Performance Specifications - Process

METERS AND GAUGES FOR HVAC PIPING.................................................................................... 2

1.0 GENERAL............................................................................................................................ 2
2.0 PRODUCTS......................................................................................................................... 4
3.0 EXECUTION...................................................................................................................... 20

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 METERS AND GAUGES FOR HVAC PIPING

1.0 GENERAL
1.1. Summary
1.1.1. Section includes the following meters, gauges and instruments for the
district cooling plant process and piping:
a. Pressure Gauges
b. Pressure Sensors
c. Differential Pressure Transmitter
d. Differential Pressure Switch
e. Pressure Transmitter
f. Thermometers
g. Temperature Sensor - Resistance Temperature Detector (RTD)
h. Temperature Transmitter
i. Pressure or Temperature Test Stations j.
Magnetic Flow Meters
k. Insertion Flow Meters
l. Thermal Flow Switch
m. Liquid Level Gauge
n. Liquid Level Transmitter - RF capacitance type
o. Liquid Level Transmitter - Guided Wave Radar Type
p. External cage Liquid Level Switch
q. Transmitters, and Sensors for Condenser Water
r. Control Valves
s. Pressure Regulating Valves
t. Pressure Safety / Relief Valves
u. Outside Air Temperature/Relative Humidity Sensor/Transmitter
v. Refrigerant Leak Monitoring System
w. BTU Meter
1.2. Standards and Codes
1.2.1. The following standards and codes shall be complied, as applicable.
Latest revisions shall be referred at the time of manufacturing and testing.
a. American Society of Mechanical Engineers (ASME):

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 i. ASME B 40.100: Pressure Gauges and Gauge Attachments ii.
ASME B1.20.1: Pipe Threads, General Purpose.
b. American Society for Testing and Materials (ASTM):
i. ASTM E1-05: Standard Specification for ASTM Liquid-in-Glass
Thermometers
ii. ASTM E 77 - Standard Test Method for Inspection and Verification of
Thermometers
c. American National Standards Institute (ANSI), Fluid Controls Institute (FCI):
i. ANSI/FCI 70-2 - Fluid Controls Institute, Control Valve Seat Leakage
d. Instruments Society of America (ISA):
i. ISA 75.01 - Flow Equations for Sizing Control Valves
ii. ISA 75.02 - Control Valve Capacity Test Procedures
iii. ISA TR75.04.01 - Control Valve Stability
iv. ISA 75.05 - Control Valve Terminology
v. ISA 75.13 - Method of Evaluating the Performance of Positioners with
Analog Input Signals and Pneumatic Output.
vi. ISA 75.19.01 - Hydrostatic Testing of Control Valves
vii. ISA 75.25.01 - Test Procedure for Control Valve Response
Measurement from Step Inputs
viii. ISA TR75.25.02 - Control Valve Response Measurement from Step
Inputs

e. MIL - STD - 1472 - Department of Defense Design Criteria Standard,

Human Engineering (USA)
f. National Fire Protection Association (NFPA), USA:
i. NFPA-70- National Electric Code
1.3. System Description
1.3.1. As stated in the section '23 05 00 - Basic Mechanical Requirements and
System Description', the District Cooling Plant and chilled water system
design shall be based on Constant Primary and Variable Secondary Flow
concept, unless agreed otherwise by the Engineer.
1.3.2. The instruments, meters and gauges shall be designed and selected to
suit the system requirement. The instruments, gauges and meters briefly
described in this section is not a complete list required for the project, but
are intended only to outline the general requirements of some of the
instruments. Contractor shall include all required instrumentation, meters
and gauges as per the Engineer approved design and shop drawings and
system requirements.
1.3.3. The instruments, meters and gauges shall be suitable to operate in the
environment these are proposed to be installed (Temperature, Relative
Humidity, Air cleanliness, suitable IP rating etc).

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 1.3.4. Typically consider +10°C to +40°C (DB) and 10 to 90 % RH for indoor
and +10°C to +55°C (DB) and 10 to 100 % RH for outdoor environment for
the selection of instruments meters and gauges. Follow instrument
manufacturer's recommendations for the maximum and minimum
temperatures and Relative Humidity (RH) for the safe and accurate
operation.
1.3.5. Engineer's approval shall be obtained for all instruments, meters and
gauges proposed.

2.0 PRODUCTS
2.1. Manufacturers
2.1.1. Acceptable manufacturers:
a. Temperature, Pressure, Differential Pressure transmitter, Magnetic Flow
meter, Ultrasonic Level transmitter, pH/Conductivity transmitter and analyzers
required for the process: All the process instruments output shall be
Modbus/ProfiBus communication type.
i. Endress+Hauser, Germany
ii. Siemens, Germany
iii. Yokogawa, Japan iv.
Rosemount, USA
v. ABB, Sweden
b. Differential Pressure Switch:
i. Ashcroft
ii. Rosemount, USA iii.
Static-O-Ring iv. Wika,
Germany
c. Pressure Gauges, Thermometers:
i. Trerice, USA
ii. Ashcroft Inc, USA iii.
Wika, Germany iv.
Mc Daniel, U.S.A.
d. Control Valves (other than PICV)
i. Fisher
ii. DeZurik
iii. Rotork IQ Series iv.
Bray controls
e. Pressure Independent Control Valves
i. Warren controls, U.S.A
ii. Flow tech, U.S.A

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 iii. Flow control Industries,INC, U.S.A
f. Solenoid Valve:
i. ASCO
ii. Or Approved Equivalent
g. Pressure Regulating Valves:
i. Fisher
ii. Or Approved Equivalent
h. Pressure Safety/ Relief Valve:
i. Crosby
ii. Or Approved Equivalent
i. Energy Meter:
i. Kamstrup - Multical 801
ii. Endress+Hauser, Germany iii.
Siemens, Germany iv. ABB,
Sweden

Note: Manufacturers mentioned above are intended to state the minimum acceptable
standard and these are acceptable subject to meeting the specifications and design
requirements, and as approved by the Engineer.
2.2. General Requirements
2.2.1. All instruments, meters, gauges and devices furnished shall be brand new
and unused.
2.2.2. Provide instruments from same manufacturer and of same model when
multiple units of same item are required.
2.2.3. All instruments, meters and gauges shall be installed such as to allow
easy access, easy removal for maintenance and installed at eye level for
ease of reading.
2.2.4. For condenser water piping system, material of gauges shall be suitable
to work with treated sewerage effluent water (TSE water).
2.2.5. Provide instruments, valves and associated equipment rated as industrial
grade to provide a 30-year installed equipment life.
2.2.6. Provide manufacturer's verification that instruments and control valves
supplied are appropriate and acceptable to meet specified performance
criteria for the intended application.
2.2.7. Communication protocol of all the instruments shall be suitable to the
plant control system selected and approved by the Engineer.
2.2.8. Provide Instruments including pipe, tubing, manual valves, supports, pipe
and tube fittings, wire/cable, conduit, tray, terminations, racks, mounting

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 stands, mounting plates, and other accessories as needed to complete a
working and operable instrumentation and control system.
2.2.9. Provide equipment labels for field instruments and valves that meet the
human factors guidelines stated in the MIL standard mentioned above and
following:
a. Mounting: Attach label to field device with stainless steel wire as to preclude
accidental removal and not cause interference with equipment operation.
b. Shape: Circular. c.
Content: TAG ID
d. Material: Stainless steel/Brass.
2.2.10. Factory calibrates instruments to verify accuracy and linearity in
accordance with standard industry practices or manufacturer's
recommendations.
a. Record calibration data points, in each direction (ramp up and ramp down): 0,
25, 50, 75, and 100% of range.
b. Provide labour, supervision, services tools, special equipment and
consumable supplies required to perform instrumentation and controls
checkout and calibration.
c. Test equipment shall have a minimum accuracy four times or better than
equipment being tested, traceable to NIST.
d. Instruments shall be calibrated individually and where applicable as a system.
e. Factory calibration and installation records shall be prepared and maintained
with the following information:
i. Tag number and Equipment name.
ii. Date component received.
iii. Purchase order number. Serial
iv. number.
v. Calibration data.
vi. Date of calibration.
vii. Person performing calibration. Date
viii. component installed.
ix. Test Equipment: Manufacturer, model number, date calibrated,
calibration lab, and accuracy.
x. Attach calibration sticker to the instrument. Submit sample calibration
stickers to Engineer for approval. Coordinate sticker location on each
type of instrument with Engineer. Sticker content shall be:
• Date calibrated.
• Calibration due date
• Initials of person performing calibration

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2.3. Pressure Gauges
2.3.1. Pressure gauges shall be heavy-duty, bourdon type with stainless steel
case, ring, helical tube and stainless steel 316 movement systems,
stainless steel bushings, Stainless steel 316 socket, laminated glass
window etc.
2.3.2. Gauges shall be dial type of robust construction, enclosed in dust tight
cases.
2.3.3. Diameter of dials shall be 150mm for water service, unless approved by
Engineer.
2.3.4. Range shall be appropriately selected for the system operating pressure
and to have the average operating pressure approximately in the middle of
the scale selected.
2.3.5. Dial face shall be white with black letters and pointer to be micrometer
adjustable type
2.3.6. Accuracy shall be ±1 % over full range of scale.
2.3.7. Shall be designed to withstand 300% full scale pressure without rupture
of the bourdon tube and 130% full scale pressure without loss of accuracy
2.3.8. Gauges shall be provided with pressure snubbers
2.3.9. Scale shall be in dual range in Bar and KPa.
2.3.10. For condenser water piping system, material of gauges shall be
suitable to work with TSE water.
2.3.11. For the Differential pressure measurement the range shall be
selected in 'mbar' or lower range available for the process
application.
2.3.12. Pressure gauges shall be installed in the subsystems where the
transmitter measurement is not available. Except pressure vessels, no
redundant measuring instrument required in any sub systems.
2.4. Pressure Transmitter
2.4.1. Transmitter shall provide ProfiBus output signal directly proportional to
the pressure measured.
2.4.2. Sensing element shall be capsule, diaphragm, bellows, Bourdon tube, or
solid state as applicable for the installation.
2.4.3. Pressure transducer shall withstand up to 300 percent of rated pressure,
with an accuracy of ±0.1 % of calibrated span to put the design range of the
measured pressure in the middle third of the transducers range.
2.4.4. Transmitter shall be located where shown in the approved schematic /
design / shop drawings, mounted integrally with sensor, pipe mounted or
installed in control panel

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 2.4.5. Distance between sensor and transmitter shall not exceed manufacturer's
recommendation.
2.4.6. Wetted parts shall be minimum stainless steel 316; electronic enclosure
shall be rated for NEMA 4X, IP 67.
2.4.7. Pressure shall be measured in Bar or KPa. Transmitter output error shall
not exceed 0.1 percent of calibrated span.
2.4.8. All the transmitters shall be equipped with integral local indicators unless
otherwise specified.
2.5. Differential Pressure Transmitter
2.5.1. DP Transmitter shall provide a ProfiBus output with output signal directly
proportional to the pressure measured.
2.5.2. Accuracy shall be ±0.1% of full scale reading.
2.5.3. Over pressure rating shall be a minimum of 200 % of operating pressure.
2.5.4. Transmitter shall be located where shown in the approved schematic /
design / shop drawings, mounted integrally with sensor, pipe mounted or
installed in control panel.
2.5.5. Distance between sensor and transmitter shall not exceed manufacturer's
recommendation.
2.5.6. Wetted parts shall be minimum stainless steel 316; electronic enclosure
shall be rated for NEMA 4X, IP 67.
2.5.7. Transmitter shall be suitable for installation with low-pressure connection
removed.
2.5.8. For level Applications, the above applies except that the low-pressure
connection is open to atmosphere.
2.6. Thermometers
2.6.1. Thermometers for water application shall be liquid in glass (non mercury)
industrial of adjustable angle type with locking device.
2.6.2. Thermometer to be with 225 mm (9 inch) scale, cast aluminium casing
with cured polyester powder coating and with brass separable thermo well
(Stainless Steel 316 thermo well for condenser water system).
2.6.3. Range shall be appropriately selected for the system operating pressure
and to have the average operating pressure approximately in the middle of
the scale selected.
2.6.4. Accuracy shall be ±1 % over full range of scale.
2.6.5. Scale shall be in °C.
2.6.6. For condenser water piping system, material of gauges shall be suitable
to work with TSE water.

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 2.6.7. Where insulation thickness exceeds 50 mm, long stem thermometer shall
be used with an extension neck brass thermo well. Extension neck shall be
at least 50mm.
2.6.8. Thermo well shall be sized to allow for stem insertion length into process
pipe of no more than half of the pipe diameter, or as approved by the
Engineer.
2.6.9. Ensure thermo well has appropriate lagging extension to provide
clearance for insulation.
2.6.10. Thermometers shall be installed only for the auxiliaries/sub
systems where the transmitter measurement option is optional. The local
gauge or transmitter type measurement will be subjected to Engineer
Approval.
2.7. Temperature Sensor - Resistance Temperature Detector (RTD)
2.7.1. Temperature sensor shall be of 100-Ohm Platinum RTD
2.7.2. Temperature range shall be selected to suit the system operating
temperature
2.7.3. Accuracy shall be ±0.1% at 0°C.
2.7.4. Output shall be ProfiBus/or communication, it shall be directly
proportional to the temperature measured.
2.7.5. RTD shall be encapsulated in stainless steel series 316.
2.7.6. Provide Stainless Steel 316 bar stock thermo well with the sensor from
same manufacturer.
2.7.7. Thermo well shall be sized to allow for stem insertion length into process
pipe of no more than half of the pipe diameter, or as approved by the
Engineer.
2.7.8. Where insulation thickness exceeds 50 mm, long stem thermo well shall
be used with an extension neck. Extension neck shall be at least 50mm.
2.8. Temperature Transmitter (Except for Energy Meter; For Energy Meter RTD refer
specifications of Energy Meter)
2.8.1. Temperature sending element (RTD) 100 ohm platinum, 2 wire
2.8.2. Temperature transmitter shall be digital single-sensor type, with
microprocessor based sensing technology.
2.8.3. LCD display shall be available for digital read out of measured value.
2.8.4. Unless otherwise approved by the Engineer, each temperature sensor
shall be provided with a transmitter, selected to match the sensor, from
the same manufacturer.

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 2.8.5. Except where specifically approved by the Engineer, transmitter shall
provide a ProfiBus/or communication output signal proportional to
temperature measured.
2.8.6. Accuracy shall be ±0.1% of full-scale reading.
2.8.7. Transmitter shall be mounted where indicated on approved piping
schematic / design / shop drawings or instrument detail.
2.8.8. Mount transmitter integrally with sensor, pipe mounted or installed in a
control panel, depending on the application, as per the Engineer approved
drawings.
2.8.9. Distance between sensor and transmitter shall not exceed manufacturer's
recommendation.
2.8.10. Enclosure shall be cast aluminium alloy with polyurethane resin
baked finish, IP 67, NEMA 4X.
2.8.11. Power supply - 24 V DC loop powered.
2.8.12. Temperature range shall be -50 to 600 deg
C.
2.8.13. Temperature transmitter (display) location shall be coordinated
with Engineer prior to installation.
2.8.14. Transmitter shall provide ProfiBus output signal directly
proportional to the pressure measured.
2.9. Pressure or Temperature Test Stations
2.9.1. Fitting shall be as below:
a. Threaded brass fitting (Stainless Steel 316 for condenser water), which shall
be designed to accept 3 mm temperature or pressure test probe.
b. Core material shall be self-sealing, rated for 135ºC fluid.
c. Gasketed cap rated for 70 bar pressure with retention chain.
d. Body length or extension shall extend above the finished surface of insulation
for easy removal of cap.
2.9.2. Test kit with the following shall be provided:
a. Water pressure gauge with gauge adapter suitable for the pressure range
and as per the specification of the pressure gauge mentioned above.
b. Thermometer with adapter suitable for the temperature range and as per the
specification of the thermometer mentioned above.
c. Protective carrying case for the above

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2.10. Magnetic flow meter
2.10.1. Design:
a. Shall be industrial type, inline electromagnetic type, bidirectional flow meter
utilizing Faraday's law of electromagnetic induction to measure the volume
flow rate of water
b. Shall be suitable for the medium proposed to be handled by the flow meters
c. Average flow rate shall be approximately in middle range of the flow meters
d. Shall be with back lit, multi line LCD display
e. Body shall be carbon steel, flanges to ANSI 16.5 class150 or higher suitable
for system design pressure, pipe to Stainless Steel 304 and electrodes of
Stainless Steel 316.
f. Liner shall be EPDM or equivalent of approved manufacturers recommended
g. Bidirectional flow rate measurement capability.
h. Accuracy shall be minimum of 0.35% of flow rate over flow velocity range
from 0.01 to 10 m/s.
i. Shall be suitable for fluid temperature up to 80°C and pressure up to 40 bar
where ever required

2.10.2. Transmitter:
a. Output shall be 4 to 20 mA DC output signal proportional to temperature
measured.
b. The Contractor shall avoid using the custody flow meter signal for control and
custody metering purpose. The Contractor can use the 4-20mA output for
control and the pulse output for energy metering.
c. Other than custody transfer/metering application, all the other flow meters
output shall be ProfiBus type communication.
d. Transmitter shall be integrally mounted on the sensor.
e. IP 67, NEMA 4X rated cast aluminium enclosure and shall be suitable for
ambient environment of up to 60°C and 100% RH
f. Shall be with self-diagnostic capability.
2.11. Liquid Level Gauge
2.11.1. Level gauge described herein is the shielded tubular glass level
gauge.
a. Materials:
i. Body: Type Stainless Steel 304 (for condenser water application
Stainless Steel 316 shall be used).
ii. Wetted parts - Type 316 Stainless steel iii.
Tubing - glass, high pressure clear type.

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 iv. Glass protection - Clear polycarbonate
b. Vent and drain shall be provided for easy glass cleaning
c. Shall be with flanged connections.
d. Height of the scale length to be suitable for the height of the tanks and the
scale shall be in metric
e. Shall be with integral shut off valves.
f. Pressure and temperature ratings shall be suitable for the system maximum
design pressure.
2.12. Level Transmitter - Ultrasonic type
2.12.1. All the level measurement shall be of ultrasonic technology to
measure the wide range of liquids.
2.12.2. Shall be of integrally temperature compensation, capable of
working in dusty applications, self-cleaning and low-maintenance,
chemically resistant and hermetically sealed features.
2.12.3. Contractor to select the range of transmitter based on the
application and submit to engineer for review the range and features of the
transmitter proposed.
2.12.4. Capable of working in indoor and outdoor conditions with
temperature of -40deg.c - +95Deg.c and RH up to 100%. Degree of
protection shall be IP67.
2.12.5. Output signal shall be ProfiBus, in proportion to the level
monitored.
2.12.6. Preferred to have remote installed electronic components. Length
of cable shall be coordinated tank design.
2.12.7. Shall be suitable for the medium of fluid in the tanks.
2.12.8. Accuracy shall be ±0.25mm of the measured value.
2.12.9. Shall be suitable for ambient temperature of 0°C to 75ºC and up
to RH of 100%.
2.12.10. Electronic housing shall meet minimum IP 66
2.13. Analysers for Chilled & Condenser Water
2.13.1. pH / Conductivity transmitter:
a. pH sensitive glass electrode, double junction reference electrode, platinum-
plated titanium earth pin and temperature dependent resistor
b. Operating range shall be - 2 to 12 pH, -10 to 105 ºC.
c. Display: Shall be custom LCD
d. Accuracy shall be less than or equal to 0.01 pH and ± 0.02 mA

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 e. Shall be universal conductivity / resistivity, software switchable, on-line
sensor checking
f. Shall have four fully configurable SPDT contact outputs, two fully configurable
mA outputs and built-in PI controller.
g. Input specifications: Two or four electrodes measurement with square wave
excitation using maximum 60 m cable and cell constants from 0.008 to 50.0
cm^-1.
h. Detection method: Frequency, read-pulse position and reference voltage are
dynamically optimized.
i. Input ranges:
i. Conductivity: 0.000 microS/cm to 1999 mS/cm at 25 ºC reference
temperature
ii. Temperature: Pt100 and Ni100: -20 to 200 ºC
j. Temperature compensation: Automatic, for temperature ranges mentioned
under inputs.
k. Accuracy: less than or equal to 0.5% ±0.02 mA
l. Display: Shall be custom LCD.
m. Ambient operating temperature: -10 to 55 ºC. Temperature up to 70 ºC shall
not damage the instrument.
n. Housing shall be cast aluminum case with chemically resistant coating.
2.14. Control Valves
2.14.1. General:
a. All control valves shall be marked with the manufacturer's name, pressure
rating and flow direction on the outside of the valve body.
b. All control valves, actuators and associated equipments of same type shall be
from a single manufacturer, as far as possible. Different manufacturers shall
be allowed only at Engineer's discretion.
c. Asbestos packing in valves and associated equipments shall not be
acceptable.
d. All control valves shall be sized in accordance with the appropriate standards
listed above. All valves shall be sized to allow 110% of the maximum flow.
e. All control valves shall be provided with manual means of operation
independent of the actuator.
f. Valves shall be rated for the shut off pressure in the system or not less than
16 bars.
g. Valve failure mode (fail safe open or close) shall be designed to ensure safe
operation and shut down of the appropriate process equipment.
h. All terminology of the control valves shall be as per the standards listed
above.

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i. Control valves shall be with equal percentage or modified equal percentage
flow characteristics for modulating applications and to achieve linear flow or to
suit the system design.
j. Control valve leakage shall comply with ANSI/FCI standard listed above,
Class IV.
k. All valves shall be hydrostatically tested at the factory simulating end of the
line service at the design pressure in KPa / psig.
l. All control valves for condenser water system shall be suitable for TSE water
application.
2.14.2. Electric Motor Actuated Control Valves Diameter smaller than
80mm
a. Type: Pressure Independent Control Valve with integral differential pressure
control over built in control valve and flow control. Refer specifications in
clause 2.17 below.
b. For condenser water system, materials shall be suitable for TSE water
application.
c. Also refer specification section 23 05 23 'General Duty Valves for HVAC
Piping'
2.14.3. Electric Motor Actuated Control Valves Diameter Larger Than
80mm
a. Type: Pressure Independent Control Valves - Refer clause 2.17 below.
2.14.4. Electric Solenoid Valve
a. Material:
i. Body: Stainless steel.
ii. Seats and Disc: NBR or PTFE
iii. Springs: 304 Stainless Teel.
iv. Core tube, core and plug nut - Stainless steel
v. Coil: Continuous Duty, encapsulated, with minimum 450 mm leads
vi. Electrical: As per system design and manufacturer's details
vii. Process Connection: 3 mm to 65mm (⅛ to 2 ½ inch NPT)
viii. Enclosure: NEMA 4 / IP 66.
ix. Shall be suitable to work up to 52 °C ambient temperature
x. Operation: Normally closed (energize to open) or Normally open
(energize to close) depending on the system application
2.14.5. Additional Requirements for Electric Actuators for Control Valves

a. Include the motor, reversing starter, power disconnect, control transformer,

relays, power gearing, limit switch gearing, limit switches, phase failure relay,
adjustable torque switches, heaters, local mechanical position switches and
indicator lights, motor brake, stem nut, auxiliary hand wheel, drain holes with
threaded plugs, local control station, switch housings and floor stand if
required, all as a self-contained unit.

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b. The operator shall develop 200% of the required unseating torque and 150%
of the required running torque under actual operating conditions. Operating
conditions shall take into consideration the pressure differential across the
valve and shutoff head.
c. Motor speed reduction by hardened steel spur gears and self-locking worm
gear. Quarter turn valves shall have a gear head with adjustable mechanical
stops internally located that can withstand full torque requirements of the
valve in both open and closed positions.
d. Rotating Components: Gearing and shaft supported on anti-friction bearings;
thrust component supported on tapered roller bearings.
e. Lost Motion Device: Operators on open-close service shall have a built-in
lost motion device to permit motor to attain full speed before load is
encountered, thus permitting a hammer-blow to be imparted to start valve in
motion in either the closing or opening direction.
f. Manual Override: By hand wheel.
g. Motors shall have a duty rating of not less than 15 minutes and shall be
capable of operating the valve through 2 cycles against full unbalance
pressure without exceeding the permissible temperature rise specified.
h. Motors shall be suitable for operation of valve under maximum differential
pressure with standard deviations of voltage and frequency as defined by
NEMA and operating temperatures of 60ºC.
i. Position Indication: Local and to DCS. Open/close for isolation valves using
limit switches. Modulating valve with 4 to 20 mA DC position transmitters for 0
to 100% open indication.
j. Valve operators shall be equipped with two adjustable torque switches, one
for protection in the opening direction, the other for control seating the valve.

k. Torque switches shall be responsive to load encountered in opening or

closing direction and shall be adjustable to desired operating characteristics to
permit protection should an obstruction be met in either direction of valve
travel.
l. Closing torque switch shall be employed to control predetermined seating
thrust. Travel and thrust shall be independent of wear in disk or seat rings.
m. Limit switches shall be an integral part of the valve operator. They shall be of
the adjustable type capable of being set to trip at any point between fully
open and fully closed. Limit switch gearing shall be of the intermediate type of
stainless steel or high tensile bronze. Gears shall be grease lubricated. Valve
operators shall be provided with geared limit switches s required.
n. Limit switches shall be geared to driving mechanism and in step at all items
whether in power operation or manual operation.
o. Limit switches and torque switches shall be housed in an enclosure integral
with power compartment of valve control. Push buttons, hand-off-auto
switches, and indicating lights shall be corrosion resistant, and watertight, and
shall be rated NEMA 4x / IP67.

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 p. A terminal strip shall be provided in the switch compartment. Controls and
switch compartments shall be shop wired to a terminal complete and ready for
field installation. At least 4 spare terminals shall be supplied.
q. For power and control conduits to the operator, there shall be two conduit
openings, one for power and one for control.
r. Space heaters shall be provided in the switch and motor compartments of
wattage suitable for keeping the compartments dry at all times. There shall
be installed suitable breather and drain holes plugged with threaded plugs.
s. A schematic wiring diagram shall be permanently attached and protected
from the environment, for maintenance use.
2.15. Pressure Regulating Valves
2.15.1. A Shall be suitable for the application of liquid, inlet and outlet
pressures
2.15.2. Direct acting or pilot acting as per the design requirements
2.15.3. Body material: Cast steel.
2.15.4. Guiding: Stem
2.15.5. Characteristic: Diaphragm
2.15.6. Seat Material: Stainless Steel type 302 and Stainless Steel type
416
2.15.7. Trim Material: Stainless Steel 416
2.15.8. Standard diaphragm material and rating
2.15.9. Ancillaries- Position indicator and locking device
2.15.10. Selection shall be based on valve sizing calculations and
approved by Engineer. Calculations shall demonstrate valve is
suitable for maximum and minimum conditions.
2.16. Pressure Safety / Relief Valves
2.16.1. A Shall be suitable for the industrial application with variable back
pressures.

2.16.2. Shall be suitable for the of liquid, pressure and temperature where
the safety valves are proposed.
2.16.3. Shall be screwed end connections for sizes 50mm and smaller,
while flanged end connections shall be used for sizes 65mm and
larger.
2.16.4. Body: Stainless Steel type 304
2.16.5. Guide: Stainless Steel type 400
2.16.6. Spring: Alloy steel

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 2.16.7. Selection shall be based on safety / relief valve sizing calculations
and approved by Engineer. Calculations shall demonstrate valve
is suitable for maximum and minimum conditions.

2.16.8. Materials for condenser water application shall be suitable for sea
water used in the system
2.17. Pressure Independent control Valves
2.17.1. General:
a. Pressure Independent control valves (PICV) shall be installed as shown in the
drawings and strictly as per the recommendations of the manufacturer.
b. All valves for a particular project shall be from the same manufacturer.
c. Pressure independent control valve (PICV) shall consist of two functional
controlling segments. The first serves as a electrically actuated control valve,
capable of responding to a control signal from a controller that is not part of
the PICV.
d. The second segment shall be an integral and external differential pressure
control valve, connected in series with the first, and serves to sense and
regulate the preset flowing differential pressure across the control valve
segment.
e. Both segments shall include pressure balanced control elements of industrial
quality manufacturing.
f. The valves shall be manufactured in accordance with ISO 9001 quality
standards.
g. The pressure independent control valve (PICV) shall be factory assembled
complete with sensing lines and actuators ready for field installation as a
complete unit.
h. The PICV shall be pre-calibrated to a specified flow, set differential pressure
which shall be able to adjust in the site without removing the actuator, if
required.
i. The pressure independent control valve set shall be designed to meet the
system design pressure, shut off pressure and differential pressure. Refer
minimum pressure requirements mentioned in sections below.
j. Shut off pressure of valves and actuators and valve body pressure rating
shall be minimum of 12 bar and 10 bar respectively.

k. Pressure Independent Control Valves shall be rated for a maximum

differential pressure of 10 bar. Each valve shall be selected and designed
based on the design differential pressure expected across each valve.
l. Control valve rangeability shall be 100:1. The actuators provided with the
valve(s) shall have a minimum of 100 steps in 90° rotation to assure 100:1
turndown.
m. Each control valve shall be individually flow tested and factory verified to
deviate not more than ±5% through the selected operating pressure range.

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n. A calibrated performance tag shall be provided with each valve that verifies
the flow rate in 10° rotation increments up to full rated flow. All testing shall be
performed with instruments calibrated to the requirements of ANSI/NCSL
Z540-1-1994 with traceability to NIST and/or ISO standards. The flow
verification shall be performed at the manufacturer's works.
o. Class IV leakage or better is required for control valves up to 50 mm diameter
and Class III or better for valves larger than 50 mm, as per ANSI leakage
testing standards.
p. All valves shall have three integral ports, factory installed, capable of being
used to measure pressure or temperature.
q. Valve shall be protected against over pressure with a safety spring
r. Actuators shall be selected based on system close-off requirements. Valves
and actuator shall be capable of a close-off rating of 12 bar.
s. Torque requirements for actuator selection shall be provided by the valve
manufacturer
t. For electric actuation it shall be possible to set the end stroke of the actuator
with mechanical stops, signal adjustment or a control signal limit at the full
design flow listed on the performance tag furnished with each valve.
u. Valve actuators shall be furnished with battery backup for fail safe operation
or shall be fail safe open.
v. Electric actuator shall be suitable to operate with input signal of 0-10 V DC
supply.
w. Manufacturer of pressure independent control valves shall confirm
balancing valves and associated balancing shall not be required where
pressure independent modulating control valves are installed.
x. All valves shall be warranted by the manufacturer for a minimum period of 5
years from the date of commissioning and taking over by the Employer/
Engineer. The warranty provision shall apply to the actuators as well.
y. Pressure Independent control valves shall be suitable for thermal insulation
all around.
z. Compliance to this specification shall be submitted along with the material
submittal for Employer/ Engineer's approval.
aa. Control valves together with actuators shall be suitable to work at ambient
temperature of 0 to 50 °C and relative humidity of up to 100%.

2.17.2 Valve Body:

a. Body material : Cast Iron
b. End connections : ANSI 125 lb.RF Flanges
c. Trim Designs : Single seat or double seat balanced, ANSI class
IV leakage based on the process

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 d. Trim material : Stainless steel or Bronze, EPDM or Fluoraz seal
e. Trim Limits : Max flowing DP 10.3BAR(g)
f. Packing : Long life multi stack EPDM lip packing
g. Stem - SS 316 or bronze
2.17.3 Electric Actuator:
a. Control signal : 4-20mAdc b.
Feedback signal : 4-20mA
c. Manual override : Yes
d. Construction : Polycarbonate motor housing with steel linkage &
yoke
e. Connections : Coded screw terminals
f. Housing : NEMA Type 4 / IP55
g. Temperature range : 0 DEG.C - 50 DEG.C
h. Mounting : Factory aligned, vertical, horizontal, inclined
2.17.4 Double acting diaphragm actuator with spring
a. Control signal : DP from control valve
b. 0.2-0.4 BAR(g) Nominal, Preset at 0.35BAR(g), Adjustable from
0.2-0.4
c. Construction: Ductile iron, epoxy coated, epoxy coated spring, SS
components, woven neoprene diaphragm.
2.18. Outside Air Temperature / Relative Humidity Sensor / Transmitter
2.18.1. Combined probe with high accuracy, capacitance type humidity
sensor and precision platinum RTD temperature sensor in one
probe.
2.18.2. Shall be installed in same manufacturer's naturally ventilated and
aspirated radiation shields.

2.18.3. Operating temperature: -10 to +60°C

2.18.4. Measuring Range: RH-0-100%, Temperature- -50 to +50 °C
2.18.5. Accuracy at 20°C: ±2% RH, Accuracy at 0°C to ±0.3°C
2.18.6. Response time: 10 seconds (without filter)
2.18.7. Sensor type - For RH, Rotronic Hygrometer and for temperature
Platinum RTD

2.18.8. Output signals: 4 to 20 mA DC, one each for temperature and RH

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 2.18.9. Radiation shield: Naturally ventilated and aspirated radiation
shields
2.19. Refrigerant Leak Monitoring System
2.19.1. Multiple area leak detection monitor with port expansion module.
a. Detector Range: 10 - 1000 ppm
b. Calibrated Range: 0 - 100 ppm
c. Sensitivity: 1 ppm
d. Response Time: 5 - 90 seconds, depending on tube length and gas
concentration.
e. Environmental considerations shall be weighed while selecting the leak
monitoring system.
f. Operating Temperature: 0°C - 50°C
g. Drift Tolerance: 0.3% per °C of reading.
h. Primary monitor module has seven single point locations, plus eight on
expansion module.
i. Enclosure shall be wall mounted.
j. Maximum sample tubing length shall be 150 meter of 6 mm diameter tube
k. Analog output: 4 to 20 mA DC equivalent to 0 - 100 ppm. 2.20.
Energy Meter
2.20.1. Contractor shall procure KAMSTRUP MULTICAL 801 model (or
approved equivalent by the Engineer from one of the manufacturers
mentioned above) energy meter with 4 wire pt 500 temperature sensors
purchased as one unit.
2.20.2. Energy meter shall comply with the custody transfer application
requirements and EN 1434:2007 certification shall be produced after
commissioning.
2.20.3. Flow meter shall be ULTRAFLOW model from Kamstrup or
approved equivalent by the Engineer from one of the manufacturers
mentioned above, to ensure the chilled water metering line to the
customer comply with EN 1434:2007 requirements.

3.0 EXECUTION
3.1. Installation
3.1.1. General Installation Requirements:
a. Meters and gauges shall be provided where shown in the approved design /
schematic / shop drawings and as required for the satisfactory and efficient
operation of all systems of the district cooling plant.

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 b. Scale ranges shall be selected appropriate for the service and shall be
approved by the Engineer.
c. Installation of gauges and thermometers shall be suitable convenient viewing
by operator standing on the floor. All instruments connections shall be
oriented to ensure that the instruments or piping will not obstruct aisles,
platforms, or ladders and will not impede removal of adjacent equipment.
d. Install all instruments and gauges in accordance with manufacturer's
recommendations.
e. Installation of instruments and associated equipments shall be mounted to
building structures using pipe mounting stand or field fabricated mounting
brackets.
f. Provide 3 valve manifolds for all pressure transmitters and 5-valve manifolds
for all differential pressure transmitters.
g. Ensure that adequate extended neck shall be provided for clearance for
insulation in insulated piped services.
3.1.2. Installation of Gauges
a. Follow manufacturer's recommendations for installation
b. Install impulse dampeners, shut off valves, needle valves, pressure snubbers
etc for the installation of gauges, as required.
3.1.3. Installation of Flow Meters
a. Install flow meter in straight length of pipe.
b. Follow manufacturer's recommendations for minimum pipe lengths upstream
and downstream of device.
c. All components of the flow meter shall be readily accessible for maintenance,
calibration and removal.
d. Identify setting and range flow and differential on tag.
3.1.4. Temperature Instruments
a. Thermo wells suitably designed and selected shall be provided for all
insertion thermal measurement devices.
b. Provide Stainless Steel 316 extension nipple and screw cap for test wells.
c. Also refer to the clauses above under 'Products' on the temperature sensors,
transmitters, thermometers etc.
d. Ensure that adequate extended neck shall be provided for clearance for
insulation in insulated piped services.
3.2. Field Quality Control
3.2.1. Cleaning:
a. All instruments shall be thoroughly cleaned before assembly or installation of
temporary protective coatings and foreign materials.

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b. After installation of instruments and gauges, clean external surfaces of oil,
grease, dirt, or other foreign material.
3.2.2. Instruments and gauges faces shall be adjusted to proper angle for best
visibility.
3.2.3. Verify instrument and control valve installation in the piping system for
proper alignment, cleanliness and freedom from foreign materials
prior to equipment installation.
3.2.4. Inspect threads on both the valve and mating pipe for correct thread form
and cleanliness.
3.2.5. Inspect internal length of threads in the valve ends and proximity of the
valve internal seat to ensure pipe will not hit the seat when assembled.
3.2.6. Inspect mating flange facings for conditions that might cause leakage.
3.2.7. Check flange bolting for proper size, length and material. 3.2.8. Check
gasket materials for defects or damage.
3.2.9. Inspect the completed installation to verify equipment was installed per
approved documents and manufacturer's instructions. The following shall
be inspected as a minimum:
a. Instrument mounting.
b. Air supply.
c. Process tubing.
d. Wiring and cabling. e.
Piping.
3.2.10. Provide schedule of calibration and testing activities and
document test results at least 4 weeks in advance; Engineer reserves the
right to witness testing activities.
3.2.11. Field verify all instrument calibrations at 5 points (0, 25, 50, 75,
and 100 percent) prior to start-up testing. Document verification with same
information required for calibration records. If instrument is out-of-tolerance
then recalibrate, recording 5 points in each direction.

END OF SECTION

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