Air Washer Unit

TECHNICAL SPECIFICATIONS For

AIR WASHER UNIT FOR

POWER CONDITIONING SYSTEM (Indus-2) Techno-commercial Bid (Part-I)

Indent No: RRCAT/Indus-2/SC/2009/05 Specification No.RRCAT/IOAPDD/SC/2009/05

INDORE M.P. INDIA

Contents

Section-A 1. Introduction 2. Scope of work 3. Site location 4. Basis of design 5. Building Description 6. Ventilation System 7. Applicable drawings 8. Applicable Standards 9. Evaporative cooling equipment 10. Centrifugal Fans 11. Filteration 12. Ducting 13. Electrical & Motors 14. Instrumentation & Control 15. Preferred make of Materials 16. Drawings and Documentations 17. Inspection and Acceptance Criteria 18. Sub Contract 19. Delivery Schedule 20. Shipping & Storage


SECTION -A:

Technical Specification for the air washer unit Power conditioner units room Indus-2 1.0

INTRODUCTION: Raja Ramanna Centre for Advanced Technology Indore M.P. is engaged in electron accelerator development Programme. A 2.5GeV electron storage ring Indus-2 is under commissioning. Sophisticated subsystems of this particle accelerator machine require high quality conditioned uninterrupted AC mains power for their smooth and reliable operation. Indus-2 machine require high quality conditioned uninterrupted AC mains power for their smooth and reliable operation. Six nos. (3 x 1670 kVA and 1 x 1100 kVA -present) and (2 x 1100 kVA -future) of Rotary type Power Conditioning System (PCS) are being planned to cater to the load requirement of the subsystems. These units require dust free and cool ambient conditions for smooth operation. This specification covers the requirement for the design/engineering, manufacture, assembly, inspection, testing at supplier’s works, supply, installation, testing & commissioning at purchaser’s site and guarantee of two nos. of air washers unit as per the purchaser’s tender specifications and drawings referred herein.

2.0

SCOPE OF WORK: The scope of work involves design/engineering, manufacture, assembly, inspection, testing at supplier’s works, delivery to purchaser’s site installation, commissioning and balancing of two nos. of air washer unit for existing power conditioning system (PCS) building. The tenderer has to carry out following specific jobs: 2.1 Providing two number of 40000CMH capacity air washer unit including evaporating cooling unit, two centrifugal fans with motors, filtration units, GI ducting for supply ducting, fresh air louvers,


4.2 Room Design Conditions:

Following are the required design room air conditions: o

o

o

o

Dry bulb temperature of supplied air ( C): 0 – 30 C (daily average ≤ 30 C) Relative Humidity of Supply air : Not exceeding 95% (non condensing nature) Filteration level of Supply air : 95% Filteration efficiency down to dust particle of 5 microns 4.3 Occupancy and Equipment load of Building

I. Total Occupancy in the Building: One II. Equipment load : 600 kW III. Lighting load : 1.2 kW

5.0

BUILDING DESCRIPTION: The existing Power Conditioning System Building is an adjoining building to the Indus substation. The plinth area of the building is 216 SqM with mezzanine floor. PCSs are proposed to be installed at ground floor as shown in our drawing no. RRCAT/Indus-2/PCS/SC/09/01. Ventilation is proposed for cooling of this area and these equipments. Separate rooms for locating the air washer unit are provided on east side of the building as shown in our drawing.

6.0

VENTILATION SYSTEM: Power conditioners are designed to work in the clean atmosphere. In order to meet the ventilation requirements, an evaporative cooling with filtration system is proposed. Fresh air is drawn through air intake louvers and then made to pass through a battery of pre filters. This filtered air then further passed through a battery of fine filters where it gets filtered up to 95% Filtration efficiency down to dust particle of 5 microns. This fresh and filtered air is then passed through air washer section and loses it heat to water and in turn gets cooled. Fresh, filtered & cooled air is supplied to power


9.0

IS: 4894

Specification for centrifugal fan testing

AMCA 210 IS: 823 IS: 1363 & 1367 IS: 808 IS: 816 – 1969 IS: 325 IS: 1231 IS: 4029 BS: 2831 (latest)

Test code for air moving device Welding requirements Bolts & nuts Dimensions of rolled steel section for structural use Metal arc welding for general construction in mild steel Specification for 3Ø induction motors Dimensions of 3Ø foot mounted motors Guide for testing 3Ø induction motors Testing of air filters

IS: 13947-Part 1 & 2

Low voltage switchgear and controlgear

EVAPORATIVE COOLING EQUIPMENT: Type of cooling Section Air Handling Capacity CMH Face Velocity Air-cooling

Cellulose paper fill type air washer with water recirculation arrangement and PVC water eliminator 40,000 2.5 m/sec cross section 90% plus

(Efficiency saturation)

Humidification media Distribution System

Bleed off arrangement

Honeycomb structured fill pack blocks made of cellulose paper impregnated with chemicals and anti-soluble salts. GI B class perforated pipe impinging on half cut GI pipe to distribute on distribution pads or similar construction to get even wetting of media. Supplier shall furnish complete detail of the distribution system Wheel valve which can be set at requisite rate


Fan Speed

: 1480 R.P.M.

The bidder shall work out actual pressure drop of fan based on actual duct layout arrangement.

10.1 General requirement of these fans: These fans shall handle the quantity of air at the static pressure mentioned against each. The other parameters of the fans offered shall be c lose to the figures mentioned in the table. The noise level shall be in accordance with the AMCA codes and the fans shall be balanced statically and dynamically. Base frame and vibration isolators with all necessary hardware shall be such that it ensures minimum vibrations. 10.1.1 The casing shall be fabricated from mild steel sheet suitably stiffened externally by means of angles or flats as required. The variable inlet guide vanes shall be of easily detachable type. The discharge of the fan shall be provided with a rectangular drilled flange and a removable access door shall be fitted in the convenient position on the fan scroll to permit the examination of the fan interior without dismantling. 10.1.2 The impeller shall be of the limit load type, sloped, backward and manufactured from mild steel balanced and mounted on a polished EN-8 steel shaft. The bearings shall be heavy-duty double roll self-aligning ball/roller bearing with thermo blocks of SKF/FAG make only. The shaft being extended for accommodating the driving pulling. 10.1.3 Each fan shall be complete with a suitably rated motor, meeting the specifications with suitable slide rails for the motor, the necessary cast iron ‘V’ grooved pulleys for fan and motor shafts, the required number of V belts and belt guard. The fan shall be painted suitably and shall be complete in all respects. 10.1.4 Wherever the door sizes are less than the fan sizes, the fan should be dismantled and taken in.

10.2 Performance of the fan


Filtration Efficiency

: 90% Filtration efficiency down to dust particle of 15 microns

Pressure drop

: 10 mm WG

Filter media

: HDPE

Construction

: Several layers of high density poly ethylene(HDPE) mesh stitched together with an aluminum expanded metal layer reinforcement in between the high density polyethylene(HDPE) mesh layers

11.2 FINE- FILTERS:

Type of Filters

: Dry, fine filtering(MICROVEE) Air filters

Air Handling Capacity CMH : 40,000 Face Velocity air

: 2 M/sec (cross section)

Filteration Efficiency

: 95% down to dust particle of 5 microns

Pressure drop

: 5-6 mm WG (When cleaned) : 10-12 mm WG

Construction Cleaning of filters

: Matrix of 610mm X 610mm cells

2

: Dry, using compressed air of 1.0 kg/cm

Fine and Pre filter shall compliance to IS: 7613. Filters should be easily removable type for cleaning purpose.

12.0 DUCTING: The tentative duct layout is shown in the drawing RRCAT/Indus-2/PCS/SC/09/01. The supplier shall submit the exact ducting layout for approval after detail engineering.


Ducts above 2250 mm and larger require special field study for hanging and supporting methods.

Air Handling Capacity CMH of the ducting: As shown in the drawing 12.2

SUPPLY DUCTING:

Filtered and cooled air from blower section shall be delivered to power conditioner room through air conveyance GI ducting and supplied air grills. A general arrangement of ducting layout with support system is shown in the enclosed drawing. Supply duct shall be insulated wherever exposed to sun. 12.3

RETURN DUCTING (Not in the present scope of the supply):

12.4

FRESH AIR LOUVERS: Type: Fresh air intake louvers with bird mesh. Material: Aluminum Velocity: 2 m/s Location: As shown in dwg

12.5

EXHAUST AIR LOUVERS (Not in the present scope of the supply):

12.6

DUCT INSULATION:

Whenever ducting is exposed to sun, thermal insulation of ducting with 50mm thick expanded polystyrene duly claded with 28G Al sheet. Asphalt used for setting the insulation shall be nonabsorbing, non-hardening, odourless and low penetrative type. 12.7

DAMPERS:

All dampers shall be multi-louvered dampers of robust construction and tightly fitted. The dampers shall be fabricated from 14 Gauge GI material. The design, method of handling and control shall be suitable for the location and services required.

Indent No: RRCAT/Indus-2/SC/2009/05 Specification No.RRCAT/IOAPDD/SC/2009/05 12.9.2

The Supplier shall provide and neatly erect all sheet metal work as shown on drawings or as may be required to carry out the intent of these specifications and drawings and this work shall be carried out strictly in accordance to the approved drawing for all its parts and details. All necessary allowances and provisions shall be made by the Supplier for beams, 12.9.3 pipes or other obstructions in the buildings, whether or not the same are shown on the drawings. Where necessary to avoid beams or other structural work or plumbing or other pipes or conduits, the ducts shall be transformed, divided or curved to one side, the required area being maintained, all as approved. Supply ducting shall be supported on the RCC column/MS mezzanine. 12.9.4 12.9.5 All ducts shall be rigid and shall be adequately supported and braced where required with standing beams, tees or angles or sample size to keep the duct true to shape and to prevent buckling, vibration or breathing. All joints shall be made tight and all interior surfaces shall be smooth. Bends shall be 12.9.6 made with radius not less than one half of the width of the duct or with curved vanes inline with good engineering practices. The vanes shall be so spaced that the aspect ratio of each of the individual elbows formed by the vanes will be about five. All sheet metal connections, partitions and plenums required to confine the flow of air to 12.9.7 and through the filters and fans, shall be constructed of 1.25 mm galvanized iron thoroughly stiffened with 25 x 25 mm angle iron braces and fitted with all necessary doors as required by the Engineer. Where metal ducts or sleeves terminate in brick or masonry openings, tight joints shall be made by means of closely fitting heavy flanged collars. 12.9.8

Fans shall be connected to duct work by inserting all air inlet and air outlet with a double canvass sleeve. Each sleeve shall be 100 mm long minimum securely bonded and bolted to ducts and units. Each sleeve shall be made smooth and the connecting ductwork rigidly held in line with unit inlet or outlet. The canvass shall have Zip of length 200 mm. Testing The entire ducting layout including fittings shall have to be approved before taking up the


13.1.3 All the required power and control cabling required for air washer plant shall be in the scope of supply however incoming cable for feeding the motor control center shall be carried out by RRCAT. The scope of work includes supply, installation, testing and commissioning of all the 1100 V grade aluminum/copper conductor, XLPE/PVC insulated, PVC extruded inner sheathed, flat/round wire armoured, FRLS PVC outer sheathed (black) power/control cables conforming to IS 7098 (Part-1) & IS: 1554 (Part-1). Cable identification tags of aluminum strips shall be fixed on each cable at each bend, joint and also at end termination. 13.1.4 The supply and installation of the earthing connection for the motor control center / equipment to the existing Earth pits by suitable size of GI strip/wire (as per IS 3047) shall be carried out by the supplier.

13.2 System Voltage: Electrical power will be available at 415 V ±10%, 3 phase, 4 wire and 50 Hz ±3% for all the motors including Monoblock/ three phase motor driven pump for operation. If any equipment is to be operated at any other voltage, then necessary step down transformer, etc. shall be included in the equipment supply of the bidder. 13.3

Standards:

The equipment shall be designed, assembled and tested in accordance with the relevant Indian Standard. The equipment shall also conform to the latest Indian Electricity Regulators regards safety, earthing and other essential provisions specified therein for installations and operation of electrical equipment. 13.4

Selection of motors:

The bidder shall work out the rating of the motor depending on the torque requirement of the fans offered. The same shall be in line/exceeds the requirements given by the fan


iv. The starting torque shall match the load torque and the starting current shall not exceed 4 to 5 times full load current. v. Even though the motors shall run continuously they should be suitable for frequent starting. Any limitation on no. of starts shall be specified. vi. To facilitate starting arrangement wherever required at site the motor will have all six terminal points of the stator winding brought out at the terminal box. vii. The starting method for various motors is as given below: 1. Up to 10 HP – DOL (Direct On Line) 2. Above 10 HP – Star delta viii. All starters shall be of air break totally enclosed metal clad, dust proof, air insulated and shall be suitable for the specified supply system and the ambient condition. Starters shall be provided with thermal overload on all the three phases with adjustable settings and magnetic short circuit protection. The starters shall be supplied with prevention for single phasing and under voltage protection. The starters shall conform to IS: 2559. Starters should be provided with suitable rating of back up MCCB ix. 4 NO + 4 NC auxiliary contacts of adequate current rating capacity shall be provided for functional interlocks indicating lamps, metering on ON/OFF switches for local/remote operation. Indicating lamps where provided shall have resistance connected in series so that low voltage bulbs can be used. Starters shall be mounted on suitable framework or as required or as shown in the drawings. Two spare sets of auxiliary contacts 1 NO + 1 NC should also be provided apart from use for functional interlocks as per specification. 13.5

Motor Control Centre:

The Motor Control Centre shall be of fabricated MS enclosure of CRCA sheet duly powder coated with plinth and side covers suitable for housing of Starters of required capacity and quantity, backup MCCBs along with required auxiliaries and other control instrumentations


14.0 INSTRUMENTATION & CONTROL: 14..1

REQUIREMENTS: Proper instrumentation /control is needed to ensure the required dry bulb (DB) temperature and relative humidity of the air at the power conditions units specified in clause 4.2 of the specification.

14..2

TEMPERATURE: Dry bulb temp of the air at the entry of any one of PCSs shall be less than 30 deg C. Type of device for measuring the Dry bulb temp shall be RTD sensor with measuring range of 0-50 oC. Before reaching the high temperature thresh hold, alarm should be annunciated in the control room. In case temperature is lower than DB temperature the cooling pump shall be stopped.

14..3

HUMIDITY: Humidistat .The relative humidity will never be allowed to exceed as specified in clause 4.2 of the specification. Alarm should be annunciated in control room. RH trip above 95 % shall be introduced suitably. Bidder shall provide the suitable dehumidifier/pre–heaters with necessary control to achieve the RH.

14..4

DIFFERENTIAL PRESSURE: Suitable instrumentation shall be provided for measurement of differential pressure across the filters In case of chocking of filters, pre-alarm should be annunciated. Filter choked alarm shall be annunciated after a preset pressure.

14..5

ALARM: In the event of any electrical /mechanical failure of the system, Alarm shall be provided for this purpose with indication on panel showing status by incorporating a suitable flow switch to sense failure.

The bidder shall give the complete detail make, type, range, accuracy and least count of the instruments.

15.0 PREFERRED MAKE OF MATERIALS:


Note: a) All the offered makes shall comply with the technical specifications b) Offered makes for the items not listed above, shall be of reputed make and duly approved by RRCAT.

16.0

DRAWINGS AND DOCUMENTATIONS: 16.1 With the Bid: Tenderer shall furnish all technical details, ducting layout, single line and GA drawings for MCC, P&I diagram, design calculations, performance curves, detailed catalogue/literature in support of the capacities of equipment quoted in their tender. 16.2 After the order placement: Supplier shall summit for approval complete shop drawings, including details of bills of materials, all relevant manufacturers and assembly procedures, characteristics curves, process and instrumentation diagram, inspection and test specifications, design calculations involved. One copy of each drawings will be returned to you marked ‘ APPROVED” 16.3 After completion of work: The supplier shall give two No. of bond copies of final instruction for installation, operation and maintenance manual of all the equipments furnished. The manual shall include drawings, performance curves etc.

17.0 INSPECTION AND ACCEPTANCE CRITERIA: 17..1 Inspection and testing of fans, motors, evaporative cooling system, electrical panel, instrumentation panel and all other components shall be carried out in presence of representative(s) of RRCAT at factory as per the technical specifications. 17..2 Fans shall be tested as per Standard test code of AMCA 210; the tests shall be approved by the purchaser’s representative. The fans shall be tested for the performances and the following test results shall be furnished: i. ii.

3

Capacity (M /Hr) Static pressure (mm WC)


19.0 DELIVERY SCHEDULE: The bidder shall quote for minimum deliver period indicating a bar chart for all the activities pertaining to the subject work. Expected delivery schedule for design/engineering, manufacture, assembly, inspection, testing at supplier’s works, supply, installation, testing & commissioning at purchaser’s site is 10-12 weeks.

20.0 SHIPPING AND STORAGE: The purchaser shall be responsible for shipping and storage of all the sub-systems ate site.

21.0 INSTALLATION & COMMISSIONING: Bidder shall prepare an installation and commissioning procedure for approval by the purchaser and test and commission the system as per the specifications. The entire air distribution system shall be balanced to supply the air quantities as required in the various regions to maintain the specified conditions. After completion all duct systems shall be tested for air leakage. The system shall be operated continuously for 96 hours before handing over to RRCAT. This endurance test shall be considered completed only when the system has given the desired performance and no failure is observed /none of the component/sub-system has behaved adversely. The final balance of air quantities through each grill, register or diffuser shall be recorded and submitted to the RRCAT for approval.

22.0 GUARANTEE: Material shall be guaranteed for a minimum period of 24 months from the date of commissioning towards faulty design, construction, manufacturing of materials.


SECTION -B: (Schedule of Prices) Part-I

Notes: 1.

2. 3.

Item No. 1.

BIDDERS SHALL SUBMIT TECHNICAL AND COMMERCIAL OFFER AND PRICE BID IN SEPARATE SEALED COVERS WITH THEIR IDENTIFICATION CLEARLY MARKED ON THE COVERS. TECHNICAL PART SHALL BE OPENED FIRST. AFTER EVALUATION OF TECHNICAL BIDS ONLY THE PRICE BIDS OF TECHNICALLY APPROVED BIDDERS SHALL BE OPENED. BIDDERS ARE REQUESTED TO QUOTE THE PRICES IN INDIAN RUPEES WITH COMPLETE DETAILS OF TAXES AND DUTIES APPLICABLE. Description

Qty

Rate

Amount

Design / Engineering, Fabrication, Assembly, Testing at works, Supply of Air washer unit including evaporating cooling unit, two centrifugal fans with motors, filtration units, GI ducting for supply, fresh air louvers, grills & diffusers, electrical pump with motors, piping, instrumentation & controls as per the specification.

1.1

Evaporative air cooling equipment

Two sets

1.2

Blower units with control dampers and Motors

Two sets

1.3

Pre filters+ fine filters + grills + louvers

Two sets

1.4

Ducting including Insulation

Two sets

I t r a P n i


Item No.

Qty

3.

Prices should be firm through out the currency of Contract.

4.

If Prices are subjected to escalation, state-

4.1

Formula for Price variation

4.2

Base Price formula

4.3

Base Price Reference

5.

Terms of Payment

6.

Validity of the offer (Minimum 90 days from opening of price bid)

7.

Price for supply of Maintenance tools and recommended spare parts and accessories required for five years of trouble free operation of the complete system (Bidder shall furnish detailed list of the recommended spares and accessories as per Section -C)

Rate

Amount


SECTION - C Schedule of Recommended Spares and Accessories

Bidder shall give below a list of spare parts and accessories recommended for five years trouble free performance of the equipment offered by him. Sr No. Name of Component

Quantity Recommended

Unit Price

Total Price

I t r a P n i d e l l i f


SECTION - D Schedule of Deviations from Technical specification The Bidder, clause by clause in this schedule, shall fill in all deviations from the specifications

Section

Specification No.

Clause No.

Deviation

Bidder hereby certifies that the above mentioned are the only deviations from technical specifications of the enquiry.

Air Washer Unit

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