Technical Specifications

TECHNICAL SPECIFICATION FOR AIR CONDITIONING SYSTEM AT VFD ROOM AT CDU II

TS- Air Conditioning System at VFD room in CDU II

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Technical Specifications

1.0

GENERAL The intent of this Scope of Work is to define clearly the Vendors scope of supply and services for providing the packaged air conditioning system at the VFD room above site office building in CDU II in the Kochi Refinery of BPCL. This specification along with the other attachments listed elsewhere, outline the requirements for design, engineering, manufacturing, inspection, testing and painting at works, supply, transportation to stores & job site, erection, testing, commissioning, performance guarantee testing at site and handing over of the Packaged air conditioning system complete in all respects including all associated works viz. electrical, instrumentation, piping, civil works wherever specified, painting, insulation etc. The requirements laid down in this specification are the minimum requirements and the same should not to be interpreted as limiting and the vendor shall meet the performance guarantee specified.

2.0 2.1 2.1.1

SCOPE OF SUPPLY AND SERVICES General scope Carryout design, engineering, manufacturing, inspection, testing and painting at works, supply, transportation to stores & job site, erection, testing, commissioning, performance guarantee testing at site and handing over of the new Packaged air conditioner at the VFD room above site office building in CDU II in the Kochi Refinery of BPCL, complete, in all respects, including all associated works viz. electrical, instrumentation, piping, civil works wherever specified, painting, insulation etc. The Tonnage of new a/c plant shall be a minimum of 20 TR and 50 % capacity shall be provided as stand by. However, vendor shall design the system with available information and check whether this capacity is sufficient to meet the performance guarantee requirements and the responsibility to meet the contractual requirements shall be purely to his account. Conditioned air delivery shall be free flow through a powder coated plenum installed above the unit with suitable supports and hence there shall be no ducting above the false ceiling. The plenum shall be acoustic insulated and shall have grills with adjustable louvers for free flow. Scope of Supply The scope of supply for the air conditioning plant shall consist of but not limited to the following. The items indicated below are for vendors guideline. Any item not specifically mentioned, but required for reliable, safe and unattended trouble free operation shall be included in the scope of vendor.

2.1.3

2.2

S. No.

Quantity

Description

2 working + 1 Standby

Design, supply, erection, commissioning, testing and handover of air cooled Packaged air conditioner with scroll compressors with 10 TR (Nominal) air cooled packaged air conditioners with blower of minimum 6250 CFM capacity for each unit, with microprocessor based control panel comprising of scroll

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Technical Specifications

compressor, electric motor for compressor, air cooled condenser with support evaporator, interconnected insulated refrigent piping complete with necessary fittings, evaporator, air cooled condenser which is to be kept outdoor at the terrace of the site office building, expander interconnecting copper tubes and electrical cables between indoor and outdoor units, centrifugal blower with an capacity of at least 6250 CFM, control and line accessories including pre filter, cubicle type gauge panel, structural frame work for mounting the assembly, antivibration mounting, first charge of R-22 refrigerant gas and oil, painting etc. internally grooved upsized copper tubings , inbuilt digital micro processor controller which shall maintain the guaranteed indoor conditions at all load conditions of adequate capacity, with volume control dampener at the outlets of each unit of packaged air conditioners. The 100% capacity of the plant shall be a minimum of 20TR. However, if a higher value is required, as per vendors design, same shall be considered, with suitable backup data. In addition, 50% of plant capacity designed by vendor shall be provided as standby for the plant. This 150% capacity (as designed by vendor), shall be supplied as 3 skids each of 50% capacity. 2 skids shall deliver 100% of plant capacity and the 3rd skid shall be available for maintenance. Capacity control shall be provided through microprocessor control for part load operation linking all the three skids. Air handling unit blower shall have a minimum capacity of 6250 cfm comprising of fan section with centrifugal fan, fan motor and belt drive package, filter section with prefilter(90% down to 10 micron). AHU section shall have damper with proportionating thermostat, fittings, instruments like pressure gauges, temperature gauges, control and safety arrangements, acoustic and thermal insulation, drain piping, flexible connections etc Tubings and electrical cables Refrigent piping of adequate size which interconnects indoor and outdoor units with insulation, vibration dampners, electrical cable interconnecting indoor, outdoor units to BPCL-KRs power source, cable tray for laying copper pipe and electrical cables. All interconnecting piping and tubings shall be suitably supported

1 Lot

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Technical Specifications

Lot

Powder coated Galvanised Stainless Steel plenum of 18 Gauge with acoustic insulation and grills with adjustable louvers for free flow of air. Plenum shall be suitably supported on to the roof structure through the false ceiling. Manually operated dampers shall be provided at the outlet of machines. Insulation Insulation materials for acoustic insulation Drain Pipe Supplying PVC pipe of adequate size and to drain condensate water to the nearest drain. Condensate water line shall have water seal arrangement and fully insulated. Painting (including touch up painting at site) Controls, Instruments and safety devices required for smooth and unattended operation of equipment/plants. Full microprocessor based controls shall be available for operating the plant at optimum efficiency Foundation nuts and bolts, virgin neoprene vibration isolation pads for package units, filter, etc. Civil works like: a) Providing foundations for packaged units b) Supply and fixing of steel supports for duct/cable/pipe/tubing etc. c) vibration isolation system for air conditioning equipments d) Breaking and making good of openings in wall e) grouting of equipments on foundations. Structural steel works as required for equipment support and base frame of equipments. Grouting of equipments including supply of grouting material. All scaffolding jobs required for carrying out the erection jobs at various elevations Electrical panels and electrical works as per electrical specification. Spare parts for commissioning and start up. (Price of these spares shall be included in the lump sum price of the equipment Spares for two years of normal operation including those required for Electrical as specified in the specifications. (Bidder to furnish recommended list indicating part no., quantity, etc. Price to be given separately for each spare. Purchaser shall select the spare.) Audio communication to be provided for common trip alarm trip for each unit. Initial change of refrigent (R-22), coolants, lubricants etc, including pressure / vacuum testing.

Lot

5 6

Lot Lot

7 8

Lot Lot

9 10

Lot Lot

11

Lot

12 13 14 15

Lot Lot Lot Lot required

16 17

Lot Lot

2.3

Scope of Services

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Vendors scope of services shall be broadly as follows :a) b) c) d) e) f) g) i) j) k) Design and engineering. Manufacturing. Procurement of items from sub vendors, inspection at sub vendor's works. To allow purchaser's inspectors to witness inspection. Inspection and Testing at works shall be as per vendors approved QAP. Vendor shall have to submit approved QAP and test certificates. Surface preparation, protective coating and painting. Insulation works. Packing and transportation of material up to purchaser's job site. Storing, handling of material at site All temporary scaffoldings required during erection, commissioning and testing stages Erection, testing, commissioning and performance guarantee test of complete system at job site Preparation and submission of drawings and documents as per Vendor Data Requirement.

3.0 3.1

SPARE PARTS required Recommended Spares Vendor shall furnish list of recommended spares for two (2) years normal operation & maintenance of the offered equipment with item wise price along with the Bid. Recommended spares and their quantities should take into account related factors of equipment reliability, effect of equipment downtime upon production or safety, cost of parts and availability of vendors service facilities around proposed location of equipment. BPCL-KR will order selected spares, separately, at a later date as per these rates Commissioning Spares required Vendor shall supply adequate quantity of commissioning spares so as to ensure that commissioning of the system is not hampered for shortage of commissioning spares. Vendor shall submit the list of commissioning spares included by him along with the Bid. Vendor shall supply any spares required during commissioning, over and above the quoted spares, without any price or time implication. The cost of the commissioning spares shall be included by Vendor in the cost of the equipment. The unused commissioning spares will become property of BPCL.

3.2

3.3

All spares parts shall be wrapped and packaged so that they are preserved in original as-new condition, under normal conditions of storage to be anticipated in India, and shall be properly tagged and coded so that later identification for intended equipment usage will be facilitated. The two years recommended spares and commissioning spares shall be packaged separately and clearly marked as Spare Parts and Commissioning Spares respectively and shipped at the same time as the equipment.

4.0

EXCLUSIONS

TS- Air Conditioning System at VFD room in CDU II

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Technical Specifications

Following shall be excluded from the Vendors Scope of Work and shall be provided within Vendors Battery Limit by Purchaser. b) Electrical power supply and earthing shall be provided at one point near the VFD room. VFD room for erecting the indoor units and space on roof of the site office building for erecting the exterior units. Lighting for the room.

c)

d)

5.0 5.1

TECHNICAL REQUIREMENTS The equipment shall be designed, manufactured, tested and supplied in accordance with the enclosed data sheets,(datasheets to be enclosed) this Technical specification, Electrical data sheet for package equipment, enclosed drawings and all other attachments of these Technical specifications. Standard Specification for air conditioning plant (give the EIL standard no)shall be followed for applicable items by vendor. Vendor may cross check the estimated plant capacity in his own interest before accepting the same. However, minimum capacity (100%) of the plant shall be 20TR, which shall be complied by the vendor. Vendor shall guarantee the inside conditions in clause 6.3 below, throughout the year irrespective of variation in outside weather condition and/or inside heat loads. Vendor shall be solely responsible to demonstrate the specified inside conditions. In case vendor desires to increase the plant capacity, he shall furnish adequate technical reasons and necessary technical data including heat load calculations in support of such increased plant capacity in his bid. Vendor shall include all items required to complete the intent of this requisition not withstanding the fact that such items may have been omitted from the specification or drawings. Vendor should note that entire data presented by them at bid stage will be taken as indicative only. Purchaser shall review the data during detailed engineering after award of contract, within the framework of this requisition. All comments of Purchaser shall be taken care without any cost and time effect. The layout of air conditioning plants have been made clear in the enclosed drawing. Accordingly, vendor shall provide all items on lump sum basis and SHALL NOT INDICATE QUANTITIES OF VARIABLE ITEMS IN THE BID Vendor shall furnish psychometric mixture conditions and the processes which air undergoes in the conditioning equipment. Vendor shall furnish all data sheets and drawings for purchaser's review before commencement of fabrication/ construction.

5.2

5.3

5.4

5.5

5.6

5.8

5.9

5.10

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Technical Specifications

5.11

Chipping of RCC slab for duct hangers is not allowed. Vendor shall provide anchor fasteners. Complete supporting structure for duct/cable/pipe etc. shall be provided by vendor. Wherever a pipe/pipes passes through a wall/slab/roof, adequately sized sleeve shall be provided. Air conditioning units shall provide cooling and dehumidification in summer/ monsoon by handling mixture of fresh and return air. Reheating shall be provided in monsoon to achieve specified inside conditions, by means of finned strip heaters actuated by humidistat, backed up by safety thermostat. Vendor shall ensure that fixing arrangement of diffusers is such that there is no load on false ceiling. Diffusers shall be firmly fixed with the ductwork.

5.12

Not requried
5.14

5.15

Entire duct shall be provided with insulation. Duct acoustic lining shall be provided for initial duct length Insulation material to be used for duct shall have factory laminated aluminum foil. Not required Where duct is provided below the ceiling, aesthetically acceptable ducts as approved by the Engineer in charge shall be provided. 5.16 Requisite multi layer virgin neoprene pads shall be provided by the Vendor between foundation blocks & equipments e.g. chillers, AHU, Condensing Unit, Tanks, Package Units, Pumps etc. All the equipment, electrical and controls shall be suitable for electrical area classification in which they are installed. All couplings, gears and exposed rotating parts shall be provided with appropriate guards. Fire dampers shall be spring actuated with fusible link or with motorized damper actuator. Safety factor shall be considered as 12.5% in respect of Room Sensible Heat and 10% in respect of Room Latent Heat. Two-stage air filtration shall be provided. In first stage, pre-filters shall be provided at Package units/ AHU suction, these shall have 80% efficiency upto 20 microns for Package Units and 90% efficiency upto 10 microns for AHU. In second stage fine filters at downstream of Package units/ AHU shall be provided, these shall have 95% efficiency upto 5 microns. Fine filters shall be mounted in a suitable G.I.Plenum. Package units, Fire dampers shall be interlocked with gas / smoke detection and fire fighting system. Velocity at outlet of AHU/PU shall not be more than 1800 FPM. Further velocity in supply and return air ducts shall not be more than 1500 FPM and 1000 FPM respectively.

5.19

5.20

5.21 5.22

5.23

5.24

5.25

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5.26

In addition to Foster adhesive for duct insulation other equivalent adhesive compound shall also be acceptable.

Vendor to furnish all datasheets and drawings for purchasers review before commencement of fabrication/ construction

Chipping of RCC slab for duct hanger is not allowed. Vendor to provide anchor fasteners. Vendor shall consider minimum 1 air change/ hour while designing the AC system.
6.0 6.1 DESIGN DATA Area to be air-conditioned Area to be air-conditioned shall be VFD room in FCCU at 4.30 M (Floor level) elevation as shown in the drawing No. KR-A2-f-01-5860 Rev 0 attached. 6.2 Out Side Condition
0

Temperature C Summer Winter Monsoon 6.3

Dry Bulb 35 22.2 29.4

Wet Bulb 27.8 18.3 27.8

Inside Design Conditions DBT,C i) VFD Room above site office building in CDU II 23 +/- 1 % RH 50 +/- 5

6.4

Equipment / Instrumentation Load The power consumption due to Instrumentation and Electrical panels, lighting and occupancy in the control room are as under :

Sl. No. 1

Motor Tag No CP 24A

Unit CDU-II

Pow er Ratin g (kW) 160

Heat Load of VFD panel VFD location Above Module Losses( in KW ) 3.9 Panel Loss (in KW) 5.85 Total Heat load of VFD panel (KW) 9.75 Total Heat load of VFD panel (KW)

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Technical Specifications

2 3 4 5 6

CP 26A CP 34A CP 39B CP 277A CP 302A CP 304A

CDU-II CDU-II CDU-II CDU-II CDU-II CDU-II

132 55 160 110 75 75

Site Office, CDU II

2.53 1.42 3.9 2.43 1.93 1.93

3.795 2.13 5.85 3.645 2.895 2.895

6.325 3.55 9.75 6.075 4.825 4.825 45.1 kW

Vendor to consider a lighting load of 1000 W while designing the AC system

6.5 Roof Insulation Under deck roof insulation (false ceiling) for air conditioned space shall be provide by BPCL-KR

Vendor shall furnish the heat load calculation for all 3 seasons during detail engineering. However bidder is advised to cross check the indicated capacities before submission of his bid. In case the heat load calculated by the Bidder works out to be more than as specified above, the Bidder shall offer the higher size plant and submit the detailed supportive calculation in his bid. Vendor shall be solely responsible for maintaining inside conditions throughout the year irrespective of any variation in the outdoor conditions. required 6.7 Ducting design and layout shall be finalized by vendor. Ducting work shall be carried out by the Vendor as per IS : 655, for the VFD. Vendor shall submit air conditioning ducting layout drawings for during detailed engineering. 7.0 SYSTEM DESCRIPTION The system shall have a minimum tonnage of 20 Tonnes and air flow capacity of 12500 CFM. Vendor shall check the adequacy of the tonnage/ capacity to meet the guarantee conditions specified in this tender. The reheat load shall be designed by the vendor. The air conditioning system is to be operated at the rate of 24 hours/ 365 days with R-22 refrigerant 8.0 Air Distribution Scheme Supply air shall be distributed through supply air duct and return air will be sucked back to the system from the room directly. BATTERY LIMIT Vendor shall supply all equipment, interconnecting piping, instrumentation for measurement and control, control indications as well as safeties and all other items in order to meet the load requirements specified in this Specification and to start up, operate and shut down the plant in a smooth and efficient manner. Purchaser shall provide power connection (one point) at one location near the VFD room.

6.6

9.0 9.1

9.2

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Technical Specifications

9.4

Instrumentation for providing indication of following parameters shall be provided as a minimum requirement for getting sufficient data for analysis of the system. 1. 2. 3. 4. Compressor inlet and outlet temperature and pressure Refrigerant temperature and pressure at inlet and outlet of evaporator. Packaged Units inlet / outlet air, pressure & temperature Refrigerant temperature and pressure at inlet/outlet of air condenser.

10.0

VENDOR DRAWING AND DATA REQUIREMENT The Vendor shall furnish the information, data and documents along with the Bid and after the award of job as per the Vendor Data Requirement attached with this Technical specification. PAINTING AND SHIPMENT Equipment and materials supplied shall be painted after tests at shop. Touch up painting shall be done at site after installation & testing. The units shall be disassembled into major components suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection. All machined and bearing surfaces shall be protected against rust with a thick coat of grease. Each equipment shall have an identification plate giving salient equipment data, make, year of manufacture, equipment number etc. GUARANTEE All equipment and components shall be guaranteed by the Vendor against any defective material, design and workmanship for the period specified in commercial part of the bid document. The performance guarantee test mentioned in clause 14.3 below shall be completed to the satisfaction of BPCL/Third party inspection agency. The vendor shall have final and total responsibility for the design and mechanical performance of the entire system under this enquiry.

11.0

12.0

13.0 14.1

INSPECTION AND TESTING Equipment shall be subjected to inspection and testing at Vendors / Subvendors works by purchaser / its authorised inspection agency. Manufacturers Quality Assurance (QA) Plans shall be submitted for purchasers review before taking up manufacturing. Inspection and Testing shall be carried out as per the applicable Codes and Standards and approved Manufacturers Quality Assurance (QA) Plan. Inspection and testing at vendors and sub-vendors works shall be as per the Standard Specification for Air Conditioning Plant. Any or all the tests, at purchasers option, shall be witnessed by Purchaser / its authorised inspection agency. However, such inspection shall be regarded as check up and in no way absolve the Vendor of his responsibility. After installation and commissioning at site, the Air Conditioning System shall be tested for operation at no load & full load conditions. After successful commissioning, the Performance Guarantee Test shall be

14.2

14.3

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Technical Specifications

carried out by vendor in accordance with the Standard Specification for Air Conditioning Plant and enclosed "Instructions to vendor for site performance guarantee". Vendor at his own cost shall arrange all instruments and gadgets for testing at Site. 15.0 CONFLICT In the event of conflict between various documents forming a part of this material requisition, the following order of precedence shall prevail: Data Sheet This specification Standard specification Codes and standard

16.0

Vendor shall arrange to visit the site and acquaint themselves of all the requirements of the enquiry, before quoting for the job. Complaints of lack of clarity in the scope, or disputes regarding the supply / service involved in the contract, for completing the jobs to the satisfaction of engineer in charge, shall not be entertained, at a later stage. MAKES OF BOUGHT-OUT EQUIPMENT / MATERIAL ITEM Chiller Package/Condensing Units Package Units Scroll Compressors Condenser/Evaporator MAKE OF EQUIPMENT Voltas/Blue Star/Kirloskar Pneumatic/York/Carrier Voltas/Blue Star /Emerson/ Carrier/ Batliboi Voltas/Blue Star/Kirloskar Pneumatic/ACCEL check the make available with vendors and include them also Voltas/Blue Star/Kirloskar Pneumatic, Industrial Mfrs Mumbai/Thermo Transfer Engineers,Mumbai/Reynolds Engg. Mumbai/Project Technologists (P) Ltd. Baroda Paharpur/ Mihir/Advance Voltas/Blue Star/Fedders Llyod/Carrier/Hitachi Blue Star/Voltas/Zeco/Carryiare Tenacity / Kirloskar / Anfilco / Dyna Alstom TSC Instruments/ George Rao & Co/Caryaire Indfoss/Penn/Honeywell/Johnson Controls Sulzer Pumps India Ltd./ Beacon Weir Ltd./ Mather & Platt (India) Ltd./ Bharat Pumps and Compressors Ltd./Kirloskar Brothers Ltd./ KSB Pumps Ltd.

17.0 S.N O. 1 2 3 4

5 6 7 8 9 10 11 12

Cooling Tower Split/Windor Airconditioner AHU Filters Exhaust Fan Fire Dampers Modulating Motor with Prop. Thermostat Water Pump

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13 14 15 16 17 18

Grill/Diffuser Damper Actuator 3-way modulating valve Chemical Filter Pipes Pipe Fittings(Water)

Ravistar/Carryaire/Air Master Siemens/ Belimo Honeywell/ Johnson Purolator/ Circule Air/ Bry Air/Caryaire ITC / BST / Jindal / Ajanta / Zenith M.S.Fittings Calcutta / EBY Bombay / STEW Arts & Lloyds / ECHJAY Bombay Commercial Supplying Agency Bombay / BHARAT Forge / Metal Forgings Gujrat Engg.Works Bombay / Union Tools & Engg. Stores Bombay National Steel & General Mills Ghaziabad. Sakhi/Globe / J.K. Ind., Baroda / Leader / Neeka Valves, Nagpur / Niton Valves / Precision Valves, Nasik Ratnamani / Nuclear fuel Complex Bhartia Lloyds / Metthur Beardsell / U.P.Twiga H.Guru / Gen.Instruments Asco / Rotex / Harion Brassomatic Indfoss/Switzer/Honeywell Brassomatic Fenner / Dunlop

19

Valves(Water)

20 21 22 23 24 25 26 27

SS Tubes Thermal Insulation Pr./Temperature Gauges Solenoid Valves Refrigerant Valves HP/LP/Oil Pressure Refrigerant Strainer/Filter Drier/Sight Glass Pulleys & Belts

For items not covered in the above list, vendor shall propose the sub-vendors for the same, with their proven track record in similar service, which shall be subject to BPCL-KRs approval. Attachments: 1) 2) 3) 4) Datasheet for packaged air conditioning units VFD room layout drawing (KR-A2-Y-01-5932) (1Sheet) Technical Specifications for air conditioning system at VFD Room Standard Specifications ____________________________

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