SPECIFICATION NO:-742/ PYRO / ME / E.O. DATED 01.06.

2011
TECHNICAL SPECIFICATION OF TEMPERATURE & HUMIDITY CONTROL (THC) SYSTEMS HAVING WATER-COOLED CHILLER UNIT WITH MULTIPLE SCROLL COMPRESSORS A PURPOSE Four THC plants having Water-Cooled Chiller unit with Multiple Scroll Compressors are required to provide Temperature and Humidity Control to 12 explosive Production buildings (Annexure). These plants will be installed at existing sites.THC plants & Air handling Units (AHU) shall be integrated with (a) existing chilled water lines, external to the THC plants & (b) existing supply ducts in production buildings. [This specification will be read in conjunction with the general conditions supplied along with the tender documents.] B GENERAL SCOPE

It shall include 1 Removal of the entire existing THC plants from bldg 121, 122, 149 & 151 and its associated existing AHUs and Cooling Towers & its connected pipelines from respective buildings, one by one, in consultation with OFDR. The supplier shall shift the scrap materials to OFDRs scrap yard. 2 Design, manufacture, supply for all equipments(Factory assembled THC plants having Water Cooled Chiller unit with Multiple Scroll Compressors, AHUs, cooling towers) as described in para C. 3 4 5 Provision of RCC civil foundations for above equipments and civil works as in para C 1.8. Supply of materials required for the purpose mentioned at Para A Provision of pipeline with its support interconnecting various equipments as in para C1.7.

6 Breaking and making good of walls for ducting, pipelines, mounting of return air filter frame, cable etc as in para C1.8. 7 Painting of the new chilled & condenser water lines

8 Electrical cabling work(including supply of the materials) at THC plant and AHU, from single point power supply provided by OFDR. 9 Erection, testing, all weather trials and satisfactory commissioning of above equipments as in para D & E. (Because of constraint of production commitment of OFDR, Erection of each THC plant & its associated AHU is required be completed within six working days). C GENERAL DESCRIPTION OF THE SYSTEM

Each THC system shall consists of a THC plant, desired no. of AHUs (as specified in Annexure), a cooling water tank with its Make up suitably connected to achieve the purpose mentioned in para A. 1 THC Plant : It shall consist of following subsystems interconnected to carry out the job mentioned at para A. 1.1. Scroll package chiller unit (Make: Voltas / Blue Star/Danfoss/York) Each packaged chiller unit in a THC plant shall be cross connected on chilled water and condenser water side with suitable no. of Isolating Butter Fly Valves. One Motorised Butterfly valve each shall be installed at the outlet of chiller and condenser. Each chiller shall be provided with Balancing valve at the outlet. 2

=2= Each such Unit shall consists of 1.1.1 Water-cooled chiller Unit : Each unit shall have multiple Scroll compressors, chiller, condenser. It shall have following features : i. Factory assembled Scroll Chiller compressor ii. Shell and Tube type condenser iii. Chiller and expansion valves with loading and unloading controlled by Microprocessor based control panel. iv. Electronically/ thermostatically refrigerant flow control system v. Inter-connecting refrigerant piping vi. New chilled water pipe line with insulation and expansion tank for chiller water vii. Max. energy consumption of chiller package : 0.95 IKW/TR viii. Refrigerant R-134A or any eco friendly refrigerant which is easily available in Indian market (R 22 refrigerant shall not be acceptable.) 1.1.2 Factory mounted microprocessor based Control Panel for Chiller unit (Make- Softhard/Siemens/Proto or Equivalent Reputed Brand) : It shall sequence the operations of Scroll package chiller unit, air handling units and cooling tower. These shall be installed in each THC plant room. It shall have following features : i. Digital control & setting of temperature in steps. ii. Display of actual compressor current in Amps with Underload & Overload protection. iii. Auto cut Off/On in steps of compressors with run time equalization. iv. Automatic starting of unit in case of power resumption after failure v. Built in time delays for compressor and condenser fan vi. Non-volatile memory backup for all set value parameter. vii. Current sensing single phase / phase reversal protection. viii. In-built anti-freeze safety ix. Provision of Antifreeze setting [50 C cut-out & 80 C cut-in ] to be provided. x. Early detection and warning of refrigerant loss xi. Auto reset of chilled water , based on return water xii. Automatic shut down protection with manual reset for a) Low evaporator refrigerant temperature and pressure b) High condenser refrigerant pressure c) Loss of chilled water flow d) High motor temperature e) Low oil level f) Electrical distribution faults e.g. Phase reversal, Phase loss, phase imbalance, motor current overload, g) High compressor discharge temperature. h) Critical sensor or detection of circuit fault in i. Starter transition failure. ii. External or local emergency stops xiii Automatic shut down protection with automatic reset when condition is corrected for loss of 1) chilled water and condenser water flow, 2) high compressor discharge temperature

xiv. The unit control panel should be capable of avoiding unit shut down due to transient abnormal operating conditions associated with low evaporator refrigerant temperature, high condensing temperature and motor current overload. If the abnormal operating condition persists and the protective limit is reached, the machine will be shut down. In case of power failure, the compressor shall automatically shut down and restart after resuming the power. The microprocessor-based panel should be compatible to building management system. ..3

xv xvi xvii xviii xix xx xxi

=3= Power supply : phase, Voltage: 180 to 260V AC, 50 Hz + 3% Display : 8 (Character) X 2(Lines) Backlit LCD, LED indicators and touch key pad LCD Display & Keypad unit : Door mounting Temperature control accuracy : + 1% Entering water temperature range : 8 - 250 C Cooling range : 2 - 100 C Temperature sensors : Thermistor sensor (SS enclosure) with 5m long cable

1.1.3 CONDENSER WATER PUMP SET (Make: Kirloskar /KSB/ Crompton Greaves) Three condenser water pump sets shall be installed (Two working & one standby for each plant) in each THC plant room. a) The pump set shall be of centrifugal mono block type. The pump shall be with gland packing. b) The pump set shall work on 440 V, 3 phase, 50 Hz AC Supply. c) It shall be complete with pump, motor, base frame & starter with Microcomputer Motor Protection device & Microcomputer Voltage Protection Device for protection of the Pump from Phase Unbalance, Current unbalance, Phase loss, Phase reversal, overload, under / over voltage & supply failure. d) The motor with suitable starters shall be TEFC type and suitable for continuous operation. e) Suitable ON/OFF type Butterfly valve, flow switch, Pot strainer and Non Return Valve shall be provided at inlet and out-let of each pump. 1.1.4 CHILLED WATER PUMP SET (Make: Kirloskar /KSB/ Crompton Greaves) Three chilled water pump sets shall be installed (Two working & one standby for each plant) in each THC plant room. a) The pump set shall be of centrifugal mono block type. b) The pump shall be with gland packing. c) The pump set shall work on 440 V, 3 phase, 50 Hz AC Supply d) It shall be complete with pump, motor, base frame & starter with Microcomputer Motor Protection device & Microcomputer Voltage Protection Device for protection of the Pump from Phase Unbalance, Current unbalance, Phase loss, Phase reversal, overload, under / over voltage & supply failure and no volts protection device. e) The motor with suitable starters shall be TEFC type and suitable for continuous operation. f) Suitable ON/OFF type Butterfly valve, flow switch, Pot strainer and Non Return Valve shall be provided at inlet and out-let of each pump. g) Chilled water pumps should be cross connected for alternate Operation. h) The chilled water pipe line shall be insulated with 50 mm-thick TF Quality Expanded Polystyrene wrapped with chicken wire mesh and finished with thick sand cement plaster. 1.1.5 EXPANSION TANK FOR CHILLED WATER : One Expansion tank of 1000 L capacity for Each cooling tower shall be provided to cater requirement of continuous 8 hours operation of plant. a) The expansion tanks shall be fabricated out of 6 mm thick MS Plate complete with drain, overflow and inlet water connection with 1 Brass/Gun metal valve & 1 Brass/Gun metal float valve and a hinged Cover to facilitate cleaning and maintenance. b) Tanks shall be internally painted with two coats of Epoxy based water and acid resistance paint & with proper external insulation. 1.1.6 a) b) c) POT TYPE STRAINERS : Strainers shall be made of either C.I. or fabricated steel body Shall withstand 16 kg/cm2 pressure. The strainers shall have bronze screen with 3 mm perforations to provide minimum net free area of 4 times the cross section area of the pipe-line in which it is installed. d) The strainers shall be provided with flanged ends. e) They shall be provided with removable cover to clean the accumulated dirt and facilitate replacement of screen without replacement of the main pipe. ..4

=4= 1.1.7 GLYCERINE FILLED PRESSURE GAUGES: (Make : PIONEER/ WAREE/ H-GURU) a) Its Dial shall be minimum 150 mm dia. of appropriate working range. b) They shall be complete with siphon, shut off gauge cocks etc. duly calibrated before installation. c) Pressure gauges shall be provided at the following locations and or as indicated on the drawings: Supply & return of chillers and condensers Suction and discharge of chiller and condenser pumps Inlets and outlets of heat exchangers Supply and return of all Chilled water coils in air handling units. 1.1.8 THERMOMETERS a) Thermometer shall be either 150 mm dial type with capillary tube & protective sheets (not of thermocouple element) or Direct Reading Industrial type of appropriate range, duly calibrated before installation. b) Thermometers shall be installed in separable walls. c) Thermometers shall be provided at the following locations and indicated in the drawings. Dial type thermometers on supply and return of chiller and condensers. Direct Reading Industrial Type on supply and return of all water coils in air handling units. 1.1.9 COOLING TOWER (Make: Advance/ Mihir / Bell/ Flow tech) a) One dedicated cooling tower of suitable capacity shall be installed to cater to the requirement of each THC plant. b) The Cooling Tower shall be Induced draft made of Fiberglass reinforced plastic (FRP) and shall be of bottle shape. c) The direct driven axial fan with FRP Blades shall be provided for uniform distribution for optimal heat dissipation. d) The whole unit shall be of aesthetic appearance, weatherproof and made of non-corrosive material. The basin shall have necessary pipe connections for inlet and outlet of water with 1 Brass/Gun metal float valve. e) Automatic cut-off control system for fan motor with respect to difference of water temperature in its inlet & outlet shall be provided. f) The supplier shall provide Metallic ladder & platform at the top for inspection of motor. g) The supplier shall trim the tree branches coming in the way of cooling tower installation. 1.1.10 MAKE UP WATER TANK FOR COOLING TOWER a) One Make up water tank of 2000 L capacity shall be provided for Each cooling tower to cater requirement of continuous 8 hours operation of plant. b) It shall be fabricated out of 6 mm thick MS plates finished externally and internally with two coats of Epoxy base water resistant paint. c) It shall be complete with inlet connection with 1 Brass/Gun metal float valve, outlet connections, and drain with 1 Brass/Gun metal valve and overflow connections. d) The supplier shall provide Metallic ladder, masonry support, PCC pavement underneath the tank with drain. 1.1.11 Factory mounted PLC Control Panel for THC plant : One Electrical Panel for each THC plant shall be compartmentalized. It shall be provided with hinged doors on front side with flexible copper braids for earthing. The features of the control panel shall be : a) Door interlock facility for switch fuse unit shall be provided. b) All meters should be flush mounted type. c) Detachable gland plates with holes drilled suitable for cable entry should be provided. d) Main incoming switch with fuse unit. e) Bus bar chamber with tinned copper bus bars. f) Out going / in coming indicating lamps, voltmeter and ammeter with rotary selector switch in THC plants. g) The switches, starter, indicating lamp, ammeter for the condenser water pumps, chilled water pumps etc shall be installed in the cubicle panel. ..5

=5= h) Power and control wiring for all equipments in the Plant Room from cubicle panel boards. All cables shall be neatly laid in trenches with saddles. All control cable inside the cubicle panel shall be neatly bunched. i) Power earthing of all electrical equipments in the THC Plant Room. j) The electrical wiring, Insulation all main and sub-mains shall confirm to IS: 732 of 1963 (revised) with latest amendments. 1.2 AIR HANDLING UNITS: One Air Handling Unit shall be provided for each production building to maintain the temperature & R.H. within the stipulated limits in Annexure. Each AHU shall be designed to provide 6 air changes per hours. AHUs shall be provided with 3 Way Mixing Valves along with Digital control Controller system for cooling and heating coil. Inlet, Out let and by pass Valves for Chilled Water & Heating line shall be provided. Each Air Handling Unit shall consist of following systems enclosed in a cabinet. Pre-Filter Section with G.I Flanged Type 10 micron Pre-filters Blower Fan Section Fresh Air Fan & Exhaust air fan system Steam heating coil & CHW Cooling Coil with piping Ducting with insulation Control panel 1.2.1 CABINET : a) It shall be Horizontal Floor mounted type, Single Skin Construction fabricated from Panels, made from GI Sheet 15/16 SWG , powder coated from outer side of panel sheet and inner side GI finish. b) The coils heating coils & cooling coils and the blower shall have easy access for periodical maintenance. c) The cabinet shall be suitably insulated from inside with 1 thick thermocol fixed with bitumen plastic and cladded with 26 gauges Aluminum Foil. d) The exterior of the cabinet shall be painted with two coats of epoxy base acid and water resistant paint. e) It shall be provided with SS Drain tray with necessary slope to Facilitate fast removal of condensate. The condensate outlet pipe line should be taken out to a distance of 1 m from the AHU Room through piping. The tray shall have sufficient depth and proper size Drain connection. 1.2.2 Blower Fan Section : It shall have following features: a) The Fan Motor assembly shall be mounted on a base frame outside the casing. b) Fan Section with DIDW Forward/ Backward Curved Centrifugal Fan with Driven Package with Motor. c) The fan motor shall be of adequate capacity, TEFC type squirrel cage induction motor (with IP-55 protection) Suitable for Fan operation on 415 + 10% V, 50 Hz, 3-phase AC Supply with automatic star-delta starter. d) Double inlet type Centrifugal blower with suitable driving motor. e) Statically & dynamically balanced Impeller & fan with self aligning ball/roller bearings with grease pack. f) The shaft of the blower unit should be simply supported on pedestals at both ends Fitted on the AHU Casing. g) Fan motor shall be connected to the Blower with oil-resistant V Belt Pulley drive with guard. h) The fan outlet velocity shall be maximum 580 m/min. i) Fan motor housing shall be mounted on common steel base, mounted outside the AHU on anti vibration springs. ..6

j) k) l) m) n) o) p)

=6= Blower section will consists of extruded sections of proper size to facilitate the mounting of fan and motor bracket. Direct contact of fan base frame and AHU casing will be eliminated through vibration isolator. Flexible connection will be provided at the fan outlet. Suitable panel of blower section from phase unbalance, current unbalance, phase reversal, overload, under/ over voltage, supply failure and no volt protection device. For easy accessibility, access doors shall be provided in fan section. Motor shall be specially designed for quite operation & it should be mounted out side of the AHU Panels. The Starter shall be provided with Microcomputer Motor Protection (MPD) & Microcomputer Voltage Protection Device to protect the motor from Phase Unbalance, Current Unbalance, Phase loss, Phase reversal, overload, under / over voltage & Supply failure, overload and no volt protection device.

1.2.3 FRESH AIR AND EXHAUST AIR FAN One Exhaust air & One Fresh Air Fan each of suitable capacity shall be provided in each AHU. a) The Exhaust and fresh air fans shall be propeller type of adequate capacity with suitable flame proof electric motor and flame proof electric starter operating n 440V, 3 Phase supply with Cowl Frame Ducting arrangements with Wire mesh & metallic filters. b) Damper arrangements from 0-100% regulation shall be provided. 1.2.4 CHW Cooling Coil One Set of CHW Cooling coil, six Rows deep, fabricated out of copper tubes OD x 0.4 mm thick shall be provided. The followings shall be provided. a) Copper tubes with aluminum fins of adequate capacity for AHU with inlet, outlet and bypass, b) Outlet header with suitable Butter fly valves, c) Pressure gauges and thermometer for both inlet & outlet temperatures. d) Suitable Starter Panel for the AHU Motor & Mixing Valve shall be provided. 1.2.5 Steam Heating Coil : a) One Set of heating coil fabricated out of copper tubes size OD, two rows deep, fabricated out of OD X 0.4 mm thick shall be provide. b) Copper tubes, steam coil having 12 to 13 aluminum fins per inches. c) The coil shall be complete with inlet, outlet moisture trap and by-pass connections. d) Steam is available at a point max. 2 m away from AHU Room. e) The tenderer should provide necessary inter connection of steam coil and steam supply point complete with pressure gauge, by pass connection, necessary valves, steam solenoid valve for control connections etc. The materials to be used for steam line system shall be as per IBR. f) Seamless Pipe of Schedule 40 size 25 mm N.B. approx. 12 m for each AHU shall be provided to carry the steam from steam point to AHU. This pipe shall insulated by glass wool 40 mm thick covered with aluminum sheet 24 SWG. 1.2.6 Factory mounted microprocessor based Control Panel for AHU One compartmentalized Electrical Panel for each AHU plant shall be provided. a) It shall control the function of the AHU efficiently to maintain required Temperature and relative humidity in the conditioned space. b) It shall control the RH % in inlet air supply by auto regulating the mixing valve of the CHW Cooling Coil and Steam Heating Coil. c) It shall indicate the Supply air and return air temperature, RH%, heating temperature and cooling temperature, current in digital display. 7

=7= d) The accessories and control of AHU shall be comprising a modulating three way-mixing valve with temperature sensor and controller. e) The features of the control panel shall be : i. It shall be provided with hinged doors on front side with flexible copper braids for earthing. ii. Door interlock facility for switch fuse unit shall be provided. iii. All meters should be flush mounted type. iv. Detachable gland plates with holes drilled suitable for cable entry should be provided. v. Main incoming switch with fuse unit. vi. Bus bar chamber with tinned copper bus bars. vii. Out going / in coming indicating lamps, voltmeter and ammeter with rotary selector switch in AHU. viii. Power and control wiring for all equipments in the Plant Room from cubicle panel boards. All cables shall be neatly laid in trenches with saddles. All control cable inside the cubicle panel shall be neatly bunched. ix. Power earthing of all electrical equipments in the AHU Plant Room. x. The electrical wiring, Insulation all main and sub-mains shall confirm to IS: 732 of 1963 (revised) with latest amendments. 1.3 Return air filter section Return air after passing through dry metallic wire mesh filter shall be washed in an Air washer. The filter shall be mounted on a metallic rustproof frame with facility for easy cleaning . The frame sizes for metallic filter have mentioned in Annexure-A Air Washer Each AHU shall be provided one air washer. This shall be floor mounted double bank air washer complete with Header, Brass/Gun Metal spray nozzles, GI eliminators, Sump tank, Hinged type inspection door, cat walk, non priming type spray pump, inter-connecting and make-up water piping, 1 float valves, necessary fittings for over-flow, drain piping connections strainer of adequate size.

1.4

a) b) c) d) e) f) g) h) i) j) k)

The box and sump tank air washer should be made of 6 mm thick MS sheet. The sump tank shall be welded on MS angles. Remaining structure of air washer shall be 3 mm thick MS sheet duly quoted with corrosion resistant paint. Piping for air washer shall be M.S. (IS: 1239). The drain of air washer shall be 1 m away from AHU. (No return air washer required for Buildg.No.123) 1.5 AIR WASHER PUMPS : (Make: Kirloskar /KSB/ Crompton Greaves)

a) Each AHU shall be provided with Two Nos. for (one working & one standby). b) The pump shall be mono-block centrifugal pump with adequate capacity. c) The motor of the pump shall be of continuous rating and TEFC type, of adequate HP working on 400/440 V, 3 Ph, 50 Hz mains with starter & protection devices against overload & no volt. d) Pressure gauge shall be provided at all the delivery side of the pump. e) Gun metal gate valves ( spec. IS 778) shall be provided at inlet, outlet and bypass of the pump. ..8

=8= 1.6 DUCTING a) Existing air ducts inside the building with existing / diffuser shall be connected with a new ducting and insulation from AHU outlet as per Annxure A. b) Fire dampers shall be provided in supply duct in each AHU. c) The quantities of ducting included in our offer is based on the layout line diagram of existing AHU The material of insulation shall be 15mm thick fiber glass with thick sand plaster finish. 1.7 PIPING 1.7.1 CONDENSER WATER PIPING The condenser water piping shall be made with MS pipe of adequate size as per IS: 1239 class C with suitable valve at the outlet of cooling tower, strainer at cooling tower outlet. Pot strainers with Gun metal / Phosphorous Bronze wire mesh strainer shall be provided at inlet of each condenser (annexure-A for length of condenser pipe line) 1.7.2 CHILLED WATER PIPING a) M.S. pipe heavy duty [class C', IS 1239:1979] with all required valves and fittings shall be duly insulated with 50mm thick thermocol pipe sections and subsequent sand cement plaster. b) Auto air purging valve shall be provided for all bridges. c) All Equipment and valve connections or connection to any other mating pipes shall be through unions/screwed flange up to 50mm dia and welded flanges for larger diameters. 1.8 CIVIL WORK The plant supplier shall undertake the following Civil works. a) Demolition of existing foundation and removal of debris outside building. b) PCC foundation for package chiller and pump sets. c) Breaking and making good of non-load bearing walls for laying duct pipe lines, ducting, pipelines, mounting of return air filter frame etc. d) Foundation support and stone PCC pavements for cooling tower and make up water tank. e) Trenches for power & control cables in two Plant Rooms with MS chequered plate covers & Drainage. f) Provision of bridge supports at road crossings and brick supports for chilled water . g) Finishing the floor inside the plant with PCC, after the complete erection of the plant. h) Plastering of all wall openings inside the AHUs with cement plaster.

1.9

Electrical works :

a) The tenderer shall include in his offer the following electrical work. b) Electrical Panel: One no. for THC plant and & 12 Nos. (One No. for Each AHU) should be compartmentalized & should be provided with hinged doors on front side with flexible copper braids for earthing. Door interlock facility for switch fuse unit should be provided. Panel should be suitable for front Operation. All meters should be flush mounted type. Detachable gland plates with holes drilled suitable for cable entry should be provided. Panel should be suitable for 440 Volt, 4 wire, 50 Hz., A/C system. c) Main incoming switch fuse unit. d) Bus bar chamber with tinned copper bus bars. e) Out going / in coming indicating lamps, voltmeter and ammeter with rotary selector switch in all AHUS and THC plants. f) The switches, starter, indicating lamp, ammeter for the condenser water pumps, chilled water pumps etc shall be installed in the cubicle panel. g) Power and control wiring for all equipment in the Plant Room & all the AHUs from cubicle panel boards. All cables shall be neatly laid in trenches with saddles. All control cable inside the cubicle panel shall be neatly bunched. h) Power earthing of all electrical equipment in the THC Plant Room and AHU Room.The electrical wiring, Insulation all main and sub-mains shall confirm to IS: 732 of 1963 (revised) with latest amendments there in suitable supply point shall be provided by OFDR in the respective plant and AHU Rooms. ..9

=9=

INSPECTION & TESTING

a) All piping shall be tested to hydrostatic test pressure of minimum 1.5 times the maximum operating pressure, but not less than 7 kg/cm for a period of minimum 24 hours. All leaks and defects in joints revealed during the testing shall be rectified. b) Piping required subsequent to the above pressure test shall be re-tested in the same manner. c) Systems shall be tested in section and such sections shall be securely capped. d) The plant supplier shall ensure that proper noise-free circulation of fluid is achieved through all coils and other heat exchange equipment in the system. Auto purge valve with proper draining of fluid shall be provided in pipe lines. The plant supplier shall rectify the defective connections which fails to achieve proper circulation due to air-bond connections. e) Insulation shall be applied to piping only after the successful completion of the pressure testing at above para. f) The plant supplier shall provide all materials, tools, equipment, instruments, services and labour required to perform the test and to remove water resulting from cleaning and / after testing. h) Cooling/heating capacity of the various air handling unit models shall be computed from the measurements of air flow and dry and wet bulb temperatures of air entering and leaving the coil. Flow shall be measured by Anemometer. Temperature shall be measured by calibrated mercury thermometers. Computed results shall conform to these specified capacities and quoted ratings. Power consumption shall be computed from measurements of incoming voltage and input current. E Performance and Operational Tests : The plant supplier shall make all the arrangement for all tests on scheduled dates as mutually decided by the plant supplier and GM/OFDR. If the outcome of test shall not be satisfactory, the plant supplier shall at his own cost, rectify/replace the defective installation or any part there of. The installation is subject to test after the rectification. The decision of GM/OFDR as accepting authority shall be final and binding. Phase I Test : After the erection work is completed, the entire installations will be run continuously for performance testing. The installation will be provisionally taken over if this test in phase I is found to be satisfactory. The last results shall be recorded in a suitable test chart. The plant supplier shall ensure preset of all the controls prior to start of the test. During testing, there shall be no adjustment of controls. Reading shall be recorded on Hourly basis on test charts. Operational Phase II Test. The plant supplier shall be bound to give three seasonal test i.e. summer, winter and monsoon test within one year of Phase I test. Each test shall last continuously for 72 hours. F a) b) c) d) e) f) g) h) i) j) k) SAFETY FEATURES The safety provision for air conditioning installation shall be conformity with IS 629 1964. All units will have Built-in features to provide safety to operators and equipments. The electrical wiring fuses and equipments should be properly rated to ensure safety against overheating/over loading. All electrical parts shall be properly earthed. An audio alarm is provided in all control panels to signal any overshoot of the safety overload. Noise level should not exceed 85 dB. Emergency stop shall be provided on control desk. Safety interlocks shall be provided for safe functioning of THC system. Access door to the blower fan in AHUs shall be provided. Fan and motor base of AHUs shall be properly earthed Fan performance rating and power consumption data with operating points clearly indicated shall be submitted and verified at the time of testing and commissioning of the installation. The noise level should be less than 85 dB when measured from 1 meter distance from AHU. 10

=10= G GENERAL FEATURES

1 As the new plant has to be adopted to the existing ducting and to be installed in existing buildings, firm has to be visit the site before quoting for the plant. 2. Carrying out of the related civil works is mandatory our the put and part of the palnt supplier & no exclusions to the specifications shall be permitted. 3 THC Systems shall be energy efficient. The supplier shall quote the power consumption of THC Systems. 4 Each THC plant shall be provide with energy meter and a system for PF connection with PF meter. PF ,any time of operation shall be minimum 0.99. 5 THC Systems will be tropicalised to perform satisfactorily at ambient temperature up to 50 0 C and ambient R H from 40 % to 95%. 6 THC Systems shall have robust design for easy maintainability. The operation manual will contain details of trouble shooting methods to overcome problems likely to be encountered during the running of the THC Systems and of the special care to be taken for efficient running of the THC Systems. The workmanship of the THC Systems in situ shall meet the purpose indicated in para A of this specification. 7 The plant supplier will supply in quadruplicate, the manuals for operation, mechanical maintenance, electrical maintenance with wiring diagram, and electronic maintenance with circuit diagram with complete description, spare parts drawing and list . The documentation will include the System description, technical specifications and manufacturers maintenance schedule for all the equipments of the entire THC system. The documents shall be in English language. The supplier shall supply these manuals in soft copy also. 8 The supplier will furnish detailed specification of various consumables to be used in THC Systems with its Indian equivalent. The document will contain the periodicity of replacement of consumables. 9 The manuals will contain complete list of electrical/electronic parts/ IC/PCB cards /subassemblies used in the machine giving the following details : a) Nomenclature b) Part Number c) Order Code d) Type / make d) Full mailing address of Parent Manufacturer with Telephone no., Fax no. & e-mail address e) Complete address of authorised Indian Service Center f) Quantity used 10 The supplier will provide technical literature of all bought out units/sub-assemblies fitted in the THC system. 11 The price quoted by the tenderer shall include any minor details of construction, which are obviously and fairly intended and may not have been referred to in. The supplier shall provide all items, required to complete the job of erection & commissioning testing etc. of the plant, even if not covered in this specification. 12 a) b) c) d) e) The tenderer shall submit Complete literature of all the equipment supplied with spare part list and drawing and specification for AHU, heating, cooling coils. General layout and assembly drawings. Schematic diagram of the package chiller & condenser piping Spare parts catalogue, equipments for package chillers, line valve, strainers, sight glass, controls, including electronic components, Evidence of his capability to deliver such system by a reference to at least 10 similar system already built and delivered (preferably reputed customers). 11

=11= 13 The tenderer will indicate the price of individual subsystems separately.

14 The tenderer will indicate and quote separately for critical spare parts sufficient for two years operation. The tenderer will quote separately for (a) essential accessories (b) consumables and (c) optional accessories. 15 The tenderer shall quote in his tender the total price of all works connected for Plant room as per the tender requirement on lump-sum basis separately. However, the tenderer shall also quote the unit rates for diameter wise pipe, fitting etc. 16 The supplier will forward the service requirements, that shall be necessary for the operation and maintenance of the THC systems, 3 months prior to pre -despatch of systems. 17 Before proceeding with the work, the supplier shall submit following documents. a) Schematic diagram of the package chiller & condenser piping b) Test certificate for Motor, compressor, pumps, condenser chillers etc. c) General layout and assembly drawings. d) Foundation drawing for all units. e) AHU and Ducting lay out drawing as per existing AHUs. f) Chilled water line and interconnection of chilled water line drawing Before taking up the insulation work at Site, the supplier shall get the insulation Drawing approved by OFDR. 18. Painting of the installation and equipment shall be as per relevant colour code for AC Plant and electrical installations. 19. The tenderer may visit to OFDR for on spot assessment of scope of this tender. 20 The supplier will impart training for Operation and Maintenance aspects for THC system, free of cost at the installation site i.e. Ordnance Factory Dehu Road. 21 a) b) c) d) e) f) The plant supplier shall supply following spares & tool set. Hermetically Sealed Scroll Compressor- 4 Nos Flow Switches : 4 Nos Pressure Relief valve : 4 Nos. Catchall Filters: 4 Nos. Bearing for Pump Sets: 1 set for each pump. Air handling units: Bearing 1 set for each AHU. i. AHU Motor 1 no. for each to suit output of 14000,18000, 20000,25500 CFM ii. VEE Belt 1 set for each AHU. Electrical Contactors for AHU Blower : 1 set for each AHU. PCB for Microprocessor based control panel for Chiller Package : 4 Nos Cooling Tower Fan Motor with hub & blades : 2 set for 150 TR cooling tower & 1 set for 200 TR cooling tower Motorised 3 way control valve : 2 Nos WARRANTY :

g) h) i) j) H

THC Systems along with all sub-components and accessories should be guaranteed for a period of one year for any damage, defect or malfunctioning that is attributed to deficiencies during manufacture and supply of THC Systems. The supplier shall be liable to provide free replacement of THC Systems /sub-system in any such eventuality to ensure proper functioning of the system.

Jt.GM/E

JWM/ME

JWM I/cAC Plant

Sub: - Forwarding of specification:- TEMPERATURE & HUMIDITY CONTROL (THC) SYSTEMS HAVING WATER-COOLED CHILLER UNIT WITH MULTIPLE SCROLL COMPRESSORS

The specification