for bases and stuffing boxes piped to discharge into floor drains.

5.13.9

Provide air cock and drain connection on horizontal pump casings.

5.14

Deleted

5.14.1

Dedicated Pump Logic Controller

5.14.1

Number of Pumps
DPLC can be able to control pumps as required. However, DPLC can have provision for
future expansion (modular type) to control upto 8 pumps.

5.14.2

Analog Input Processing

DPLC can continuously scan the incoming signal from DPT all the time and keep on
processing the output. Output can be the most deviated one compared to the set point,
which will be fed by the user, in DPLC.

5.14.3

Two Additional Analog Inputs

DPLC can have provision for two additional analog inputs for:
a. Taking input signal from Flow sensor. This can help the system to protect the pumps
against End Of Curve condition.

29

b. Taking the input from any external sensor (e.g. return temperature sensor, supply
temperature sensor, etc). This input can be used to influence the system externally.
5.14.5

Set Point
DPLC can be set for separate set points as per real time clock. If a lower differential
pressure is acceptable during certain periods, for instance after normal working hours or
weekends, the set point can be lowered to minimize power consumption.
An external input may also be used to switch between set points, or manually adjust a set
point at any time.

5.14.6

Automatic cascade control of pump

DPLC can start other pumps, which are available for operation, whenever system is not
able to meet the demand for chilled water. Once demand is met then all the pumps will cut
out with changeover, except for one pump. At least one pump will run at minimum 25%
speed if DP value is satisfied.

5.14.7

Automatic Sequence Change

DPLC can have automatic changeover facility based on:
a. Fault When any pump/motor/starter fails.
b. Operation While running/cascading.
c. Time As per the time set in the DPLC (daily or weekly).
To ensure equal number of hours run by each pump and to control the number of starts (to
avoid hunting) on each pump, the system will alternate the sequence of the pumps used
each time the system starts.
Additionally, should the demand not allow the pump set to completely shut down over a 24
hr. Period, the DPLC can stop the pumps that are running and start the remaining pumps at
a predetermined time of the day.

5.14.8

Auto Testing
DPLC can start the pumps, which have not been cut-in because of lower load, for 2
seconds each day, to ensure that all the rotating elements do not bind.

5.14.9

Displays
Through the monitor keypad, all variable parameters are adjustable, current status of
settings and measured values to be displayed on the minimum 2 line x 24 character liquid
crystal display.
Individual menus are available for monitoring individual pumps, zones, settings, alarms and
ON/OFF functions.
PUMP STATUS
* Running Hours of each pump
* Actual pump status, (running, not available, standby, allocated to zone,
fault)
ZONE STATUS
This menu is the main operating menu where all the setting and operating parameters can
be viewed e.g.
* Current operating set point
* Measured values in the system
30

* Operating capacity in terms of total output

* Mode of operation for the zone
* Clock programs (relating to set point differential pressure value)
* Standby pumps (if any)
* Pump change over time
* Friction loss compensation
* Pump priority
* System response times
SETTING MENU
In this menu all parameters for the operation of the pump set can be
adjusted as required
* Set points (up to 10)
* On/Off function (used to prevent unnecessary cycling at low demands)
* Displayed differential pressure units (Meter, Bar, PSI, mBar, kPa)
* Real time clock programming for any time of the day, week, or weekend)
* Zone configuration / Friction loss compensation
5.14.10

Pump Priority
It is possible to give the required running sequence to the pumps e.g.
1 2 3 etcIn this case pump marked as no 1 will always start first. However, in case of
equal piority (1 1 1) all pumps will become pump no 1, whenever pumps are cascading.

5.14.11

ALARM
The alarm menu to display all faults that occur during operation, logging the time and date
of when the fault occurred and when it was corrected, or whether it is still an actual fault,
and up to 10 faults to be maintained as history in the controller.
Examples of faults
* Mains failure
* Analogue input (differential pressure transducer) fault
* High discharge pressure fault
* Low discharge pressure fault
* Motor thermal overload fault

5.14.12

Communication features:
- Communication protocol MODBUS will be provided to
display the system values in BMS such as an option:
a. DP value(s).
b. Current drawn by each pump.
c. Power consumed by each pump.
BMS agency will bring his RS 485 (MODBUS) link directly to this DPLC communication
port.

5.15

Deleted

5.16

TRANSMITTERS:
Differential pressure transmitters can be field mounted and can transmit an isolated 420mA DC signal indicative of process variable to the pump logic controller via standard two
wire 24 DC system. Unit can have stainless steel wetted parts with two 0,25male NPT
process connections. It can be protected against radio frequency interference and can have
watertight, NEMA 4 electrical enclosure capable of withstanding 14 bar static pressure with
a 0.5NPT conduit connection. Accuracy can be within 0.25% of full span.

31

5.17

CONTROL ENCLOSURE
IP-55 powder coated steel double enclosure for outdoor installations can house all the
electrical components.
The enclosure will be supplied loose for remote mounting. It will be adequately ventilated
for use in conditions up to a maximum ambient temperature of Mumbai but not less than
45deg C.

***** ***** ******

ROW COOLING SYSTEM CHILLED WATER BASED.

Units shall be 42 U, with minimum width & include casters and levelling feet to allow ease of installation in
the row and provide a means to level the equipment with adjacent IT racks. The Fans shall be configured
for draw-through air pattern to provide uniform air flow over the entire face of the coil. Each unit shall have
hot swappable fans with at least one fan in redundant mode. Fans shall be variable speed capable of
modulating from 30-100%. Fans shall soft start to minimize in-rush current when starting. Row cooling can
be the product of a manufacturer normally supplying this type of equipment and who can show evidence
having completed at least five installations of approximately the same capacity, that have been in
successful operation for the last five years.
Input Power Feeds should be Dual. Each unit should be supplied with display to allow monitoring and
configuration of the air conditioning unit through a menu-based control. Functions include status reporting,
set-up, and temperature set points. The microprocessor based controller shall activate a visible and audible
alarm in the occurrence of all possible events through the unit display.
A leak detection sensing cable shall be shipped along with the unit. If water or other conductive liquids
contact the cable anywhere along its length, the main controller visually and audibly annunciates the leak.
The unit shall include a network management card to provide management through a computer network
through TCP/IP. Management through the network should include the ability to change set points as well as
view and clear alarms.
Chilled water system shall utilize a three-way valve to regulate the amount of chilled water to the cooling
coil to maintain desired conditions. Valve shall be piped internally with unions to allow for easy replacement
in the field. The standard valve pressure rating shall be 600 psig.
Valve Actuator: Actuator shall be direct connect rotary floating point style actuator and should be capable of
being replaced without disconnecting piping from the valve.
Factory Installed and wired condensate pump shall be provided along with the units.
Standard Air filter: <20% efficient per ASHRAE 52.1, MERV 1 per ASHRAE 52.2, 1/2 washable mesh filter.
Flow meter shall be factory piped inside the unit and connected to microprocessor controls to provide water
flow rate through the unit. The microprocessor controller shall also use this information to provide total unit
capacity out of the unit while in operation.
The unit shall be piped in accordance with the highest commercial quality procedures. All pipes forming
shall be tool bent with the proper bend radii to prevent flattening in the curve. The chilled water piping shall

32

be insulated with closed neoprene thermal insulation. All piping connections should be made at the rear of
the unit for top or bottom accessibility.
All the cooling units shall connect each other to work as a group. Capacity modulation shall be done by all
the units together based on the number of live units available in the group.
6.0

PIPING:

6.1

Scope:

6.1.1

The scope of work comprises the supply and laying of all pipes required for this Project.
The engineers drawings show the general layout of the piping and they are not meant as
working drawings.

6.2

Chilled Water and Drain Piping:

Drain piping can be same thickness as chilled water piping. Drain piping can be GI.

6.2.1

All piping can be black steel unless otherwise stated. Pipes/fittings can be externally
cleaned with wire brush and given two primary coat of red primer before being installed.
Piping/fittings can be painted with a suitable anti corrosive paint before insulation. Pipes
can be sloping towards drain points. Drain piping & fittings can be GI.

6.2.2

Fittings can be new and from standard manufacturers. Fitting can be malleable casting of
pressure ratings suitable for the piping system. Fittings used on welded piping can be of
the welded type. Flanges can be new and from standard manufacturers. Supply of flanges
can include bolts, washers etc. as required. Metered or fabricated fittings cannot be
permitted. All piping 50mm and below can have socket welt fittings.

6.2.4

Tee off connections can be through equal or reducing tees, as required. Ferrules welded to
the main pipe can be used for tee connections which are 2 sizes smaller than the main pipe.
Drilling and tapping of the walls of the main pipe cannot be accepted. Standard tees can be
used in case the tapping is the same as pipe size or one size smaller.

6.2.5

All equipment and valve connections, or connections to any other mating pipe can be
through flanges. Flanges can be screwed upto 50mm size and welded above 50mm.

6.2.6

All piping is subject to the approval of project engineer and sufficient number of flanges
and unions can be provided as required.

6.3

Butterfly & Ball Valves:

6.3.1

Butterfly valves can have stainless steel shaft and gray iron body. Body style can be lug
type flanged. Disc material can be nylon/ epoxy coating coated SG iron with black nitrile
seat providing bubble tight shut off. All valves 150mm and above can be provided with gear
operators. Valves can conform to BS 5155/ IS 1536. Valves can be suitable for 15 Kg/cm2
operating pressure.

6.3.2

Valves 50mm and below can be Ball valves.

6.4

Balancing Valve:

6.4.1

Balancing valves up 50mm size can be made of copper alloy with Brinell hardness of at
least 130 and a pressure rating of 20 Bar.

6.4.2

Valves 65mm and larger can be of CI flanged (CI as per BS 1452). Valve can be fitted with
a pressure balanced cone to allow the valve to be closed and opened easily.
33

Adjustment and setting can be made with a digital Hand wheels.

6.4.3

Flow measurement and balancing can be with an accuracy of 4% to 7% in the normal

operating range. Pressure measuring nipples can be provided for measuring differential
pressure and can be integral with the body. Nipples can have leak tight shutoff when not in
use.

6.4.4

All valves can be double regulation type with indicator scale from 0 (full shut) to full open
with integer setting position.
Valves can be suitable for 15 Kg/cm operating pressure.
All valves can be manufactured as per ISO 9001.

6.4.5

One computerized balancing instrument with ISO certificate can be supplied by the agency
to the owner which can be handed over after testing and commissioning. In addition to
measuring flow rate, DP and temperature the instrument can have capability to store the
results of balancing and to log the measured values. The saved data can be printed out as
part of the agencies commissioning documents.

6.5

Check Valves:

6.5.1

Check valves can be provided conforming to the following guidelines:

Size

Construction

Ends

12mm to 50mm

Gun Metal

i. Screwed Female

65mm & over

Seat & Disc Gun Metal

Body C.I.

ii. Flanged.

Swing check valves can normally be used in all water services. Lift type valves may be
used in horizontal runs. All release and clean out plugs can be provided and valves can be
suitable for 21 kg/sq.cm. test pressure. Check valves can be of non slamming type to
prevent water hammer either by providing springs or accumulators. Valves can be suitable
for 15 kg/cm2 operating pressure.
6.6

Strainers:

6.6.1

Strainers can be Y type with Cast Iron or fabricated steel bodies designed to the test
pressure specified for the gate valves. Strainers can have a removable stainless steel
screen with 3mm Sq. perforations. Strainers can be provided with flanges or threaded
sockets as required. They can be designed so as to enable blowing out accumulated dirt
and facilitate removal and replacement of screen without disconnection of the main pipe. All
strainers can be provided with equal size isolating valves so that they may be cleaned
without draining the system. Strainers can be provided on the suction side of the pump as
indicated in the drawings.

6.6.2

Y type strainers can be provided at the inlet side of heat exchange equipment
Test Pressure:
These strainers can have pressure rating of15 Kg/cm. They can be of thread ends for
20mm to 50mm and above can be with flanged ends.

6.7

Piping Installation:

6.7.1

The drawings indicate schematically the size and location of pipes. Pipe runs and sizes
may, however, be changed to meet the site conditions. The agency on the award of the
work can prepare detailed drawings, showing the cross section, longitudinal sections,
details etc. They must keep in view the specific openings in buildings and other structures
through which the pipes are designed to pass. Piping can be pressure tested at 10 Bar
34

6.7.2

Piping can be properly supported on or suspended from stands, clamps, hangers, etc. as
specified and required. The bidder can adequately design all the brackets saddles, clamps
handles, etc and be responsible for their structural integrity.

6.7.3

Pipes supports can be of Galvanised steel, adjustable for height. Where pipe and clamp
are of dissimilar material, a gasket can be provided in between. The supports can be
recoated with cold galvanising spray/paint wherever the base coat is damaged.

6.7.4

Di-electric couplings or unions can be provided between and copper pipes and on
connection to cooling coils.

6.7.5

Galvanised Hanger rods can be the following diameters:

Pipe Size (mm)
20 to 50

Hanger Rod dia. (mm)

10

60 to 90

6.7.6

12

100 to 125

20

125 to 200

20

200 and above

22

Spacing for the pipe supports can be as follows:

Pipe Size (mm)

12 to 20

Spacing (mtrs)
7.5

25 to 40

2.0

50 to 75

3.0

100 and above

3.0

Where required additional supports can be provided at no extra cost.

6.7.7

Pipe hangers can be fixed on walls and ceilings by means of approved shear load
fasteners of required sizes. Where pipes are supported from steel structure provide beam
clamps

6.7.8

All piping connected to coils and apparatus requiring tube cleaning or removal, can run
clear of such area except for removable connections.

6.7.9

All piping can be independently supported at equipment so that the weight of piping cannot
be carried by the equipment.

6.7.10

All pipe supports on terrace should be painted with 2 coats of primer, 2 coats of epoxy paint,
finally apply 2 coats of paint with the approved shade. As options provide all pipe supports
on terrace can be galvanised.

6.7.11

Piping cannot be located over electrical equipment without adequate protection against
condensation dripping and leakage.

6.7.12

Piping passing expansion joints can provided with expansion loops.

35

6.7.13

Vertical risers can be parallel to walls and column lines and can be straight and plumb.
Risers passing from floor can be supported at each floor by clamps or collars attached to
pipe and with a 12mm thick rubber pad or any resilient material. Where pipes pass through
the terrace floor, suitable flashing can be provided to prevent water leakage. Risers can
also have a suitable elbow or concrete pipe support at the lowest point. Holes on the
supporting clamps should be made using drill machines.

6.7.14

Pipe sleeves of 50mm larger dia meter can be provided wherever pipes pass through walls
and the annular space filled with non-flammable material and finished with retaining rings.

6.7.15

Insulated piping can be supported in such a manner as not to put undue pressure on the
insulation. 4.80mm metal sheet can be provided between insulation and the clamp saddle
or roller extending at least 150mm on both sides of the clamp, saddle or roller. At pipe
supports provide PU foam pipe support of 100 kg/cum shaped to suit the pipe diameter
between pipe and hanger so as to prevent metal to metal contact and sweating of support.
The PU foam pipe support can have rectangular base.

6.7.16

Cut-outs required in the floor slabs for taking the various pipes are indicated in the
drawings. Bidders can carefully examine the cut-outs provided and clearly point out
wherever the cut-outs shown in the drawings do not meet with the requirements.

6.7.17

Piping work can be carried out with minimum disturbance to the other work on the site. A
program of work can be chalked out in consultation with the owner.

6.7.18

Agency can make sure that the clamps anchor sets are adequate for the pipes supported.
Piping layout can take due care of expansion and contraction in pipes.
All pipes using screwed fittings can be accurately cut to the required sizes and threaded in
accordance with IS 554 and burns removed before laying. Open ends of the piping can be
blocked as the pipe is installed to avoid entrance of foreign matter. Wherever reducers are
to be made in horizontal runs, eccentric reducers can be used if the piping is to drain freely,
in other locations, concentric reducers may be used.

6.7.19

6.7.20

Air valves can be provided at all high points in the piping system for venting. Valves can be
of double flat type with GM/CI body, vulcanite balls, rubber seating etc. Air valves can be
associated with an equal size gate valve with rising spindle. General guidelines as follows
can be considered:Mains

Air valves.

Upto 100mm

25mm

100mm to 300mm

30mm

Over 300mm

50mm

Discharge from the air valves can be piped through and equal sized GI pipe to the nearest
drain or floor waste or as shown.
6.7.21

Drains can be provided at all low points in the piping system and can be of the following
sizes:
Mains

Drain.

Upto 150mm
Over 150mm

25mm
40mm

Drain can be provided with gate valve of equal size with rising spindle. Drains can be piped
through equal size GI pipe to the nearest drain or floor waste or as shown in drawings.
Piping can be pitched towards drain points.
6.7.22

Pipe Welding:
The agency can generally follow the applicable codes as listed below.
IS- 2823 Code of Practice for welding MS piping
36

IS 823: 1964 - Code of Procedure for manual metal arc welding of mild steel.
IS 1261:1959 - Code of practice for seam welding in mild steel .
IS 10234:1982 - Recommendations for general pipeline welding.
6.8

Pressure Gauges:

6.8.1

Pressure gauges of stainless steel construction can be not less than 150mm dia. and of
appropriate range and be complete with shut off gauge cocks etc. duly calibrated before
installation.

6.8.2

Pressure gauges with stainless steel U tube can be provided at the required locations. U
tube can be insulated to prevent sweating:
Supply and returns of chillers and condensers
Suction and discharge of pump
Supply and return of all water coils of Precision Air Handling Units.
Altitude (Pressure and Vacuum) To suction side of all pumps.

6.8.3

Care can be taken to protect pressure gauges during pressure testing.

6.9

Thermometers:

6.9.1

Thermometers shall be Digital type of appropriate range duly calibrated before installation.

6.9.2

Thermometers can be installed in separate brass well with oil.

6.9.3

Thermometers can be provided the following locations and as indicated in the drawings:
On supply and return of chillers.
On supply and return of all water coils of Precision Air Handling Units.

6.10

Insulation:

6.10.1

Pipes can be insulated as shown in the drawings and in accordance with guideline in
section Insulation

6.11

Vibration Eliminators:

6.11.1

Piping installation can be carried out with vibration elimination fittings and supports and
design and make approved in the air conditioning plant room and upto 30 meters from plant
room and upto 10 meters from AHU connections. Provide 6mm insulator equivalent
material for all piping supports between pipe and support.

6.12

Guidelines for Expansion Tanks:

Expansion tanks can be pre-charged horizontal type complete with replaceable heavy duty
butyl rubber diaphragm. Tank can have system, drain and charging valve (standard tire
type) connection to facilitate on site charging of the tank to meet system requirements. The
tank can be constructed in accordance with section VIII of ASME boiler & pressure vessel
2
code and stamped 10Kg/cm working pressure. Tank required for chilled water system can
be suitable for system volume. Maximum and minimum temperature of 45 C and 5C
respectively, fill pressure of 0.8 Kg/cm2 and maximum tank pressure of 8 Kg/cm2.
Pressurization system can comprise of pumps (1 working + 1 standby) Starters, pressure
relief valve, complete with all components such as PVC fill tank, IP 55 control panel, pressure
switch, pipes, fittings, valves etc.

6.13

Air Separators:
Air separator working on basic centrifugal force and low velocity flow, complete with inlet
and outlet connections, high capacity float type air vent, pressure reducing valve, cold
water fill connection, drain valve, flanged connections etc. The air separator can be suitable
for required water flow.

6.14

Testing:
37

6.14.1

All piping can be tested to hydrostatic test pressure of at least one and half times the
maximum operating pressure, but not less than 10 Kg/Sq.cm for a period of not less than
24 hours. All leaks and defects in joints revealed during the testing should be can be
rectified

6.14.2

Piping repaired subsequent to the above pressure test can be re-tested in the same
manner.

6.14.3

System may be tested in sections and such sections can be securely capped.

6.14.4

The agency can test a section or sections of piping and all testing can be witnessed by the
project engineer or his authorized representatives.

6.14.5

The agency can make sure that proper noiseless circulation of fluid is achieved through all
coils and other heat exchange equipment in the system concerned. If proper circulation is
not achieved due to air bound connection, the agency can rectify the defective connections.
He can bear all the expenses for carrying out the above rectification, including the tearing
up and re-finishing of floors, walls etc as required.

6.14.6

No insulation can be applied to piping until after the completion of the pressure testing t.

6.14.7

The agency can provide free of any additional cost, all materials, tools, equipment,
instruments, services and labour required to perform the test to remove water resulting
from cleaning and/ after testing.

6.15

Painting:

6.15.1

After all the piping has been installed tested and run for at least some days or eight hours
each, the piping can be given two finish coats 3 miles, each as follows:
Services
Flow
Chilled Water/condenser water Supply
Return

6.15.2

The direction of flow of fluid in the pipe can be visibly marked in appropriately coloured
arrows

***** ***** *****

38

7.0

PIPE CLEANING AND CHEMICAL WATER TREATMENT:

7.1

General:

7.1.1

Description:
Provide flushing, cleaning and chemical treatment program in accordance with the Contract
Documents. Pipe cleaning and chemical water treatment is an integral part of the piping
guidelines and bill of quantities and will not be measured separately.

7.1.2

Work Included:
Pipe Cleaning & chemical treatment.

7.1.3

Submittals:

7.1.3.1

Submit shop drawings listing chemicals. Provide layouts of feeding equipment, details of
testing equipment and describing treatment program, including calculations and quantities
of chemicals to be used. Provide system schematics showing the following:
-

Chilled Water

volume
circulation rates
pressures
temperature differentials

7.1.3.2

Provide written report containing log and procedures of system cleaning, giving times,
dates, problems encountered and condition of water, witnessed by Agency.

7.1.3.3

Submit written report containing result of tests and list of chemicals updated every 14 days
during temporary use of treated system.

7.1.3.4

Provide inspections and submit written reports on a twice monthly basis. Provide for one (1)
year after acceptance of system. Take samples of water at each inspection, analyze, and
certify. Submit the analysis made on the water to the Engineer and the Owner. Include in
the analysis report, recommendations as to any changes in water treatment required.
Provide an initial dosage of 1.5 gallons of an aqueous solution of sodium nitrite base
corrosion inhibitor (NALCO 2536 or any approved make) for each 100 gallons of water in
the system.

7.1.3.5

Provide written maintenance instructions to be included in Maintenance and operating

Manual.

7.1.4

Quality Assurance:

7.1.4.1

The chemical pipe cleaning service supplier must be a recognized specialist, active in the
field of industrial pipe cleaning for at least ten years, whose major business is in the field of
pipe cleaning, and who has full time service personnel within the trading area of the job
site. Laboratory facilities must be available.

7.1.4.2 Cleaning and Treatment Guidelines which can be followed

-

Closed Recirculating Water Systems:

System Treatment and Control Level Chemical Conditions
Chilled

Non-toxic organic 2000 ppm as total Water corrosion and scale

organic
Inhabitor
Molybdate as 200-300 ppm Na2Mo04 or
Nitrite as NO2 500-700
pH
7.0-8.0
39

7.2

Products:

7.2.1

Pipe Cleaning:

7.2.1.1

Furnish all required pipe cleaning chemicals, chemical feed equipment, materials, and labor
necessary to clean the piping as herein specified. In addition, permanently install necessary
chemical injection fittings complete with stop valves and coupon racks, etc.

7.2.1.2

Provide a pre-startup non-foaming, liquid detergent dispersant cleaner for cleaning of all
systems to remove oil and foreign matter from the piping and equipment prior to the final
filling of the systems. Use a chemical that is not injurious to persons, piping, pipe joint
compounds, packing, coils, valves, pumps and their mechanical seals, tubes or other parts
of the system.

7.2.1.3

Furnish instructions dictating the quantities of the cleaner to use, methods and duration of
the operation.

7.3

Execution:

7.3.1

General:

7.3.1.1

Installation and startup can be supervised by factory representatives of the equipment

manufacturer and chemical manufacturer.

7.3.2

Preliminary Cleaning:

7.3.2.1

Clean new piping internally by flushing prior to the application of pressure tests, and before
the chemical cleanout procedures specified herein. Provide temporary strainers at the inlet
to the chilled water Pumps before the start of cleaning procedures.

7.3.2.2

Block off and isolate Chillers, circulating pumps, cooling coils, other equipment during the
preliminary flushing and draining process.

7.3.2.3
7.3.3
7.3.3.1

Provide temporary by passes to fully circulate through all branch piping.

Pipe Cleaning:
All Piping Systems

7.3.3.1.1

Provide temporary connections with valves to fill and drain the piping and equipment after
completion of the chemical cleanout procedure. Provide temporary blind flanges and /or
caps to isolate the piping and equipment.

7.3.3.1.2

Provide temporary piping connections, valves, strainers, bypasses, and blank connections
where required to clean out systems

7.3.3.1.3

After each hydrostatic leak testing procedure is complete drain the system until empty. The
piping systems are internally chemically treated and protected during the hydrostatic testing
procedure as described in the Section entitled Testing, Balancing and Adjusting.
Thoroughly clean the piping and flush as follows:
-

Prior to the start of the chemical cleaning procedure submit three-two (2) foot
lengths of the piping installed on this project to the chemical manufacturer for
analysis of the interior coating on the piping. Refer to the Section entitled Testing,
Balancing and Adjusting For additional requirements.

Before the chemical cleaning procedure is begun, install in each closed

recirculating water system a temporary skid mounted portable side stream filtering
system. The filtering assembly can have 6 flanged connections and multiple
cartridge filters capable of least 600 gpm, an integral Barco type flow venturi, and
40

be pressure rated for the system to which it is connected. Install the filter cartridges
and change out until the system is clean. Initially provide twenty (20) micron
cartridges, the intermediate set five (5) microns, and the final set one (1) micron.
-

Add chemical pipe cleaning compound as recommended by the chemical

manufacturers representative to the system simultaneously with the filling of the
system.

Circulate the cleaning compounds in the system for the time period specified by the
chemical manufacturer.

Drain the system until empty from its lowest point.

Fill the system again with fresh water and flush thoroughly until clean water is
obtained. (Maintain continuous blow down and make-up as required during flushing
operation). Use a one (1) micron cartridge type strainer element at end of drain
hose to confirm that discharge water is free of foreign material.

The cleaning and flushing procedure must be approved in writing by the chemical
manufacturer. The chemical manufacturers representative can supervise and
certify in writing the cleaning and flushing of the piping systems. The Agency can
provide and install injection pumps, water meters, and coupon racks to control and
monitor the cleaning process.

7.3.4

Filling of Water Systems:

7.3.4.1

After completion of chemical cleanout, fill the water system with fresh water, air vent, and
immediately provide treatment to passivate metal.

7.3.4.2

Furnish the following chemicals as required for the system until the Owner has issued a
Certificate of Substantial Completion.

7.3.4.3

PH Adjustment Chemicals: Provide suitable pH adjustment chemicals in 50 gallon drums to

control pH at the 7.8-8.8 level.

7.3.4.4

Corrosion Inhibitor: Provide thirty (30) gallon drums of liquid corrosion inhibitor. Provide
non-polluting corrosion inhibitor which complies with local regulations covering waste water
discharge, and as permitted by the local authorities having jurisdiction.

7.3.4.5

Dispersant: Provide thirty (30) gallon drums of dispersant. Provide non-polluting dispersant
which compilers with local regulations covering waste water discharge, and as permitted by
the local authorities having jurisdiction.

7.3.4.6

Biocide: Provide thirty (30) gallon drums of biocide. Provide non-polluting biocide which
complies with local regulations covering waste water discharge, and as permitted by the
local authorities having jurisdiction.

7.3.4.7

Recommend pH adjustment chemical, corrosion inhibitor, dispersant and biocide for the
local water characteristics.

7.4

Dosing Pot:
Provide chemical dosing pot of adequate capacity as recommended by chemical treatment
agency so as to provide necessary protection for the chilled water piping system.

7.5

Technical Service and Control:

7.5.1

The HVAC agency should ensure that after completion of system commissioning the
chemical treatment agency can make on site inspections of equipment during scheduled or
emergency outages in order to properly evaluate their effect on the water treatment
program.
41

7.5.2

Insulate water treatment piping and tanks containing chilled water, in accordance with
insulation material as specified for the respective system.

7.5.3

Wherever possible, all water treatment equipment is to be located in mechanical equipment

rooms. Locate in suitably weather proofed enclosure on roof platform
***** ***** *****

8.0

SHEET METAL WORK:

8.1

SCOPE:

8.1.1

Scope of this article comprises of supply installation of all sheet metal ducts as shown on
drawings.

8.2

MATERIALS:

8.2.1

Ducts can be made of galvanized steel sheets. The galvanized steel sheet can conform to
IS: 277

8.2.2

Thickness of sheet can be as per the guidelines given below:

-------------------------------------------------------------------------------------Maximum Side (mm)
Thickness (mm)
-------------------------------G.S.S.
-------------------------------------------------------------------------------------Upto 750

0.80

751-1500

0.80

1501-2250

1.00

2250-2500

1.20

Plenums & Ducts above 2500

1.60
------------------------------------------------------------------------------------The bracing can be as per DW143-144. Supports for ducts at 2.4m distance apart up to
2250/1.2m distance apart for larger ducts.
8.2.3

Ducts can be rectangular in cross section and can be factory fabricated in accordance with
the following guidelines:
------------------------------------------------------------------------------------------------------------------------Max. Size
Min. Thick
Transverse joints
Reinforcement
Hanger
Rod dia.
-----------------------------------------------------------------------------------------------------------------------Up to 400
8

0.8

38 x 38 x 4.2

Cross break

Companion flanges
401 to 750

0.8

38 x 38 x 4.2
Companion flanges

42

25 x 25 x 4.2
Girth angle @
1000

751 to 900

0.8

901 to 1500
10

0.8

8 x 38 x 4.2
Companion flanges
38 x 38 x 4.2
Companion flanges

25 x 25 x 4.2
Girth angle @
1000

38 x 38 x 4.2
Girth angle @

--------------------------------------------------------------------------------------------------------------Max. Size
Min. Thick
Transverse joints
Reinforcement
Hanger
Rod dia.
--------------------------------------------------------------------------------------------------------------1501 to 2250 1.00
38 x 38 x 4.2
38 x 38 x 4.2
10
Companion flanges
Girth angle @
760
2250 to over
12

Plenums
12

1.25

1.25

50 x 50 x 4.2

50 x 50 x 4.2

Companion flanges

Girth angle @
610

50 x 50 x 4.4

50 x 50 x 4.4

Companion flanges

Girth angle @
300mm
-------------------------------------------------------------------------------------------------------------------Girth angles and companion flanges can be metered and welded at corners and riveted to
duct sheets at 75mm centers. Flanged joints can be made with 9.5mm G. I. bolts spaced at
15cm centers and provided with 4.2mm rubber gasket. All joints and seams can be
rendered airtight. All duct seams and joints to be sealed with silicon sealant to stop supply
air leakage. Duct panels are not to be cross-broken if insulated. Longitudinal seams can be
inside groove of Pittsburgh type.
All ducting supports, bracing & frame work can be G.I. (50 microns). All weld joints can be
coated with cold galvanizing paint / spray. Ducts supports can be constructed from Unistrut
box sections.
8.3

ACCESSORIES:

8.3.1

All dampers, except where shown, can be louver dampers having multiple opposed blades
type or with parallel blades of airfoil construction. The construction of the dampers can be
robust and tight fittings. They should make up of 18 gauge galvanized sheets. The depth
should minimum 150 mm and flanges of 40 mm. Blades can be connected with a suitable
linkage for operation by an extending lever which can have a locking quadrant with
positions of the damper indicated on it. Dampers and their operating device can be made
robust, easily operable and accessible through suitable access doors in the ducts. Shafts
to be mounted in iolite sintered bronze bushes.

8.3.2

Dampers can be provided in ducts at every branch supply or return air duct connections
whether or not indicated on the drawings for the proper volume control and balancing the
system.

8.3.3

Where shown or required splitter dampers can be installed. This damper consists of double
thickness air foil blade hinged on the downstream edge. The operating lever can extend
43

outside the duct and insulation with an airtight hub and locking arrangements. The
thickness of the damper blades can be the same as the duct in which they are installed but
not less that 1.5mm thickness.
8.3.4

Fire dampers can be motorized wherever specified can be provided in the ducts to
minimize spreading of fire through ducts i.e. points where duct passes fire (rated 1 1/2 hrs.
or more) wall or slab. Fire dampers can be 230mm deep and face area as required. The
outlet casing of the damper can be fabricated out of 12 gauges M. S. sheet. The louvers
can be provided with smooth pivotal linkage, tripping mechanism of steel bar with heavyduty spring assembly and provision of motor. The louvers to be arranged to pivot and hold
in an open position and can be closed be an electrically operated motor. The damper can
be used in conjunction with a smoke alarm system. The entire assembly can be duly epoxy
primer (epoxy paint) or aluminium spray painted. The dampers can be designed for
automatic as also manual tripping.
Motor can be rated for fire damper (spring to close power to open) operation and can be
suitable for outdoor installation (IP55). Fire damper are closed on a signal from the fire
control module. Module supply and wiring by fire control agency.

8.3.5

Motorized fire dampers should be aerofoil profile multi blade dampers with 18 gauge
galvanized construction with spring return type. Opening time should be more than 75 secs
and closing time should be 30 secs. The power can be given from the electrical panel and
will be routed through the unit.

8.3.6

300mm x 300mm access panels with gasket neoprene and stud bolt type can be provided
near louver dampers/splitters damper and fire damper.

8.3.7

All duct can be supported from the slab above or from beams. Duct supports can be fixed
through use of anchor fasteners of beam clamps.

8.3.8

Transverse joints can be provided with rubber gaskets (6mm thick) of non-flammable type.
In no case can the use of felt be permitted.

8.3.9

Wherever ducts are acoustically lined the duct size can be increased by the thickness of
the duct lining.

8.3.10

Motorized Dampers for treated fresh air connection in AHU rooms can be galvanized steel
aerofoil construction opposed blade type with nylon bushes and provision for installing
modulating actuator.

8.4

INSTALLATION:

8.4.1

The duct fabrication and installation can generally conform to DW143-144.

8.4.2

The agency can provide and neatly erect all sheet metal work as shown on drawings or as
may required to carry out the intent of those guideline and drawings and this work can meet
with the approval of the Engineer in all its parts and details. However supports can be fixed
to the ceiling through anchor fasteners 2 nos. for each leg. The anchor fasteners can be of
approved make.

8.4.3

All necessary allowances and provisions can be made by this Agency for beams, pipes or
other obstructions in the building, whether or not the same are shown on the drawings.
Where necessary to avoid beams or other structural work or plumbing or other pipes or
conduits, the duct can be transformed, divided or curved to one side the required area
being maintained

8.4.4

All metal work in dead or furred down spaces can be created in time to occasion no delay
to other agencies on the building.

44

8.4.5

Ducting over furred ceiling can be supported from the slab above, or from beams. In no
case can the duct be supported from the ceiling hangers or be permitted to rest on a hung
ceiling.

8.4.6

If a duct cannot be run as shown on the drawings the agency can install the duct between
the required points by any path available

8.4.7

All ducts can be rigid and can be adequately supported where required with standing
seams tees or angles of ample size to keep the ducts true to shape and prevent buckling,
vibration and breathing.

8.4.8

All duct joints can be made tight with rubber gaskets of non-flammable type and all interior
surfaces can be smooth. Bends can be made within radius not less than one-half of the
width of the duct or with scientifically designed interior curved vanes as approved by the
Engineer. Two vanes can be spaced so that the aspect ratio of each of the individual
elbows formed by the vanes will be about five to one.

8.4.9

All sheet metal connections, partitions and plenums required to confine the flow of air to
and through the filters and fans, can be constructed from 16 G galvanized iron, thoroughly
stiffened with 25mm x 25mm angle iron braces and fitted with all necessary doors as
required by the Engineer to give access to all parts of the apparatus. Doors cannot be less
than 46 cm x 71 cm. Sheet Metal connections to indoor units can be flexible, double
thickness fibreglass cloth or equivalent non-flammable material.

8.4.10

Where metal ducts or sleeves terminate in woodwork, brick or masonry openings, and tight
joints can be made by means of closely fitting heavy flanged collars.

8.4.11

Provide resistoflex or similar vibration isolation material of 6mm thickness between duct
and duct supports.

8.4.12

Where ductwork is connected to rotating equipment duct as fans, air handling units (indoor
unit of split/package system) the connections can be made with double thickness nonflammable flexible material.

8.4.13

Provide RTV or equivalent non-flammable, non-hardening silicon sealant for all longitudinal
& transverse joints.

8.4.14

Pressure test complete duct work between fan outlet and VAV inlet (except flexible duct) as
per DW procedure.

8.4.15

Provide Instrument test ports at the outlet of all fans/blowers

8.5

GRILLES AND DIFFUSERS:

8.5.1

Supply airside wall outlets:

Wherever specified can be in Aluminium construction.
Double Deflection Grilles:
Wherever specified can be in Aluminium construction. Aluminium double deflection grilles
for supply air can be provided with vertical and horizontal adjustable bars and an approved
blade damper adjustable from the front face of the grille. The finish of the grilles will be
powder coated in a shade to be approved.
Fixed Bar Linear Grilles:
Fixed bar grilles will be in extruded aluminium construction. Bars can be fixed in position
using vertical tie bars. Bar spacing cannot exceed 12mm and the grilles can have 60% free
area. Finish of the grille can be powder coated in a shade Irrespective of grille finish,
vertical tie bars can be powder coated in Matt black. Supply air outlets can be provided with
volume control dampers to be installed in the duct collar. Dampers can be in black Matt
45

powder coated finish. Grilles can be similar to Dynacraft models EP-00/EP-15/EP-30/EP-45

or equal. Wherever required the grilles can be provided with a margin on all sides. Supply
air outlets can be provided with end closure pieces for the supply portion of the grille. The
end closure pieces cannot come to the grille face.

Floor grilles
Floor grilles can have similar specs as above but can have VCD. The loading capacity can
be as required.
Continuous grilles can butt with hairline joints and be provided with interlocking splines.
8.5.2

All return air grilles can be similar and equal to the above.

8.5.3

All exhaust air grilles can be similar and equal to the supply air grilles specified above.

8.5.4

Ceiling Outlets:
A]

Square/Rectangular Diffusers:
Wherever specified can be aluminium construction swirl type. Corners of inner and outer
cores can be assembled to provide precise metered corners. Supply air diffusers can be
provided with butterfly dampers and plenum box. Damper flap can be provided with a nylon
worm gear assembly to enable ease in operation. Diffusers will be powder coated in a shade.
Select diffusers fitting in the acoustic tile framework.
Return air diffusers can be perforated ceiling diffusers fitting in the acoustic tile framework.
The diffusers can be aluminium construction. Open able face to simplify damper adjustment.
The perforations can be high quality accurately punched on CNC machine.

B]

Modulinear Diffuser
Furnish extruded aluminium Slot Diffuser where shown on the plans. Diffusers can be
provided with adjustable pattern adjustment. The pattern controllers can be positive
positioning when providing a horizontal air path. Constant static pressure can be
maintained at a fixed volume under all positions of pattern adjustment. Diffuser margins
can be as shown on the plans to overlap the openings as required to suit the wall or ceiling..
Diffusers can be furnished in one piece up to 72 inches in length. Continuous diffuser
sections can butt with hairline joints and be provided with interlocking splines. Diffuser
margins can be metered at 900 and mechanically fastened to provide a neat hairline
appearance. Diffuser slot openings can be inch or inch or 1 inch as shown in the plans
to provide specified design volumes. Slot diffusers can be anodized/primer
coated/emulsion painted/powder coated. Pattern controllers can be powder coated matt
black irrespective of external finish.
Performance ratings of pressure, sound throw and room velocity can be tested in
accordance with ADC guidelines. Diffuser sizes can be selected to provide required throw
and room velocity at NC 35 level.
Linear slot diffuser can be Cosmos Diffusers / Dynacraft model MD or approved equal.

8.5.5

Installation of grilles/diffusers:
Installation of the grilles /diffusers can be done by the air conditioning agency irrespective
of the type/model of false ceiling systems the diffusers will have to be individually
suspended from the duct and aligned to match the ceiling line level. No weight will be
added on to the false ceiling by diffuser. In case of gypsum ceiling system all wooden
frames or G.I. Sections required for supply/return/exhaust air diffusers or grilles will be
provided by the Air conditioning agency.

46

8.5.6

All air outlets/return air inlets in the same room can be of the same size unless otherwise
specified.

8.6

INSULATION:

8.6.1

Duct work can be insulated as specified in Article Insulation.

8.7

TESTING & BALANCING:

8.7.1

The duct system can be tested and balanced. The air quantities readings can be recorded.
All dampers can be set and locked in position after the final adjustments. Air quantity
measurement at all air outlets (supply, return & exhaust) can be taken by use of flow hoods
or a combination of Pitot tubes and digital anemometers.

8.8

Insulated Flexible Ducts:

8.8.1

Supply, installation, testing and commissioning of Aluminium flexible ducting conforming to

these guidelines and in accordance with requirements of drawings and of schedule of
quantities.

8.8.2

Provide insulated flexible ducts are specified inner core for the same should be made of
triple lamination of Aluminium foil, Polyester & Metalized Polyester film permanently
bonded to coat spring steel wire helix. Fiberglas insulation of minimum 14 kg/cu. Meter
density, having R-Value 4.2 F-Ft2 hr/Btu and 1.25 thickness can be wrapped over the
inner core & covered with strong outer jacket cum vapour barrier made of fibreglass
reinforced metalized polyester film laminate.

8.8.3

Care must be taken to install all the flexible duct in fully extended position and bends made
with adequate radius as per manufacturer recommended practices.

8.8.4

Duct should conform to fire rating standards BS-476 part 5, 6 & 7.

8.8.5

INSTALLATION PRACTICE:

8.8.5.1

Support Hangers:
The flexible duct must be installed fully extended to produce optimum results.
The maximum allowable sag, between any two adjacent suspension points, should not
exceed 50mm per meter. Maximum length of a single flexible duct connection cannot
exceed 3meters.
The distance between any two adjacent suspension points may vary from 1.50 to 3.00
meter, depending upon the type of flexible duct in use.
Flexible ducts above suspended ceiling should always be independently supported. Ducts
mounted in these locations are susceptible to damage whenever ceilings panels need to be
periodically interchanged, unless they are separately supported.

8.8.5.2

Bending Radius:
All bends should be made as large as possible and should have a radius of not less than
the diameter of the duct in use. This reduces un-favourable pressure losses and is
particularly important for metal-based products, which are more susceptible to stress
rupturing. Double bends should be avoided, however if un-avoidable, ensure that each
radius is not less than R = 2 x D.

8.8.5.3

Straps:
The hanging straps should support the flexible duct with a minimum of half the
circumference surface in contact, and without reducing the effective inside diameter of the
duct. It is also recommended that the minimum width of material to be used for the hanging
straps should be at least 25mm.
47

8.8.5.4

Flexible Duct to conventional Duct Connection:

Extra care should be taken when making flexible connection to fix conventional ducts, etc.,
and ensure that they do not become too stressed. An additional support is recommended to
obviate this potential problem.
Metal based flexible duct products are particularly prone to fracturing due to stress caused
as a result of sharp connections.

8.8.5.5

Longer Length Installation:

In the event where extreme length of flexible duct is to be installed, round duct connectors
made of galvanized sheets of at least 30cm long should be used to connect the duct at
every distance of 10mtrs. Use metal or galvanized hangers to support the point where
connections are made. Alternatively light railings can be used for hanging support when
using long length of flexible duct.

8.8.6

The Flexible duct can be fixed using C clamps which can be tightly fixed to prevent
leakage of air. Necessary sealant can be provided to make an airtight joint. The clamps can
be G. I. with a minimum width of 75mm. Flexible duct connections can be provided where
shown on the drawings and where specified i.e. at inlet to VAV boxes and at inlet to square
diffusers and diffuser plenums.

***** ***** *****

48

9.0

INSULATION:

9.1

Scope:

9.1.1

Scope of this Article comprises supply and installation of insulation as herein specified.

9.2

General:

9.2.1

All tests like pressure testing should be complete and recorded before insulation is applied
to the equipment and piping. Insulation material can be supplied by approved
manufacturers and can be of the type specifically intended for the services specified.

9.3

Piping Insulation:

9.3.1

All pipes operating at temperatures lower than ambient can be insulated with insulation of
the following material.
PUF preformed pie sections having thermal conductivity of 0.028 Kcal/m/hr/C and density
of 16 Kg/m3/ 10%. The material can be fire-inhibited type.

a)

9.3.2

9.3.3

Thickness of pipe insulation can be as follows:

Temperature
Range (C)

Pipe Dia.
(mm)

Insulation Thickness
(mm)

a) -1.1 to 4

15 - 80
100 - 30

b) 5 to 16

upto 200
300 & above

80
100
50
75

Application:
Chilled water piping and accessory insulation application can be follow the below mentioned
guidelines:
a) Pipes can be thoroughly cleaned with wire brush and rendered free from all rust and
grease and painted with primer and anti corrosive paint.
b) One coat of shalikote primer can be applied over the entire surface of
pipe and fitting and accessories like valves etc.
c) Two coats of industrial hot bitumen 85/40 or 85/25 as per IS 702-1961 can be applied on
the cleaned pipe surface uniformly at the rate of 1.5 kg/sq. m.
d) Rigid pipe sections of insulation can be fixed tightly to the surface. Insulation can be
PUF. Seal all the transverse and longitudinal joints using hot bitumen.
e) Cover the insulation with polythene (800 gauge) sheet. Seal all joints with bitumen and
tape.
f) Every 300mm provide PVC bands over polythene sheet covering.
g) Cover polythene sheet with kora cloth dipped in Foster compound weatherproof grade.
h) Finally cover all insulation with 24 Grade aluminium cladding. Aluminium sheet should be
grooved and held in position with self tapping screws. All joints at bottom.
49

i) All piping running outdoors on terrace can be provided with GI wire mesh netting
covered with two layers of sand cement plaster. The final finish with 24 G aluminium
cladding. Aluminium sheet should be grooved and held in position with self tapping screws.
All joints at bottom.
All valves, fittings, strainers, etc. for chilled water piping and drain piping can be insulated
to the same thickness as specified for the main run of pipes and applied generally in the
manner specified for chilled water piping. Valves, joints, yokes and spindles can be
insulated in such a manner as not to cause damage to the insulation when the valves are
used or serviced. All valves fittings, strainers etc. can be insulated and finished with Al.
cladding for chilled water piping. Serviceable component of valves and strainers to have
removable boxes with locking arrangement.
Drain piping can be insulated with 13mm tubular Nitrile rubber applied as per guidelines for
refrigerant piping. Drain piping in AHU room can be covered with 24 G aluminium
cladding.
9.4

Refrigerant Piping:

9.4.1

Insulation Material:
Insulation should follow be of closed cell tubing type.
All refrigerant pipes from indoor to outdoor units (both suction and liquid line) can be
insulated with insulation of the following material.

9.4.2

Thickness of pipe insulation can be minimum 13mm tubular closed cell.

9.4.2.1

Clean the outer surface of refrigerant copper piping. Insert the pipes in tubular Armaflex.
Join two ends of tubular insulation using suitable adhesive. Tape the joints with masking
tapes.

9.5

Drain Pipe Insulation:

9.5.1

Insulation Material:

9.5.2

Thickness of pipe insulation can be as per below mentioned guidelines:

9.5.3

Temperature
Range (C)

Pipe Dia.
(mm)

Thickness
(mm)

a) upto 10 deg C

as required

13mm

Piping and accessory insulation application can be as follows:

a. Pipes can be thoroughly cleaned with wire brush and rendered free from all rust and
grease.
b. Apply adhesive Pidilite SR998 on the cleaned pipe surface.
c.

Use closed cell type insulation of density 80 Kgs/ m of suitable diameter.

d. The insulation of straight pipe use slips on method. Use snap off method for elbows
and bends.
e. Insulation can be fixed tightly on the surface taking care to seal all joints.
50

f.

Provide adequate size PVC self adhesive tape to seal all joints.

9.5.4

Drain piping can be insulated with 13mm Nitrile rubber The insulation can be applied as
recommended by manufacturers. All joints can be taped and sealed to ensure that there is
no sweating of pipes. Insulation can be fixed with approved adhesive.

9.10

Duct Insulation with Fiberglas:

9.10.1
Ducts

Thickness of insulation for ducting work can be as per below mentioned guidelines
Insulation
Material
Remarks

a] Supply Air Ducts

i] Unconditioned50mm

Fiberglas

Ducts exposed to be covered

with 22 G Al. i.e. (density32 kg/ m3)
in plant room or spaces having no false

ceiling
ii] Conditioned 25mm

-- --

b] Return Air Ducts:

i] Unconditioned

25mm

ii] Conditioned
Area

Fiberglas

c] Air Plenums:

25mm

Ducts exposed to
be covered with 22 G Al. i.e.
(density 32 kg/m3) in plant room
or spaces having no false ceiling
-

Fiberglass

To be internally lined.(density 48 kg/m3)

25mm Fiberglass Thermally insulated
externally (density 48 kg/ m3)

Duct insulation for exposed ducts on terrace can 50mm TF quality thermocole applied as
per 10.3.3 pipe insulation items a to h.
9.10.2

Application of thermal insulation can be as follows:

a]
b]
c]
d]
e]
f]

Clean the surface of ducts and apply a coat of shalikote primer over entire surface
of duct, spot bitumen can be applied at 1 ft. regular intervals.
Fix factory applied aluminium foil backed fibreglass insulation of specified thickness
to the surface of the duct tightly, taking care to seal all joints.
Joints can be covered by use of 75mm wide aluminium foil backed tape using
approved adhesive.
Provide 75mm wide PVC straps for duct insulation at 450mm distance between
bands.
Apply 75mm x 0.63mm wire netting over complete duct insulation, butting all joints
and laced down with GI wire.
At duct supports provide 20G GI, 12 long protection saddle between insulation and
duct support.

9.11

Acoustic Insulation:

9.11.1

Coat interior of duct with shalikote primer. Fix 25mm thick resin bonded fibreglass rigid
board finished with RP tissue to duct using spot hot bitumen. Seal all joints with bitumen.
The acoustic lining to be covered with RP tissue and perforated aluminium sheets of 26G
thickness. The lining of aluminium sheet facing to be mechanically fastened to the duct with
GI bolts/nuts & washers agency to ensure a smooth internal finish.

51

9.11.2

All plenums, connecting pieces connected to air handling units and return air pieces can
also be acoustically treated.

9.11.3

There can be a minimum of 75mm overlap between the acoustically and thermal insulation
on ducts.

9.12

Equipment Insulation:
Insulation can be cut and metered wherever necessary to fit the contour of the
equipment/vessels, etc. Insulation can be applied with edges tightly butted and secured with
wires and or bands. Two coats of sand cement, plaster each of 7mm thick can be applied over
the insulation and finished with two coats of enamel paint of approved colour. Where equipment
is mounted outdoors apply two layers of tarfelt with joints properly sealed with Hot bitumen.
Provide 24 Gauge aluminium cladding over finished insulation.
Insulation guideline can be as follows:
a.

Chilled Water Pump Housing:

PUF pipe sections for chilled water applied with adhesives/bitumen. Care can be taken to
apply the insulation in a manner so as to allow dismantling of the pumps without damaging
the insulation. Thickness of insulation and application can be same as for chilled water
piping insulation. Provide aluminium jacket over pumps.

b.

Tanks/Air Separator:
Wherever required expansion tanks can be insulated to the same thickness as for the pipe
to which they are connected. Insulation material can be thermocole TF or equivalent
expanded polystyrene insulation. Cover the insulation with sand and cement plaster over
chicken wire mesh. (2 layers 7mm thickness). Provide 2 layers of tarfelt with joints sealed
with hot bitumen. Provide 24 G aluminium cladding over finished insulation as for piping.
Insulation sheet be grooved and held in position with self tapping screws.

9.13

Acoustic Insulation In AHU Room:

9.13.1

Provided by base building infrastructure.

9.14

Under Deck Insulation:

9.14.1

Entire areas fed through below false floor air supply can be insulated with 19 mm nitrile rubber
sheet class O.
Under deck duct insulation can be applied as follows:
a.

Clean the surface and make it free from dust and loose particles.

b.

Apply a coat of adhesive SR 998,pidilite

c.

Press the slab in position. Butt the joints together.

d.

Seal the intra slab joints with self adhesive aluminium tapes.

d.

In addition to the above, the insulation can be screwed to RCC slab with nylon rawl plugs
and 65mm screws fixed through 75mm x 75mm washers at 450mm centers (4 screws for
each 900 x 600 slab of insulation) and securely tied with GI binding wire with final layer of
chicken wire mesh.
Floor Insulation:

52

Entire areas of DC, Staging can be insulated with two layers of 12 mm nitrile rubber sheet class
O.
Under deck duct insulation can be applied as follows:
a
b.
c.
d.
e.

9.15

Clean the surface and make it free from dust and loose particles.
Apply a coat of adhesive SR 998,pidilite
Press the 12 mm layer in position. Butt the joints together.
After jacks installation, apply adhesive & press as above.
Seal the intra slab joints with self adhesive aluminium tapes.

Mode of Measurement for Insulation:

a.
b.
c.
d.

e.
f.
g.

All duct insulation can be measured on the basis of the finished insulation surface area and
excluding all openings for grilles, diffusers but including all flanges, dampers etc.
In case of bends, tapers etc. the duct prime surface can be determined on the basis of
average dimensions.
All pipe insulation can be linear measure along the length of the pipe, over all fittings,
excluding flanges and valves.
Each independent flange insulation can be measured as 300mm equivalent length of piping
of same size. Insulation of flanges associated with equipment (equipment and mating
flange) and valves (flanged or screw-ended valves with flanged tail pipes) can form part of
the valve or equipment.
Insulation of valves together with the flanges as above can be measured as 600mm long
equivalent length of piping of same size.
All pump insulation can be measured as 1500mm long piping of diameter equal to the
suction size of the pump and this can include the cost of insulation of the suction and
discharge flanges.
Insulation for tanks/vessels can be on basis of external finished area.

***** ***** *****

53

10.0

PAINTING:

10.1

Scope:

10.1.1

Scope of this section comprises painting of various equipment, piping etc. as specified
herein.

10.2

General:

10.2.1

Prime and finish paints used for mechanical work can be of standard brands, ready mixed,
products of qualified manufacturers, of approved make and shade.

10.2.2

Deliver paints in their original contains with seals unbroken bearing manufacturers label
specifying trade name, brand and quality.

10.2.3

When requested, submit manufacturers written statement that a particular brand of paint
as recommended and guaranteed by him for surfaces on which it will be applied. Also
when requested, submit analysis of pigment and vehicle used for a particular brand of paint.

10.3

Application:

10.3.1

All external equipment can be painted with anti corrosive paint suitable for the site at Malad.
Paint manufactures specific written confirmation is required .This also applies to all support
structures .All steel surfaces can be wire brushed and then given two coats of primer and
two coats of anti-corrosive paint

10.3.2

All equipment which does not have factory finish can be given two coats of paint. Where
paints are damaged in transit in case of factory finished products, two coats of the original
colour can be applied.

10.3.3

Equipments which are insulated can be given two coats of approved colour paint over the
surface.

10.3.4

All exposed ducts can be given two coats of paint.

10.3.5

All grilles and diffusers can be powder coated to match with the interior of the rooms as
directed.

10.3.6

All equipment such as air cooled chiller, air handling units, pumps and base frames which
are mounted outdoors can be given 2 coats of anti-corrosive paint over 2 coats of primer
except where supplied with factory finish.

10.4

Piping:

10.4.1

All pipes running inside the building can be given colour codes
ALL PIPES CAN HAVE ARROW MARKS TO INDICATE THE DIRECTION. ARROW CAN BE
PAINTED IN WHITE.

10.4.2

All surface to be painted can be thoroughly cleaned with wire brush and thus remove all
rust and other extraneous substance. Two coats of red oxide primer can be applied over
the cleaned surfaces so that all exposed surfaces are covered. After ensuring the dryness
of the prime coat, the main coat of painting can be applied.

***** ***** *****

54

11.0

ELECTRICAL WORKS:

11.1

The scope of work will cover supply and installation of all panel, cabling and earthing
required for the air-conditioning. Power along with double earthing will be supplied by
others in the Main AC Panel, in each AHU local control starter panel and each split AC unit.
For main AC panel two separate incoming feeders each of 50% capacity of total chiller
plant and terrace air scrubber load can be provided. All further electrical distribution work
connected with air conditioning plant will be in scope of AC agency.

11.2

LT panels:

11.2.1

The LT panel can be fully compartmentalized totally enclosed, free standing/ wall mounting
dust and vermin proof. LT Panels for outdoor installation can be of IP-65 weatherproof,
neoprene gasketed double door construction with glass visors on outer doors in front of
each compartment.

11.2.2

The material of enclosure can be sheet steel CRCA. The thickness of sheet steel can be
2mm for load bearing surfaces, doors and 1.6mm for non load bearing surfaces. All panels
can be front operated and front maintained.

11.2.3

Structure can contain horizontal and vertical bus bars running throughout the length of bus
bar chamber and be readily accessible. Each vertical panel structure can contain a vertical
cable alley.

11.2.4

The LT panel can undergo metal treatment of derusting, phosphating, degreasing, putty
work etc. after which two coats of red oxide primer and two coats of synthetic enamel paint
of approved shade can be applied.

11.2.5

Neoprene or synthetic rubber gasket can be provided.

11.2.6

Suitable hooks can be provided to lift the panels.

11.2.7

The bus bars can be high conductivity tinned copper with fault level capacity of 50KA for
one second adequately supported on epoxy insulators. The minimum clearance between
two phases can be 40mm and between phase and neutral or earth can be 30mm.
Lacquering of copper/plastic coating to be provided.

11.2.8

A continuous copper earth strip can be provided inside the LT panel. The earth bus can be
same size as that of neutral.

11.2.9

Internal wiring - Panels can be supplied completely wired ready for external connections at
terminal block. Wiring can be carried out with 1100/ 650 V grade, PVC insulated, stranded
copper conductors to suit rated circuit current. Engraved identification ferrules, marked to
correspond with the wiring diagram can be fitted at both the end of each wire. All wiring can
be terminated on terminal blocks. Terminals can be numbered and provided with
identification strip for identification of the circuit.

11.2.10

All live accessible parts can be shrouded.

11.2.11

Panels should be extensible on both sides.

11.2.12

All compartment doors can be interlocked with Switch/MCCB front operating handle so that
it is not possible to open the compartment door when the switch is ON position.

11.2.13

Hardware can be hot dip, galvanized, brass/ cadmium plated.

55

11.2.14

All terminal blocks for termination of power cables above 4 Sq.mm can be suitable for
bolted type connections.

11.2.15

Labels can be of anodized aluminium with white engraving on black background. They can
be properly secured with fasteners.

11.2.16

Agency will submit 6 sets of drawings showing constructional details of the panels and get
it approved before commencement of fabrication work.

11.2.17

Tests:
a)
b)
c)

11.2.18

Insulation resistance test with 1000 volt megger.

H.V. Test
General inspection and performance test.

Approval by electrical inspector and certification of complete electrical installation to be

done by AC Agency. This implies preparation and submission and drawings to electrical
inspector as per his requirement and subsequent approval of drawings and complete
installation.
Sanction for power supply will be obtained by others.

11.3

STARTERS:

11.3.1

Starters - The selection for starter can be as under:

Up to and including 7.5 HP
Dol Starters
Above 7.5 HP
Star Delta Starter
All star-delta starters can be fully automatic.

11.3.2

DOL starter can be comprising of the following components of appropriate ratings.

1.

MPCB with short circuit protection and having breaking capacity as specified or Fuse
switch unit.

2.

HOA selector switches.

3.

Power Contactor.

4.

Thermal overload Relay with built in single phasing preventer.

5.

ON-OFF indicating lamps.

6.

Start stop push buttons.

7.

Control fuses.

8.

4 NO + 4 NC Auxiliary Contactor.

11.3.3

Star-Delta Starter can be comprising of the following components of appropriate ratings.

1.

MPCB with short circuit protection and having breaking capacity as specified or fuse switch
unit.

2.

HOA selector switches.

3.

Power Contactor.

4.

Thermal overload Relay with built in single phasing preventer.

56

5.

Synchronous Timer.

6.

ON-OFF indicating lamps.

7.

Start stop push buttons.

8.

Control fuses.

9.

4 NO + 4 NC Auxiliary Contactor.
Operating coils of contactors can be suitable for 230 V, 50 Hz supply system.

11.3.4

CURRENT TRANSFORMERS:
Current Transformers can be of accuracy class I and suitable VA burden for operation of
connected meters. These can be resin bonded and epoxy cast type.

11.4

INSTALLATION OF LT PANELS:

11.4.1

The work can be carried out strictly as per the instructions and layout drawings of the
Manufacturer. In case of any misunderstanding as to the correct interpretation of the
drawings or instruction.

11.4.2

The switch gear can be checked for dimensions as per the manufacturers drawings. The
locations of LT switch gear can be checked as per the layout drawing.

11.4.3

The switch gear should be handled with care under guidance of a competent supervisor.

11.4.4

All the panels can be assembled, aligned and levelled as per the instruction of the
manufacturers drawings. It should be checked that panel to panel coupling bolts and bus
bar links fit properly without any strain on any part. It should also be checked that lowering,
lifting racking in an out of breakers and all motions are free from any obstruction.

11.5

LT CABLES:

11.5.1

Cable can confirm to IS 1554 (part-I) amended up to date.

11.5.2

Voltage grade 1.1 K V

11.5.3

The PVC insulated overall PVC sheathed steel armoured cables can have electrical grade
aluminium conductor expect control cabling and cables of 6 sq. mm size and smaller which
can have electrical grade copper conductor.

11.5.4

The cables can be laid in trenches trays or conduits or along wall/ceiling or buried in ground
as specified in cable schedule or drawing, cable routing given on the drawings can be
checked in the field to avoid interference with structures, piping, ducting and minor
adjustment can be made to suit the field conditions.

11.5.5

All cables can be carefully measured and cut to the required length leaving sufficient length
for final connections to the equipment.

11.5.6

The agency can ascertain the exact requirement of cables and cable trays by measuring at
site along the actually finalized route.

11.5.7

Cable can be neatly arranged in the trenches/trays in such a manner, that criss crossing is
avoided and final take off to the equipment is facilitated.

11.5.8

All cables can be identified close to their termination point by cable marker as per the cable
schedule.

57

11.5.9

Cables can be handled carefully during installation to prevent mechanical damage to the
cables.

11.5.10

BMS cabling to generator set can be buried underground in protective GI pipe with water
proof covering.

11.5.11

Cable installed above ground level can be run in GI perforated type cable trays or run along
the wall duly clamped.

11.5.12

Individual cables or can group of cables can be clamped by means of 2mm thick aluminium
saddles of 25 x 6mm aluminium strips. The cost of such saddle can be included in the cost
of installation of cables.

11.6

Cable Termination:

11.6.1

All PVC cables can be terminated at switch gear/equipment by means of single

compression type brass glands and copper/aluminium lugs.

11.6.2

In case of control cables, all cores can be identified at both ends by their terminal numbers
by means of PVC ferrules.

11.6.3

Agency can drill holes for fixing glands where ever necessary at no extra cost. All holes
required can be made by circular saw cutter only.

11.6.4

Cable leads can be terminated at the equipment terminals by means of crimped type solder
- less lugs.

11.7

EARTHING:

11.7.1

Entire installation of earthing can be confirming to the Indian Standard guideline IS:30431966 code of practice for earthing.

11.7.2

Size of copper earthing wire/strip can follow the below mentioned guidelines:
Up to
15 HP
-12 SWG
Copper wire
Up to

20 to 30 H

--

8 SWG

Copper wire

Up to

35 to 50 HP

--

4 SWG

Copper wire

Above 50 HP -- 25 X 3 mm copper strip

11.8

CABLES TRAYS:

11.8.1

Cable tray can confirm to relevant IS guideline.

11.8.2

The cable trays can be Hot dipped, galvanized GI perforated type made out of 2mm thick
sheet steel 2.5 meters long and 50 in height as per IS standards.

11.8.3

Cable trays installed outdoor can be covered with GI sheet steel covers after cables are
laid.
Note: For ease of maintenance, service and performance especially items like switch gear,
cables etc. only one make can be used. Contactor coil rated voltage can be 230 V AC.

12.0

PREVENTIVE MAINTENANCE CONTRACT:

12.1

The equipment supplied and installed can be maintained by agency as per the below
mentioned guidelines:

12.1.1

REGULAR SERVICE:

58

All equipment will be checked and serviced 12 times in a year. Each such preventive
maintenance service can mainly consist of:
a.
b.
c.
e.
f.
g.

Checking general functioning of all the equipment.

Checking and adjusting belt tension/alignment of all drives, tightening of bolts, etc.
Lubricating bearings of motors and fans and checking oil levels in various
equipment like compressor, motor starter and gear boxes, wherever required.
Checking refrigerant leaks.
Inspecting/adjusting refrigeration controls.
Checking microprocessor panel.

Break down call will be attended to as and when called upon by the owner.
Regular periodic service can also be provided during the warranty / defects liability period
Provision of periodic reports detailing:
12.1.2

Work done
Advance warning of deterioration and proposed remedial action required.
Key status and measurement data for pressures, temperatures etc.

The following will be included in Preventive Maintenance Contract:

a.

Free replacement of defective/worn out parts with new or serviceable parts at

Owners option.

b.

Free over hauling/repairing of equipment at site/service station as and when

necessary.

c.

Chemical cleaning of air cooled condenser coil and fins whenever required

d.

Free replacement of consumables.

e.

Replenishment of refrigerant gas and compressor oil in the system required as a

result of leak in the system.

f.

Painting of equipment installed on terrace/ outdoors

g.

Repairs to or replacement of electrical installation like cabling, dressing of lugs,

switch boards isolators, panels, fuses, strip heaters with associated
ammeters/voltmeters.

i.

Day to day/routine maintenance of plant.

Reapplication of anticorrosive coating frequently as required to avoid

deterioration of components due to air borne chemical attack-- including application
off Lacquer/protective light, oil, films etc.

***** ***** *****

13.0

MAKE OF EQUIPMENT AND MANUFACTURES:

Vendor to provide the data

I.

AIR CONDITIONING
Proposed Makes

1.

Chillers

2.

VAV boxes
59

3.

Fan Coil Units

4.

Pumps

5.

Closed Expansion Tank

6.

Aluminium Grilles

7.

Opposed Blade Damper

8.

Volume Dampers

9.

Fire Dampers

10.

Motors

11.

Starters & Contactors

12.

Air Filters

13.

Sound Attenuators

14.

Pipes & Valves:

14.1

MS Pipes

14.2

Valves & Strainer:

a.

Gate Valve

b.

Balancing Valves

c.

Butterfly Valves with

d.

Butter fly & Ball Valves

e.

Check Valves

f.

Strainer Y type

g.

Vibration Eliminators

15.

Motorized actuator

16.

Insulation:
Fiberglass
Phenotherm
TF Thermocole
Nitrile Rubber class o

17.

Pressure Gauges &

Thermometer

18.

Vibration Isolation Pads

19.

Vibration Isolators

20.

Variable Speed Drives

21.

Controls

22.

Flexible Ducts
60

II.

HVAC RELATED ELECTRICAL WORKS LIST:

1.

Motors

2.

Air Circuit Breaker

3.

Moulded Case Circuit Breaker

4.

Motor Protection Circuit Breaker

5.

Miniature Circuit Breaker

6.

Contactors

7.

Overload Relays

8.

Ammeter, Voltmeter (Digital)

9.

CTs

10.

Selector switches

11.

Indicating Lamps (LED type)

12.

TPN Switches/SFU/Fuse Switches/

HRC Fuses/Control Fuses

13.

Push Buttons

14.

Terminations

15.

Cables

16.

Connectors

17.

Digital KWH Meter with capability

18.

Variable speed drives (VSD)

14.0

Precision air conditioning system for Disaster recovery centre

The following parameters shall be maintained in the Disaster recovery Centre
Temperature : 22+/- 2 Degree C
Humidity: As per latest ASHRAE guidelines.
Detailed Technical Specifications
The package unit shall be in two parts namely INDOOR unit and OUTDOOR unit.
The outdoor unit preferably shall be located at GF level.

14.1

INDOOR UNIT
The indoor unit shall be floor mounted type consisting of Compressor, Cooling Coil, and
Indoor fan. The casing shall be single/double skin design. The outer skin shall be minimum
16G sheet. The front panels are attached to the framework by means of rapid-coupling

61

"fasteners". The standard panels shall be lined up with 15mm thick PUF insulation. Fiber
glass is not acceptable in of insulation.
14.2

COMPRESSOR :
The compressor/s shall be housed in the lower portion of casing. Each compressor shall be
mounted on vibration isolator. Each compressor shall have crank case heater. Machine
should be capable of operation on part load & utilizing total condensation designed for full
load at part load also to achieve high part load efficiency. Each compressor to have
individual circuit for better reliability.

14.3

POWER AND CONTROL PANEL:

The power and control panel for the unit shall be located within the casing. The panel shall
be accessible from front. This panel shall have main power isolator, contactors for
compressor/s, indoor fan/s, outdoor fan/s, humidifier /s, electric reheat etc., Terminal block
with identification ferrules shall be provided to inlet and outlet circuits etc., to suit the
equipment operation. The panel will be connected with main incoming 3 Ph + N power
supply and all other distribution for different components of package unit should be taken
from this panel only. The suction accumulator for each compressor near to it shall be
installed. The control shall be of high end precision fully electronic type control that
maintains the temperature within 0.5C tolerance and the humidity within 5% tolerance.

14.4

COOLING COIL:
Provide cooling coil constructed from copper tubes and aluminium fins with slits. The face
velocity shall be limited to 2.5 m/s (500 fpm) with 5% tolerance, complete with a hydrophilic
treatment to reduce the surface tension between the water and the metal surface, thus
favouring film-wise condensation Shut off valve, Filter drier and Electronic Expansion Valve
for each circuit shall be installed in this chamber. The return air temperature sensor shall be
fixed. If electronic expansion valve is used without any modulating capacity device in the
compressor care shall be taken not to get liquid into compressor while trying to maintain set
superheat. The condensate drain tray shall be of stainless steel and provided to cover full
projected area of cooling coil to collect all the condensed water.

14.5

FILTER:
The return air opening to the under floor discharge unit shall be at top of casing.
The
filter shall in V shape / slant coil to provide maximum area and least pressure drop. The filter
frame shall be designed for easy mounting and dismantling of filter. The filter shall confirm to
EU4. The media can be of pleated type if required. Filter shall arrest particles 3 to 10 size
from 70% to 84.9% as per G4. The face area shall be sized for minimum pressure drop. For
top discharge ducted units the return air inlet shall be either in front or at the rear with filter
suitable located. Low airflow and clogged filter alarm sensors consisting of two pressure
switches for controlling the operating conditions of the fans and the build-up of dirt on the air
filters inside the unit.

14.6

FAN:
Aluminium single-inlet centrifugal electronically commuted EC fans with backward curved
blades with EC. The fan motor shall be multi-speed type. The fan speed shall change as
per the return air temperature based on the signal from controller based on actual cooling
load required. For ducted top discharge unit it shall be located suitable in casing. The plug
fan has an advantage of delivering air in any direction after the impeller position. Though
the top discharge is standard arrangement should be made available to get the air
discharge either from front / rear also. The outlet velocity from the unit shall be in the range
of 7.5 to 8.5 m/s.

14.7

ELECTRICAL HEATING:
Electric heating with aluminium-finned heating elements, complete with safety thermostat
for manual resetting to cut off the power supply and trigger the alarm in the event of
overheating. Thanks to the low surface temperature of the heating elements, the air
ionization effects are also limited. This heating system serves a dual purpose:
62

- heating the air in order to reach and maintain the set point;
- reheating in the dehumidifying phase, so as to restore the air temperature to the set point.
As a result, the installed heating capacity is sufficient to maintain the dry bulb temperature
in the room during operation in dehumidifier mode.
14.8

HUMIDIFIER:
Immersed-electrode humidifier for modulating sterile steam production
with the automatic regulation of the concentration of salts in the boiler to allow for the use
of untreated water. Proportional control of the humidifier's operation (achieved by
controlling the electric current allowed to pass through the cylinder's electrodes) and the
periodic flushing cycle (controlled (30% to 100%) by continuously monitoring the water's
conductivity) guarantee a perfect efficiency of the system, a low energy consumption and
a greater durability of the components.

14.9

REMOTE AIRCOOLED CONDENSER:

The Remote Air-cooled condenser shall consists of condenser coil/s constructed from
copper tubes) enclosed in a powder coated CRCA frame. The coil shall be V type with fan
mounted at the top suitable for vertical air throw. Minimum face area of coil shall be 1.83m.
The condenser fan shall be propeller type driven directly by brushless direct current (BLDC)
EC motor with multiple speed facility. One condenser shall be coupled to one compressor
for high efficiency performance. This type of condenser is most suited for installation on
terrace. Speed shall vary as per set pressure.

14.10

REFRIGERANT:
Refrigerant shall be CFC free with zero ODP. Accepted refrigerant is R 410 A. The
refrigeration oil shall be synthetic type suitable for the refrigerant on which the unit is
designed. Similarly the components shall be designed with safety factor to suit the
operating pressure of corresponding refrigerant.
Electronic Expansion Valve (EEV) controlled by the microprocessor with special software
created and tested by the manufacture shall be provided. This enables to adjust the flow of
refrigerant fluid through the evaporator, controlling the real evaporator superheating in
relation to variations in the ambient conditions in the room being air-conditioned

14.11

UNIT MICROPROCESSOR CONTROLS:

The microprocessor controller manages the unit operations autonomously. In direct
expansion unit the algorithms permits integral management of the Electronic expansion
valve ( EEV) with consequent optimization of energy saving, constant air flow during
dehumidification and absolute operating stability. Units have been designed and developed
to interact with all the most widely used Building Management Systems, exchanging data
via the most common communication protocols through serial connections.
The unit is capable of communicating through an RS-232 communication support to link
upto 99 units for monitoring and control purposes. The controller should also incorporate 2
additional spare alarm inputs for customer interface ( e.g. Unauthorized entry alarm,
building fire alarm etc) manual override switches & selectable alarms. Local & remote
alarms will be triggered in case of any alarm conditions being reached
The microprocessor control system can be supplied with the following optional cards:
- RS485 serial adapter for data transfer to a central supervisor system with STD protocol or
MODBUS protocol;
- Clock card for managing scheduling operations and for the operations counter functions
- WATER LEAK DETECTOR comprising a control module installed on the electric
switchboard and an external sensor.
Unit should start automatically functioning when power is restored after power failure.

14.12

GROUP CONTROL FUNCTION:

The group control for the multiple units in Disaster recovery center shall be through
intelligent controller loaded with logic software to equalize the running of each unit,
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controlling the working of only required number of units based on the feedback of existing
rack load, switching on the standby unit when there is failure of running unit etc., The
controller shall be compatible to communicate with main IBMS system of the facility with
open protocol and be able to monitor the parameters of Disaster recovery center and flash
alarm if the parameters are out of set range.
14.13

15.0

Tenderer to explore the possibility of free cooling option for DX units for DR site and for
Primary Data Center and provision/include in the proposed solution design.
MISCELLANEOUS CIVIL WORK FOR PLACING CHILLERS AND COOLING TOWER FOR
DATA CENTER
Due shortage of space, it is decided by technical committee for placing the chiller and cooling tower
on the terrace of library building which is proposed for primary data center .For carrying the load of
the system, it is proposed to utilize the column grid of library building. The size of supporting
structure and loading is not available since system is Tenderer specific .Supporting arrangement
shall be worked out by the selected Tenderer and got it approved from IIT Delhi before execution.
Following to be considered by Tenderer for the proposed solution,
Philosophy to carry out the work :
The chillers & cooling tower for Data Centre shall be placed on the roof the library building for that
the drawing of column grid are enclosed herewith the tender documents. The vender require to
construct a platform with frame of grid of I-girders (structural steel) and design of the plate form
shall be carried out in such a manner that load of the entire system will directly be transferred to the
column underneath .In order to ensure transferred of load concentrically to the column below , the
portion of waterproofing including concrete part just above the column head is required to be
removed .The stub column of concrete will be erected with concrete having (1:1:2 nominal mix) on
the column head which include provision of reinforcement for stub column including welding of
reinforcement with the existing reinforcement .The stub column will then support the frame of I
girders (structural steel ) which will be supporting the cooling towers and chiller etc. The size of the
platform and other supporting details shall be finalized by the vender. The work shall be carried out
with CPWD specifications. Tenderer shall require to work out the design and drawing of the
supporting structure as per the proposed system and required to submit as a part of technical bid.
Tenderer shall require carrying out the design the complete system and submitting to IIT Delhi for
vetting before execution.
The measurement of work for payment shall be as under:
All miscellaneous civil works for provision of cooling tower shall be as per DSR 2012, Tenderer
shall require to quote a single percentage above /blow/at per of DSR 2012 rates. The items are
required to be executed as per the approved drawings. All items shall be measured separately for
the quantities executed at site.

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