Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman 22. Execution 1. Installation Install in accordance with manufacturer's instructions. Provide for connections to electrical service. Include for connection of oil pump. Provide for connection of electrical wiring between starter and chiller control panel, oll pump, and purge unit. Furnish oll cooling units and purge condensers if required Arrange piping for easy dismantling to permit tube cleaning. Provide piping from chiller relief device to outdoors. Size as recommended by manufacturer. Chiller manufacturer shall furnish spring vibration isolator pads for mounting equipment on a level concrete surface H. Chiller vibration isolation and the base type ((.. floor pad) will be in accordance witn ASHRAE Handbook, 1995, HVAC Applications, Chapter 43 Table 42. Open centrifugal chillers shall require installation onto a base type "C" as defined by ASHRAE. This concrete base type °C" shall cansist of a steel pouring form with welded-in reinforcing bars, provision for equipment hold-down, and isolator brackets. Hermetic centrifugal chillers require installation onto a base type "A" as defined by ASHRAE. mmo om ® 2. Manufacturer's Field Services A. Manufacturer shall furnish a factory trained service engineer without additional charge to start the unit(s). Representative shall provide leak testing, evacuation, dehydration, and charging of the unit (s). Chiller manufacturers shall maintain service capabilities no more than 75 Kilometers from the jobsite. B. A start-up log shall be furnished by the manufacturer to document the chiller’s start-up date and shall be signed by the owner or his authorized representative prior to commissioning the chillers C. The manufacturer shall furnish an alternative price for: 1. Extended parts warranty for five years. 2. Extended parts and labor warranty for five years 3. The manufacturer shall furnish complete submittal wiring diagrams of the centrifugal chiller(s) starter(s) and associated components like cooling towers, pumps, interlocks, etc. as applicable. 173 AIR HANDLING UNITS a) This shall be custom built and manufactured in accordance with the ARI standards 430 for fans and 410 for coils. Unit performance shall be EUROVENT certified. b) Airhandiing units shall be provided where shawn on the drawings and shall be of a double skinned construction in a draw-through format. They shall be of the horizontal type as required each capable of the duty scheduled ©) The contractor shall ensure that the proposed air handling units can be installed within the space allocated including clearance for maintenance Wis Semac & Partners LLC. Page 317 oF 631 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman d) Equipment design shall be such that the selected filter media, bearings, insulation, motors, etc. shall be suitable for the ambient temperature existing within and around the unit. e) All air handling units and major accessories shall be supplied by the same manufacturer experienced in the design and construction of similar units. All unit sections shall be constructed to prevent drumming or distortion of panels up to a pressure differential of 2500 Pa with minimal air leakage. 1) Plant items contained within the unit sections shall be sized and selected in order to maintain specified face velacity restrictions. 4) All lubrication points shall be easily accessible with external lubrication nipples provided to enable recharging of bearings whilst the plant is running fh) Units shall be factory assembled and sections shall be of modular construction for case of replacement or introduction of additional sections. Sections shall be sized to suit the limited site access conditions. |) Each section shall have matching cross sectional dimensions, be of the same construction type and will present a clean intemal appearance to ensure even airflow through the plant items. }) Rolled steel channel bases shall be provided for units higher than 130mm k) Air handling units shall consist of the following components and shall be as set out in the schedules or indicated on the appropriate drawings. |. Filter section with cleanable pre-filter & Bag type Filter Il. Cooling coil section with cooling cail Ill. Drip eliminator if specified or air velocity across coil exceed 2.5 mtr /Sec IV. Heat recovery Heat pipe if specified V. Supply air fan section with plug fan (EC Fan) if specified otherwise belt driven centrifugal backward curved fans VI. Suction intake box Vil. Return air fan section with pre fiter & plug fan (EC Fan) if specified 17.3.1 Basic Construction a) Construction shall consist of a five: angle Penta-post heavy gauge galvanized steel framework to provide maximum strength with minimum weight. Minimum galvanized sheet metal thickness shall nat be less than 1.0mm for the inner skin and 1.0mm for outer. Both inner & outer casing shall be powder painted. b) Unit framework shall be fully welded at each mitred comer and shall incorporate welded attaching mounts to enable intermediate stiffeners to be accommodated where necessary. Wis Semac & Partners LLC. Page 318 oF 631 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman ¢) Plant construction shall be suitably stiffened to conform to the maximum operating pressure and to suppart the components and fittings forming the air handling unit. 4) All enclosure panels shall be of double skinned insulation construction with a precoated steel outer skin to provide a tough, yet attractive surface finish. The inner skin will be manufactured from pre-galvanized steel and painted on outside Waterproof and airtight recoverable type gaskets shall be installed at the jointed edges between panels and frames. All panels shall be flush mounted into the unit framework. Joining of section ta section shall be by means of purpose made comer and intermediate clamps. Waterproot and alttight recoverable type gaskets shall be installed on each mating surface €) Ta provide access into every section, all side panels shall be easily removable by means of quarter-turn, quick release fasteners and shall be "lift-off for general maintenance access or "hinged" for more frequent access to items such as filters 1) Top and bottom panels shall be fixed to the unit framework by means of internally located removable spring clips pitched at a distance to ensure sufficient strength and rigidity. Clips shall not be visible on the exterior of the unt ) Unit framework shall be of Penta-post construction painted with a high quality two coat paint system in a contrasting colour to the unit panels. h) Vision panels shall be provided on fan, filter and cooling coil section. Internal bulkhead light with external switches shall be provided |) AILAHU section shall be labeled to identity the components therein specification’ schedule. (. filter grade, heat transfer rate, electrical rating, flow rate, pressure dropirise) 17.3.2 Insulation a) Insulation shall be provided to all exposed surfaces to prevent condensation occurring on the outer surfaces of the units. Insulation shall be inorganic, vermin proof, nan-hygroscopic. Shall be Phenolic foam minimum density of 45 kg/m3. ) All sections shall have double skinned panels having a minimum thickness of 50mm and shall have a rigid foam insulation infil providing a thermal conductivity not greater than 0.0246 WimK as per ISO 8301 standards, the fire resistance shall comply to ISO 3582 standards, Closed cell percentage shall meet to 97% as per ASTM D2856 standards and shall provide a high degree of noise attenuation, minimizing noise breakout. Insertion loss thraugh the panels shall be Octave Band Hz 63 125 250 500 1K 2K 4K ak Insertion Loss dB -26 -31 -33 -36 -36 -40-42 -a4 ¢) All Penta-post framework members shall be fully insulated with formed inserts, or with injected polyurethane foam. Wis Semac & Partners LLC. Page 319 oF 63T WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman d) The overall heat transmittance shall nat exceed 0.5 Wim? °K. ) The AHU manufacturer shall guarantee that no condensation shall take place on the exterior of the panels. Any stacked or double height calls shall have separate, drain pans to reduce carryover, such pans shall be piped to the main drain, not into the lower pan. 17.3.3 Ean Section — EC Motor Plug Fans a) The EC plug fan, optimized for a very compact construction design. IEC-three phase motor with a PTC for fail-safe aperation. Motor less impeller with backward curved blades. Impeller made fram sheet steel with surface protection achieved through powder coating. Equipped with hub (taper lock hub or fixed hub) and inlet ring b) Electronically commutated (EC) motors are operated with specially matched EC controllers. The perfectly coordinated system shall enable highly precise speed control with the highest degree of energy efficiency, free of electromagnetic motor noises. EC controllers shall be available in a variety of designs: As a simple speed controller for single-phase or three-phase AC powered motors, either mounted in an IP54 housing or ready for control cabinet installation as devices with integrated selectable control modes, e.g. Temperature, pressure, alr velocity, air volume. Fan Impeller The impeller is made of sheet steel, welded and painted with 60 jum thick epoxy powder paint, (colour: RAL 6029, green). The impellers are dynamically balanced ta ISO Standard 1940 — 1973 G 2.5 (sizes 035 — 140) and G 6.3 (sizes 022 — 031) at the maximum speed. The vibration level of the fan is below 7.1 mm/s RMS Fan Inlet The design of the fan inlet is vitally important to the fan efficiency and the low level of sound generated by the fan. The inlet cones are deep-drawn in ‘one piece and are fitted to the end panel. The inlet cone and end panel remade of galvanized sheet steel Motor base with base frame The motor base is made of galvanized sheet steel or of welded sheet steel and painted with 60 um thick epoxy powder paint (colour: RAL 7005, dark grey). The base frame is made of galvanized steel (size 022 - 071) or of steel, welded and hot-dip galvanized (size 080 - 140 and sizes 050 - 071 if motor Is IEC 160). Hub The fan impeller is either equipped with a standard hub (separate for each motor size) or with a taper lock type hub. The standard hub Is made of aluminum or welded steel. The taper lack hub (sizes 022-100) is made of cast iran and phosphatized Wis Semac & Partners LLC. Page 320 oF 651 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman Air flow sensor The air flow sensor is used for measuring the airflow of the plug fans. The method Is based on differential pressure. The pressure is measured at a specific point in the inlet cone and the reference pressure is measured upstream of the inlet cone. The air flow sensor is supplied factory mounted in the inlet cone. 17.3.4 Motor a) ATEX certified motor & fan if specified for AHUs b) Direct driven plug fan supplied as a complete fan unit with IEC standard, toot- mounted ATEX certified motor mounted on a stable base frame. Motor shall be ATEX (sizes 022-100) far Group II, Category 3G according to Directive 94/9/EC (ATEX-100). Fan performance has been measured in accordance with ISO 5801 and 13347-2 ©) Fans shall be capable of giving the specified performance when tested in accordance with BS 848. Although estimated values of the resistance to airflow of items of equipment may be indicated this does not relieve the Contractor of the responsibility for providing fans capable of delivering the required air volume through the system. d) The make and design of fans shall be approved by the Engineer and evidence supporting claimed noise levels and fan efficiencies shall be submitted for approval prior to placing the order. Where fans are supplied with noise attenuators full details of the attenuators shall be given. Motors shall conform to relevant British Standard 8.5000 and BS.4999 and have a synchronous maximum speed of 1500 revimin and be suitable for 415 volts. 3 Phase 50 Hz electrical supplies. 17.3.5 Cooling coils a) All air cooling coil casings shall be of sheet steel not less than 1.2mm thick with angle framing at each end drilled ready to receive the counter flanges on the connecting ductwork and shall be galvanized after manufacture. Cooler batteries shall be constructed of copper tubes with aluminum fins, unless otherwise stated in this Specification. The secondary extended cooling surfaces shall be bonded to the primary cooling tubes. Headers for copper tube batteries shall be of copper or bronze. The bottom of a casing shall be made in the form of a watertight drip tray complete with drain connection ) The drain shall be fitted with a water seal to prevent the ingress and discharge of air to and from the system; the drain pipe shall be run to the nearest sump or gully. 1) A separate drain trough shall be provided for at least each 1.2 m height of coll Water shail not be carried over from a cooler into the air stream; an eliminator section shall be fitted where necessary to prevent carry-over. Wis Semac & Partners LLC. Page 321 oF 631 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman g) The resistance to air flow shall not exceed 125 Pa and the face velocity shall nat exceed 2.5 mis. h) Before leaving the maker's works coolers shall be tested to 1 % times the working pressure or to 10 bar whichever is the greater. i) Eliminator Plates shall be fitted if the face velocity exceeds 2.5 m/s. J) Cooling Colls shall be supported so that their weight is not transmitted to ductwork and so that they can be removed without disturbing adjacent ductwork. k) Inspection doors shall be provided on both the upstream and downstream sides of the cooler. |) On any system where the air static pressure at the cooler exceeds 750 Pa airtight cover boxes shall be provided aver (tic headers and bends; provisions shall be made for draining the cover boxes. m) Coils with fins which have been badly damaged during transport or erection or which have became fouled or coated with builder's materials will not be accepted 17.3.6 Chilled water coils a) Cooling coils shall be manufactured from 16mm (0.D) solid drawn seamless copper tubes, staggered in the direction of air flow. Tubes shall be hydraulically expanded under high pressure to permanently bond the tubes to the fins. b) Fins shall be “activated air" pattern manufactured from aluminum. Support plates shall be fitted as required to provide adequate support and rigidity to the fin tubes. Headers shall be a heavy gauge seamless copper tube with die formed lipped holes to receive the tube end -which shall be brazed. Tube sheets and top and bottom plates shall be of heavy gauge mild steel with mild steel angle flanges galvanized. All tube sheets shall have die comed lipped holes to receive them. Coil headers shall be fitted with plugged vent tapings to facilitate draining and venting. Coil sections shall be arranged to provide remaval of colts fram the access side of the section. ¢) Coils will be vertically and horizontally split where necessary and piped across internally to enable same side connection to the supply / retum pipe work Connections will be screwed BSPT. 4) Coils shall be air pressure tested to 20.6 bar by immersing the coil in a tank of water after completion €) Insulated drain pans shall be incorporated inside all cooling coll sections and shall extend undemeath the headers and beyond the fin black to ensure adequate collection of condensate. On stacked coils intermediate drain pans shall be fitted to provide drainage for the condensate formed on the elevated coil bank. Water lock/gas trap shall be provided on drain pan outlet. 1) Drain pans shall be manufactured from Stainless steel and given 2 two-coat pitch epoxy finish as International Paint Ltd. 2-pack epoxy Black P.T. No. JJA24/25 or Wis Semac & Partners LLC. Page 322 oF 631 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman equal. The drain pans shall be fitted with a drain connection to remove the collected condensate trom the unit section. No part of the coll tube ends or headers shall be external to the section. Air baffles shall be arranged so as to prevent air by-pass of the coil. Drain pan shall be permanently insulated from bottom side with minimum 13 mm thick nitril rubber closed cell insulation. 4) All cold pipe connections protruding-through the unit casing shall be sealed with purpose made high pressure grommets. h) Coils shall be arranged in a contrafiow pattern, with the flow of chilled water entering at the leaving air end and leaving at the entering air end. The flow and retum connections and headers shall be so arranged to ensure an equal flow of water through all the tubes. Provision shall be made for expansion of the tubes, for effective venting of the cooler battery and connections and for draining of the cooler battery headers and tubes. Connections up to and including 65mm bore shall be screwed or fianged; connections 80mm diameter and above shall be flanged. Isolating valves shall be provided on inlet and outlet connections, arranged so as to facilitate removal of the cooler. Mixing boxes a) Dampers shall be fitted in the required locations to provide the facility of bringing in a mixture of fresh air, re-circulated air and exhausting the required quantity of air to the atmosphere b) Dampers shall have opposed operating blades with the fresh and re-circulated airstreams directed towards each other to effect complete mixing ¢) Side seals shall be-provided to prevent air leakage d) Damper blades shall be formed shape designed to interlock. ) Control rods shall be extended beyond the unit casing to allow the fitting of hand quadrants. Hand quadrants shall be provided on each set of dampers. Shut-off dampers a) Dampers shall be fitted and shall have opposed blade action. Side seals shall be provided to prevent air leakage. Dampers shall be formed shape designed to interlock Air filters a) Filters shall operate to at least the efficiencies specified in this Section. They shall be complete with holding frames sufficiently robust to ensure that no distortion occurs in operation b) All filters shall be installed witn edge seals which shall prevent air bypassing the filters. The seals shall, remain effective even though the cells are periadically removed and refitted Wis Semac & Partners LLC. Page 323 oF 651 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman ¢) Filters shall be arranged so that there is easy access for cleaning and/or removal. A differential pressure gauge of the dial or inclined manometer type shall be provided for each fier bank and shall be fixed in such a position outside the duct system that itis accessible and easily read d) The gauge shall be marked to show maximum pressure differential indicating a filter change requirement ) Air velocity through Filters shall be such that the clean resistance (ar operating resistance of automatic Filters) as indicated is not exceeded and that fiter fabric or oil is not carried aver into the system ) Filter assemblies shall be of a standard type and dimensions and shall be such that replacement filters medium is readily available from a number of manufacturers. Q) A three stage air filtration system shall be employed unless otherwise shown on the drawings and schedules: a. Sand Trap Louvers, Roughing or Dry Replacement media type filter, Bag Filter Sand Trap Louvers (for AHUs Air Intake) The sand trap louvers shall be provided ta all fresh air intakes section and shall consist of an auter frame, separator vanes and a discharge blade ensuring sand disposal outside. Each unit shall have an insect screen attached to the rear. The louvers shall be constructed trom extruded aluminum alloy sections and the frames shall be 100mm deep. In next Pages see and trap louvers Roughing or Dry Replacement media type filter- Second stage low velocity roughing filters shall comprise side withdrawal washable 50mm. thick fiter panels mounted either vertically or in Y bank formation within a stout frame. The filter shall be of the flat panel type contained in a galvanized steel front or side withdrawal frame. Each cell shall comprise a pad of glass fiber or synthetic fiber filter media, 50mm thick, retained within a rigid frame of durable cardboard. The filter shall have an efficiency of not less than 92% based on the tests specified in BS 2831 with test Dust No. 2, a maximum face velocity of 2m/s and an initial pressure drop not exceeding 70 Pa. Sufficient spares cells shall be provided to replace the entire filter bank Bag Filter-Final stage high efficiency bag filters shall be provided. Bag filters shall be rigid type with glass fiber media with close pleated construction having extended filter life. Bag filters shall have minimum 90% efficiency, Class F7 in accordance with EN 779 standards The fitters shall be suitable for mounting from front end appropriately sealed against the filter frame using a permanently elastic gasket to a standard compatible with the filter efficiency. The fiers shall be clamped against the frame using a locking arrangement. Filter materials shall be flame-retardant, incombustible, nan- ‘odorous and offer no sustenance to vermin. Heat Pipe Heat Recovery section Wis Semac & Partners LLC. Page 324 oF 651 WGN-RW-CO-TED-337Tender: Civil, MEP & Structural Steel Works Mis Karwa Motors LLC. for Majan Project, Duqm, Sultanate of Oman a) Energy recavery heat pipes shall be included within the AHU. The heat pipe shall be a single section and will straddle the airways in the supply and extract decks of the AHU b) The heat pipe shall be suitable for top and battam mounting with the warmer air flowing through the bottom section (vertical heat pipe). The length of the heat pipes in the supply and extract section shall be selected so as to match the respective air volumes ¢) The external fins shall be of vinyl coated aluminum with a minimum thickness of 0.14mm. Fins shall be of the continuous plate type to optimize the airside heat transfer. d) Tubes shall be of refrigeration standard seamless copper C106 for heat exchanger use. Tube diameter shall be 12mm with a groaved inner surface to enhance the internal surface area and minimum root thickness of the tube shall be 0.35mm €) Casings shall be from galvanized sheet steel with a minimum thickness of 1.4mm. The casing shall incorporate tube plates, continuous side plates and a centre dividing plate to prevent crass-cantamination between the two airstreams. 1) The working fluid shall be refrigerant type classified as ASHRAE safety group A1 The refrigerant shall be either R22 or R134a ) There shall be a multitude of loops in the heightwidth of the heat pipe and each loop shall be individually charged. Heat pipes with header assemblies containing a single circuit are not suitable as a single leak will render the entire heat pipe inoperative. h) Heat pipe performance shall be independently type tested and certified in line with the requirements of British Standards BS 5141 ptt / European Standards EN 305 & 306 / American Standards ARI 410 for testing and rating of heat exchangers. i) The heat pipe should have a third party independent test report conducted by a certified laboratory from CETIAT (FRANCE) / BSRIA (UK). j) The heat pipe manufacturer shall have minimum 10 years experience in manufacturing of heat pipes and must have heat pipes commissioned for a minimum period of 5 years in the Middle East market. k)_ The Heat Pipe shall be from one of the following approved manutacturer: HEAT PIPE TECHNOLOGY (U.S.A.), SPC HEAT PIPES (UK.), AMERICAN HEAT PIPE (U.S.A) 174. Chilled Water Fan Coil Units a) Fan Cails shall be rated in accordance with AHRI/ Eurovent standard. Wis Semac & Partners LLC. Page 325 oF 651 WGN-RW-CO-TED-337