EPC Bid Document

WBPDCL Sagardighi Thermal Power Project

1x660 MW Unit No. 5, Phase - III

CONTENTS

VOLUME: II-J2 VENTILATION AND AIR CONDITIONING SYSTEM

SECTIONS DESCRIPTION

SECTION-I : AIR CONDITIONING SYSTEM

SECTION-II : VENTILATION SYSTEM

Development Consultants Pvt. Ltd. Volume: II-J2

Ventilation & Air Conditioning System
 EPC Bid Document
WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

SECTION - I

TECHNICAL SPECIFICATION

AIR CONDITIONING SYSTEM

Volume: II-J2
Development Consultants Pvt. Ltd. Section: I
Air Conditioning System
 EPC Bid Document
WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

CONTENT

CLAUSE NO. DESCRIPTION PAGE NO.

1.00.00 SYSTEM DESCRIPTION 1

2.00.00 SCOPE OF SUPPLY 5

3.00.00 CONTROL PHILOSOPHY 19

4.00.00 DESIGN CRITERIA 26

5.00.00 DESIGN AND CONSTRUCTIONAL REQUIREMENT 30

6.00.00 TESTING AND INSPECTION 58

7.00.00 DOCUMENTS, DATA TO BE FURNISHED 59

ATTACHMENT

8.00.00 LIST OF DRAWINGS 62

Volume: II-J2
Development Consultants Pvt. Ltd. Section: I
Air Conditioning System
 EPC Bid Document
WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

SECTION - I

AIR CONDITIONING SYSTEM

1.00.00 SYSTEM DESCRIPTION

This Specification covers the Air Conditioning Systems required for One (1) unit
of 660 MW, Phase – III Extn. Unit # 5 at Sagardighi Thermal Power Station
located in Manigram, Murshidabad, West Bengal, India.

1.01.00 The air conditioning system shall cover minimum of the following areas: .

I. POWER HOUSE BUILDING :

a) Unit Control Room on Operating Floor

b) EER unit Room on Operating Floor

c) Record Room on Operating Floor
d) Shift In-charge Room
e) C & I Lab at operating floor
f) Computer Room at operating floor
g) Maintenance Room ,if any
h) DC charger & UPS Room on Mezzanine Floor
i) UPS Battery Room (In case of NiCad batteries) at Mezzanine Floor
j) 24V DC Battery & Battery Charger Room at Mezzanine Floor
k) Workstation between Unit #4 & Proposed Unit #5
l) Operators room at Ground Floor
m) IO Panel Room for CPU at ground floor
n) Dry Panel Room of Steam and Water Analyzer System (SWAS) at
Ground Floor
o) R & I Lab at mezzanine floor and Workstation area, if any

II. ESP CONTROL BUILDING FOR UNIT - 5

a. ESP Control Room

III. CW PUMP HOUSE FOR UNIT – 5

a) CW Pump House Control Room

IV. FGD & SCR Control Room

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Air Conditioning System
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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

V. Wagon Tippler control room

VI. CW Treatment & CW Chlorination Control Room

VII. Vacuum Pump House RIO Room Unit # 5

VIII. AC Plant Control Room

IX. Centralized Fire Fighting Control Room.

X. All elevator machine rooms

XI. Control Room of the Ash Handling Plant

XII. Control Room of the Coal Handling Plant

Any other local Control Room with or without Programmable Logic

Controllers (PLC) or having controllers with microprocessor based
operation.

B. For any existing building, if augmentation of AC system is required due to

the increase in equipment load/room areas, the same is also to be
included.

NB: Wherever NiCad Battery, AC System is to be provided with small fume

vent with louver to be provided

1.02.00 One Central Chilled Water Plant for the Unit-5 shall be provided which shall
cater to the Air conditioned areas of the Power House Building. Following
AHUs shall be fed with chilled water generated in the Central Chilled Water
Plant:

3 X 50% capacity AHU to be considered for the for the Control Room,
EER Unit Room, C&I Maintenance Room, if any, C&I Lab, Computer
Room, Shift in-charge Room, Record Room, Computer room on
operating floor. These AHUs shall be located in one common AHU
room and shall be complete with duct mounted High Efficiency Filter
as well as necessary Heater and Humidifier.

3 X 50% capacity Air Handling Units (AHU) shall be provided for DC

charger & UPS Room, 24V DC Battery & Battery Charger Room on
Mezzanine floor. These AHUs shall be located in one common AHU
room and shall be complete with duct mounted High Efficiency Filters
as well as necessary Heater and Humidifier.

2 x100% capacity Air Handling Units (AHU) shall be provided for

Workstation between Unit #4 & Proposed Unit #5 and C&I Lab.

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Air Conditioning System
 EPC Bid Document
WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

2 x100% capacity Ceiling Suspended Air Handling Units (AHU) shall be

provided for SWAS Dry Panel Room at Ground Floor.

2 x100% capacity Ceiling Suspended Air Handling Units (AHU) shall be

provided for AC Plant Control Room.

NB: If any other Control Room is envisaged inside the power House
Building, then it will also be served by AHUs.

Above mentioned air distribution system with AHUs and GI ducting shall be
complete with supports and hangers and thermal & acoustic insulation,
grilles/diffusers, volume control dampers, flexible connection, Heaters &
Humidifiers and motorized Fire dampers with frame and support etc.

The condenser cooling water shall be circulated through the condensers of

Chiller units and Cooling Towers by means of centrifugal type Condenser
Water (CW) Pump sets. The chilled water produced by the chilling unit/s shall
be circulated to the Air Handling Units (AHU) by centrifugal type Chilled Water
(CHW) Pump sets. At the AHUs, air from the service space will be cooled by
exchanging heat with the chilled water through cooling coil to maintain the
specified design conditions, as indicated under Clause No.4.01.00. The flow
of chilled water through the cooling coil of each AHU will be controlled by
means of a motorized 3-way mixing valve provided with the cooling coil outlet.
Such control valve will operate with the sense of the Temperature sensors
placed in the RA path through Central Control Panel.
The conditioned air from AHUs is distributed to the areas being air
conditioned, through a network of galvanized sheet steel ducting, thermal
insulation (for entire SA Ducting) and acoustic insulation (5.0 M from the
outlet of AHUs) of ducting, duct mounted Electric Strip Heater & Pan type
Humidifiers (wherever applicable) and supply air diffusers/grilles. The return
air is conveyed over the False Ceiling through RA grilles and diffusers and led
back to the AHU rooms.

1.03.00 The Central chilled water plant to serve the Turbine building areas will be,
consisting of:

3 X 75% capacity Water cooled Semi-hermetic Screw Chiller

3X50%capacity Condenser Water (CW) Pumps in line with the capacity
of screw chiller.
3x50% capacity Chilled Water (CHW) Pumps in line with the capacity of
screw chiller.
2 x100% capacity Induced Draft Cooling Towers of FRP construction
with FRP basin (1R+1S) in line with the capacity of the condenser water
pumps.
One no. Make-up water tank with two nos. (1R+1S) Make-up water
booster Pumps with associated piping & valves, if required.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

One no. Non chemical water treatment equipment at the common

header of CW pumps.
One no. Chilled Water Expansion tank
Condenser Water piping and insulated Chilled Water piping with valves
& other accessories.
Required nos. of suitable capacity Tube Axial Exhaust fans shall be
provided for Ventilation system of Chilled water Plant Room.
Necessary electrical equipment like MCC, Local PLC panel for AC
Plant room equipment, Local Starter Panels (LSP) housing PLC and
Push-button Stations, power cabling, control & Instrumentation
cabling, grounding and controls and instrumentation including Central
Programmable Logic Control system (PLC) with Supervisory controller
and workstation PC.

Among these water chilling units, one of the three nos. Screw Chiller will
remain as stand-by. Of these three chilled water pumps, condenser water
pumps and Cooling Towers, one unit will act as stand-by in each case.

1.04.00 As per the discretion of client/consultant 3 X 50 % or 2 X 100% capacity

Water Cooled Packaged Units (Precision Type) shall be used for air
conditioning of the ESP Control room in ESP Control Building, depending upon
the cooling requirement. The Condenser water pumps and the Cooling towers
serving Power house building will also cater to the requirement of the Precision
Air Conditioners of the ESP Control room.

Capacities of the Cooling towers and Condenser water pumps shall be so

designed that they can be able to serve both TG building chillers as well as
Precision Air Conditioners for ESP building.

1.05.00 As per the discretion of client/consultant 3 X 50 % or 2 X 100% capacity Air

Cooled Packaged Units (Precision Type) shall be used for air conditioning of
the Control room in Ash handling Plant, depending upon the cooling
requirement.

1.06.00 As per the discretion of client/consultant 3 X 50 % or 2 X 100% capacity Air

Cooled Packaged Units (Precision Type) shall be used for air conditioning of
the Control room in Coal handling Plant, depending upon the cooling
requirement.

1.07.00 Air cooled non-duct-able Split Air Conditioners with 100% Standby Capacity
shall be provided for the IO Panel Room for CPU at Power House Building
ground floor, CW Pump House Control Room, FGD Control Room, , Operator’s
room, Vacuum Pump House RIO Room Unit # 5, Centralized Fire Water
Control Room, office rooms, elevator machine rooms and any other local
control room/s where chilled water transportation is not possible.

1.08.00 Systems described above is only minimum requirement. Any other area/s, if
demanded by the process / equipment should be air conditioned with 2 X 100

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

% capacity Spilt ACs and 2 X 100 % or 3 X 50 % Precision ACs, depending

upon the cooling requirement.

1.09.00 Motorized Fire Dampers shall be provided in the Supply air ducting crossing
the walls of the individual control rooms.

1.10.00 Smoke Exhaust system shall be incorporated with Air handling system to be
provided inside the AHU rooms of Power House Building. Such system shall
comprise of the wall mounted tube-axial smoke exhaust fans of suitable
capacities combined with the drive motors, supports, motorized isolating
dampers, exhaust cowl with bird screen, vibration isolators etc. All parts of
this system coming in contact with hot smoke shall be suitable for handling
hot gas / smoke at 4000C for 2 hours. This system will be operated manually
at the discretion of the firefighting personnel, after the fire is extinguished by
the automatic gas suppression system.

2.00.00 SCOPE OF SUPPLY

The subsequent clauses specify the equipment/system for general guidance

only, any other equipment and /or materials necessary to ensure safe and
satisfactory erection, commissioning and operation of the plant shall be
supplied by the bidder.

Quantities of equipment in consideration of the specified redundancy

requirement shall be included in the scope of the Bidder.

2.01.01 Central Chilled Water Plant (Power House Building) consisting of :

i) 3 X 75% capacity Water cooled Semi-hermetic Screw Chiller

ii) 3 x50% capacity Condenser Water (CW) Pumps - (2R+1S)

iii) 3 x50% capacity Chilled Water (CHW) Pumps - (2R+1S)

iv) 2 x100% capacity Induced Draft Cooling Towers of FRP construction

with FRP basin -(1R+1S)

v) One no. Make-up water tank with two nos. (1R+1S) Make-up water
booster Pumps with associated piping & valves

vi) One no. Non Chemical Water Treatment equipment at the common
header of CW pumps.

vii) One no. insulated Chilled Water Expansion tank

viii) Condenser Water piping and insulated Chilled Water piping with
valves & other accessories.

ix) Required nos. of suitable capacity Tube Axial Exhaust fans shall be
provided for Ventilation system of Chilled water Plant Room.

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 EPC Bid Document
WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

x) Necessary electrical equipment like MCC, Local PLC panel for AC

Plant room equipment, Local Starter Panels (LSP) housing PLC and
Push-button Stations, power cabling, control & Instrumentation
cabling, grounding and controls and instrumentation including Central
Probrammable Logic Control system (PLC) with Supervisory controller
and workstation PC.

2.01.02 Clarified water shall be used as supply to the make-up water tank and Chilled
water expansion tank. This condenser cooling water will be treated through the
Non-Chemical Water Treatment Device installed in the common header of
Condenser water pump outlets.

2.01.03 Central Chilled water plant consists of the following equipment.

2.01.04 Water Cooled Screw Chiller Unit of adequate capacity each consisting of :

Screw Compressor : Quantity(As per Manufacturer’s standard)

Type : Rotary Screw type, hermetic/semi-hermetic,

directly driven, R-134a duty or any better
equivalent green gas

Accessories : Accessories including Suction and

discharge valves, Oil Separator, Large
suction strainer, muffler, HP, LP, OP (if
applicable) Motor overload cutout, High
winding temperature cut-out with PTC
sensor and other safety devices as per
Manufacturer’s standard Pressure and
temperature gauges for suction and
discharge, oil chargers and oil check valves,
relief by-pass valve, Automatic capacity
control arrangement with automatic
unloaded starting device, Anti Recycle
device, Heater, Setting and Overhauling
tools, foundation bolts, vibration isolating
device etc.

Drive motor for above : Adequately sized Induction Motor suitable

for AC 415V 10%, 3-Phase, 50Hz 5%
power supply for above

Refrigerant Condenser

Quantity : One (1) No.

Type : Water cooled, horizontal, shell and tube R-

134a duty & capacity to match the above

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

compressor with integrally finned copper

tubes with steel shell having adequate
surface area to cater to the requirement of
the above compressor & to provide
sub-cooling by 20C at least.

Design fouling factor : Not less than .0002 Hr.-Sq. M.0C/Kcal (.001
Hr.-Sq.ft0F/BTU).

Heat removal and Water

flow rate : To be calculated and furnished by the Bidder.

Accessories : Relief valve, vent connection with valve, De-

scaling connection, charging connection,
water flow switch, drain connection with
valve. Thermo-well connections on water
side, liquid trap etc.

Refrigerant Chiller : One (1) No.

Type : Horizontal shell and tube direct expansion

type R-134a/water duty with copper tube
having adequate surface area to provide
superheating by 3 Deg.C. Flooded type
chiller (for capacity more than 100TR) may
also be acceptable.

Design fouling factor : Not less than 0.00013 Hr.-Sq. M. 0C / Kcal

(0.00065 Hr.-Sq. ft 0F / BTU ).

Heat removal and

Water flow rate : To be calculated and furnished by the Bidder.

Accessories : Liquid and water connection provided with

thermo-wells, water flow switch and pressure
gauge connections. Bidder shall provide at
least 38 mm thick insulation of Aluminium foil
faced closed cell elastomeric Nitrile Rubber
/XLPE or equal, with removable type
insulated flange cover, water side drain
connection with valve in every portion of the
chiller isolated by baffle plates.

Piping & Auxiliaries : Common base frame for compressor,

condenser, chiller unit fabricated of M.S.
angles, channels etc. anchor bolts, nuts, hot
gas piping, cold gas piping, liquid refrigerant
piping all of seamless steel or ERW steel
pipes, insulation of cold gas piping with
minimum 38 mm thick Aluminium foil faced
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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

closed cell elastomeric Nitrile Rubber /XLPE

section /sheet (for pipe sizes over 100 NB)
finished with treated woven UV-protected
glass cloth ( factory laminated with the
insulation material) (for outdoor piping),liquid
valves, muffler if needed, gauges and
instrument piping, filters, drier, moisture
indicator isolating valves etc. as may be
required for safe and trouble free operation.
The entire chiller package assembly shall be
installed with spring type vibration isolation
devices.
Equipment drain water connection with
siphon and valves, fittings etc. up to the
nearest drain point with proper insulation
shall also be included.
Controls : Electronic expansion valve, solenoid valve in
the refrigerant circuit, operating thermostat
and anti freeze thermostat.
Microprocessor based control panel of each
Chiller unit will provide safety against high &
low refrigerant pressure, low oil pressure,
freezing of chilled water, overload, winding
heating and single phasing and phase
reversal of compressor by means of high &
low pressure transmitter, oil pressure
transmitter, temperature sensors &
transmitter, O/L relays, thermistor relays, etc.
It will also provide capacity control by sensing
low chilled water return temperature through
operating thermostat/ temperature sensor,
flow switches for the condensers and chillers,
compressor unloaded starting device
Such Microprocessor based Control Panel
shall be provided with 20% extra properly
wired I/O units.
Oil and Refrigerant : First charge of refrigerant R-134a and oil for
the above chiller units.
2.01.05 Condenser cooling water piping between cooling towers and condensers
through the condenser cooling water pumps complete with valves, bends,
strainers, fittings, instruments, hangers and supports etc. Equipment drain
water connection and valves, fittings etc. up to the nearest drain point shall also
be included. A single line diagram in this connection is to be furnished by the
Bidder.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

Necessary condenser cooling water piping (with all valves, fittings, supports
etc.) between the central plant and Precision Air Conditioners of ESP control
room shall also be included.

2.01.06 Chilled water piping connecting the chillers, chilled water pumps and cooling
coils of air handling units and expansion tank, complete with valves, bends,
strainers, fittings, instruments, hangers and supports, insulation etc. Equipment
drain water connection with siphon and valves, fittings etc. up to the nearest
drain point with proper insulation shall also be included. A single line diagram in
this connection is to be furnished by the Bidder.

The insulation shall be at least 38mm thick closed cell elastomeric Nitrile
Rubber /XLPE section /sheet (for pipe sizes over 100 NB) finished with treated
woven UV-protected glass cloth ( factory laminated with the insulation material)
(for outdoor piping).

Indoor piping shall be insulated with Aluminium foil faced (factory laminated)
insulation like closed cell elastomeric Nitrile Rubber or XLPE pipe section/sheet
(for pipe sizes over 100NB).

The insulation shall be at least 38mm thick Aluminium foil faced Nitrile Rubber
/XLPE or equal (Refer elsewhere for detailed specification of insulation).

For Chilled water drain pipes the insulation thickness shall be at least 26 mm.

2.01.07 Make up water piping of medium class GI complete with fittings, hangers /
supports from Make-up Water tank shall be provided to various points of
consumption like cooling tower sumps, expansion tank and Humidifiers.

2.01.08 Condenser Cooling

Water Pumps : Three (3) Nos. (2 working + 1 Stand-by)

Type : Centrifugal, horizontally split casing/Back

Pull-out type, single stage directly coupled to
electric motor and mounted on a common
base frame.
Speed : Preferably not more than 1500 rpm.
Capacity & Head : To be calculated and furnished by the Bidder.
Duty : Continuously running.
Accessories : Pressure gauges at suction and discharge,
isolating valves, all integral piping, required
for sealing, cooling etc. strainers, check
valves, flexible coupling guard, foundation
bolts and nuts etc. and other standard
accessories as may be necessary for
successful operation. Vibration isolators shall
also be supplied.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

Motor for the above : Adequately sized TEFC, squirrel cage

induction motor, suitable for 415 V ±_10%, 3
pH, 50 Hz ± 5% supply

2.01.09 Chilled Water

Circulating Pumps : Three (3) Nos. (2 working + 1 stand-by)

Type : Centrifugal, horizontally split casing/Back

Pull-out type, single stage directly coupled to
electric motor and mounted on a common
base frame.

Speed : Preferably not more than 1500 rpm.

Capacity and Head : To be calculated and furnished by the Bidder.

Accessories : Pressure gauges at suction and discharge,

isolating valves, all integral piping required
for sealing, cooling etc., mechanical seal
strainers, check valves, flexible coupling
guard, foundation bolts and nuts, complete
insulation with minimum 38 mm thick closed
cell elastomeric Nitrile Rubber / XLPE or
equal with 24G aluminium sheet cladding.
For the pumps, vibration isolators shall also
be supplied.

Duty : Continuously running.

Motor for the above : Adequately sized, TEFC squirrel cage

induction motor suitable for 415 V ± 10%, 3
Phase, 50 Hz ±5% supply.

2.01.10 Cooling Tower : 2 Nos.

(1 working + 1 stand-by)

Type : Induced draft cross/counter flow type.

Duty : To meet the requirement of the Chilled

water plant.

Design Wet bulb temp. : 32.50 C.

Approach (Maximum) : 40 C.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

Construction

• Casing : FRP

• Louvre : FRP

• Fill : PVC

• Drift eliminator PVC

• Strainer : Brass /SS wire mesh

Headers and pipe

connection : G.I.

• Basin : FRP

Nuts and Bolts etc. : Suitable corrosion resistant material

i.e. G.I. or cadmium plated.

• Accessories : Supports, supporting structure, make-up

water piping with float valve, drain
connection with siphon and valve, over flow
and quick fill connections, Low Level Switch
with alarm, platform with ladder to attend the
fan deck etc.

2.01.11 Expansion Tank

The expansion tank shall be made of FRP and shall be of adequate thickness
& suitably reinforced. It shall be complete with make-up connection with float
valve, quick fill connection, overflow connection and drain connection with
valve. The tank shall be provide with level gauge glass and shall be completely
insulated with 6 mm thick Aluminium foil faced closed cell elastomeric Nitrile
Rubber /XLPE or equal. The capacity shall be selected based on 1.2% of
circulated chilled water capacity. Soft and filtered water shall be supplied as
make-up.

2.01.12 Make-Up Water Tank

The Make-up water tank shall be made of FRP and shall be of adequate
thickness and suitably reinforced. It shall be complete with make-up connection
with float valve, quick fill connection, overflow connection and drain connection
with valve. The tank shall be provided with level gauge glass. This tank will
supply make-up water to Cooling towers, Expansion tank and humidifiers. The
tank size is to be designed based on capacity to hold water for minimum15
minutes of make-up water requirement for above.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

2.01.13 Make-Up Water Booster Pumps

Two (2) Nos.(1R+ 1S) Mono block type centrifugal pump to supply make-up
water from the Make-up water tank to the Cooling towers, Expansion tank and
humidifiers, each complete with drive motor, common base plate, isolating
valves, non return valve etc shall be provided.

2.01.14 Non Chemical Water Treatment Equipment

One (1) No. Non Chemical Water Treatment Equipment shall be provided at
the common Discharge Header of the CW pumps.

Type & Accessories : On line Non-chemical water treatment

equipment to suit the common condenser
water header. The equipment shall be
complete with flanges at ends and
supports/hangers.

2.02.00 Air Handling Units

2.02.01 Each Air Handling Units (AHU) shall consist of the following:

a) DIDW Centrifugal Fan having backward curved blades and belt driven
by TEFC squirrel cage Induction motor suitable for AC 415V ± 10%, 3
Ph, 50 Hz ±5% supply shall be provided.

Accessories shall include V-belts with pulleys, belt guard, slide rail,
common base frame, volume control damper, spring type vibration
isolators etc.

b) 1 No. Cooling Coil will be provided in each AHU. The cooling coil will be
chilled water circulating type.

Construction shall be seamless copper tubes with aluminium fins,

number of fins as per manufacturer's standard but not greater than
five (5) per Cm. [thirteen (13) per inch].

Design fouling factor shall be 0.00013 hr-Sq. M.- 0C / Kcal.

c) Panel type dry HDPE filter having an efficiency of 90% down to 10

micron size particles shall be provided with each AHU. Such filter
modules shall be fixed in a ladder frame and held in position with
quick release mechanism.

2.02.02 GI casing of double skin type with at least 25 mm thick PUF insulation
sandwiched between two skins (made of 24 G GI sheet) and complete with
supply air outlets with volume control dampers and flexible connections,
structural frame work with supports and serrated rubber pads as vibration
isolators and shall be provided with thermal break at the joints of different

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

sections. Outer skin of the AHU shall have electrostatic polyester powder
coating. The casing shall be complete with insulated SS drain pan, insulated
drain piping etc. The AHU's shall be cabinet type with Fan section, Coil section
and filter section.

2.02.03 One set of operating controls consisting of motorized 3-way mixing valve with
cooling coils of AHUs with temperature sensor placed in the RA path, and
associated transmitter for controlling the flow of chilled water.

Temperature & Relative Humidity Indication( At least Three Nos) shall be

provided at CCR

Temperature & Relative humidity sensors and transmitter for heater and
Humidifier control.

2.03.00 Fresh Air System

Fresh air unit each consisting of a tube axial flow/centrifugal fan with drive
motor, inlet louver with bird screen, dry panel HDPE filters, high efficiency filter
for critical areas, volume control damper, supports, supporting structures etc.
for each AHU station/room. 1 x100% capacity Fresh air unit shall be provided in
each AHU room where as for areas with ceiling suspender, there shall be
provision for suitable arrangement of fresh air intake from the nearest
evaporative cooled areas.. Control Rooms airconditioned by Split Air
Conditioners, fresh air shall be taken care of by the opening and closing of
doors.

2.04.00 High Efficiency Filter

High efficiency filter having an efficiency of 99 % down to 5 microns mounted in

supply air duct plenum on a ladder frame with quick release mechanism is to
be provided for air conditioning of all control rooms and allied area. Such filter
set shall be provided with differential pressure switch with alarm. The filter
plenum shall be provided with suitable access for filter maintenance.

2.05.00 Humidifier

Electrode type humidifier consists of high temperature Polypropylene water

tank, electrodes, auto flash cycle activated on demand from the microprocessor
based control system with humidity sensor, located in the AHU room. Infrared
type Humidifier as per manufacturer’s standard shall also be acceptable.

2.06.00 Electric Strip Heaters

One common set of electrical strip heater package of suitable capacity

complete with contactor, air-stat/safety temperature sensor, controlling
temperature and relative humidity sensors and associated transmitter, heater
box with insulation etc. for winter heating and monsoon reheat, mounted inside
the Supply air plenum/duct suitably insulated with aluminium foil faced
fiberglass/mineral wool/rockwool.
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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

2.07.00 Smoke Exhaust System

2.07.01 Smoke Exhaust system shall be incorporated with Air handling system of
control room areas. Such system shall comprise wall mounted tube-axial
smoke exhaust fans of suitable capacities complete with drive motors,
supports, motorized isolating dampers, exhaust cowl with bird screen,
vibration isolators etc. All parts of this system coming in contact with hot
smoke shall be suitable for handling hot gas/smoke at 4000C for2 hours.

This system will be operated manually at the discretion of the fire fighting
personnel, after the fire is extinguished by the automatic gas suppression
system.

2.08.00 Duct Work

Duct work shall include:

a) G. I. Duct having zinc deposition of at least 180 gm/m².

b) Damper with control arrangement at each branch off and wherever

necessary.

c) All supply and return air grilles and diffusers made of extruded
aluminum powder coated and complete with volume control dampers
(for SA grilles / diffusers only) and supporting frames.

d) Flexible connections of rubberized canvas.

e) Hangers and supports.

f) Sealing compound and jointing gasket for ducts.

g) Minimum 13 mm thick Aluminium foil faced Nitrile Rubber / XLPE or

equal or equivalent thermal insulation for the entire air conditioning
ducting.

h) Acoustic insulation of 25 mm thick open cell elastomeric Nitrile Rubber

shall be provided in the ducting up to a length of 5 M from the air
handling unit outlet.

i) Motorized fire damper with sensors, control etc. at strategic locations,

as required. Provision of manual overriding operation through latch shall
also be kept with the Motorized Fire Damper.

2.09.00 Water Cooled Precision Air Conditioners (ESP Control Room)

Water Cooled Packaged Units (Precision Type) of 3x 50% or 2x 100% capacity

(depending on the cooling load) shall be provided for the ESP Control room.
The Condenser water pumps and the Cooling towers serving Power house

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building will also cater to the requirement of the Precision Air Conditioners of
the ESP Control room

Each Water Cooled Precision Air Conditioner shall comprise scroll

compressors (suitable for R-410A/R-407c refrigerant or any better equivalent
green gas as per latest norms) and water cooled shell and tube condensers
(located separately), interconnecting refrigerant piping (duly insulated) between
condensers and PAC units, evaporator fans with EC drive motor and drive
accessories, cooling coil with electronic expansion valve, SS condensate drip
tray (duly insulated) with insulated drain piping, insulated refrigerant piping
inside the PAC unit, high efficiency filters, electrode / infrared type humidifiers,
electric strip heaters and built-in microprocessor based control panel, thermally
and acoustically lined powder coated sheet metal casing (double skin type)
with Supply air outlets and RA grille and maintenance access door of double
skin construction. The casing shall be of double skin type having thickness of
both sheets not less than 22G with minimum 25 mm thick PUF/EPS/ Fibre
glass insulation sandwiched between two skins. Such double skin casing shall
be on all sides including the top surface. Such Air Conditioners will be
associated with air distribution system consisting of a GI duct - work as
elaborated in clause no. 2.08.00(a to i) above.

Provision of a Fresh Air handling unit consisting of Air Inlet Louver with Bird
Screen, Dry panel HDPE filters, Tube Axial Flow Fan with Drive Motor, Volume
control damper, Supports and supporting structures etc. as described in
Clause No. 2.03.00 above shall be kept for each PAC Room.

As per the discretion of client/consultant 3 X 50 % or 2 X 100% capacity Air

Cooled Packaged Units (Precision Type) shall be used for air conditioning of
the Control rooms of Ash handling Plant and Coal Handling, depending upon
the cooling requirement.

Each Air-cooled Precision type Air Conditioner shall be complete with scroll
compressors (suitable for R-410ARefrigerant), Remote air cooled Condensers
with fans and drive motors, D-X type cooling coil with electronic expansion
valve, Evaporator Fans with EC drive motor and drive accessories, SS
condensate drip tray (duly insulated) with insulated drain piping, insulated
refrigerant piping inside the PAC unit, High Efficiency Filters, Electrode type
Humidifiers with controls, Electric Strip Heaters and built-in microprocessor
based control panel, thermally and acoustically lined powder coated MS casing
with Supply air outlets and RA grille. The casing shall be of double skin type
having thickness of both sheets not less than 22G with minimum 25 mm thick
PUF/EPS/Fibre glass insulation sandwiched between two skins. Such double
skin casing shall be on all sides including the top surface and insulated drain
piping. Such Air Conditioners will be associated with air distribution system
consisting of a GI duct - work as elaborated in clause no. 2.08.00(a to i) above.

Provision of a Fresh Air handling unit consisting of Air Inlet Louver with Bird
Screen, Dry panel HDPE filters, Tube Axial Flow Fan with Drive Motor, Volume
control damper, Supports and supporting structures etc. as described in
Clause No. 2.03.00 above shall be kept for each PAC Room.
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2.10.00 Air Cooled Non Duct-Able Split Air Conditioners

Air cooled non-duct-able Split Air Conditioners with 100% Standby Capacity
shall be provided for the CW Pump House Control Room, FGD Control Room, ,
Operator’s room, Vacuum Pump House RIO Room Unit # 5, Centralized Fire
Water Control Room, office rooms, elevator machine rooms and any other local
control room/s where chilled water transportation is not possible.

Air Cooled Non Duct-able Split Air Conditioners complete with hermetically
sealed rotary compressors and air cooled condensers in the outdoor units with
powder coated GI casing, built-in electrical items & supports and Indoor units
housing dry panel type HDPE filters, cooling coils, evaporator fans with two
speed drive motors, all encased in powder coated GI casings with swiveling
type supply air grilles and decorative RA grilles and interconnecting refrigerant
piping duly insulated with 26 mm thick closed cell elastomeric Nitrile Rubber
/XLPE section finished with treated woven UV-protected glass cloth (factory
laminated with the insulation material) for outdoor piping between outdoor and
indoor units and insulated drain piping duly insulated with 13 mm thick closed
cell elastomeric Nitrile Rubber /XLPE section finished with treated woven UV-
protected glass cloth -factory laminated with the insulation material ,
microprocessor based cordless remote control panel and 240V, single phase
MCB with connecting cable for each split unit.

(100% stand-by modules are to be provided for each Control room).

2.11.00 415V Power-Cum-Motor Control Centre / Power Distribution Board

2.11.01 One (1) 415 V Motor Control Centre (MCC) cum Power Distribution Board
(PDB) for supplying power to Water cooled Screw chillers, CW & CHW pumps,
cooling tower fans, Make-up water booster pumps, AC Plant room Ventilation
fans, AHU for AC Plant Control room, feeders (one for each AHU room LSP
and Local & Central PLC Panels. The MCC cum PDB shall be located in the
central Air- Conditioning Plant room.

Such MCC cum PDB will house In-coming MCCB, Aluminium Bus bar,
outgoing DOL starter with MCCB/MCB with power contactors for Cooling tower
Fans, Chilled Water and Condenser Water Pumps, Condensate transfer
pumps, Plunger pump, Makeup water Booster Pumps, Plant room Ventilation
fans, outgoing feeders with MCCBs for Screw Chillers and LSP (located in AHU
room), outgoing feeder with MCB for AHU of AC Plant Control Room and Local
& Central PLC Panels, auxiliary contactors, thermal overload relays, Start-Stop
push buttons, indication lamps for incoming power supply, meters with selector
switches at the Incomer, ON/OFF/TRIP indication lamps, terminal block, etc.

2.11.02 One (1) no. Local Starter Panel (LSP) for each AHU room of Power House
Building. This LSP will house In-coming MCCB, outgoing DOL starter with
MCCB/MCB for AHU fan, fresh air fan and Smoke exhaust fans, if any, and
outgoing feeders with MCBs for 3-way mixing valves, Heaters (wherever
applicable), Humidifiers (wherever applicable) and motorized fire dampers. The
Local Starter panel shall be located in respective AHU rooms.
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2.11.03 One (1) 415V Power Distribution Board (PDB) cum LSP each for supplying
power to the PAC units and associated Fresh air fans (if any) of ESP Control
Room. This PDB cum LSP will house In-coming MCCB, outgoing DOL starter
with MCB for fresh air fan and outgoing feeders with MCCBs for PAC units.

2.11.04 Each MCC cum PDB shall be fed by 2 x 100% incoming feeders, which shall
be located at either end of the panel.

2.11.05 All loads as per process requirements requiring electric power shall be fed from
each MCC cum PDB / PDB cum LSP/LSP under the scope of this specification.

2.11.06 Non Duct-able Split units shall be fed from local distribution board / nearest
power source available in the respective building.

2.11.07 The MCC cum PDB / PDB cum LSP/LSP shall be as per VOLUME II-F/1 &
VOLUME II-F/2 ( SPECIFICATIONS FOR ELECTRICAL EQUIPMENT &
ACCESSORIES [IN TWO VOLUMES)

2.12.00 PLC Based Control Panel

For Details of PLC based Control panel the relevant portion of VOLUME II-E:
SPECIFICATIONS FOR CONTROL & INSTRUMENTATION is to be referred.

2.13.00 Local Push Button Stations

2.13.01 Local Push Button Stations shall be provided for the drive motors of Cooling
Tower Fans, AHUs and Make-up Water Booster Pumps etc.), suitably located
near the said drives. LPBS shall consist of one no. emergency Red Stop P.B
(pressed to latch and turn to release type) for each drive.

2.13.02 Local Push Button Stations shall be as per the relevant Volume of the electrical
specification.

2.13.03 For Other detail VOLUME II-F/1 & VOLUME II-F/2 ( SPECIFICATIONS FOR
ELECTRICAL EQUIPMENT & ACCESSORIES [IN TWO VOLUMES) shall be
referred to.

2.14.00 Local Distribution Board (240V)

Local Distribution Boards containing Switch / MCB for Non Duct-able Split Air
Conditioners.
For detail specification VOLUME II-F/1 & VOLUME II-F/2 ( SPECIFICATIONS
FOR ELECTRICAL EQUIPMENT & ACCESSORIES [IN TWO VOLUMES)shall
be referred to.

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2.15.00 Drive Motors

2.15.01 For Motor details detail VOLUME II-F/1 & VOLUME II-F/2 ( SPECIFICATIONS
FOR ELECTRICAL EQUIPMENT & ACCESSORIES [IN TWO VOLUMES)
shall be referred to.

2.16.00 Supply, Erection, Testing And Commissioning

2.16.01 Supply, erection, testing and commissioning of all electrical drives and
equipment mentioned hereinabove including supply erection, testing and
commissioning of cables, cable trays, grounding of all drives and equipments
for each AC plant and system as required for efficient and trouble free
operation and successful commercial operation.

2.16.02 Erection, testing and commissioning of electrical drive motors and equipment
shall be as per VOLUME: II-F1 & F/2 of specification.

2.17.00 Erection, testing and commissioning of all the equipment and accessories
mentioned hereinabove including supply of all grouting pieces, all matching
flanges, connecting flanges, valves and other fittings bolts, nuts, gaskets and
supporting arrangement as required.

2.18.00 Base plate and foundation plates including anchor bolts, nuts, loose fittings etc.
for equipment and as would be necessary for erection and complete anchoring
of steel materials for the pipes, hangers and supports for water chilling unit and
other equipment.

2.19.00 At least 39mm thick closed cell elastomeric Nitrile Rubber /XLPE section
finished with treated woven UV-protected glass cloth (factory laminated with the
insulation material) on refrigerant piping as required for the Precision type PAC
units and Duct-able units and 26 mm thick similar insulation for Non Duct-able
Split units.

2.20.00 Consumables

All consumables such as grease, lubricating oil for three years trouble free
operation.

2.21.00 Spare Parts

Supply of Mandatory and recommended spare parts for three years trouble free
operation and maintenance is in the scope of the bidder.

2.22.00 Special Tools and Tackles

Supply of special tools and tackle including toolbox required for operation,
maintenance and overhauling of the system is in the scope of the bidder.

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2.23.00 Documents

Drawing, data, characteristic curves and instruction manuals for the equipment
and system.

2.24.00 Training Of Purchaser’s Personnel

Contractor is to arrange for training of purchaser’s personnel for operation and

maintenance of the plant and equipment supplied.

2.25.00 Above clauses specify the equipment for general guidance only. Any other
equipment and/or materials necessary to ensure safe and satisfactory erection,
commissioning and operation of the plant shall be supplied.

3.00.00 CONTROL PHILOSOPHY

3.01.00 Chilled Water Air Conditioning System

The chilled water plant shall operate with, 3 x 75% capacity Packaged Screw
Chiller unit (Two (2) nos. working and One (1) no. Standby), 3x50% capacity
(Two (2) nos. working and One (1) no. Standby), Condenser water (CW)
pumps, 3x50% capacity (Two (2) nos. working and One (1) no. Standby)
Chilled water (CHW) pumps and 2x100% capacity (One (1) no. working and
One (1) no. Standby) induced draft Cooling Towers.

All system will operate from PLC. There will be Connectivity from PLC to DCS
for display of AC plant at running condition. No control is envisaged from
DCS.. Furthermore cooling tower fans and make up Water Booster Pumps
shall also be operated from their individual local Push-button stations.

One (1) no. Local Starter Panel shall be installed in each AHU room which will
feed power to all the AHU fans, motors of 3-way mixing valves of AHUs,
Fresh air fans (wherever applicable), Smoke Exhaust fans (wherever
applicable) and their motorized isolating dampers, Fire damper motors,
Electric heaters and Humidifiers.

One (1) no. Local starter Panel shall also be provided in each of the SWAS
dry panel room and other rooms with Ceiling Suspended AHUs to feed power
to the AHUs for SWAS room, These panels located in each AHU room,
SWAS room, shall be operated and controlled from the workstation through
PLC system located in the AC Plant Room as well as from these Local PLC
Panels.

Motor starters for the drive units of Packaged Screw Chiller Units are
provided in the built in microprocessor based control panels of the respective
Screw chiller units. The drives of these units will be normally controlled from
these built in microprocessor based control panel panels. However, provision
of operation & control of chillers shall also be kept with the AC Plant Room
PLC based Control Panel through proper interfacing between the AC Plant
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Room PLC based Control Panel and Built in Microprocessor based control
panels of respective Screw chiller units.

This AC Plant Room PLC based Control Panel shall also be suitably
interfaced with the DCS system for monitoring purpose.

The Packaged Screw Chilling units can be started only when its associated
cooling tower fan, condenser & chilled water pumps are in operation.

All the drives of the AC system shall be manually started / restarted through
PLC from the work stations after any trip.

The chilled water system shall be provided with the following safety &
operating controls:

a) OPERATING CONTROL

• Room temperature control with the help of modulating 3-way

chilled water flow regulating valve with the cooling coil of AHUs
through the AC Plant Room PLC system, getting sense from
the temperature sensor and associated transmitter placed in
the return air path.

• Chilled water temp. Control based on the room load with the
help of operating temperature sensor and through
compressor’s automatic unloading mechanism for screw
chillers through the built-in Microprocessor based control panel
of Packaged Screw Chiller. This control shall also be possible
through the AC Plant Room PLC system.

• Room RH control with the help of humidifiers (if required) &

duct mounted re-heaters through the AC Plant Room PLC
system getting sense from the RH & Temperature sensors and
their associated transmitters placed in the return air path inside
AHU rooms.

b) SAFETY CONTROL

The chilled water system shall be incorporated with the following

safety controls and interlocks:

• High discharge pressure cutout (HP)

Applicable for Screw

• Low suction pressure cutout (LP) Chillers

• Low oil level cutout

• High winding temperature cutout through PTC sensors

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• Low chilled water temperature cutout by anti-freeze

thermostat /temperature sensor for Screw chiller.

• Cutout due to low flow of chilled water & condenser water by

flow switches.

• Cutout due to overload of all drive motors

• High air temperature cutout by safety thermostat / temperature

sensor for duct mounted electric heaters.

• Low cooling tower sump water level cutout for CW pumps.

(Alarm for low water level in expansion tank & humidifier as
applicable shall be provided).

• Stopping of AHU fans in case of fire in the respective zone

through the central PLC system

• Short circuit protection

• Closing of fire dampers at the air supply duct from AHUs in

case of fire with the sense from room mounted fire/smoke
detector through zone fire panel and the PLC system.

• The Heater for compressors will be energized during

compressor idling time. This safety control shall be actuated
through the built-in Microprocessor based control panel of
each Screw chiller.

• Safety controls of Screw chillers will also include Over/Under

voltage and voltage unbalance protection, Single phase &
Phase reversal preventer, over/under current and current
unbalance protection and others as per manufacturer’s
standard.

c) INTERLOCKS

The system components shall be interlocked with one another in the

following way:

The Screw Compressor shall not start unless:

• At least one cooling tower fan is running.

• At least one condenser water pump is running.

• At least one chilled water pump is running.

The duct mounted electric strip heater shall not be energized unless the
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respective AHU fans are running.

All the above Interlocking shall be actuated through the PLC Panel.

On-Off-Trip status for all the drives, electric heaters & humidifiers (if required)
shall be available at the work stations of the PLC Panel located in the
respective AC plant rooms.

Motors of fire dampers provided in supply air duct of AHU shall remain
energized in normal condition to effect opening of dampers. In the event of
fire, the motors of fire dampers will be de-energized and the damper will close
due to spring action, the relevant AHU fan motors will be tripped at the same
time. The motorized isolating dampers connected to smoke exhaust fan will
be energized to open and the smoke exhaust fan will start after getting signal
from relevant room/ smoke detectors through the fire alarm panel and the
Local Starter Panel located in the respective AHU rooms.

Provision for one common audio annunciation for any kind of malfunctioning
in AC plant shall be kept through a hooter located in the AC Plant Control
Room and suitably interfaced with the PLC Panel.

The control system shall comprise central PLC Panels, Local PLC panels ,
One engineering workstation PC and one operator workstation PC located in
the AC Plant control room.

The basic function of the system is as follows: -

• To closely control and monitor inside temperature and humidity

condition inside the air-conditioned spaces

• To optimize / minimize energy consumption by automated operation.

• To provide centralized monitoring and control for various mechanical

facilities including sequential start / stop of the whole AC system.

• To generate maintenance data and alarms

• To maintain records of plant operation

• Programmed start / stop of individual AHU as per operating

requirements and for maintaining the room temperature / RH by
controlling the 3 way mixing valves at chilled water line, humidifier and
duct heater.

• Safe and reliable operation, supervision & control, alarm & event
management and optimization, maintenance management of the
entire AC system shall be accomplished with the PLC system.
The PLC system shall be interfaced with:

• The Air Conditioning MCC cum PDB

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• The Microprocessor based control panels of Screw Chiller.

• The Local Starter Panels located in each AHU rooms and in the rooms
served by Ceiling Suspended Air Handling Units.

• The Temperature and RH sensors and their associated transmitters

located in the AHU rooms.

• The zone fire panels/ smoke detectors.

• The work station PC and the Hooter.

3.02.00 System Operation

3.02.01 Central AC Plant (Power House Building)

All controls and operation of the AC system equipment and its accessories
with alarm annunciation of the entire AC system shall be achieved through
the PLC in the central AC plant control room.

Over and above, all the screw chiller units shall be provided with built-in
Microprocessor based control panels for their stand alone operation and
control. These built-in control panels of the Chillers shall also be interfaced
with the central PLC system so that all the operation and control for chillers
can also be possible centrally.

A Hooter shall be provided in the AC Plant room and shall be suitably

interconnected with the PLC system so that visual alarm generated in the
PLC system for any malfunction of the AC system and equipment can be
manifested as Audio alarm through the Hooter.

Room temperature and RH control with the operation of motorized 3-way

Mixing Valves, heaters and Humidifiers as applicable and other fire safety
control and operation of smoke exhaust system, AHU fans and fresh air fans
(wherever applicable) shall also be actuated through the central PLC system.

3.02.02 Air Conditioning System with Water-cooled Precision Air Conditioner

This system shall operate round the clock for ESP Control Room.

Water Cooled Precision Air Conditioners of 3x50% or 2x100% capacity

(depending upon the cooling requirement) shall be provided for ESP Control
Rooms, at the discretion of Owner/Consultant.

The Precision Air Conditioners shall be operated from the respective unit
mounted microprocessor based control console.

i) Operating Control

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The Precision Air Conditioners shall have following operating controls:

ON / OFF control of the compressor of Precision Air

Conditioners to maintain the desired room temperature

Superheat control as well as condenser head pressure control

by means of Electronic expansion valve

Room RH control (wherever required) with the help of

humidifier & heater installed within AC units getting sense from
the humidistat placed in the return air path.

ii) Safety Control

The compressor of each Precision Air Conditioner shall be

incorporated with the following minimum safety controls and
interlocks:

High refrigerant pressure cutout.

Low refrigerant pressure cutout.

Low Oil Pressure Cut out (if applicable).

Cutout due to overload of all drive motors.

Stopping of evaporator fans in case of fire in the respective

zone.

Closing of fire dampers at the supply duct from Precision Air

Conditioners in case of fire with the sense from duct/room
mounted fire/smoke detector through zonal fire panel.

Low condenser water flow cutout.

iii) Interlocks

The system components shall be interlocked with one another in the

following way:

The compressor shall not start unless:

a) Condenser water flow is adequate.

b) The evaporator fans are running.

The electric strip heater shall not be energized unless the

respective evaporator fans are running. The Strip heaters will
trip with the help of safety thermostat in case the temperature
of air at the downstream side of the heaters exceeds a pre-
determined value.

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On-Off-trip indications for all the drives & electric heaters shall
be provided at the unit mounted microprocessor based control
console.

3.02.03 Air Conditioning System with Air-cooled Precision Air Conditioner

This system shall operate round the clock for the Control Rooms of Coal
Handling and Ash handling Plant.

Air Cooled Precision Air Conditioners of 3x50% or 2x100% capacity

(depending upon the cooling requirement) shall be provided for the above
Control rooms, at the discretion of Owner/consultant. The Air Conditioners
shall be operated and controlled from the respective unit mounted
microprocessor based control console.

(i) Operating Control:

The Precision type Air Conditioners shall be incorporated with the

following operating controls:

Precision unit compressor/s shall maintain the desired room

temperature on the basis of input from temperature sensor and
associated transmitter placed in the return air path.

Superheat control by means of electronic expansion valve.

Room RH control (wherever required) with the help of humidifiers and

re-heaters getting sense from the humidity sensor placed in the return
air path.

(ii) Safety Control:

The Precision type Air conditioners shall be incorporated with the

following safety controls and interlocks:

High refrigerant pressure cutout

Low refrigerant pressure cutout

Low Oil Pressure Cut out (if applicable)

Cutout due to overload of all drive motors

Stopping of evaporator fans in case of fire in the respective

zone

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Closing the fire damper at the supply duct from PAC units in
case of fire with the sense from room mounted smoke / fire
detector through zonal fire panel.

Safety controls of Precision Air Conditioners will also include

Over/Under voltage and voltage unbalance protection, Single
phase & Phase reversal preventor, over/under current and
current unbalance protection and others as per manufacturer’s
standard.

(iii) Interlocks:
The system components shall be interlocked with one another in the
following way:

The compressor shall not start unless:

The condenser fans are running.

The evaporator fans are running.

The electric strip heater shall not be energized unless the respective
evaporator fans are running. The Strip heaters will trip with the help of
temperature sensor in case the temperature of air at the downstream
side of the heaters exceeds a pre-determined value

3.02.04 Non Duct Able Split Air Conditioners

Non-duct able Split air-conditioners will be controlled from the unit mounted
Control panel or from the cordless hand operated remote.

4.00.00 DESIGN CRITERIA

4.01.00 The following criteria shall be considered for determining the capacity of air
conditioning system and selection of individual equipment.

The bidder shall calculate independently based on following design parameters

and satisfy himself regarding inside conditions and confirm the same.

Outdoor design condition : Summer : 41.5 Deg. C (DB),

32.5 Deg. C (WB)

Monsoon : 34.45 Deg. C DB,

31.0 Deg. C WB

Winter : 13.05 Deg. C DB,

10.5 Deg. C WB

Inside design condition : 230C ± 10C DB & RH 50 % ± 5% (for

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associated areas of in operating floor,

UPS & associated areas in mezzanine
floor of power house building, ESP
control room of ESP control building.)

23°C ± 1°C DB & RH not exceeding 65%

for SWAS room(dry panel), CPU
regeneration control room, mill reject
control room in ground floor, AC plant
control room located near AC plant room
in power house building, Service building,
small control rooms (served by non-
ductable split AC) located in other
buildings.

Control Room Temperature to be maintained at 23 +/-1 Deg C. Bidder shall

design accordingly considering temperature at plant site shoot up to 55 Deg C.

Any equipment/process demanding any other (less) temperature shall be

provided with.

Floor area : As per actual layout

Roof area : As per actual layout

Glass area : As per actual layout

Lighting load : 20 Watt / Sq. M (or actual) for all areas

except C & I Engineer's Room where 15
watt per Sq. M (or actual) shall be
considered.

Occupancy : One (1) person in 12 Sq. M (or actual)

Equipment/Panel load : As actual.

Solar load : Solar and transmission load through

walls, roofs, doors, windows, glazing,
floors etc. should be considered.

Ventilation Air : Fresh air to be considered at the rate of

1.5 air changes per hour for the control
rooms and 1 air change per hour for
other areas or at least 34 Cu. M / Hr. per
person, whichever is higher, should be
considered to achieve pressurization of
air conditioned space and to meet the
ventilation requirement of occupants.

Other loads : Heat load due to AHU fan motor, duct

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

friction etc. shall be considered while

finding total heat load.

Plant sizing : Plant sizing is to be done by allowing

10% margin on total cooling load
(sensible and latent) calculated on the
basis of above design considerations. An
overall margin of 10% on calculated
cooling load shall be considered in
selecting Plant capacity.

All Condenser cooling water pumps, chilled water pumps and AHUS shall have
further, 10% margin on their flow capacities.

Insulation : Roof over AC space exposed to sun will

be provided with 50 mm thick expanded
polystyrene or equivalent. Roof over AC
spaces not exposed to sun will be
provided with similar insulation of 25mm
thickness.

4.02.00 Individual Air Handling Unit shall be provided for individual facilities. Chilled
water flow control valve (3 way), strip heater and pan humidifier are to be
provided for maintaining inside conditions as applicable.

4.03.00 All water piping for the make-up at cooling tower sump, Electrode/ Infrared
humidifiers, Expansion tank and Make-up water tank etc. shall be provided by
the bidder. Such make-up water piping shall be taken from the nearest clarified
water header.

4.04.00 Electric power supply will be 415V ± 10%, 3 phase, 50 Hz. ± 5% AC. Provision
of single phase power if required for split Acs and other equipment shall be
arranged by the Bidder from their related MCC cum PDB/ LSP.

4.05.00 The basic proposal by the bidder shall be for equipment strictly according to the
technical specification. The location of air conditioning equipment, layout of
ducting, piping etc. shall be designed by the bidder and approved by the
Consultants/Owner.

4.06.00 The bidder shall satisfy himself regarding the refrigerating capacity required for
maintaining the end conditions inside AC spaces before submitting the offer.
For this purpose, Clause 4.01.00 shall be referred to, where the basis of
computing air-conditioning loads is furnished. The bidder shall have to
guarantee the end conditions mentioned in Clause 4.01.00. The Bidder should
furnish all equipment sizing calculations for approval of the Purchaser/
Consultant.

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4.07.00 Codes and Standards

Design, manufacture, inspection and testing of the equipment covered by the

specification shall unless otherwise specified conform to the latest edition of the
standards and codes including all addenda mentioned below :

IS-659 : Safety code for air-conditioning

IS-660 : Safety code for mechanical refrigeration

ASHRAE-23 : Standard method of testing and rating [67

Standards] Air Conditioner.

AR1-450-6 : Standards for water cooled refrigerant

Condenser.

IS-4503 : Shell and tube type heat exchanger.

ASHRAE 22-72 : Method of testing for rating water cooled

refrigerant condenser.

ANSI-8-31.5 : Refrigeration piping.

ANSI-8-9.1 : Safety code for mechanical refrigeration.

AR1-410 : Standard for air cooling and air heating

coils.

AR1-210 : Standard for unitary air conditioning

equipment.

IS-3588 : Specification for electrical axial flow fans.

AMCA-210 : Methods of performance test for fans.

BS-2831 : Methods of test for air filters used in AC

and general ventilation.

IS-4671 : Expanded polystyrene for thermal

insulation purpose.

IS-702 : Industrial bitumen.

IS-1239 : Heavy class Pipes for sizes up to 150

mm dia.

IS-8188 : For Water conditioning.

IS-325 : 3 phase induction motors.

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IS-4029 : Guide line for testing 3 phase induction

motor.

IS-210 : Specification grey iron casting.

IS-2062 : Structural steel

AMCA -Bulletin No. 210 : Standard code of testing centrifugal &

axial flow fans

IS-2825 : Code of practice for welding mild steel

IS-2676 : Dimensions for wrought aluminum and

aluminum alloy sheets and strips.

ASHRAE Code : for various filter

IS-655 - 2006 : Specification for metal air ducts

BS-4735 : Horizontal Burning for XLPE insulation

BS- 4370 Part-1 : Dimensional Stability for XLPE Insulation

BS-476 Part 6 & 7 : Surface Spread of Flame and Fire

Propagation for insulating material

ASTM D 1056 : Water Absorption for XLPE Insulation

Pump design and testing should correspond to the procedure mentioned in

IS-1520.

4.08.00 The refrigerant for Split units shall be as per latest norms.

4.09.00 For requirements of materials of construction, 5.00.00 of this section shall be

referred to.

4.10.00 Special Note

In case any discrepancy is found between requirements of this section and

those mentioned in other sections, stipulations of this section shall prevail.

5.00.00 DESIGN AND CONSTRUCTIONAL REQUIREMENT

5.01.00 General Instruction to The Tenderer

5.01.01 The Tenderer shall refer only to those of the following clauses which are
applicable for this particular project as detailed in clause 1.00.00 and 2.00.00 of
this specification. The clauses which are not applicable for this project shall be
ignored.
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5.02.00 General Design And Constructional Requirement

5.02.01 All the equipment shall be capable of withstanding the stresses which may be
experienced during normal operation and test.

5.02.02 All the equipment shall be designed to permit inter-changeability of parts and
ease of access during inspection, maintenance, installation and repair of
various parts.

5.02.03 All parts subject to substantial temperature changes shall be designed and
supported such as to permit free expansion or contraction without resulting in
leakages, harmful distortion, misalignment or play.

5.02.04 Proposals for repair or any similar operations involving the plugging, welding,
boring or addition of metal to the original castings shall be submitted to the
Purchaser/Consulting Engineer and approval shall be received before any such
work is carried out. Drawing showing details and locations of such
modifications shall be submitted to the Purchaser/Consulting Engineer for his
records.

5.02.05 All equipment shall be heavy duty type suitable for installation in heavy
industries and for long period of uninterrupted service.

5.02.06 All materials used shall conform to the specification and shall be new and first
class in all respects.

5.02.07 Anchor bolts, nuts and seating steel work shall be supplied with the equipment.
Only hexagonal nuts shall be used for holding down the equipment, with proper
lock nuts. All bolt holes shall be spot faced for nuts. In specific cases where not
necessary, spot facing may be omitted.

5.02.08 Casting and welding shall conform to their respective specifications and shall
be free from flaws and objectionable imperfections, machined true and in a
workmanlike manner.

5.02.09 The separate pieces of equipment shall be marked with unit number The
assembly drawings shall indicate part number of each equipment and unit
number for easy correlation.

5.02.10 Coupling guards and belt guards shall be furnished as applicable.

5.03.00 Water Cooled Semi Hermetic Screw Chiller

A Twin Screw Multi Circuit Multi Compressor with built in redundancy

i. The refrigerant compressors shall be screw type as mentioned

in previous sections of the specification.

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ii. The compressor may be hermetically/ semi hermetically sealed

and shall be designed for direct drive and suitable for.R-134A
refrigerant.

iii. The compressor assembly shall be adequately designed for

minimum vibration and noise disturbances.

iv. The shaft seal, if applicable for semi hermetic type shall be of
proven design.

v. All safety devices against high pressure refrigerant, low

pressure refrigerant and low oil pressure shall be provided.
The compressor units must be provided with oil pressure
regulator. All safety devices should be electronically controlled.

vi. The compressor shall also be provided with an oil drain plug.
This should be so located that the oil can be drained out
without removing the compressor.

vii. Capacity control must be achieved by use of slide valve, which

provides fully modulating capacity control from 100% to 10%
(20%, at least) of full load. The slide valve shall be actuated by
oil pressure controlled by external solenoid valves.

viii. The horse power of the compressor motor shall be sized for
115% of maximum rated power required for the unit including
the drive loss.

ix. The compressors shall be provided with built-in-unloaded

starting device. The compressor shall have automatic capacity
control device preferably built-in-type to match reduced
refrigeration load.

x. The oil separator should be effective enough to incur gravity

drop out of oil from the refrigerant gas before it enters the
condenser.

B Heat Exchangers (Condensers & Chillers)

i. All condensers shell be of shell and tube type with water in the
tubes and refrigerant in the shell.

ii. All chillers for chilled water plant shall also be of shell and tube
type.

iii. The heat exchangers shall be designed for a minimum working

pressure of 10.5 kg / Sq. Cm gauge (about 150 psig) on the
water side and 12.0 kg / Sq. Cm (for R-134a refrigerant), 17 kg /
Sq. Cm (for R-22 refrigerant) and 27 kg / Sq. Cm (for R-410A

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refrigerant), on the refrigerant side and shall conform to the

latest ASME CODE for unfired pressure vessels SECTION VIII.

iv. The design pressure shall have a reasonable margin over the
maximum working pressure.

v. The average velocity of water in tubes shall not be more than

2.5 M/Sec.

vi. Water heads or refrigerant heads of the heat exchangers shall

be designed such as not to allow leakage of fluid from one pass
to the other.

vii. Tube supports of adequate strength shall be provided to prevent

the tubes from sagging and vibrating. The supports shall be as
per TEMA Standard.

viii. The overall fouling factor for the condensers and chillers shall
be minimum 0.0002 and 0.00013 hr.Sq.m Deg. C/K.Cal
respectively.

ix. The condensers shall be designed to provide at least 2 C. sub

cooling of refrigerant under rated design condition. The water
chillers also shall be designed to superheat the refrigerant by at
least 3 C. under rated design condition.

x. Testing and other design feature of the beat exchangers shall

meet the requirements of TEMA Class-C heat exchangers or
approved equal.

xi. The heat exchangers shall have open able water boxes for ease
in maintenance.

xii. The tube for water chillers shall be of de-oxidized copper with or
without integral fins. The tubes for the condensers shall also be
of copper with integral fins. The tube wall thickness at any point
shall not be less than 18 SWG.

xiii. The baffle plates and the tube sheets shall be made of steel.
The shell shall be made up of seamless steel tube or shall be
fabricated from flange quality steel plate (ASTM-A 285
Grade-C). The tube support plates shall be made of flange
quality carbon steel plates and shall be as per TEMA Standard.
(Class C).

xiv. The heat exchangers shall be provided with vent valve, relief
valve, and or safety fusible plug on refrigerant side and vent
valve and drain valve on water side (at every section of the
baffled shell of heat exchanger).

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xv. The tenderer shall quote packaged unit having compressor,

condenser and chiller assembly together in a single frame work
and mounted on a common base plate.

xvi. Each heat exchanger shall be provided with water flow switch.
This shall be interlocked with the control of the individual
refrigeration system.

xvii. All the heat exchangers shall be provided with standard

connections like thermo- wells, inspection valve, antifreeze
thermostat for chillers and external equalizer connection for
expansion valves for chillers.

C GENERAL

i. Twin Screw Multi Circuit Multi compressor chiller to provide in

built redundancy while operation & maintenance.

ii. Input Power Kilowatt/ TR at duty condition should be less than

or equals to 0.66 Kw/TR for a AHRI/EUROVENT certified chiller

iii. Average yearly Power Kilowatt/TR for the water cooled twin
screw chiller not to exceed 0.52 KW/TR for a AHRI/EUROVENT
certified chiller.

iv. Duty Condition for Chiller is 12/7 Deg C in evaporator & 31/36
Deg C in
condenser.

5.04.00 Air Handling Unit

Each Air Handling Units (AHU) shall consist of the following:

a) DIDW Centrifugal Fan having backward curved blades and belt driven
by TEFC squirrel cage Induction motor suitable for AC 415V ± 10%, 3
Ph, 50 Hz ±5% supply shall be provided.

Accessories shall include V-belts with pulleys, belt guard, slide rail,
common base frame, volume control damper, spring type vibration
isolators etc.

b) 1 No. Cooling Coil will be provided in each AHU. The cooling coil will
be chilled water circulating type.

Construction shall be seamless copper tubes with aluminium fins, number of

fins as per manufacturer's standard but not greater than five (5) per Cm.
[thirteen (13) per inch].

Design fouling factor shall be 0.00013 hr-Sq. M.- 0C / Kcal.

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c) Panel type dry HDPE filter having an efficiency of 90% down to 10

micron size particles shall be provided with each AHU. Such filter
modules shall be fixed in a ladder frame and held in position with
quick release mechanism.

d) GI casing of double skin type with at least 25 mm thick PUF insulation

sandwiched between two skins (made of 24 G GI sheet) and complete
with supply air outlets with volume control dampers and flexible
connections, structural frame work with supports and serrated rubber
pads as vibration isolators and shall be provided with thermal break at
the joints of different sections. Outer skin of the AHU shall have
electrostatic polyester powder coating. The casing shall be complete
with insulated SS drain pan, insulated drain piping etc. The AHU's shall
be cabinet type with Fan section, Coil section and filter section.

e) One set of operating controls consisting of motorized 3-way mixing

valve with cooling coils of AHUs with temperature sensor placed in the
RA path, and associated transmitter for controlling the flow of chilled
water.

f) Temperature & Relative humidity sensors and transmitter for heater and
Humidifier control.

5.05.00 Water Pumps

I. Material of the pump shall preferably as follows:

a) Casing : Cast iron, grade 20 as per IS-210
b) Impeller & Wear Rin : Bronze
c) Shaft : Carbon steel C-45, IS 1570 or Class-
IV, IS1875
d) Shaft sleeve : Bronze / SS

II. Each water pump set shall consist of the following:-

a) One no. horizontal split type centrifugal pump of adequate capacity to
match the package chiller system requirement.
b) One (1) No. adequately sized TEFC sq. cage induction motor, suitable
for 415V 10%, 3 phase, 50Hz 5% AC Supply.
c) One (1) no. Y-Type strainer at inlet complete with brass screen, drain
arrangement etc.
d) 150mm dia. Dial Type pressure gauges one each at suction &
discharge side of the pump set.
e) Gate valve, one each at suction side and Globe valve, one each at
discharge side of pump set.
f) One (1) no. non-return (check) valve at discharge side of pump set.
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g) One set of base plate (common for pump and motor), mechanical
seal, coupling, coupling guard, anti-vibration mountings, foundation
bolts etc.
h) One (1) no. Flow measuring device at the common discharge header.
i) Operating speed of the pump shall not preferably be more than 1500
rpm.

5.06.00 Induced Draft Cooling Towers (Frp Type)

a) Cooling Tower : 2 Nos. (1 working + 1 stand-by)

b) Type : Induced draft cross/counter flow type.

c) Duty : To meet the requirement of Chilled water

plant.

d) Design Wet bulb temp. : 32.50C.

e) Approach (Maximum) : 40C.

f) Material of construction
Casing : FRP
Louvre : FRP
Fill : PVC
Drift eliminator : PVC
Strainer : Brass /SS wire mesh
Headers and pipe connection : G.I.
Basin : FRP
Nuts and Bolts etc. : Suitable corrosion resistant
material i.e. GI or cadmium
plated.

g) Other accessories shall consist of supports, supporting structure,

make-up water piping with float valve, drain connection with siphon and
valve, over flow and quick fill connections, Low Level Switch with alarm,
platform with ladder to attend the fan deck etc.

5.07.00 Non-Chemical Water Treatment Equipment

One (1) no. Non Chemical Water Treatment Equipment shall be provided at the
common Discharge Header of the CW pumps.

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It shall consist of On-line Non-chemical water treatment equipment to suit the

common condenser water header. The equipment shall be complete with
flanges at ends and supports/hangers.

5.08.00 Expansion Tank (Insulated)

The expansion tank shall be made of FRP and shall be of adequate thickness
& suitably reinforced. It shall be complete with make-up connection with float
valve, quick fill connection, overflow connection and drain connection with
valve. The tank shall be provided with level gauge glass and shall be
completely insulated with 6 mm thick Aluminium foil faced closed cell
elastomeric Nitrile Rubber /XLPE or equal. The capacity shall be selected
based on 1.2% of circulated chilled water capacity. Soft and filtered water shall
be supplied as make-up.

5.09.00 Make-Up Water Tank

The Make-up water tank shall be made of FRP and shall be of adequate
thickness and suitably reinforced. It shall be complete with make-up connection
with float valve, quick fill connection, overflow connection and drain connection
with valve. The tank shall be provided with level gauge glass. This tank will
supply make-up water to Cooling towers, Expansion tank and humidifiers. The
tank size is to be designed based on capacity to hold water for minimum15
minutes of make-up water requirement for above.

5.10.00 Fresh Air System

Fresh air unit each consisting of a tube axial flow/centrifugal fan with drive
motor, inlet louver with bird screen, dry panel HDPE filters, high efficiency
filter for critical areas, volume control damper, supports, supporting structures
etc. for each AHU station/room. 1 x100% capacity Fresh air unit shall be
provided in each AHU room where as for SWAS room AHUs, there shall be
provision for suitable arrangement of fresh air intake from the nearest
evaporative cooled areas.

5.11.00 High Efficiency Filter

High efficiency filter having an efficiency of 99 % down to 5 microns mounted in

supply air duct plenum on a ladder frame with quick release mechanism is to
be provided for air conditioning of all control rooms and areas served by AHUs
and PACs only.

Such filter set shall be provided with differential pressure switch with alarm. The
filter plenum shall be provided with suitable access for filter maintenance. Face
velocity of air across the filter shall not exceed 1.25 M/Sec. Maximum air
pressure drop across this filter shall be limited to 15 mm WG.

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5.12.00 Humidifiers

Electrode type humidifier consists of high temperature Polypropylene water

tank, electrodes, auto flash cycle activated on demand from the
microprocessor based control system with humidity sensor, located in the
AHU room. Infrared type Humidifier as per manufacturer’s standard shall also
be acceptable.

5.13.00 Electric Strip Heaters

One common set of electrical strip heater package of suitable capacity

complete with contactor, air-stat/safety temperature sensor, controlling
temperature and relative humidity sensors and associated transmitter, heater
box with insulation etc. for winter heating and monsoon reheat, mounted
inside the Supply air plenum / duct suitably insulated with aluminium foil faced
fiberglass / mineral wool / Rockwool.

5.14.00 Make-Up Water Booster Pumps

Two (2) Nos.(1R+ 1S) Mono block type centrifugal pump to supply make-up
water from the Make-up water tank to the Cooling towers, Expansion tank and
humidifiers, each complete with drive motor, common base plate, isolating
valves, non return valve etc shall be provided.

5.15.00 Smoke Exhaust System

Smoke Exhaust system shall be incorporated with all the AHU rooms. Such
system shall comprise wall mounted tube-axial smoke exhaust fans of
suitable capacities complete with drive motors, supports, motorized isolating
dampers, exhaust cowl with bird screen, vibration isolators etc. All parts of
this system coming in contact with hot smoke shall be suitable for handling
hot gas/smoke at 4000C for2 hours.

This system will be operated manually at the discretion of the fire fighting
personnel, after the fire is extinguished by the automatic gas suppression
system.

5.16.00 Duct Work

Duct work shall include the following :

a) G. I. Duct having zinc deposition of at least 180 gm/m².

b) Damper with control arrangement at each branch off and wherever

necessary.

c) All supply and return air grilles and diffusers made of extruded
aluminum powder coated and complete with volume control dampers
(for SA grilles / diffusers only) and supporting frames.

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d) Flexible connections of rubberized canvas.

e) Hangers and supports.

f) Sealing compound and jointing gasket for ducts.

g) 13 mm thick Aluminium foil faced Nitrile Rubber / XLPE or equal or

equivalent thermal insulation for the entire air conditioning ducting.

h) Acoustic insulation of 25 mm thick open cell elastomeric Nitrile Rubber

shall be provided in the ducting up to a length of 5 M from the air
handling unit outlet.

i) Motorized fire damper with sensors, control etc. at strategic locations,

as required. Provision of manual overriding operation through latch shall
also be kept with the Motorized Fire Damper.

5.17.00 Water Cooled Precision Air Conditioners (ESP Control Room)

Compressor

The compressor shall be hermetically sealed scroll type medium speed,

designed for R-410A duty.

The compressor shall have proper lubrication system. The Suction and
Discharge lines shall be provided with suitable vibration absorbers in order to
reduce the leakages caused due to excessive vibrations during compressor
on/off. Safety devices viz. high-pressure switch, low-pressure switch, low oil
pressure (if applicable) shall be provided and such devices shall be
electronically operated. Manual reset on safety cut out shall be provided. The
horsepower for the compressor motor shall be adequately sized or 110% of
the rated power required for the unit including drive loss.

Capacity control shall be devised by providing at least two compressors.

a. Condenser

All condensers shall be of shell and tube type with water in the tubes and
refrigerant in the shell.

The heat exchanger shall be designed for a minimum working pressure of

10.5 kg/cm2 gauge on the water side and 27.0 kg/cm2 for R-410A on the
refrigerant side and shall generally conform to the latest ASME CODE or any
other European Code for unfired pressure vessels. The design pressure shall
have a reasonable margin over the maximum working pressure.

The average velocity of water in tubes shall not be more than 2.5 m/sec.

Water heads or refrigerant heads of the heat exchangers shall be as not to

allow leakage of fluid from one pass to the other.
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Tube supports of adequate strength shall be provided to prevent the tubes

from sagging and vibrating.

The overall fouling factor for the condensers shall be 0.0002 Hr.M2oC/K.Cal.

The condensers shall be designed to provide at least 2 °C sub cooling of

refrigerant under rated design condition.

Testing and other design feature of the heat exchanger shall meet the
requirements of TEMA Class-C heat exchangers or approved equal.

The heat exchangers shall have open able water boxes for ease in
maintenance.

The tubes for the condensers shall also be copper with integral fins. The tube
wall thickness at any point shall not be less than 18 SWG.

The baffle plates and the tube sheets shall be made of steel. The shell shall
be made up of seamless tube or shall be fabricated from flange quality steel
plate (ASTM-A285 Grade-C or any other relevant European standard). The
tube support plates shall be made of flange quality carbon steel plates and
shall be as per TEMA Standard or any other relevant European standard

The heat exchangers shall be provided with vent valve, relief valve, and/or
safety fusible plug on refrigerant side and vent valve and drain valve on water
side (at every section of the baffled shell of heat exchanger).

The tenderer shall quote packaged units having compressor, and evaporator
assembly together in a single framework and mounted on a common base
plate. Water cooled condenser with its frame and supports shall be provided
separately external to the PAC unit and suitably connected with the PAC unit
through insulated refrigerant piping and necessary fittings. Provision for
refrigerant charging and chemical cleaning of water tubes shall be provided.

Each heat exchanger shall be provided with water flow switch. This shall be
interlocked with the control of the individual refrigeration
system/corresponding compressor drive.

All the heat exchangers shall be provided, with standard connections like
thermo wells, inspection valve. Insulation shall be terminated in such a
manner that it will not be damaged during removal of bolts, covers etc.
Separate covers similar to flange covers shall be constructed to facilitate easy
removal.

b. Evaporator Cooling Coil

The cooling coil shall be direct expansion type with multi-row deoxidised
copper tubes with aluminium fins. Air velocity across the coil shall be limited
to 2.5 m/sec. The coils shall be pressure tested and thoroughly dehydrated
before assembling.
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The coil shall be placed to make the system draw through type. Refrigerant
feed control shall be by electronic expansion valve. Temperature control shall
be through microprocessor based control panel.

The cooling coil shall be to produce the capacity required under specified coil
condition and air quantity. Heat load calculation to check the system selection
shall be carried out and submitted by the tenderer.

c. Evaporator Fan

The fan shall be heavy duty SISW/DIDW centrifugal type statically and
dynamically balanced with forward / backward curve blade, directly driven
with EC motor designed for high efficiency, stepless control of room
conditions and quiet operation. Such control of room conditions by changing
the air flow rate shall be activated through the built-in microprocessor
based/PLC control panel of the unit.

Fan shall have aluminium impeller mounted on steel shaft. The bearings shall
be ball bearing type mounted on vibration absorbing rubber mounts. The fan
motor shall be mounted within the cabinet. Motor horsepower shall be sized
for 120% of the rated power required including the drive loss.

The supply fan shall be sized to deliver the required air quantity against the
total external static pressure required for the system application, after taking
care of all internal static pressure requirements of the units.
.
d. High Efficiency Filter

A set of High efficiency filters will be located inside the PAC unit cabinet. The
filters shall be high efficiency of 99% down to 5 microns. The filters shall be of
cleanable type construction of reinforced glass fibre or cotton fabric or
fabric-like material sand witched in between two galvanized wire netting
arrangement in an uniformly corrugated form to increase the surface area.

The filters shall have G.I. frames of adequate thickness suitable for long use in
an industrial plant. The filters may be in panels of size about 600 x 600 for easy
handling them.

The filter panels shall be mounted on the ladder type angle iron holding frames.
The frames shall be designed strong enough to take the load of double the
pressure drop in dirty condition of the filters. Face velocity of air across the
filters shall not exceed 1.5 m/sec.

e. Humidifier

The humidifier shall be of Electrode type and shall be placed inside the PAC
unit cabinet. The humidifier shall be electronically controlled through the built-in
microprocessor based control panel of the unit. A provision of make-up water
connection with the humidifier shall be kept with the Unit cabinet.
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Electrode humidifier consists of high temperature Polypropylene water tank,

electrodes, auto flash cycle activated on demand from the microprocessor
based control system with humidity sensor, located in the RA path. Such
Humidifier shall be controlled by its own stand-alone microprocessor based
control panel. Alarm indication will be provided for low water level in the water
tank.

Whenever the relative humidity of the conditioned space reaches the

minimum allowable percentage of humidity, the humidifier shall be energized
to restore the relative humidity. The humidifier shall be such controlled that it
shall not exceed the maximum allowable limit of relative humidity in the
conditioned space. The humidifier shall be sized and designed accordingly.

Electric Strip Heater

The PAC unit will be provided wit built-in electric strip heater electronically
controlled through the built-in microprocessor based control panel of the unit.
Such control includes both operating and safety controls with the sense of air
temperature at the RA path and at the downstream side of the heater
respectively.

f. Casing and Cabinet

All components shall be housed in a welded sheet metal cabinet of double skin
of not less than 22 G thick MS powder coated sheets. The gap between two
skins is filled up with at least 25mmthick PUF/ EPS insulation. Different
sections will be constructed with frame work and connected with each other in
an air tight manner through gaskets, thermal barriers and sealant. Such double
skin casing shall be on all sides including the top surface.

Removable panels shall be constructed of framed 1.6 mm sheet steel with

angle iron framing. Units shall be provided with 316 L.S.S. fasteners for easy
removal and access for servicing. Air handling section of evaporator shall be
provided with an acoustic lining of 25 mm thick fibreglass covered with fibre
glass cloth and perforated aluminium sheet/Open cell Nitrile rubber of density
not less than 140 Kg/M3 on the inside surface of the unit casing. Insulated
condensate drain pan of SS construction shall be provided within the unit. The
unit shall be factory assembled, wired, with inter connecting refrigerant piping
and built-in microprocessor based control console and tested as per the
relevant code.

The built-in Microprocessor/PLC based Control panel shall perform at least

the following control functions;

– Room temperature and Relative Humidity

– Speed of delivery fans (EC);
– Alarms on two levels;
– Automatic controlled reset of high and low pressure alarm;

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– Alarm log;
– Management of more than one unit in local network, with automatic
rotation logic and no interference;
– Serial connection to supervision systems.
• The display shall show:
– Room temperature and Relative Humidity
– Alarm description;
– Operation counter;
– Status of the controlled devices.
The display should be graphical with touch screen.
The return air opening shall be on the front face with a matching grille of
same colour finish.

5.18.00 Air Cooled Packaged Air Conditioner (Precision Type)

5.18.01 Compressor

The compressor shall be hermetically sealed scroll type medium speed,

designed for R-410A duty.

The compressor shall have proper lubrication system. The Suction and
Discharge lines shall be provided with suitable vibration absorbers in order to
reduce the leakages caused due to excessive vibrations during compressor
on/off. Safety devices viz. high-pressure switch, low-pressure switch, low oil
pressure (if applicable) shall be provided and such devices shall be
electronically operated. Manual reset on safety cut out shall be provided. The
horsepower for the compressor motor shall be adequately sized or 110% of
the rated power required for the unit including drive loss.

Capacity control shall be devised by providing at least two compressors.

5.18.02 Condenser

The Condenser shall be of Air Cooled type and shall be constructed of copper
tube with aluminum fins. Tubes shall be designed for a minimum working
pressure of 30 kg/ sq.cm. The condenser shall be complete with fans with drive
motors and shall be provided with charging connection, safety relief valve and
standard accessories, all encased in a powder coated GI casing with built-in
electrical items and supporting frame. The condenser shall have the matching
capacity with the compressor. There shall be a provision of isolating switch for
the fans.

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5.18.03 Evaporator Fan

Same as for Water cooled Unit described above.

5.18.04 High Efficiency Filter

Same as for Water cooled Unit described above.

5.18.05 Humidifier

Same as for Water cooled Unit described above.

5.18.06 Electric Strip Heater

Same as for Water cooled Unit described above.

5.18.07 Casing and Cabinet

All components shall be housed in a welded sheet metal cabinet of double skin
of not less than 22 G thick MS powder coated sheets. The gap between two
skins is filled up with at least 25mmthick PUF/ EPS insulation. Different
sections will be constructed with frame work and connected with each other in
an air tight manner through gaskets, thermal barriers and sealant.

Removable panels shall be constructed of framed 1.6 mm sheet steel with

angle iron framing. Units shall be provided with 316 L.S.S. fasteners for easy
removal and access for servicing. Insulated condensate drain pan of SS
construction shall be provided within the unit. The outdoor unit shall be
constructed on a base of electric resistance welded 250 mm channel frame
braced to prevent vibration and weather protection with rust preventive paint for
outdoor installation. Air handling section of evaporator shall be provided with an
acoustic lining of 25 mm thick open cell elastomeric Nitrile rubber of density not
less than 140 Kg/M3 on the inside surface of the unit casing. The unit shall be
factory assembled, wired, with inter connecting refrigerant piping and built-in
microprocessor based control console and tested as per the relevant code.

The return air opening shall be on the front face with a matching grille of same
colour finish.

5.19.00 Air Cooled Non Duct-Able Split Air Conditioners

Air Cooled Non Duct-Able Split Air Conditioners shall be provided in CW

Pump House Control Room and any other confined areas deemed essential by
the bidder.

Air Cooled Non Duct-able Split Air Conditioners complete with hermetically
sealed rotary compressors and air cooled condensers in the outdoor units
with powder coated GI casing, built-in electrical items & supports and Indoor
units housing dry panel type HDPE filters, cooling coils, evaporator fans with
two speed drive motors, all encased in powder coated GI casings with

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swiveling type supply air grilles and decorative RA grilles and interconnecting
refrigerant piping duly insulated with 26 mm thick closed cell elastomeric
Nitrile Rubber /XLPE section finished with treated woven UV-protected glass
cloth (factory laminated with the insulation material) for outdoor piping
between outdoor and indoor units and insulated drain piping duly insulated
with minimum 13 mm thick closed cell elastomeric Nitrile Rubber /XLPE
section finished with treated woven UV-protected glass cloth -factory
laminated with the insulation material , microprocessor based cordless remote
control panel and 240V, single phase MCB with connecting cable for each
split unit.

(100% stand-by modules are to be provided for each Control room).

5.20.00 Piping

A.

B Refrigerant Piping

I. Refrigerant piping shall be either of M.S. Seamless (as per IS- 1239),
Part-I heavy grade) or copper tube (IS-5493) or ASA-B-31.5.

II. Instrument piping for gauges, switches etc. shall be of copper only.
Capillary tubes will be used wherever possible.

III. Spacing and location of pipe hangers shall conform to preferred

engineering practice. Hangers and supports shall be made up of
structural steel sections. The design of the hangers and supports shall
provide for suitable protection to insulation on the pipes, wherever
applicable. All materials for anchoring the hangers with reinforced
concrete work or building structural beams and columns shall be
furnished by the bidder.

C Water Piping

I. Condenser cooling water piping and chilled water piping for 100 NB or
below shall be of GI Heavy Class conforming to IS-1239, Part-I. Pipe
sizes above 100 NB shall be of black steel pipe, heavy grade
conforming to IS-3589, Fe 410 grade. Drain water piping shall be of
M.S. heavy grade/GI-Heavy Class.

II. The piping shall be so designed that the water velocity through the
piping shall not exceed 2.5 m/sec and also the piping friction drop shall
be limited to 2 m per hundred meters of pipe length. Pipe sizes
indicated in tender drawings shall be followed.

III. The pipes shall be of plain end in case of M.S. Pipes (i.e., suitable for
welded connections) as far as possible.

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IV. Counter-flanges for connecting to flanges on valves or equipment shall

be made of IS-2062 or superior and shall preferably be slip on type,
suitable for welding on the piping in case of M.S. Piping.

V. All bolts and nuts for flange connection shall be hexagonal carbon steel
type as per IS-1363 and with the material and other requirements as
per IS-1367. All threaded valves shall be provided with nipples and
flanged pairs on both sides to permit flanged connections for ease of
removal / replacement of valves.

VI. For piping of size above 100 mm bends and fittings, fabricated at site
from straight length of piping, would be acceptable. If instead, the
contractor uses the regular type fittings/bends that shall be as per
IS-1239, Part-II. Welding of joints of fabricated fittings should be such
that they do not obstruct in air the flow or increase the fluid resistance
appreciably.

VII. Spacing and location of pipe supports shall conform to preferred

engineering practice. Hangers and supports shall be made up of
structural steel sections. The design of hangers and supports shall be
provided for suitable protection to insulation on the pipes, wherever
required.

5.21.00 Valves

A. General

Valve pressure classes, sizes, types, body materials, and end prepa-
rations shall generally be as described herein. Special features and
special application valves shall be utilized where required.

Valves specified to have flanged, socket-welded, or screwed

connections shall have ends prepared in accordance with the
applicable ANSI standards. Steel flanges shall be raised face type
unless otherwise required. Cast iron and bronze flanges shall be flat-
faced type. Butt-welding ends shall be prepared in accordance with
2.11.5 Butt Weld End Preparation and Piping Fit-Up.

Steel body gate, globe, angle, and check valves shall be designed and
constructed in accordance with ANSI B16.34 as applicable. Valve
bodies and bonnets shall be designed to support the valve operators
(hand wheel, gear, or motor) with the valve in any position, without
external support.

B. Steel Body Valves 50 mm and Smaller

Steel body valves 50 mm and smaller shall have forged steel bodies.
Forged steel valves complying with the standards and specifications
listed in Table 126.1 of ANSI B31.1 shall be used within the manufac-

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turer's specified pressure temperature ratings with the following limita-

tions. The use of Class l500, 2500, and 4500 forged steel valves shall
be limited in accordance with the pressure temperature ratings
specified in ANSI B16.34, and the criteria established in MSS SP-84.

Class 800, 1500, 2500 and 4500 forged steel valves shall be
constructed as follows: -

a) Class 800 valves shall have bolted bonnet joints. Class 1500,
2500 and 4500 valves shall have pressure seal, integral, or
breech lock bonnet joints. Gate, globe, and angle valves shall
have outside screw and yoke construction.

b) All valves, except gate valves, shall have seats of the integral
type. Gate valves shall have renewable seats.

c) Class 1500, 2500, and 4500 valves shall be of loose back seat
design.

d) Class 1500, 2500 and 4500 globe valves shall be of the Y-

pattern type.

e) Valve ends shall be socket-weld type unless otherwise

required.

f) Except as otherwise required, check valves shall be of the

guided piston or swing disk type. All check valves shall be
designed for installation in either horizontal piping or vertical
piping with upward flow.

C. Steel Body Valves 65 mm and Larger

Steel body valves 65 mm and larger shall have cast steel bodies. The
face-to-face and end-to-end dimensions shall conform to ANSI B16.10.
The use of these valves shall be in accordance with the pressure
temperature ratings specified in ANSI B16.34 as applicable.

Gate, globe, and angle valves shall be provided with back seating
construction; and shall be of outside screw and yoke construction.
Gate valves 100 mm and larger shall have flexible wedge disks. Split
disks shall not be permitted. Valves shall have full size ports, except
where venturi ports are specifically permitted to Engineer’s approval.
The use of valves with venturi ports shall be limited to selected large
diameter, high-pressure valve applications.

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Class 150, 300, and 400 valves 65 mm and larger shall be

constructed as follows: -

i) Bonnet joints shall be of the bolted flanged type having flat

face flange facings for Class 150 valves; and male and female
facings for Class 300 and 400 valves.

ii) Body ends shall be butt weld type unless otherwise required.

Class 800, 900, 1500, 2500, and 4500 valves 65 mm and larger shall
be constructed as follows: -

i) Bonnet joints shall be of the pressure seal or breech-lock type.

ii) All Class 800, 900, 1500, 2500, and 4500 valves shall have
grease-lubricated antifriction bearing yoke sleeves.

iii) Body ends shall be butt weld type unless otherwise required.

Check valves used on pump discharge installations, and on

other applications in which the valves may be subjected to
significant reverse flow water hammer or fluid surges, shall be
of the non slam tilting disk type. All other check valves shall be
of the guided piston, swing disk, or double disk spring check
type. The use of double disk spring check valves shall be
limited to 350 mm and larger cold-water services. All check
valves shall be designed for installation in either horizontal or
vertical piping with upward flow. Stop check valves, where
specified, shall be Y-pattern globe type.

D. Iron Body Valves

Iron body gate, globe, and check valves shall have iron bodies with
bronze trim. The face-to-face dimensions shall be in accordance with
ANSI B16.10. These valves shall have flanged bonnet joints. Gate and
globe valves shall be of the outside screw and yoke construction. Body
seats shall be of the renewable type. Gate valves shall be of the
wedge disk type. Lined cast iron body diaphragm and check valves
used with lined piping shall be flanged body with liner and diaphragm
material suitable for the service.

Piping Design Pressure Valve Class

i) 1.8 bar and below Class 25
ii) Above 1.8 bar to 5.2 bar Class 75
iii) Above 5.2 bar to 10.3 bar Class 150

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a) Cast iron gate valves shall be limited to use with piping sys-
tems having a design temperature of 50 C or less.

b) Gate valves for other than buried service shall be of carbon

steel or cast iron body material depending on the service
application. Valves 600 mm and larger in size shall be
equipped with flanged ends. Valves 500 mm and smaller in
size shall be of the wafer type, or lug wafer type, if used with
steel piping; and shall be flanged if used with other piping
materials (cast iron, etc.).

c) Carbon steel gate valves shall be limited to use with piping

systems having a design temperature of 65 C or less. Carbon
steel gate valves shall have pressure class selected in accord-
ance with the pressure temperature ratings specified in ANSI
B16.34 for 600 mm and smaller valves.

Metal seated or Teflon seal ring seated gate valves for special
service applications shall be of the wafer or lug wafer type;
and shall be designed for installation between ANSI flanges.
The use of these valves shall be in accordance with the
pressure temperature ratings specified by the manufacturer.

E. Bronze Body Valves

Bronze gate and globe valves 50 mm and smaller shall have union
bonnet joints and screwed ends. Bronze gate and globe valves used
in control air service shall have brazed joint ends. Gate valves shall
be inside screw, rising stem type with solid wedge disks. Globe valves
shall have renewable seats and disks.

Bronze check valves 50 mm and smaller shall be Y-pattern swing disk

type or guided piston type designed for satisfactory operation in both
horizontal piping and vertical piping with upward flow.

Bronze valves 65 mm and larger shall have bolted flange bonnet

joints and flanged ends. Gate and globe valves shall be of the outside
screw rising stem construction. Gate valves shall have either integral
or renewable seats. Globe valves shall have renewable seats.

The use of these valves shall be in accordance with the pressure

temperature ratings specified by the manufacturer and in accordance
with the criteria established in MSS SP-80. Bronze valves shall
generally be Class 200, and shall be limited to service with piping
systems having design pressures of 14 bar or less, and design
temperatures of 65 C or less.

Bronze valves shall generally be limited to a size of 80 mm or less.

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Plug Valves

Plug valves shall be of the eccentric, lubricated, or Teflon sleeve plug

type, as required by the service. Plug valve bodies shall conform to
the requirements of ANSI for dimensions, material thickness, and
material specifications. Bonnets shall be of the bolted flange type.
Body ends shall be flanged, faced, and drilled for installation between
ANSI flanges. The use of these valves shall be in accordance with the
pressure temperature ratings specified by the manufacturer.

F. Ball Valves

All ball valves shall have full area ports, Teflon /PTFE seats & seals,
and chrome plated carbon steel/Nickel plated Chromed Brass or
stainless steel balls and Nickel plated brass body. Ball valve bodies
50 mm and smaller shall have threaded end connections. Ball valves
65 mm and larger shall have flanged ends. The valve handle shall be
made of powder coated steel with a finish plastic coating. The valves
shall not require lubrication. The use of these valves shall be in
accordance with the pressure temperature ratings specified by the
manufacturer.

G. Check Valves
These shall be swing check type. The body shall be of cast iron with
flanged ends.

H. Flow Regulating-Cum-Measuring Valves

These are special valves to be installed at the outlet of each cooling

coil/heating coil as shown in drawings. The Contractor shall also supply
measurement it including manometer. The valves shall be of variable orifice
design double regulating type. The valve shall have measurement ports for
connecting the manometers. The Contractor shall supply all calibration charts
etc. The valve shall have provision for locking at pre set flow condition and it
shall be possible to close the valve and again open up to this pre set point.
The valves shall be of gun-metal/bronze construction.

5.22.00 Refrigerant Valves

All refrigerant valves as may be applicable shall have Brass body with flange
connection or sweat connection for welding or brazing to pipe. For copper
pipes size 5/8” and below flare connection will be acceptable. The valve body
and bonnet connection shall have bolted and welded connection.

It is preferable to have Teflon gland packing for the valves. Construction of

the discs of the valves shall be either globe or angle type. The valve seat
shall have white metal lining or any equivalent soft replaceable lining. The
valves shall be of tested quality. Leak proof-ness of the valves shall be tested
at minimum 1.5 times the design pressure for the system but not less than 35
Kg / Sq. Cm.
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5.23.00 Miscellaneous Instruments

5.23.01 The space humidistat and thermostat shall be of reputed make. The
humidistat and thermostat shall be complete with suitable metallic enclosures
and shall be mounted in the walls of the handling unit space or conditioned
space. The instruments shall be complete with wiring encased in 3/4"
diameter conduits, terminating in the suitable terminal box.

Digital Humidity Indicator in the equipment room having local digital indication
and 4-20 mA DC output for interfacing with the PLC in the central AC control
room .

Digital Temperature indicator in the equipment room having local digital

indication and 4-20 mA DC output for interfacing with the PLCC in the central
AC control room . Temperature & Relative Humidity Indication( At least Three
Nos) shall be provided at CCR.

5.23.02 The pressure indicators and temperature indicators shall have minimum 160
mm size dial. The pressure gauges shall be complete with isolating
cocks/valves.

5.23.03 Apart from the thermostats, pressure switches, level switches and level
indicators specified in this tender document, the local instruments as required
shall also be furnished as a part of the system.

5.23.04 The range of controls and instruments should be such that the operating
range are preferably in the mid-scale or in line with the recommendation of
the manufacturer. The accuracy should not be less than ± 1% of full scale
deflection. The differential in controls should be such that the equipment is
able to operate at desired settings or maintain desired conditioned.

5.23.05 The scale of pressure indicators for refrigeration units will be in kg /Sq. cm.
Saturation temperature of the refrigerant in use, at the corresponding
pressure should also be indicated in the scale. The suction and oil gauge
shall be compound gauge.

5.23.06 All instruments should be such selected and installed that they are easily
readable from the floor.

5.24.00 Duct Work

5.24.01 General

Velocity of air in any section of duct shall not exceed 7.5 m/sec. for air
conditioning system.

5.24.02 All duct work for supply of air inclusive of accessories such as damper, vanes,
access doors etc. shall be fabricated from G.I. sheet or aluminium sheet. The
duct work shall be properly reinforced to prevent sagging, buckling or
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vibration. Interior of all ducts shall be smooth and free from obstruction. All
duct sections shall be cross broken.

5.24.03 Joints

a) All longitudinal joints for the ducts will be Pittsburgh Lock seam type.

b) Transverse joints of the low pressure ducting shall be continuous

around the four sides, the corner closures, we required. The type of
transverse joints shall be follows:

Large side mm Type of transverse joints

Up to 600 : 25 mm wide pocket, drive or S-slip

600 - 1000 : 85 mm wide, bar s-slip or pocket slip

1001-2250 : 40 mm x 40 mm x 6 mm M.S. Angle

connection

The low pressure ducting work shall be provided with intermediate

transverse bracings continuous around the four sides between the
joints according to the following sizes:

Large side mm Bracing

0 - 450 : None

451 - 1500 : 40 mm x 40 mm x 6 mm angle

1200 mm from joints.

1501 and above : 40 mm x 40 mm x 6 mm angle

600 mm from joints

All flat surfaces between bracing or joints having 900 mm or more

crosswise dimension of the duct, shall be reinforced by a longitudinal
internal standing seam located in the centre third of the duct width. All
flat surfaces over 1500 mm wide shall be reinforced by the longitudinal
internal standing seams located approximately on the third points or
the width.

5.24.04 Hangers And Supports

a) All ductwork shall be provided with adequate hangers or supports to

ensure rigid support and to prevent vibration. Spacing of duct supports
shall not exceed 3 m centers.

b) Hangers shall be suspended from the building steel with provision for
necessary auxiliaries, or special steel members, or by hooks fixed to
the embedded plates provided in the ceiling.
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c) Hangers for all ducts shall be trapeze type with the shelf construction
from 35 mm x 35 mm x 5 mm angle iron and hung by two steel rods
each of not less than 10 mm dia. for ducts, with larger side less than
2250 mm while for those greater than 2250 mm shall be with 50 x 50 x
5 angles and rods not less than 16 mm dia.

d) All hangers and supports shall be as per drawings / specifications.

When vertical ducts pass through floor slab, they shall be supported
by means of collars, constructed of steel structural angles securely
fastened about the girth of the duct and bituminous compound
between the horizontal leg of the supporting angle and the floor. The
duct aspect ratio shall not be more than 4: 1. Turning vanes are
required to be provided with bend more than 45 Deg.

5.24.05 Access Doors

All main ductwork shall be accessible throughout using tight fitted hinged
access doors. Doors shall have to be cemented on sponge rubber gaskets.
Angle joints shall be provided with felt or rubber gaskets for leak-tightness of
the joints.

Access doors/panels are to be provided at following places:

Near each fire damper
Near each heater coil
Near each filter bank.

In case access doors are to be installed in the insulated ducts, the access
door panel should be suitably insulated, such that it can be operated without
damaging the duct insulation and there should be no condensation either on
the access doors or on the duct when the plant is running.

5.24.06 Flexible Connection

Rubber impregnated canvas or equal flexible connections of at least 150 mm

length shall be provided at each connection between ductwork and fan units.

5.24.07 Dampers

i) Splitter Damper

Splitter dampers in branch take off shall be provided. Dampers blades

shall be minimum 16 SWG thick. Alternatively catcher shall be
provided in right angle tee of ducts.

ii) Fire Damper

Fire dampers (with sleeves) shall be provided as per the requirement

mentioned elsewhere in the specification. The fire dampers shall be of
motorised type operated by smoke detectors of the zone fire fighting
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system. The fire damper shall be smoke-tight type and shall have 90
min. fire rating by CBRI, Roorkee as per UL-555-1995 Standard.
Provision shall be kept for manual operation of the damper.

Blade thickness : At least 16G CRCA

Frame : At least 40 x 40 x 3 mm Angle.

Motorised Fire Dampers shall be rated for 240 V, 50 Hz, 1 Ph., AC

supply. Motor for Fire dampers shall be continuously rated. These
Dampers shall close on de-energisation and open on energisation of
Motor. Provision shall be kept for manual operation of the Damper.

Fire dampers will be provided at the supply/exhaust duct for fire-rated

walls/floors as required by National Fire Protection Association
(NFPA) and International Building Code (IBC).

Actuators:

The actuators will be UL listed.

Dampers will be equipped with operators of sufficient power to control
dampers, without flutter or hunting, through the entire operating range
at air velocities at least 20 percent greater than maximum design
velocity. Operators will have sufficient power on closure to provide
tight sealing against maximum system pressures. Damper actuators
will be designed to provide a minimum of 200 percent of the torque
required to operate the damper and to meet the air leakage criteria.
Torque developed by damper actuators will not be less than 2.26 N-m
(20 inch-pounds). Each damper section will contain one or more
damper actuators. Jack-shafting of the section is not permitted. The
Damper Actuator shall be provided with a Position Indication Switch to
be suitably interconnected with the Central Annunciation panel.

Spring-return operators will be provided for two-position control or on

reversible operators where required for fail-safe operation.

When dampers are installed on ducts to be externally thermally

insulated, each damper operator will be equipped with stand-off
mounting brackets, bases, or adapters to provide clearance between
the duct and operator not less than the thickness of insulation.
Standoff mounting items will be integral with the operator or standard
accessory of damper manufacturer.

iii) Opposed Multiple Louver Damper

Opposed multiple louvers dampers shall be provided at the fan outlets

and wherever mentioned in the drawings, specification and fan
schedule. Each blades of the dampers shall be provided with bronze,
gunmetal or nylon bearing at each end of its spindle. The spindle with
bearing shall be mounted in a strong structural framework. Operating
lever with fixing device for keeping the damper at the desired position
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shall be fitted for the manually operated dampers.

Operating level will be fixed on an indicator to show the percentage of

opening of the damper in all cases except for the application with
grilles and nozzles.

Velocity across the dampers shall not exceed 10 m/sec. Damper

blades at fan outlet shall be made up of 16 gauge M.S.

5.24.08 Diffusers, Grilles, Registers

Design of grilles & diffusers shall be such as to create desired throw and
spread of air and shall be approved by the purchaser/engineer.

All diffusers and grilles shall be made up of powder coated extruded

aluminium with finish painting. Design of all diffusers and grilles shall be made
by the Contractor matching with the lighting and other fittings and to be
approved by the Engineer. Each supply air diffusers shall be fitted with
opposed blade damper, built-in vanes and louvers arranged as per
manufacturer’s standard design.

Side throw type supply registers shall have two sets of adjustable louvers with
opposed blade dampers. The front of louvers shall be horizontal to provide
horizontal deflection and the rear set of vertical louvers shall adjust vertical
deflection. The dampers shall have horizontal opposed blades regulated by
an operating lever in the frame. All wall type exhaust / return air grilles shall
have one set of louvers in the front. The louvers shall be fitted such as to
remain in position by friction grip. All supply air grilles shall have one set of
opposed multiple louver damper at the inlet. The dampers shall be gang
operated and will have a device to keep the dampers fixed in one position.

The grille frame and louvers shall be manufactured of at least 20 SWG GI

sheet and 22 SWG M.S. respectively. No grilles should by any chance make
any rattling sound during continuous operation. All grilles shall match the
decor of the space.

All grilles/diffusers shall be fitted with suitable gasket to prevent air leakage.

5.25.00 Thermal Insulation

5.25.01 The following items are to be insulated:

a) Refrigerant suction piping from the evaporator coil outlet up to the

compressor inlet shall be insulated with minimum 39 mm (26 mm for
Non ductable Split Units) thick XLPE section /sheet (for pipe sizes
over 100 NB) finished with treated woven UV-protected glass cloth
(factory laminated with the insulation material) (for outdoor piping).
For better efficiency of operation the liquid line running side by side
with the suction line may be insulated together with the suction line
already mentioned.
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b) Double skin Casing of the cabinet type air handling unit with at least
25 mm thick Poly Urethane Foam (PUF) or equivalent.

c) Supply air duct and part of the return air duct passing through non
conditioned space, if any, with at least 13 mm thick aluminium foil
faced Nitrile Rubber / XLPE Insulation.

d) Entire chilled water piping, valves, chilled water circulating pumps, and
chillers with 39 mm thick aluminium foil faced Nitrile rubber/XLPE.

The portion of Chilled water piping exposed to atmosphere shall be

insulated with 50 mm thick EPS (TF quality) finished with 500 gauge
Polythene sheet, chicken wire mesh, 12 mm thick sand-cement
plaster and an overall cladding of 30 gauge Al. sheet.

e) Chilled water Expansion tank drain piping with 6mm thick aluminium
foil faced Nitrile Rubber/XLPE

f) Roof Ceiling of all AC spaces with 50mm thick aluminium foil faced
Expanded Polystyrene (TF Quality).

5.25.02 Insulation shall be fixed as per manufacturer’s recommendation. Due care

shall be taken to avoid damage to insulation. For EPS Insulation roll or slab
shall be attached with equipment, piping or ducts with bitumen (85/40) or
CPRX sticking compound. Insulation clips shall be used as necessary.

5.25.03 Extra insulation thickness shall be provided at duct pipe hangers and special
care shall be taken to seal the insulation and hanger member penetrations
and instruments and accessories tapings.

5.25.04 Special care shall be taken to provide satisfactory insulation for valves,
flanges, vessel connections etc. with proper facility for maintenance and
inspection.

5.25.05 Insulated ducts crossing the floors shall have to be normally protected from
damage and water splashing by providing suitable cladding up to 300 mm
from the floor level.

5.25.06 Acoustic Insulation

All supply air ducts in the air conditioning system shall be insulated
acoustically from inside of the duct up to a length of 6 meter from the blower
mouth.

Open cell type Nitrile rubber or equivalent insulation of minimum 25 mm

thickness and having minimum absorption co-efficient as indicated below
shall be used:

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q (Hz)
125 250 500 1000 2000 4000 NRC

25 mm 0.02 0.25 0.86 1.14 0.88 0.99 0.80

Insulation material should be fiber free. Density Nitrile rubber shall be

minimum 140 Kg. / Cu.M. It should have anti-microbial product protection and
should pass fungy-resistance test as per ASTM-G21 and bacterial resistance
as per ASTM-E2180. The insulating material should conform to Class-1 for
surface flame in accordance with BS-476-Part-7 and UL-94. It should pass air
erosion resistance test in accordance with ASTM Std.C-1071-05 Sec.12.7.

The insulation shall have self extinguishing & non-dripping properties against
fire attack.

5.26.00 Electricals

A. 415v Power-Cum-Motor Control Centre / Power Distribution Board

One (1) 415 V Motor Control Centre (MCC) cum Power Distribution Board
(PDB) for supplying power to Water cooled Screw chillers, CW & CHW
pumps, cooling tower fans, Make-up water booster pumps, AC Plant room
Ventilation fans, ceiling suspended AHUs wherever appliacble, feeders (one
for each AHU room LSP and Local & Central PLC Panels. The MCC cum
PDB shall be located in the central Air- Conditioning Plant room.

B. Local Starter Panel

One (1) no. Local Starter Panel (LSP) for each AHU room of Power House
Building. This LSP will house In-coming MCCB, outgoing DOL starter with
MCCB/MCB for AHU fan, fresh air fan and Smoke exhaust fans, if any, and
outgoing feeders with MCBs for 3-way mixing valves, Heaters (wherever
applicable), Humidifiers (wherever applicable) and motorized fire dampers.
The Local Starter panel shall be located in respective AHU rooms.

C. Power Distribution Board-Cum-Lsp

One (1) 415V Power Distribution Board (PDB) cum LSP each for supplying
power to the PAC units and associated Fresh air fans (if any) of ESP Control
Room. This PDB cum LSP will house In-coming MCCB, outgoing DOL starter
with MCB for fresh air fan and outgoing feeders with MCCBs for PAC units.

D. Local Push Button Stations

Local Push Button Stations shall be provided for the drive motors of Cooling
Tower Fans, Ceiling suspended AHUs and Make-up Water Booster Pumps
etc.), suitably located near the said drives. LPBS shall consist of one no.
emergency Red Stop P.B (pressed to latch and turn to release type) for each
drive.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

E. Local Distribution Board (240v)

Local Distribution Boards containing Switch / MCB for Non Duct-able Split Air
Conditioners.

F. Drive motors

NB : For detail specification VOLUME II-F/1 & VOLUME II-F/2 (

SPECIFICATIONS FOR ELECTRICAL EQUIPMENT & ACCESSORIES [IN
TWO VOLUMES)shall be referred to.

G. PLC Based Control Panel

For details of PLC based Control panel the relevant portion of

VOLUME II-E : SPECIFICATIONS FOR CONTROL &

INSTRUMENTATION is to be referred

6.00.00 TESTING AND INSPECTION

Testing and inspection both at manufacturer's works and at site after erection
shall be conducted on all equipments.

6.01.00 Following tests shall be carried out during and after completion of different
component parts as applicable and in accordance with the requirements of
the applicable codes.

Material analysis and testing.

Hydraulic test for pressure parts including pumps, compressors and its
components, vessels etc.

Dynamic balancing of all the rotating parts.

Performance test on pump, compressors, condenser, chiller cooling

towers and air handling units as per code procedure.

Tests on motors as per Indian Standard IS-325 and IS-4029 and as

stipulated in the relevant part of the specification.

Other tests, as necessary and recommended by the manufacturer.

6.02.00 Field Test

6.02.01 Overall performance of the air conditioning system with peak summer outside
conditions as well as individual equipment shall be tested after complete
installation at site. This test shall be carried out to determine whether the
plant meets the performance requirements specified here in and shall include
measurements of all parameters under various outside conditions and
establishment of correct supply of equipment. All testing and calibrating

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instruments required for this purpose shall be supplied by the contractor.

Within one month from the date of equipment is placed in service, it shall be
tested by the Purchaser. A calibration chart showing water Flow VS.
Differential pressure across cooling coil shall be supplied by the Contractor
for each cooling coil to measure chilled water flow rate through the cooling
coil.

6.02.02 Inspection And Testing Of Duct Work

All component and duct work supplied shall be subjected to inspection and
testing as per relevant codes and standard.

All duct work shall be carefully examined to determine their performance with
the specification with respect to dimensions, materials, marking, workmanship
and other requirement.

The contractor shall give assistance for all site tests of the equipment
according to prescribed procedure laid down by the Manufacturer/Engineer

7.00.00 DOCUMENTS, DATA TO BE FURNISHED

7.01.00 Documents, Data To Be Furnished With Tender Proposal

Besides submitting the bid proposal exhibit sheets duly filled in, the proposal
shall also include the following drawings, curves and information wherever
applicable.

7.01.01 Preliminary equipment layout drawings of the air conditioning plant room,
AHU room, preliminary ducting layout drawing.

7.01.02 Manufacturer's catalogues and literatures incorporating outline and sectional

drawings and ducting data for the following equipment:

a) Water cooled semi-hermetic screw chiller

b) Air handling unit
c) Precision air handling unit
d) Drive motors for various equipments as applicable
e) Condenser cooling water pump and chilled water pump
f) Cooling tower
g) Water cooled Precision Air Conditioners
h) Air cooled Non Duct-able Split Air Conditioners

7.01.03 Manufacturer's catalogues and literatures on instruments and controls.

7.01.04 Sectional drawings for air diffusers and grilles as applicable.

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7.01.05 Manufacturer's data sheets for filters, humidifier and strip heater

7.01.06 A detailed experience list about supply for system of similar type for similar
application mentioning in each case the salient technical parameters, date of
commissioning and name of customers.

7.01.07 A comprehensive write-up and/or brochure on details of manufacturing and

testing facilities in the shop of the manufacturer.

7.01.08 Any other relevant data and particulars.

7.01.09 Heat load calculation, calculation for plant sizing and requirement of water,
power and compressed air.

7.02.00 Post Award Documents, Data To Be Furnished

7.02.01 The Contractor shall submit the drawings, submission schedule indicating the
dates (counting from the date of issue of the Letter of Intent) for submission to
the Purchaser or the Consulting Engineers for approval of various drawings,
data and procedures as mentioned below:

7.02.02 Equipment layout drawing for:

a) Air conditioning plant room

b) Air handling unit rooms / PAC unit rooms
c) Cooling Tower

7.02.03 Schematic flow process and instrumentation diagram of the complete system
indicating the limits of supply and erection.

7.02.04 Ducting layout drawing including the details of duct sizes, duct joints, duct
insulation, duct supports, diffusers, grilles, dampers etc.

7.02.05 Layout drawings showing the route of refrigerant piping, chilled water piping
and cooling water piping with details of insulation hangers, supports, etc.

7.02.06 Outline drawings incorporating all principal dimensions, foundation civil

drawings and weight etc. and also sectional drawings incorporating data of
material of construction when applicable for following equipment:
a) Water cooled semi-hermetic screw chiller
b) Air handling unit
c) Precision air handling unit
d) Drive motors for various equipments as applicable
e) Condenser cooling water pump and chilled water pump
f) Cooling tower

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g) Water cooled Precision Air Conditioners

h) Air cooled Non Duct-able Split Air Conditioners
i) Fresh air units
j) Smoke exhaust fans
k) Make-up water tank and Expansion Tank
l) Non chemical Water treatment Equipment

7.02.07 Drawings and data sheet of each of instruments.

7.02.08 Drawings and data sheets for air filter, humidifier & strip heater

7.02.09 Write up on system interlock and/or interlock block diagram.

7.02.10 Electrical schematic and wiring diagram for control panel and the system as
applicable with back-up write-up.

7.02.11 Control panel / MCC outline drawings, bill of instruments, schematic & wiring
diagram and drawings showing construction of control panel / MCC.

7.02.12 Layout drawings showing the route of cables including the detail of cable
trays and supports.

7.02.13 Other drawings and data.

7.02.14 Material test certificates.

7.02.15 Shop test reports and certificates.

7.02.16 Flow Calibration charts (water flow Vs pressure difference between inlet and
outlet of cooling coil) for all the chilled water type cooling coils.

7.02.17 Performance curves for all evaporator fans.

7.02.18 Operation, maintenance and overhauling manuals.

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WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III

ATTACHMENT

8.00.00 LIST OF DRAWINGS

SCHEMATIC DIAGRAM OF PACKAGED

12A05-003-DWG-VA-001
SCREW CHILLER UNIT

12A05-DWG-003-VA-002 SCHEMATIC DIAGRAM OF WATER COOLED

PRECISION AIR-CONDITIONER

12A05-DWG-003-VA-003 SCHEMATIC DIAGRAM-COMMON CHILLED

WATER TYPE AC SYSTEM

12A05-DWG-003-VA-004 SCHEMATIC DIAGRAM OF AIR COOLED

SPLIT AC UNIT

12A05-DWG-003-VA-005 SCHEMATIC DIAGRAM OF AIR COOLED

PRECISION AIR-CONDITIONER

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