8 DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow eystem © DELHI METRO RAIL CORPORATION LIMITED DMRC ELECTRICAL STANDARDS & DESIGN WING (DESDW) SPECIFICATION NO. DMES-E/0004/ DMRC-E-E&M-VRF-01 SPECIFICATIONS FOR SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF VARIABLE REFRIGERANT FLOW SYSTEM Issued on: Date Stage 20" July 2016 Draft-3 DELHI METRO RAIL CORPORATION LTD. 7" Floor, B-Wing, Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi -110 001. Page 1 of 13Qe DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, installation, Testing & Commissioning of Variable Refrigerant Flow system Previous Record of specification Stage Date Draft -1 16/10/2014 Draft-2 18/04/2016 Draft-3 20/07/2016 Page 2 of 13,© OMRC Electrical Standards & Design Wing DMES-£/0004 Specifications For Supply, Installation, Testing & Commissioning of Varlable Refrigerant Flow system a= Contents 1. Detailed Description and Application in DRC 2, Governing Spectfications 3. Requirement. rae 3.1 Environmental Conditions... 3.2 Functional requirements... 3.2.4 VRP. 3.2.4.1 Outdoor Unit. 3.2.4.2 Indoor Unit... sncuscnmimisines 3.2.1.3 Centralized system remote controler... 3.2.1.4 Refrigerant Pipework 3.2.4.8 Drain Piping... 3.2.2 Noise Level... oo 3.2.3 Input Voltage & Frequency. 4. Additional Requirements... Safety connie Energy Efficiency Maintenance and Life Material & manufacturing Testing. 0. Training Doonan ar PxAoa Page 3 of 1386 DMRC Electrical Standards & Design Wing DMES-E/0004 ‘Specifications For Supply, Installation, Tosting & Commissioning of Variable Retrigerant Flow system as 1. tail ion and Application in DMRC 11 Variable Refrigerant Flow(VRF) type of Alt- conditioning system is to be provided at the Slevated stations(Rall Corridor), depots anc RSS of DMRC, Generally, the folowing rooms of the stations shall be air- conditioned: Station Control Room Ticket Offi * EFO ‘* Signal Maintenance Room * Signal Equipment Room * Telecom equipment Room * UPS (S&T) Room + UPS (Elect) Room + Station Manager Room + Craw Control Room at specified sites. 1.2 The scope of work related to Variable Refrigerant Flow Air-conditioning System shall generally comprise of but not limited to the following - «| Manufacturing ‘* Testing at manufacturer's works ‘+ Supply and storage, ‘+ Installation at station ‘* Site testing and commissioning * Training of DMRC staff 1.3 The VRF type air-conditioning system shall generally consist of: * Ouldoor and Indoor units along with refrigerantpiping, its insulation withcledding and layeutcabletray/ raceway. The cabletray/racewayused for refrigerant pine and lectrical cables will be a part of the VRF system and no separate payment is to be made. * Air distribution system when ducting is provided as per BOQ + Drain Piping + Electricalworks. Page 4 of 138 DMRC Electrical Standards & Design Wing DMES-E/0004 ‘+ Materials and components not specificallystated in the specifications and/or bill of materials or noted on the drawings but which are necessary for satisfactory installation and operation of the system. 2. Ov" jn: The VRF type air-conditioning system shall comply with standards mentioned particularly in the table below unless otherwise stipulated in the specifications, The latest version of standards shall be applicable, AHRI-1230 (or the latest) HRAE jatest standard and guidelines. UL-94- VO_ Indian Electricity Rules- 2005 3. Requirements ‘The VRF system shall be designed to meet the following minimum requirements: 3.1, Design Parameters 3.1.1. The following parameters shall be considered for the design 8.1.1.4 OutsideConditions for Cooling DB ] we ‘Summer & Monsoon 4045 deg C T 2724 dag C 4 Winter 20dee-S | A8deg-C 3.1.1.2 Inside Conditions ‘Summer & Monsoon 2s deg (Relative humidity not exceeding 60%) 3.1.1.3 Fresh Air: As per ASHRAE. 3.1.1.4 Lighting Load: 1.2 WiSa ft 3.44.6 Dusting|For Airconditioning) 460 -mitre/min | Herne per 00 mie-u8 | Page S of 13ea DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of 3.2 3.24 “Maximum velocity at exhaust air grile Functional Requirements VRF The Variable Refrigerant Flow (VRF) System should be air cooled, consisting of modular condensing outdoor units connected to muttiple indoor units. Each indoor unit shall have the capability of individual set point control. Each modular condensing unit should have ultiple-inverter based compressors (minimum 2 compressors for'18°HP and above Uunits)-consisting-of minimum-50% invertar_base compressor capacity oLine-medule-ard ‘obtain-to obtain 10% to 100%step less capacity control to match the air-conditioning load. The refrigerant used should be environmental friendly. The manufacturer shall take a note of the ambient air pollution prevailing in Delhi/NCR region and shall provide proven protection against corrosion to all the components of VRF module. The VRF air conditioning system shall consist of the following sub-systems.~ 3.2.1.1 Outdoor unit The outdoor unit shall be a factory assembled unit housed in a sturdy weather proof casing constructed from rust-proofed mild steel panels coated with a baked enamel finish. There should be no scaling, corrosion or any other physical deformation on the body of Outdoor unit The outdoor unit shall be modular in design and thickness of the sheet Used for manufacturing the body shall be such that it shall not deform during handling and may use corrugation to strengthen the body structure. The minimum IEER should be as below~ DU Capacity IEER (Minimum) Fiend oboweAll capacities 18 The Outdoor unit shail at least have the following sub-components:~ + Compressor The compressor shall be highly efficient and capable of capacity modulation with inverter sorollTwin rotary design. * HeatExchanger The Condenser fins must be coated with Anti-corrosive treatment. Page 6 of 13,eS DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow Sas + Refrigerant Circuit ‘The equipment must hz refrigerant distribution * il Recovery System Each unit shall be equippedwith an oil separator to ensure stable operation with long refrigerant piping. The system should have inbuilt oil balancing circuit within the compressors and between modules to avoid poor lubrication 3.2.1.2 Indoor unit Indoor unit shall be Wall mounted/Ceiling mounted/fioar maunied/ AHU with metallic body with-factoryfabricated-bedyreach complete with coil pre-filter, ete. including necessary steel supporting structure. Indoor unit should have flexibility for duct ‘extension(it required), CFM shall be as beiowhe-appreved-desiga. inbuilt refrigerant stabilization control for proper 101 Copacity CEM (Minima L 157R 500 2TR | 600 25TR | 1000 [ 47578 ! 2200 It shall have electronic control vaive to control refrigerant flow rate in response to load Variations of the room. The indoor unit should be designed such that in case of failure! trip of one indoor unit, the working of ODU and other indoor units should not be affected. - The indoor unit-fan-shall-be-cirest-driven, The indoor unit casing shall be fully insulated ‘and sealed to prevent condensation. Each indoor unit shall have the capability of individual set point control. 3.2.1.3Centralized system remote controller ; ‘A multifunctional compact centralized system remote controller shall be provided with the systemwherever—specified. The—System—Centroter—shal_provide—prover—ait ‘equipment: It should be user friendly. It should be able to contro! al-theatleast 54 indoor units connected at a station, \with-a-provision for 26% tuture-additional iadoor-uniis. The centralized system remote controller shall perform the following minimum function: Page 7 of 13,8 DMRC Electrical Standards & Design Wing DMES-E/0004 ‘Testing & Commissioning of le Refrigerant Flow .__Sterting/stopping of Air conditioners as a zone or group or individual units. IL Temperature setting for each indoor unit or zone I, Switching between temperature control modes, switching of fan speed. IV. The address of the indoor unit shall be set automatically in case of individual and ‘group control. V. Monitoring of operation status such as operation mode & temperature setting of individual indoor units, maintenance information, trouble-shooting information. VL. Scheduling of both Indoor and Outdoor units as per the requirement, \Vi_A provision. of wiring the centralizes system controller to the indoor unit-upto-a deianse shasta oe aiage 3.2.1.4 Refrigerant pipework All interconnecting pipe-work between the condensing unit & indoor units shall have quality seemless copper tubes with brazed connections and the appropriate distribution joints and headers shall be used. The piping should be routed at site in such a manner, that brazed joints in the Refrigeration Piping are Kept to @ minimum, The refrigerant pipe shall be thermally insulated by proven materials heving low thermal conductivity, high mechanical strength, non-combustible, resistance to Fungi, ozone, UV and any other environmental pollutant. Moulded tee joints of thermal insulating material shall be used. at bends, The refrigerant piping shell be extendable minimum 165 m with 50 m level without any ol trap. Distribution refrigeration pipe joints and headers shall be installed in an appropriate orientation to enable correct distribution of refrigerant. The Distribution joints shall be factory/sito insuleted. All pipe-work must be kept clean and free from contamination to prevent breakdown of the system. All pipe ends shall be kept sealed unt! immediately prior to making a joint 3.2.1.5 Drain piping The indoor units shall be connected to vertical drainage insulated G/RVCpipe. The pipes shall be laid in proper slope for efficient dreinege of condensate water, Drain pipes carrying condensate water shall be insulated. The joints shall be properly sealed with synthetic glue to ensure proper bonding of the ends, Page 8 of 13© MRC Electrical Standards & Design Wing DMES-E/0004 322 3.23 42 43 44 45 52 lation, Testing & Commissioning of Variable Refrigerant Flow Noise Level ‘The Noise level of outdoor unit shall not be more than 68 dB(A)at normal operation. The Noise Level of indoor unit shall not be more than 42 dB(A) for non ductable type and not more than-8065 dB(A) for ductable/A}Uunit type, The noise level shall be measured ai a cistance of 1m away(horizontally) and 1.Sm above ground Input Voltage & Frequency Alll the outdoor unit shall be suitable for operation with 415 V +10%, 503% Hz, 3Ph 4 wire AC supply where as all indoor units should be with 230 Vit 10%, SOHz 43 % Single Phase supplyor 415 V +10%, 5089% Hz, 9Ph 4wire iti Requirement ‘The power/controlicommunication cable between indoor and outdoor units shall run in PVG -senduiteG! conduits or armoured cable to be used ‘The insulated refrigerant piping and cable between indoor and outdoor unit shall run in a Galvanized Steel raceway/Cable traywith proper supporting arrangement-There-shall-be reper securing arrangement cf top-cever-with-the-bottom-tay- All galvanized support beams, galvanized legs, galvanized hangers, anchor bolts, vibration isolators, end ductworks shall be provided for the installation of the units, assembly and its sub-assembly. ‘The VRF type air conditioning units shall be mounted on vibration isolators and installed in accordance with the manufacturer's recommendation such that no disturbing vibration OF noise is being transmitted to the nearby structure. The centralized system Controllershall be located in a properly sized box with lock and key facility along with its battery unit. The power supply cable for the controller shall be taken in @ conduit from the nearest 230V socket. A guidance manual of the controller shall be located in this unit. Safety All necessary safety devices shall be provided in the indoor and outdoor units to ensure the safety operation of the system. The design of the safety system shall be such that the equipment is protected and defect of one unit shall not lead to consequential damage to any other units. The safety and protection design shall be submitted with the offer and shall be a part of the training course to DMRC official ‘The following safety devices shall be part of the outdoor unit: Page 9 of 138 DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Var ‘frigerant Flow system a 1. High Pressure Switch 2. Low Pressure Switch 3. Fan MotorSafety Thermostat 4. Over Current Relay 6—Fusible Rlug 6. Fuse 7, Overload protection including overload protection for inverter driven compresser. 8. Protection for indoor fan motor 5.3 All the material used in the manufacturing of VRF system shall be fire retardant. The indoor unitsnall be in conformance to UL-94 guidelines. The manufacturer shall submit UL compliance certificate with the offer. 6. Ene ici 61 Only the best manufacturing practices ie, the units with maximum IEER as per AHRI- 1230 standard with addendum will be accepted. The contractor shall study the best le designs and offer the best IEER available in industry. However, the VRF urit should provide a minimum IEER of fas per ARI conditionsupte-20-24 HP and-15-for-24 HP-and-above for 18 HP and aboveODU's. The-weightage-system-and formulas-tised-for ail-caloulationsshalibe as por 4HR4-4230. The formula used for the calculation of IEER shalibe as follows : IEER= [(0.02" COP ai 100% loading) + (0.617" COP at 75% loading) + (0.238" COP at 50% loading) + (0. 125" COP at 25% loading))* 3.41 {In case if the IEER islé3sthen 18. a consolidated penalty shallbepaid by the contractor, according fo the following formula Gost= [ 0.02(1/COPn) - /COPs) + 0.817" 0.75 (1/COP m2 — COP.) + 0.238 * 05 (WCOP 9; ~ HOP) + 0.125 * 0.25 (11COP nq 1/2OP,)} * 16 hrs * 365 days * RS T/KWih * 10 years* 3,51° TR rating Where, COP), COPa COP», COP), are referenceCOP sand are taken'as 4)°6) 6 and SiScorresponding to IEER= 18 Page 10 of 13© OMRC Electrical Standards & Design Wing DMES-£/0004 mW 72 73 74 and COPy;, COPn2 COP, COPn. are the COP's declared by the manufacturer corresponding to 100%, 75%, 50% and 25% respectively at 35° C. Alternatively = 62 Cost of energy consumption of each18HP outdoor unit with IEER of 18 running for 16 hrs a day and energy costatRs.7 per unit comes to approx Rs.26.4 Jac for 10 yearsand iteomes to Rs.27.65 lac with IEER of 17, which means for every drop of 1% IEER additional cost of energy consumption for 10 years comes to Rs.0.22 lac. Therefore for every drop of 1% IER of the offered VRF system below 18, @ consolidated penalty of Rs.0.22 lac shall be paid by the contractor. This shallaiscapply to ODUs of 20 HP and 24 HP. 6.3 Successfulbiddershallsubmit the COP of the proposed VRF systenat all four loading concitions; i.e. 100%. 75%, 50% and'25%.alongwithstipportinig documents. COP at the time of FAT willbemeasiiréd by DMRC or the representative of DMRC and #1EER isfound (o be less than 5% of dediared value, ‘penalty at double the rate as per para 6.2 willbeimposed, Maintenance and life ‘The service life of the VRF system shall be at least 15 years, with average 427hours working per dey during the year. ‘The manufacturer shall submit the list of those items whose life does not match with the ‘service life of VRF. The life of such spares shall be advised with @ certificate from the criginal manufacturer of the spares. The firm shail supply purchase specification of these items. ‘The manufacturer should also submit Annual Maintenance cost rates for the full service life of the system. ‘The manufacturer shell provide free service and guarantee for 24 months from the date of taking over the metro station by the purch: Page 11 of 13© DMC Electrical Standards & Design Wing DMES-E/0004 82 83 a 94 Material and manufacturing Quality Assurance and Controls: The Contractor's Management Systems shall emphasize quality assurance and controls. The programme shall be adequate to ensure an acceptable level of quality of the equipment supplied The concept of total quality assurance shall be based on the principle that quality is a basic responsibilty of the Contractor's organization, and shall be visible by: 1. Firm procurement and job performance specifications, 2, Firm procedures for transmission of information and date to their Subcontractors and ensuring their compliance. 3. Adequate testing to ensure repetitive product conformity to design requirements and Total programme of surveillance and verification of physical performance end configuration accountability. 4, Adequate records shell be kept by the Contractor to provide evidence of quality and accountability. These records shall include results of inspections, tests, process controls, certification of processes and personnel, discrepant material, and other quality control requirements. 5. Complaint Handling and commitment towards customer satisfaction, ‘The manufacturer shall ensure use of best manufacturing practice like quality of bends, no sharp comers, and no metallic parts with sharp edges, use of quality casket at appropriate loss to damp vibrations and sealing ete. The manufacturer shall study the environmental pollution data prevailing near the Metro Station where its equipment is going be installed. The manufacturer shall take adequate precaution either during manufacturing or installation to prevent any damage to the equipment or loss of life arising due to prevailing pollution tevel. Testing The unit shall be tested for sapacty-andlEER as per AHRI conditions at manufactures premises or at an accredited laboratory Capacity at 4345° C will also be tested, The capacity of ODU and IDU’s shail be as per the BOQand 100% capacity of ODU's should be delivered at 35°-C-and 45°C. and deration-of capacity upto A3°.C should.not be more chan 1o% Page 12 of 13eS DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Int 92 9.3 94 94 95 96 10. 104 102 ‘The manufacturer shall also submit the deration graph for different ambient conditions in the performance of their VRF system starting from the maximum ambient temperature conditions as specifiad in this specification Before delivery, owner/ their representative reserve the right to witness the test in presence of tenderers and manufacturer's representative. ‘The manufacturer shall submit Installation guidelines duly approved by Engineer-in- charge, The manufacturer shell ensure compliance of installation guidelines and shall Sign the installation certificate before commissioning of the plant to start After complete installation of refrigerant piping, it shall be pre-pressure tested and ‘epaited if necassary and further pressure tested to 3,800 Pa, to hold for a minimum 24 hours with dry nitrogen prior to insulating the Joints. After satisfactory testing, the refrigerant pipe shall be evacuated and dehydrated to (- 755 MM HG) and held for one to four hours depending on the pipe length ‘The FAT plan for VRF equipment shall be as per Annexure-A. Trainin: The contractor shall ensure training of DMRC staff as decided by DMRC at DMRC workplace or at his workplace as considered necessary. ‘On completion of installation, the manufacturer shall supply two sets of well bound handing over manuals duly approved by Consuttants/Engineer-in-charge. Each set shall include:- * As Built Drawings + Do's and Don'ts for the maintenance and operating staff + Working details of VRF system. © Operating manual. + Extracts of the warrantiDLp. + Details of service center. + List of staff trained on the said design of the VRF. ‘+ The first page of the booklet shall be signed by the manufacture, contractor and DMRC Engineer. * Soft copy of the entire documents. Page 13 of 13, Refrigerant Flow system eeeAnnexure-A FAT PLAN FOR VRE Equipment PHYSICAL PARAMETERS TO BE CHECKED COMPONENT PARAMETER _ | Requirement Remarks OUTDOOR UNIT | Casing Weather proof casing constructed from ust-proofed mild steel panos coated with a baked enamel finish Compressor Minimum 2 no. variable compressor for 18HP and above. INDOOR UNIT Component Electronic Expansion Valve Insulation fully insulated and sealed HEAT EXCHANGER | Construction condenser fins must be coated with Anticcorrosive treatment. REFRIGERANT ‘Component ‘Accumulator CIRCUIT Component Tiquid and gas shut off valve ‘Component ‘Solenoid vaives OIL RECOVERY Component Oil Separator SYSTEM SAFETY DEVICES | Component. High Pressure Switch Component Low Pressure Switch Component Fan Motor Safety Thermostat ‘Component ‘Over Current Relay Component Fusible Plugs | ‘Component | Fuse FAN MOTOR ‘Component Thermal protection | telay.TECHNICAL PARAMETERS TO BE CHECKED. Sr No. COMPONENT PARAMETER REQUIREMENT REMARK OUTDOOR UNIT Cooling capacity 100% cooling capacity at 36 Deg C ambient temperature and also at 45 deg C. Noise level 68 dB(A)at normal operation measured horizontally 1m away and 1.5m above ground. cop ‘AS per ARI Conditions INDOOR UNIT Noise level NOISE Level < 4208 for non ductable type and <65 dB for duetable/AHU unit REFRIGERANT PIPING Tength Extendable minimum165 m_ with 50 m level without any ol trap FAN MOTOR Speed Control At least two speed operation to maintain constant head pressure control at all ambient temperatures “CENTRALIZED REMOTE CONTROLLER Operation Starting/ Stopping of Air-conditioners as a zone or group or individual unit Operation Temperature setting for each indoor unit or zone | Operation Switching between temperature control modes Operation Switching of fan speedOperation Control direction of sir-flow Operation ‘Enabling/disabling of individual remote controller operation ‘Operation Monitoring of Operation status Operation Maintenance information Operation Trouble Shooting information Operation ‘Temperature setting of individual indoor units