2.

1 Ducts and Pipes Sizing and Insulation Specification

2.5.1 Duct Size Calculation

Supply, Extract, and Exhaust ducts were sized using the equal friction

method. The most economical and simple way of calculating duct sizes

and duct external static pressure (ESP). “Equal friction” does not mean

that total friction remains constant throughout the system. It means that a

specific friction loss or static pressure loss per 100 equivalent feet of duct

is selected before the ductwork is laid out and this loss per 100 feet is

used constantly throughout the design.

The suggested friction loss shall be 0.10 in.wg per 100 ft. (SMACNA 3rd

Edition, 1990-Friction loss value commonly used for lower pressure

duct sizing per 100 equivalent feet of ductwork)

Note: Solving for Supply, Extract, and Exhaust Duct Sizes, refer to list

of duct layout drawings and with the use of SMACNA Duct Friction

Loss Chart.

Meanwhile, external static pressure is essential for selecting the proper

fan size and motor power input. Duct ESP includes pressure drop from

ducting, duct fittings, dampers, air outlets, heaters, filters, etc.

The total duct static-pressure loss due to friction for a duct system can be

calculated from:

hf = ff x L

where:

hf = Total friction loss, in. wg

ff = Friction factor or friction loss, in. wg per 100 ft

= 0.10 in. wg/100 ft

L = Total length of straight duct or equivalent length of duct fittings and

accessories

Page 1
2.5.3 Chilled Water and Drain Piping

Pipework for chilled water shall be heavy grade mild steel with screwed, welded or

flanged fittings, valves, etc. Piping of 100 mm diameter and larger shall be flanged.

Valves 29 mm and smaller shall be forged brass body, diaphragm type, packless

globe valve with solder ends. Valves 35 mm and larger shall be bronze alloy, non-

rotating disk, nylon seats, bolted bonnet globe valve with solder ends. Condensate

piping shall be cast iron screwed drainage fittings, insulated. All condensate drains

from air conditioning equipment shall be trapped and vented with condensate drain

pipes to be routed to an approved receptor. Approved indirect waste receptors shall

be piped and drain to the sanitary sewer system. An alternate method shall be to

terminate condensate drain piping at outdoor dry-well type sumps where condensate

shall seep to below grade.

2.5.4 Pipe Insulation

Insulation shall be applied in accordance with VENDOR’S instructions over clean,

dry pipe after all testing is completed and approved. Pipe insulation shall be heavy

density rigid fibreglass with factory applied vinyl coated embossed foil vapour

barrier laminate jacket with pressure sealing lap adhesive. The insulation shall be

rated non-combustible by Underwriters Laboratories. Insulation for suction lines

shall have a minimum thermal resistance (R value) of 1.46 meter-degree Kelvin per

watt. Pipes outside the building shall be insulated with minimum 25 mm thick

fibreglass insulation with weatherproof covering. Insulation shall be Owens Corning

Fiberglass ASJ/SSL or equal.

Chilled water pipework, valves and fittings outside the buildings shall be insulated,

and fitted with vapour-proof covering with external mechanical and weatherproof

covering.

Page 2
2.5.5 Ductworks and Insulation

All material used in fabrication of ducts, plenums, stiffeners and supports shall be

new galvanized steel. Sheet metal shall be galvanized sheet metal with a minimum

zinc coating of 275 grams per square meter where used indoors. Where the sheet

metal is to be used for ductwork for fresh air ducts located indoors and all ducts

located outdoors additional protective powder coating shall be used. Ducts shall be

insulated to prevent condensation, according to VENDOR’S recommendation.

Duct insulation in all air conditioned space shall be 25 mm thick rigid slab of

fiberglass with density of not less than 48kg/m3. Duct insulation which is located

outside which shall be used 50mm thick.

Ductwork insulation shall be fixed to the duct with approved fire resistant adhesive

and where necessary the adhesive shall be reinforced with nylon duct clips and

washers of approved manufacturer. Insulation section will be closed butted with butt

joints and longitudinal joints sealed with an approved sealant.

Cavities in the ductwork insulation surface will be filled and sealed with an approved

vapour sealant.

The surface finish of the ductwork shall be 8 ounce canvass applied using vapour

barrier mastic and full coat of lapping cement then a second coat of lapping cement

over entire canvass surface. (Use aluminium cladding outdoors, and indoors where

duct is subject to physical abuse.

2.6 Equipment Sizing and Specifications

After the load is evaluated, the equipment must be sized with the capacity sufficient to

offset this load. The air supplied to the space must be of the proper conditions to satisfy

both sensible and latent heat load estimated. Equipment selected is designed to operate

efficiently at high ambient condition. The equipment manufacturer should abide and

gain approval and compliance certificate from international standards such as

ASHRAE, ARI, etc. must be obtained.

Page 3
 2.6.1 Air Handling Units

2.6.1.1 Air Handling Units Sizing

Air Handling Units Sizing (See the following calculation sheets below that is

typical to all AHUs and equipment schedule in the attachment)

2.6.1.2 Air Handling Units Specification

1. MANUFACTURED UNITS

A. General Description: Factory assembled, consisting of fans, motor and drive

assembly, coils, damper, plenums, filters, drip pans, mixing chambers, and
energy recovery coil.
2. CABINET
A. Materials: Formed and reinforced galvanized steel panels, fabricated to allow
removal for access to internal parts and components, with joints between
sections sealed.
B. Insulation: Comply with NFPA Standard 90A "Standard for the Installation of
Air Conditioning and Ventilating Systems," for insulation.
C. Access Panels and Doors: Same materials and finishes as cabinet and complete
with hinges, latches, handles, and gaskets.
D. Single-Wall Drain Pans: Formed sections of galvanized sheet steel. Fabricate
pans in sizes and shapes to collect condensate from cooling coils (including coil
piping connections and return bends) when units are operating at the maximum
catalogued face velocity across the cooling coil.
E. Double-Wall Drain Pans: Formed sections of galvanized sheet steel. Fabricate
pans in sizes and shapes to collect condensate from cooling coils (including coil
piping connections and return bends) and humidifiers when units are operating at
the maximum catalogued face velocity across the cooling coil. Fill space
between double- wall construction with foam insulation and seal moisture tight.
3. FANS SECTION
A. Testing Requirements: The following factory tests are required:
1. General: Sound power level ratings shall comply with AMCA Standard
301 "Method for Calculating Fan Sound Ratings From Laboratory Test
Data" and shall be the result of tests made in accordance with AMCA
Standard 300 "Test Code for Sound Rating." Fans shall be licensed to bear
the AMCA Certified Sound Ratings Seal.
2. Unit's fans performance ratings for flow rate, pressure, power, air density,
speed of rotation, and efficiency shall be factory tested and ratings
established in accordance with AMCA Standard 210/ASHRAE Standard
51 - Laboratory Methods of Testing Fans for Rating.
B. Fans: Fan section shall be composed of modular multiple, small diameter, high
efficiency airfoil plenum fans. The fan and motor unit is placed on a common
frame isolated from the AHU structure by rubber vibration isolators.
C. Fan Drives: Direct drive. The fan impeller is installed on the motor shaft.
D. Each fan array will be controlled by a single variable speed drive, which controls
the speed of all fans simultaneously.
4. MOTORS
A. Torque Characteristics: Sufficient to accelerate the driven loads satisfactorily.
B. Totally Enclosed Fan Cooled type motors
D. Service Factor: 1.15 for polyphase motors and 1.35 for single-phase motors.
Page 4
 E. Motor Construction: NEMA Standard MG 1, general purpose, continuous duty,
Design B.
1. Bases: Adjustable.
2. Bearings: The following features are required:
(a) Ball or roller bearings with inner and outer shaft seals.
(b) Grease lubricated.
(c) Designed to resist thrust loading where belt drives or other drives
produce lateral or axial thrust in motor.
3. Enclosure Type: The following features are required:
a. Open drip-proof motors where satisfactorily housed or remotely
located during operation.
b. Guarded drip-proof motors where exposed to contact by employees
or building occupants.
4. Overload protection: Built-in, automatic reset, thermal overload
protection.
5. Noise rating: Quiet.
6. Efficiency: Energy-efficient motors shall have a minimum efficiency as
scheduled in accordance with IEEE Standard 112, Test Method B. If
efficiency not specified, motors shall have a higher efficiency than
"average standard industry motors" in accordance with IEEE Standard
112, Test Method B.
7. Nameplate: Indicate the full identification of manufacturer, ratings,
characteristics, construction, and special features.
5. COILS
A. Testing Requirements: The following factory tests are required:
1. Coil Performance Tests: Cooling and heating coils, except sprayed
surface coils, shall be factory tested for rating in accordance with ARI 410
- Standard for Forced-Circulation Air-Cooling and Air-Heating Coils.
B. Coil Sections: Common or individual insulated, galvanized steel casings for
heating and cooling coils. Coil section shall be designed and constructed to
facilitate removal of coil for maintenance and replacement and to assure full air
flow through coils.
1. Multi-zone units shall have air deflectors and air baffles for balanced air
flow across both heating and cooling coils.
2. Medium- and high-pressure units shall have double gaskets between
sections and coil connection penetrations through casing sealed to
minimize leakage.
Coils, General: Drainable, rigidly supported across the full face of the coil, and
pitched to allow drainage.
(2) Fins: Aluminum or copper, constructed from flat plate with belled collars
for tubes. Fins shall be bonded to tubes by mechanically expanding
copper tubes.
(3) Tubes: Seamless copper.
(4) Coil Casing: Galvanized steel.
(5) Headers for Steam and Water Coils: Steel or cast iron, with connections
for drain valve and air vent and threaded piping connections.
(6) Water Coil Turbulators: Bronze, spring-type.
6. DAMPERS
A. General: Leakage rate when tested in accordance with AMCA Standard 500 -
Test Method for Louvers, Dampers and Shutters, shall not exceed 2 percent of
air quantity calculated at 2,000 fpm face velocity through damper and 4.0 inches
w.g. pressure differential.
B. Face and Bypass Dampers: Opposed-blade galvanized steel dampers, with steel
operating rods rotating in sintered bronze or nylon bearings mounted in a single
Page 5
 galvanized steel frame, and with operating rods connected together with a
common linkage. Damper blades shall be break-formed at the edge, have gaskets
and edge seals, and shall be mechanically fastened to the operating rod.
C. Zone Dampers: Two single-blade galvanized steel dampers offset 90 degrees
from each other on the same steel operating rod. Operating rods shall rotate in
sintered bronze or nylon bearings mounted in a single galvanized steel frame.
Damper blades shall be break- formed at the edge, have gaskets and edge seals,
and shall be mechanically fastened to the operating rod.
D. Mixing Boxes: Parallel-blade dampers in a reinforced, galvanized steel cabinet.
Damper blades shall be galvanized steel mechanically fastened to steel operating
rod. Connect operating rods for each set of dampers together with a common
linkage and interconnect linkages so dampers operate simultaneously and in the
opposite direction (one opens when the other closes).
E. Combination Filter/Mixing Box: Parallel-blade dampers in a reinforced,
galvanized steel cabinet. Damper blades shall be galvanized steel mechanically
fastened to steel operating rod. Connect operating rods for each set of dampers
together with a common linkage and interconnect linkages so dampers operate
simultaneously and in the opposite direction (one opens when the other closes).
Cabinet shall have support members to hold 2-inch-thick, pleated, flat permanent
or throwaway filters. Mixing boxes shall have hinged access panels or doors to
allow removal of filters for both sides of unit.
7. FILTERS SECTION
A. General: Filters shall comply with NFPA Standard 90A "Standard for the
Installation of Air Conditioning and Ventilating Systems."
B. Filter Section: Cabinet material and finish shall match the air-handling unit
cabinet, with filter media holding frames arranged for angular orientation.
Section shall have access doors on both sides of the unit.
C. Filter Efficiency: Refer to ASHRAE Standard HVAC Application Handbook

2.6.2 Water-Cooled Water Chillers

2.6.2.1 Water-Cooled Water Chillers Sizing (Refer also to Equipment Schedule)

2.6.2.2 Water-Cooled Water Chillers Specifications

1. PACKAGED SCREW TYPE WATER-COOLED LIQUID CHILLERS:

A. Furnish and install complete, factory-assembled water-cooled screw type liquid
chiller units of the type, size, and capacity shown on the drawings (equipment
schedule).
B. Units shall be of the packaged water-cooled type and consist of multiple screw
compressors, direct expansion liquid cooler, water-cooled condenser and factory
wiring and piping contained within the unit enclosure. Unit shall contain a
complete operating charge of Refrigerant R-134A or R-410A and factory
installed microprocessor system, capable of indicating status of all safeties and
energizing remote alarm. Unit construction shall comply with ANSI B9.1 Safety
Code, NEC and ASME Code. Unit shall be enclosed in a galvanized steel casing,
painted with weather resisting baked enamel finish.
C. Chillers shall be rated at 55 deg.C ambient temperature.
D. All Chillers shall be factory tested to verify capacity and electrical consumption
prior to shipping. Manufacturer shall provide such evidence.
E. Compressor:
1. The compressor shall be field serviceable with variable frequency drive,
single screw or twin screw type with one main screw rotor that meshes
with two diametrically opposed gaterotors. The main screw rotor shall
Page 6
 have helical grooves and shall be constructed of a high alloy steel. The two
identical gaterotors shall be located on opposite sides of the main screw
rotor. The gaterotor shall be constructed of a carbon impregnated
engineered composite material. The gaterotor supports shall be constructed
of cast iron.
2. The semi-hermetic compressor shall utilize an internal economizer cycle to
enhance the unit’s refrigeration effect and to allow the compressor to run at
a more efficient operating point.
3. A liquid refrigerant injection system shall be utilized to seal potential
leakage paths between high and low sides of the compressor.
4. Slide valve modulation shall be provided for unloading control. The
electric motor shall be semi-hermetic or hermetically sealed, squirrel cage
induction type and cooled by liquid refrigerant which allows the motor to
operate at lower temperatures. Compressor power factor shall be 0.90 or
greater.
F. Evaporator:
1. Evaporator shall be of the direct expansion shell and tube type with carbon
steel barrel, polypropylene water baffles to resist corrosion, and seamless,
internally finned high efficiency copper tubes. Tubes shall be roll
expanded into heavy carbon steel tube sheets. Refrigerant heads shall be
carbon steel and removable to permit access to tubes from either end. For
easy removal of water, vent and drain plugs shall be provided on the shell.
2. The evaporator shall be wrapped with an electric heater cable and insulated
with 19mm thick closed cell polyurethane insulation (K = 0.28 at
23.9deg.C) to provide freeze protection down to -10deg.C ambient air
temperature. The insulation shall be fitted and cemented in place, then
painted with a resilient vinyl paint to resist cracking.
3. The evaporator shall be designed for refrigerant side working pressure of
225 psig (1550 kPa) and water side working pressure of 175 psig (1207
kPa). The evaporator shall be designed, constructed, inspected and
stamped in accordance with ASME Code requirements.
G. Condenser:
1. Water-cooled condenser coils shall have copper tubes mechanically bonded
seamless and shall be cleaned, dehydrated, sealed, leak tested at 150 psig
(1034 kPa) and pressure tested at 450 psig (3103 kPa).
H. Refrigerant Components:
1. Refrigerant system components shall include hot gas muffler, high side
pressure relief device, liquid line shut-off valve, replaceable core filter
drier, moisture indicating sight glass, and expansion valve. If accessory
unloaders are to be used, they shall be electrically actuated suction cutoff
cylinder unloaders.
I. Chiller Controls:
1. The chillers shall be provided with logic control system and a remote
monitoring and sequencing controller.
2. The chiller control shall have open protocol to interface with the BMS
system.
3. Head pressure control: Each unit shall be capable of operating
satisfactorily at low indoor air temperature.
4. Capacity control: Each unit control shall be factory equipped with an
electrically-operated device for loading and unloading compressor and a
control for cycling compressors. Hot gas by-pass shall be provided.
Chillers shall have multiple capacity control. Chillers shall be provided
with either pressure gages or alpha numeric display for the suction
pressure, discharge pressure and oil pressure.
Page 7
 5. Unit controls, including microprocessor, shall be factory mounted and
wired in a weatherproof enclosure with hinged access doors, and shall
include automatic lead-lag, pump down at beginning and end of every
circuit cycle, low suction pressure protection, flow switch, low chilled
water temperature safety, low oil pressure protection for each circuit, low
input voltage protection for each compressor, field power and control
circuit terminal blocks, fan motor circuit breakers, ON/OFF switch,
replaceable relay board, individual solid state compressor protection, return
or leaving chilled water set point feature, a digital display module, a
microprocessor board, and a temperature reset feature. Programming of the
microcomputer control panel shall be through a touch key pad system.
Motors should have a three leg current sensing system. Units should be
capable of providing a hard copy of system status and faults.
J. Electrical Requirements:
Electrical requirements shall be as per equipment schedule. Factory-
mounted control transformer shall be provided. Units shall be provided
with a single point power supply and one non-fused disconnect switch to

2.6.3 Chilled and Condenser Water Pumps

2.6.3.1 Chilled and Condenser Water Pumps Sizing (Refer to sample calculation

below and to equipment schedule).

CALCULATION TABLE-16
Total Head Loss of Pump

Head Circuit Press

Size K Length Equiv L
Loss Flow Vel. Drop
Item Description
fps
(mm) ft/100ft Factor (m) (ft) gpm
(ft)
Pump Discharge
Flexible
1 250 0.7 0.12 6.60 1100 10 0.05
Connection
2 Check Valve 250 0.7 5.1 100.00 1100 0.70
3 Gate Valve 250 0.7 0.12 12.00 1100 0.08
5 Red. Tee 250 0.7 0.8 50.00 1100 0.35
6 Header Pipe 400 3.7 4 3600 9 0.15
7 Elbow 90° 250 1 0.42 25.00 2010 0.25
8 Pipe 250 1 21 68.88 2010 0.69
9 Elbow 90° 250 1 0.42 25.00 2010 0.25
10 Pipe 250 1 8 26.24 2010 6 0.26
11 Elbow 90° 250 1 0.42 25.00 2010 0.25
12 Pipe 250 1 45 147.60 2010 1.48
13 Elbow 90° 250 1 0.42 25.00 2010 0.25
14 Pipe 250 1 9 29.52 2010 6 0.30
15 Gate Valve 250 1 0.11 12.00 2010 0.12
16 Pipe 250 1 4 13.12 2010 6 0.13
17 Elbow 90° 250 1 0.42 25.00 2010 0.25
18 Pipe 250 1 4 13.12 2010 6 0.13
19 Red. Tee 250 1 0.8 50.00 2010 0.50
20 Pipe 250 1.2 20 65.60 1440 6 0.79
21 Red. Tee 250 1.2 0.8 50.00 1440 0.60
Page 8
22 Pipe 200 0.7 20 65.60 720 6 0.46
23 Y-Strainer 200 0.7 110.00 720 0.77
24 Elbow 90° 200 0.7 0.42 150.00 720 0.22
25 Pipe 200 0.7 3 9.84 720 6 0.07
Flexible
26 200 0.7 0.11 8.00 720 0.06
Connection
27 Chiller ( from chiller selection data) 720 15.00
Flexible
28 200 0.7 0.11 8.00 720 0.06
Connection
29 Pipe 200 0.7 3 9.84 720 6 0.07
30 Elbow 90° 200 0.7 0.42 25.00 720 0.18
31 PRV 200 0.7 14.00 720 0.10
32 Pipe 200 0.7 4 13.12 720 6 0.09
33 Gate Valve 200 0.7 9.00 720 0.06
34 Red. Tee 200/250 0.7 0.8 50.00 720 0.35
35 Pipe 250 0.7 8 26.24 720 0.18
36 Elbow 90° 250 2 0.42 25.00 1268 0.50
37 Pipe 250 2 13 42.64 1268 6 0.85
34 Red. Tee 250/100 3.6 0.8 50.00 1268 1.80
39 Pipe 100 3.6 8 26.24 266 0.94
36 Elbow 90° 100 3.6 0.42 10.00 266 0.36
39 Pipe 100 3.6 1 3.28 266 0.12
33 Gate Valve 100 3.6 9.00 266 0.32
39 Pipe 100 3.6 1 3.28 266 0.12
89 AHU-BL2.C 30.00
87 Pipe 100 3.3 1 3.28 266 4 0.11
88 Gate Valve 100 3.3 0.9 266 0.03
87 Pipe 100 3.3 2 6.56 266 4 0.22
86 Elbow 90° 100 3.3 0.42 10.00 266 0.33
87 Pipe 100 3.3 7 22.96 266 4 0.76
86 Elbow 90° 100 3.3 0.42 10.00 266 0.33
87 Pipe 100 3.3 21 68.88 266 4 2.27
54 E. TEE 150 1.8 0.8 30 507 4 0.54
55 Pipe 150 1.8 21 68.88 507 4 1.24
54 E. TEE 150 3.6 0.8 30 742 4 1.08
55 Pipe 150 3.6 13 42.64 742 4 1.54
54 E. TEE 200 1.5 0.8 30 948 4 0.45
55 Pipe 200 1.5 5 16.40 948 4 0.25
54 E. TEE 200 1.5 0.8 30 948 4 0.45
55 Pipe 200 1.5 3 9.84 948 4 0.15
40 Elbow 90° 200 1.7 0.42 25.00 1063 0.43
41 Pipe 200 1.7 14 45.92 1063 4 0.78
54 E. TEE 200 1.7 0.8 30 1063 4 0.51
41 Pipe 200 1.7 14 45.92 1019 4 0.78
54 E. TEE 200 1.6 0.8 30 1019 4 0.48
55 Pipe 200 1.6 14 45.92 1019 4 0.73
54 E. TEE 200 1.6 0.8 30 1091 4 0.48
55 Pipe 200 1.6 14 45.92 1091 4 0.73
54 E. TEE 200 1.7 0.8 30 1162 4 0.51
55 Pipe 200 1.7 14 45.92 1162 4 0.78
54 E. TEE 200 1.7 0.8 30 1234 4 0.51
55 Pipe 200 1.7 14 45.92 1234 4 0.78
54 E. TEE 200 2.4 0.8 30 1306 4 0.72
55 Pipe 200 2.4 14 45.92 1306 4 1.10
54 E. TEE 200 2.4 0.8 30 1377 4 0.72
55 Pipe 200 2.4 14 45.92 1377 4 1.10
Page 9
54 E. TEE 200 2.6 0.8 30 1689 4 0.78
55 Pipe 200 2.6 14 45.92 1689 4 1.19
54 E. TEE 200 2.6 0.8 30 1760 4 0.78
55 Pipe 200 2.6 14 45.92 1760 4 1.19
54 E. TEE 200 2.6 0.8 30 1760 4 0.78
55 Pipe 200 2.6 14 45.92 1760 4 1.19
54 E. TEE 250 1.6 0.8 30 1853 4 0.48
55 Pipe 250 1.6 14 45.92 1853 4 0.73
54 E. TEE 250 1.6 0.8 30 1938 4 0.48
55 Pipe 250 1.6 3 9.84 1938 4 0.16
38 Elbow 90° 250 1.6 0.42 25.00 1938 0.40
55 Pipe 250 1.6 2 6.56 1938 4 0.10
3 Gate Valve 250 1.6 0.12 12.00 1938 0.19
55 Pipe 250 1.6 5 16.40 1938 4 0.26
54 E. TEE 250 1.7 0.8 30 1960 4 0.51
118.0
55 Pipe 250 1.7 36 1960 4 2.01
8
54 E. TEE 250 1.8 0.8 30 2011 4 0.54
118.0
55 Pipe 250 1.8 36 2011 4 2.13
8
38 Elbow 90° 250 1.8 0.42 25.00 2011 0.45
55 Pipe 250 1.8 17 55.76 2011 4 1.00
38 Elbow 90° 250 1.8 0.42 25.00 2011 0.45
55 Pipe 250 1.8 7 22.96 2011 4 0.41
38 Elbow 90° 250 1.8 0.42 25.00 2011 0.45
55 Pipe 250 1.8 11 36.08 2011 4 0.65
38 Elbow 90° 250 1.8 0.42 25.00 2011 0.45
55 Pipe 250 1.8 1 3.28 2011 4 0.06
100.0
2 Check Valve 250 0.7 5.1 2011 0.70
0
3 Gate Valve 250 0.7 0.12 12.00 2011 0.08
38 Elbow 90° 250 1.8 0.42 25.00 2011 0.45
55 Pipe 250 1.8 3 9.84 2011 4 0.18
54 E. TEE 250 1.7 0.8 30 2011 4 0.51
6 Header Pipe 400 3.7 11 2011 9 0.41
5 Red. Tee 250 0.7 0.8 50.00 2011 0.35
3 Gate Valve 250 0.7 0.12 12.00 1100 0.08
100.0
2 Check Valve 250 0.7 5.1 1100 0.70
0
Flexible
1 250 0.7 0.12 6.60 1100 10 0.05
Connection
PUMP
SUCTION
Total Dynamic Head 102.48
Plus 20%, safety factor 122.98

600 GPM x 130

HP = FT
3960 x .55

HP = 35.81

NEXT CAPACITY TO BE
SELECTED
40 HP EACH CHILLED WATER
PUMP

Page 10
2.6.3.2 Chilled and Condenser Water Pumps Specifications

1. PUMPS, GENERAL

A. Pumps : Factory-assembled and factory-tested. Fabricate casings to allow

removal and replacement of impellers without necessity of disconnecting piping.
Type, sizes, and capacities shall be as indicated.
B. Motors: Conform to NEMA Standard MG-1, general purpose, continuous duty,
Design B, except Design C where required for high starting torque; single,
multiple, or variable speed with type of enclosure and electrical characteristics as
indicated; have built-in thermal-overload protection, and grease-lubricated ball
bearings. Select motors that are non-overloading within the full range of the
pump performance curve.
C. Efficiency: "Energy Efficient" motors shall have a minimum efficiency as
indicated in accordance with IEEE Standard 112, Test Method B. If efficiency
is not specified, motor shall have a higher efficiency than the "average standard
industry motors," in accordance with IEEE Standard 112, Test Method B.
D. Motor Frame: NEMA Standard 48 or 54; use pump manufacturer's standard.
E. Apply factory finish paint to assembled, tested units prior to shipping.

2. BASE-MOUNTED, CLOSE-COUPLED, END-SUCTION PUMPS

A. General Description: Pumps shall be base-mounted, centrifugal, close-coupled,

end-suction, single-stage, bronze-fitted, radially split case design, and rated for
175 psig working pressure and 225 deg F continuous water temperature.
B. Casings Construction: Cast iron, with flanged piping connections, and threaded
gage tappings at inlet and outlet flange connections.
C. Impeller Construction: Statically and dynamically balanced, closed, overhung,
single-suction, fabricated from cast bronze conforming to ASTM B 584, keyed
to shaft and secured by a locking capscrew.
D. Wear Rings: Replaceable, bronze.
E. Pump Shaft and Sleeve Bearings: Steel shaft, with bronze sleeve. Provide
flinger on motor shaft between motor and seals to prevent liquid that leaks past
pump seals from entering the motor bearings.
F. Seals: Mechanical seals consisting of flushed seals consisting of carbon steel
rotating ring, stainless steel spring, ceramic seat, and flexible bellows and
gasket.
G. Seals: Stuffing box consisting of flushed, double seals have a minimum of 4
rings of graphite impregnated braided yarn with a bronze lantern ring between
center 2 graphite rings, and having a bronze packing gland.

3. BASE-MOUNTED, SEPARATELY-COUPLED, END-SUCTION PUMPS

A. General Description: Pumps shall be base-mounted, centrifugal,

separately-coupled, end-suction, single-stage, bronze-fitted, radially split case
design, and rated for 175 psig working pressure and 225 deg F continuous water
temperature.
B. Casings Construction: Cast iron, with flanged piping connections, and threaded
gage tappings at inlet and outlet flange connections.
C. Impeller Construction: Statically and dynamically balanced, closed, overhung,
single-suction, fabricated from cast bronze conforming to ASTM B 584, keyed
to shaft and secured by a locking capscrew.
D. Wear Rings: Replaceable, bronze.

Page 11
2.6.4 Cooling Towers

2.6.4.1 Cooling Towers Sizing

2.6.4.2 Cooling Towers Specifications

Base

A) Provide an induced draft, cross flow type, factory assembled, splash

fill, industrial duty, galvanized steel cooling tower situated as shown on
the plans.
B) The cooling tower shall be equipped with outlet sound attenuation
baffles positioned and spaced horizontally across the entire fan opening.
The baffles will be constructed of perforated sheet metal and contained
within a steel box which is self supporting.

Thermal Performance and Efficiency

A) The tower shall be capable of cooling 900 GPM of water from 95 °F to
85 °F at a design entering air wet-bulb temperature of 78 °F. The cooling
tower manufacturer shall guarantee that the tower supplied will meet the
specified performance conditions when the tower is installed according to
plans. If, because of a suspected thermal performance deficiency, the
owner chooses to conduct an on-site thermal performance test in the
presence of the manufacturer, and under the supervision of a qualified,
disinterested third party in accordance with CTI (Cooling Tower Institute)
test code ATC105 standards during the first year of operation; and if the
tower fails to perform within the limits of test tolerance; then the
cooling tower manufacturer shall make alterations as it deems necessary to
overcome indicated deficiency. Should alterations prove to be inadequate,
the owner, at the cooling tower manufacturer’s option, shall be
compensated by either (or a combination of both) of the following: (a)
Installation of additional cooling tower capacity; (b) A refund of a
percentage of the contract price proportional to the deficiency as
established.

Construction
A) Except where otherwise specified, all components of the cooling tower
shall be fabricated of heavy-gauge steel, protected against corrosion by G-
235 galvanizing. The tower shall be capable of withstanding water having
a pH of 6.5 to 8.0; a chloride content (NaCl) up to 300 ppm; a sulfate
content (SO4) up to 250 ppm; a calcium content (CaCO3) up to 500 ppm;
silica (SiO2) up to 150 ppm; and design hot water temperatures up to
125°F.
B) The specifications, as written, are intended to indicate those materials
that will be capable of withstanding the above water quality in continuing
service, as well as the loads described in paragraph. They are to be
regarded as minimum requirements. Where component materials peculiar
to individual tower designs are not specified, the manufacturers shall take
the above water quality and load carrying capabilities into account in the
selection of their materials of manufacture.

Mechanical Equipment

Page 12
A) Fan(s) shall be propeller-type, incorporating wide-chord aluminum
alloy blades and galvanized hubs. Blades shall be individually adjustable.
Maximum fan tip speed shall be 13,000 ft/min. Fan(s) shall be driven
through a right angle, industrial duty, oil lubricated, geared speed reducer
that requires no oil changes for the first five (5) years of operation. The
gearbox bearings shall be rated at an L10A service life of 100,000 hours or
greater. An external oil level dipstick shall be located adjacent to the
motor at the fan deck surface and shall be accessible from a portable
maintenance ladder.
B) Motor(s) shall be 40 hp maximum, TEFC, 1.15 service factor, variable
torque, and specially insulated for cooling tower duty. Speed and electrical
characteristics shall be 1750 RPM, single-winding, 3 phase, 60 hertz, 460
volts. Motor shall operate in the shaft-horizontal position, and nameplate
horsepower shall not be exceeded at design operation. VFD Controller
shall be used and BMS controlled and monitored.
C) The complete mechanical equipment assembly for each cell shall be
supported by a rigid steel structural support that resists misalignment
between the motor and the gear reducer. The mechanical equipment
assembly shall be warranted against any failure caused by defects in
materials and workmanship for no less than five (5) years following the
date of tower shipment. This warranty shall cover the fan, speed reducer,
motor, drive shaft and couplings, and the mechanical equipment support.

Fill, Drift Eliminators and Louvers

A) Fill shall be a splash-type, non-clogging design. Splash bars shall be

hollow, extruded, structural bars of PVC, a minimum of 3/4" thick x 1
5/8" wide. They shall be installed in a horizontal position, perpendicular to
the airflow, supported by heavy-gauge HMG steel panels. Fill shall be
capable of withstanding a hot water temperature of 130°F.
B) Drift eliminators, installed inboard of the fill, shall be cellular type,
triple-pass, manufactured of PVC. They shall be removable and
replaceable, and shall limit drift to 0.010% of the circulating water flow.
The final pass of the eliminators shall direct airflow toward the fan.
C) The air intake faces of the tower shall be louvered full length, full
height. Louvers shall be corrugated FRP. They shall be slip-fit into slotted
sheet metal louver columns. Louvers shall be sloped to shed water inward
to the tower, and shall be “sight-tight” at horizontal view.

Hot Water Distribution System

A) Two open basins (one above each bank of fill) shall receive hot water
piped to each cell of the tower. These basins shall be installed and sealed
at the factory, and shall be equipped with removable, galvanized steel
covers capable of withstanding the loads described in paragraph.
B) The water distribution system shall be accessible and maintainable
during tower fan and water operation.
C) Each cell of the tower shall include a single hot water inlet connection
located as shown on the plans. An internal system of piping shall deliver
water equally to the distribution basins without the need for balancing
valves. This internal piping system shall require no scheduled
maintenance, and shall be located such that it does not interfere with
normal maintenance access. The internal piping must extend to the tower
exterior. Removable, interchangeable polypropylene nozzles installed in
Page 13
the floor of these basins shall provide full coverage of the fill by gravity
flow. Heavy-duty flow-regulator valves shall be provided at the hot water
inlet connections. These valves shall be disc-type, with cast iron bodies
and stainless steel operating stems. There shall be a locking handle to
maintain the valve setting in any position. Valves shall be right angle
configuration, precluding the need for inlet elbows.
D) The water distribution system shall be accessible and maintainable
while tower is operating.

Design Loading

A) The tower structure, anchorage and all its components shall be

designed by licensed structural engineers per the International Building
Code to withstand a wind load of 30 psf, as well as a .3g seismic load. The
fan deck and hot water basin covers shall be designed for 50 psf live load
or a 200 lb. concentrated load. Guardrails, where specified, shall be
capable of withstanding a 200 lb concentrated live load in any direction,
and shall be designed in accordance with OSHA guidelines.

Casing, Fan Deck and Fan Guard

A) The casing and fan deck shall be heavy-gauge galvanized steel, and
shall be capable of withstanding the loads described in paragraph 4.1. The
top of the fan cylinder shall be equipped with a conical, non-sagging,
removable fan guard, fabricated of welded 5/16" and 7 gauge rods, and hot
dip galvanized after fabrication. Fan cylinders 5'-0" in height and over
shall not be required to have a fan guard.

Access

A) A large galvanized, rectangular access door shall be located on both

end panels for entry into the cold water basin. Doors shall provide access
to the fan plenum area to facilitate inspection and allow maintenance to
the fan drive system. An internal ladder shall extend upward from the
plenum walkway to an elevated fiberglass bar grating platform convenient
to the care and maintenance of the tower's mechanical equipment. The
platform shall be surrounded by a sturdy guardrail and kneerail system.
The top of the tower shall be equipped with a sturdy guardrail, complete
with kneerail and toeboard, designed according to OSHA guidelines and
factory welded into subassemblies for ease of field installation. Posts,
toprails and kneerails shall be 1.5 " square tubing. The guardrail assembly
shall be hot dipped galvanized after welding and capable of withstanding a
200 pound concentrated live load in any direction. Posts shall be spaced
on centers of 8'-0" or less. A 1'-6" wide aluminum ladder with 3" I-beam
side rails and 1.25" diameter rungs shall be permanently attached to the
endwall casing of the tower, rising from the base of the tower to the top of
the guardrail.

Page 14
Cold Water Collection basin

A) The collection basin shall be heavy-gauge S300 stainless steel, and

shall include the number and type of suction connections required to
accommodate the outflow piping system shown on the plans. Suction
connections shall be equipped with stainless steel debris screens. A
factory-installed, float-operated, mechanical make-up valve shall be
included. An overflow and drain connection shall be provided in each cell
of the cooling tower. The basin floor shall slope toward the drain to allow
complete flush out of debris and silt which may accumulate. Towers of
more than one cell shall include stainless steel flumes for flow and
equalization between cells. The basin shall be accessible and maintainable
while water is circulating. All steel items which project into the basin
(columns, diagonals, anchor clips, etc.) shall also be made of stainless
steel. A hole and bolt circle shall be provided in the depressed section
of the basin for equalizer piping between cells. A full-face, .25" thick, 50
durometer gasket shall be provided at each equalizer location.
B) The interconnecting flume between cells shall be equipped with a
removable cover plate to permit the shutdown of one cell for maintenance
purposes, or to permit independent cell operation.

2.6.5 Fan Coil Units

2.6.5.1 Fan Coil Units sizing (Refer to FCU Equipment Schedule)

Fan Coil Units (FCU) are sized up according to the total sensible heat gain of
each room and calculated air flow to offset the sensible heat gain. The air flow
(CFM) and total BTUH are mostly to be considered in sizing the FCU.
2.6.5.2 Fan Coil Units Specifications

The proposed Fan Coil Units (FCU) shall be heavy duty type and should
be suitable for extreme weather conditions like here in Saudi Arabia where
they are intended to be used. Equipment selected shall comply with
ASHRAE Standard 90.1 and performance is rated in accordance with ARI
Standard 550/590. The FCU shall be consisting of rigid galvanized steel
casing, copper tube/aluminum fin coil type heat exchanger, fan board
assembly, manual coil air vent with drain pan, junction box with terminal
strip.

The unit casing shall be manufactured by 1.2mm thick galvanized steel

with internal insulation of 9mm thickness, 108 kg/m3 high density non-
flammable PU foam.

FCU motors shall have internal thermal temperature cut-out above 140°C
with permanent split-capacitor, three-speed, tap wound, induction type for
maximum efficiency. Motors shall have permanently lubricated ball
bearings and all-direction, vibration isolating mountings to ensure
vibration free operation and minimum noise. Motor wiring shall be
enclosed by flexible metal conduit and connected to the junction box.

The material of fan wheel shall be galvanized steel and mounted directly
onto each shaft. The DIDW centrifugal fans shall have balanced and
forward curved blades. Fan housings shall be made of galvanized sheet
Page 15
steel. The fan board can be simply removed by loosening the fasteners for
easy service purpose.

Coils shall be at least 3/8 inch OD copper tubes mechanically bonded to

Wavy 3B aluminum fin collars. A manual air vent with drain line to the
drain pan shall be provided to avoid any water drips when venting.
Standard coils shall be factory leak tested at 20 kg/cm2 (20 Bar) and shall
have working pressure of up to13kg/cm2 (13 Bar). Coils shall be fitted
with either sweat connection or female pipe thread connection. Coil-type
heater shall be provided for all FCU for winter application.

The FCU drain pan shall be 25mm depth with 0.8mm thickness galvanized
steel coated with internal epoxy resin coating. The drain pan shall be one-
piece stamped processed seamless and no joint to avoid leakage.
Insulation material shall be 5mm thickness, 27 kg/m3 density PE foam.
The drain pan shall have one 3/4-inch male pipe thread (JIS B 0203-1966)
connection.

2.6.6 Exhaust/Extract Fans

2.6.6.1 Exhaust/Extarct Fans Sizing (Refer to EF Equipment Schedule)

Sizing of exhaust fan is analogous to extract or AHU fans calculation where

static pressure and total length of straight duct including fittings are considered.

2.6.6.2 Exhaust/Extract Fans Specifications

Exhaust fans shall be constructed of heavy gauge rust proof, extruded

aluminum and plastic coated steel frame. The units shall be direct-driven
or belt-driven. It shall be centrifugal or plug fans complete with motor and
disconnect switch. The units shall be of low silhouette type, mounted on
curbed roof openings. Exhaust fans shall be of the capacity and sizes as
indicated on the equipment schedule & drawings.

Its Performance ratings shall conform to AMCA standard 211 and 311 and
must be tested in accordance with ANSI/AMCA Standard 210-99 and
AMCA Standard 300-96 in an AMCA accredited laboratory. Fans shall be
certified to bear the AMCA label for air and sound performance seal.

It shall have classification for Spark Resistant Construction Levels A, B or

C, and conform to AMCA 99. Each fan shall be given a balancing analysis
which is applied to wheels at the outside radius. The maximum allowable
static and dynamic imbalance is 0.05 ounces (Balance grade of G6.3). It
shall comply with the National Electrical Manufacturers Association
(NEMA), standards for motors and electrical accessories.

Base fan performance shall be at standard conditions (density 0.075

Lb/ft3) and normal operating temperatures up to 200 Fahrenheit (93.3
Celsius). Its performance capabilities shall be up to 5,000 cubic feet per
minute (CFM) and static pressure to 2 inches of water gauge. All exhaust
fans shall be statically and dynamically balanced in accordance to AMCA
Standard 204-05. The wheel cone and fan inlet will be matched and shall
have precise running tolerances for maximum performance and operating
efficiency.
Page 16
Its fan motor enclosures shall be totally enclosed fan cooled and explosion
resistant. Motors shall be permanently lubricated, heavy duty ball bearing
type to match with the fan load and pre-wired to the specific voltage and
phase.

Exhaust fans housing and bearing supports shall be constructed of welded

steel members to prevent vibration and to rigidly support the motor and
wheel.

Exhaust fan shall be either direct mounted, isolated with housed spring or
as per requirement on the equipment schedule or drawings.

2.7 Equipment Installation

2.7.1 Air Handling Units

Air handling units shall be installed with sufficient room to allow the
installation of all control components. Allow sufficient space around the
unit for removing the access panels and various parts of the unit. A
minimum clearance equal to the width of the unit must be provided on one
side of the unit for removing the coil or fan assembly and other
accessories. Add dimension of pipe chase, air hoods, ducts,
control/electrical panels, etc. to minimum clearances. Allow additional
clearance as required by local and national codes.

Unit must be installed on flat and level surface. Units must be installed in
such a manner as to provide enough elevation for properly designed
condensate traps. Condensate drain shall be properly trapped.

Ensure that all power and field wirings are installed, tag, and harnessed
properly.

Air Handling Units shall be installed complete with all accessories and
controls to operate as per design intent and project specifications.

All AHU shall be installed with due consideration for operation and
maintenance activities to be undertaken by the maintenance staff later on.

All AHU machine connections such as but not limited to piping, duct,
electrical, condensate drain shall be plumb, level, slope, supported,
anchored and shall have flexible connections as required.

2.7.2 Water-Cooled Water Chillers

Install chillers level and plumb and shall be in accordance to

manufacturer’s recommendations.

Install chillers on 4-inch thick concrete base, 4 inches larger on each side
than base of unit. Anchor chillers and vibration isolators to concrete base.

Maintain manufacturer’s recommended clearance for service and

maintenance.
Page 17
Connect piping to chillers with shutoff valves and flanges at each
connection.

Label the amount of refrigerant in the system and also the name and
pressure of refrigerant used.

Provide flanges at each condenser and chilled water connection to chillers.

Provide removable sections to permit removal for access to tube bundles
for cleaning. Pipe sections shall be no longer than 4 feet or shall consist of
a removable elbow in order to be removable without heavy equipment.

Place isolation valves on piping to permit removal of sections described

above without draining of chilled or condenser water.

Wire chillers so it cannot start unless chilled water and condenser water
circulating pumps are running and shall be controllable and monitor via
BMS.

The relief valves shall be installed or piped to the atmosphere.

All piping is installed and supported and the direction of flow shall be
indicated in accordance with the approved specification and drawings.

Gages shall be installed as required to establish design flow for the cooler
and condenser.

2.7.3 Chilled and Condenser Water Pumps

Pump shall be located in a clean, dry area free from flooding. The area
shall provide adequate space for operation, maintenance, inspection and
repair, considering complete disassembly and handling of equipment. The
pump shall have a supply of clean liquid for packing or mechanical seal
lubrication. The pump shall be positioned to provide the most efficient
pipeline system.

Pumps shall be base plate-mounted, level and grouted to a concrete

foundation which has been poured on solid footing. The foundation must
be able to absorb any vibration and to form a permanent, rigid, support for
the pumping unit to the degree that there shall not be any adverse
movement or settling over a long period of time.

Pump and drive motor shall be installed completely align (angular &
parallel) to avoid unintended contact of rotating parts and prolong pump’s
life.

Piping connected to the pumps shall be supported and meets the Hydraulic
Institute, ASME/ANSI, DIN requirements in conjunction with
construction documents and specifications.

Expansion or flexible connectors shall be properly installed on suction and

/or discharge lines of pumps so that any linear expansion of piping will not
draw pump out of alignment.
Page 18
Pumps must have properly installed suction piping for a trouble-free pump
operation. Suction piping shall be flushed before connection to the pump.

Use of elbows close to the pump suction flange shall be avoided. There
should be a minimum of two pipe diameters of straight pipe between the
elbow and suction inlet.

Use suction pipe one or two sizes larger than the pump suction, with a
reducer at the suction flange. Suction piping should never be of smaller
diameter than the pump suction.

To prevent suction cavitation, horizontal reducers should be eccentric with

the sloping side down and concentric for vertical applications.

For protection and maintenance purposes, y-strainer, isolation, double-

regulating and check valves shall be installed on the pump suction and
discharge lines.

Installation shall permit adequate circulation of air to provide proper

cooling of the motor and pump seal housing.

2.7.4 Cooling Towers

Cooling towers shall be installed in accordance with equipment

manufacturer’s written instructions and with recognized industry practices,
to ensure that cooling towers comply with the requirements and serve
intended purposes.

Provide access and service space around and over cooling towers as
indicated, but in no case less than that recommended by the manufacturer.

Install roof-mounted units on structural steel mechanical equipment stand.

Anchor cooling tower to stand with removable fasteners.

Construct mechanical equipment stand as indicated, and in accordance

with NRCA handbook and Accepted Roofing Knowledge.

Mount unit on vibration isolators if recommended by cooling tower

manufacturer. Install gaskets or sealants between cooling tower cells.

Condenser water piping shall be provided with flanged or mechanical

coupling connections to cooling tower, with flexible pipe connections if
tower is mounted on vibration isolators. Pitch lines so water will drain into
sump. Connect inlets to cooling tower with shutoff valve and balancing
valve (if two or more inlets) Connect outlets with shutoff valves.

If the tower consists of more than one cell, totally isolate each cell from
the other cell to facilitate cleaning and maintenance. Provide equalizing
piping between cells with automatic control valve.

Make-up and water piping shall be flanged, mechanical couplings, or

union connections to cooling tower. With flexible pipe connections if
Page 19
tower is mounted on vibration isolators. Pitch lines so that the water will
drain into the sump. Connect to automatic fill valve with a 3-valve bypass,
and backflow preventer.

Connect drain, overflow, and bleed lines to cooling tower as indicated on

the drawings.

Install electrical devices furnished by manufacturer but not specified to be

factory-mounted. Furnish copy of manufacturer’s wiring diagram
submittal to Electrical

2.7.5 Fan Coil Units

For proper installation and operation of Fan Coil Units (FCU), the
following shall be checked and adhered to:

Allow adequate space for the unit and free area or service clearance, refer
to manufacturer’s general unit dimensions and submittal drawings. For
proper servicing and routine maintenance, access to the unit through
removable panels in the ceiling must provided.

Before installing any unit make sure that proper preparation has been
made at each unit location for piping and electrical connections.

Check that the supporting structure is strong enough to support the

operating weights as provided by the manufacturer’s engineering data.

The clearance between drain pan and ceiling should be enough for drain
line pitch with a minimum slope of 1:50.

Ducting connected to units (where applicable) should not exceed the

external static pressure rating of the unit.

Condensate protection for the chilled water valves and piping must be
provided by installer. A drain pan extension provided by installer should
be located under the valves or else the valves and piping should be
thoroughly insulated.

Units with valve package are equipped with long drain pan which can
carry the condensation from water valves. Insulation of valve package is
not required.

Place the unit to desired angle by adjusting lower nuts up/down, and then
tighten the upper nuts to secure the unit.

Adjust the slope of the drain pan by turning the drain pan suspension
screws up/down. The drain pan should be pitched to provide proper
drainage. Note side to side as well as end to end level. Level the unit by
checking on the unit casing. Do not use the coil or drain pan for leveling
as they are pitched to provide proper drainage.

Page 20
Machine connections such as ducts, pipes, electrical, and condensate must
conform to engineering catalogue provided by manufacturer as to sizing,
location, or orientation for proper operation and maintenance of the units.

Electrical isolation switch for each FCU shall be provided nearby the unit
as safety measure during maintenance undertakings.

2.7.6 Exhaust Fans

Exhaust Fans Installation Considerations:

Exhaust fans shall always be mounted to a flat level, solid and rigid
structure. Particular caution should be exercised when installing fans on
metal buildings. Be sure wall or roofs are capable of supporting the fans.

Roofs not supported correctly will cause vibration that could cause
damage or injury.

Fans mounted off ground level should be rigidly mounted to a special

platform and be placed as near as possible to, or over, a solid wall or
column.

Supports for suspended fans must be crossbraced for live load support to
prevent side sway.

Do not install fans in an environment or atmosphere where combustible or

flammable materials, gasses or fumes are present, unless it was
specifically designed and manufactured for use in that environment.
Explosion or fire can result.

When ventilator is designed to be mounted on a curb, the curb should be

securely installed prior to fan installation.

A damper, if used, should be securely mounted within the curb or wall in a

manner that allows free and unobstructed operation.

All electrical work must be done in accordance with local and/or national
electrical codes as applicable. Installing electrical wiring must be carried-
out by a qualified electrician.

Make sure power is turned off and locked in the OFF position at the
service entrance before installing, wiring or servicing the exhaust fan.

Before wiring the motor, check the supply voltage against the motor
nameplate voltage. High or low voltage can damage the motor and void
the motor warranty.

Be sure to keep all wiring clear of rotating or moving parts.

Before starting the fan, turn the wheel to assure it rotates freely. If needed,
adjust the wheel/ shaft/bearing/motor position as required to achieve
necessary clearances.

Page 21
On belt drive units, assure belts are tensioned and aligned properly. Check
all setscrews and keys. Tighten as necessary prior to fan start-up.

2.8 Equipment Maintenance

2.8.1 Air Handling Units

AHU Recommended Maintenance Schedule

In general air handling unit do not require special attention other then
routine cleaning and maintenance work. Following is the recommended
schedule of maintenance, when units operate at normal conditions.
However actual conditions of use/operation will dictate the interval of
checking/replacement of the filters, belts etc.

Weekly:

A) Check filter condition at weekly intervals. Clean, wash or

renew/replace if necessary.
B) Check fan belt tension and adjust if necessary.
C) Check the condition of spray nozzles and float valve in air washer.
D) Check the condition of drain for free flow.
E) Check the condition of resistance in electric Humidifier.
F) Check the condition of access door hinges and lubricate if necessary.

Semi-Annually:

A) Check the fan motor running current.

B) Check function controls and their effect on AHU components.
C) Check fan and motor bearings.
D) Check electric heater battery elements.
E) Add water and flush condensate drain pan, trap and drain line.
F) Check circulating pump and motor in air washer.
G) Check the condition of inlet strainers.
H) Check the condition of chilled/hot water. Add chemicals if necessary.

Annually:

A) Check the operation of dampers.

B) Check the filter frame for proper sealing.
C) Replace synthetic media in panel filters.
D) Check the access doors for easy operation and proper locking.
E) Check the controls and operation of Roll Filters.
F) Check the coils and fin condition. Wash with water spray, if necessary.
G) Check the condition of all insulating, regulating valves etc in the
system.
H) Vent the water coils.
I) Check motor and fan bearing lubrication.
J) Replace belts.
K) Check all wiring, controls, isolating devices, terminal connections etc.
While attending to the above maintenance schedules, the following must
be noted.

Page 22
It is important to check the condition of filters once a week. When the
pressure drop across the filter exceed the maximum pressure drop. Dirty
filters reduces the air flow and hence the capacity. Do not operate the
system without filters. In case the media is synthetic or metallic, they can
be cleaned or washed. However it is recommended to replace synthetic
media once in every year and metallic media once in every two years.
Other filters such as Throw Away Panels, Bag, Absolute, Roll Filters must
be replaced with new cells of identical media and efficiency.

2.8.2 Water Cooled Water Chillers

Chiller Recommended Maintenance Schedule

Weekly:

A) Check oil level in oil separator sight glass.

B) Check liquid line sight glass/moisture indicator.
C) Record system operating temperature and pressure.
D) Check for any leaks, abnormal vibration and sound .

Quarterly:

A) Check programmable operating set points and safety cut-outs. Ensure

they are correct for the application.
B) Check compressor and evaporator heater operation.
C) Check for dirt in the panel. Check door gasket sealing integrity.

Semi-Annual:

L) Check superheat on the evaporator and the economizer feed to the

compressor.
M) Check condenser sub-cooling.
N) Leak test the chiller.
O) Check and re-tighten all electrical controls and terminals.

Annually:

A) Sample compressor oil for oil analysis and to check for acid. Replace
if necessary.

2.8.3 Chilled and Condenser Water Pumps

Pumps (Condenser/Chilled Water) Recommended Maintenance

Schedule

Monthly:

A) Check for unusual noise, vibration, and bearing temperature.

B) Lubricate the bearings.
C) Inspect the discharge pressure and temperature.
D) Check the seal, stuffing box, and piping for leaks and correct.

Semi-Annual:

Page 23
A) Check that the foundation and hold-down bolts are tight.
B) Check the packing if the pump has been left idle, and replace as
required.
C) Check the shaft alignment and re-align as required.

Annually:

A) Check the pump capacity. If the pump is not performing as design,

disassemble the pump and correct the discrepancy. Replace worn outs
parts.

2.8.4 Cooling Towers

Cooling Tower Recommended Maintenance Schedule

Monthly:

A) Inspect general condition of the unit and check for unusual noise &
vibration.
B) Check air inlet louvers for blockage and clean as necessary.
C) Check and adjust water level in basins.
D) Check operation of make-up valve.
E) Check and adjust bleed rate as needed.

Quarterly:

A) Inspect cold water basin and spray nozzles. Clean as necessary.

B) Lubricate and re-grease all rotating parts of the unit as applicable.
C) Check motor voltage, current, fan exterior and condition, uniform
pitch of blade, and all steel surface if need re-painting or re-coating.

Annually:

A) Sample oil for oil analysis (gearbox) and to check for acid. Replace if
necessary.
B) Check for alignment and unit finish if need re-furbishing or major
repair.

2.8.5 Fan Coil Units

FCU Recommended Maintenance Schedule

Monthly:

A) Disconnect electrical power source and secure in disconnected position

before servicing the unit. Failure to do so may result in personal injury
or death from electrical shock.

B) The FCU is designed to operate with a clean filter, and therefore

compliance with the maintenance schedule detailed in the manual is
essential. Inspect the unit air filter. Clean or replace clogged filter
element.

Page 24
C) Check the drain pan to be sure that it is clean and free to carry the
flow of condensate through the drain line.

Annually:

A) Inspect the unit casing for corrosion. Clean or repair in order to

provide unit protection.

B) Inspect the fan wheel and housing for damage. Rotate the fan wheel
manually ensure that no obstructions are blocking its movement.

C) Inspect the coil fins for excessive dirt or damage. Remove dirt and
straighten fins.

D) Check on the motors is advisable to ascertain that the motor is quiet

and running smoothly, check the security of all electrical connections
and fix bolts of the fan/motor assembly.

E) Drain and treat the whole system to control pipe scaling.

F) Inspection should be made to the condition of the internal surfaces of

the casework; any debris that has accumulated should be removed with
a soft brush. Vacuum any loose deposits from within the casing.

G) The coil shall be inspected to ascertain if any solids or foreign matter

has accumulated between the fins and that the coil connections are free
from leaks.

H) Access door seals are to be checked to ensure that the seals are in good
order to maintain air-tightness of the unit.

CAUTION: The use of untreated or improperly treated water in this

equipment may result in scaling, erosion, corrosion, algae or slime. The
services of a qualified water treatment specialist should be engaged to
determine what treatment if any, is advisable.

2.8.6 Exhaust Fans

Exhaust Fans Recommended Maintenance:

A) Before performing any maintenance on the fan, be sure power is

turned off and locked in the OFF position at the service entrance
before servicing the fan.

B) Exhaust Fans shall be carefully checked at least once a year. For

critical or rugged applications, a routine check every two or three
months is suggested.

C) All motors supplied with the exhaust fans carry a one-year warranty
from date of shipment. For repairs within the warranty period, the
motor must be taken to the motor manufacturer’s authorized service
dealer.
Page 25
D) A periodic motor check should consist of spinning the motor shaft with
the power off to be sure the motor turns freely and the bearings run
smoothly. The belt on belt driven units should be removed from the
motor sheave.

E) When removing or installing a belt, do not force the belt over the
sheave. Loosen the motor mount so that the belt can be easily slipped
over the sheave.

F) The belt on belt driven units should be removed and carefully checked
for radial cracks, ply separation or irregular wear. A small irregularity
in the contact surface of the belt will result in noisy operation. If any
of these defects are apparent, the belt should be replaced. Check the
sheaves also for chipping, dents or rough surfaces, which could
damage the belt.

G) The correct belt tension is important. If the belt is too tight it will
result in excess bearing pressure on the motor bearings and shaft
pillow block and may also overload the motor. If the belt is too loose it
will result in slippage, which will quickly burn out belts. A belt should
feel “live” when thumped, approximately ¼” belt deflection when
subject to finger pressure (3-5 lb.) at midpoint between sheaves.

H) The belt alignment should also be checked to be sure the belt is

running perpendicular to the rotating shafts. Motor and drive shafts
must be parallel. Improper alignments will result in excessive belt
wear.

I) Check sheave set screws to ensure tightness. Proper keys must be in

keyways.
Do not readjust blade pitch or fan RPM. If sheaves are replaces, use
only sheaves of identical size and type.

J) The standard pillow block bearings on belt driven ventilators are

factory lubricated and are provided with external grease fittings.
Re-lubrication annually or more frequently, if required, is
recommended.

2.9 Equipment Operation (System)

Operation of HVAC System and Allied Accessories

2.9.1 Chillers

The chillers are provided with three position selector switch that is,
“HAND, OFF, and AUTO.”

If the selector switch is in the “HAND” mode, manual operation will take
place with the chillers. BMS access will be disabled but the operation of
the chillers can still be monitored by BMS. With the “HAND” mode,
water flow switch will send signal to chillers controller to energize the unit
provided all the safety interlocks are meet (cooling tower, pumps, AHU,
and FCU are operational or energized).
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If the selector switch is in the “OFF” mode, chillers are stop and no chilled
water will be available in the system. This chillers mode will be monitored
via BMS.

If the selector switch is in the “AUTO” mode, the Direct Digital Control
(DDC) control will send signal to the respective motorized valves to open
and when flow switch sensed a flow of water, chillers will be energized
with confirmation from all safety interlocks.

BMS will acknowledge any abnormalities (low, high, fail) on the chillers
operation.

2.9.2 Cooling Towers

Like the chillers, cooling towers has three position selector switch for its
operation. At normal operation, cooling tower fan and condenser pumps
will be energized first prior to the operation of any chillers since
condenser water flow is interlock with the chillers operation. Water level
on the tower sump shall be check and monitor during operation. Likewise,
the tower fan rotation shall be check prior to operation. Cooling towers
operation shall be control and monitor via BMS.

2.9.3 Chilled and Condenser Water Pumps

The operation of chilled and condenser water pumps shall be as per the
demand of chillers and cooling tower units respectively via BMS based
upon a programmed loading demand.

Lead/lag starting and shutdown or rotation of pumps operation shall be set

through BMS based on equal running time.

The number of chilled water pumps in operation shall be equal to the

number of chillers in operation. While for the condenser water pumps will
be twice the number of cooling tower in operation. There shall be stand-by
chilled and condenser water pumps in case of switch over or break down
of unit.

All safety and alarm points (low, high, fail) for pressure and temperature
shall be displayed and monitored via BMS terminal.

2.9.4 Air Handling Units

Like the chillers, AHU shall have “HAND, OFF, and AUTO” selector
switch for operation and stopping of unit.

During normal operation, AHU will be energized either manually or via

BMS controller. All dampers (fire, smoke, fresh air, and extract) shall be
in open position to satisfy the condition that AHU will be energized.
Temperature sensor located in the main supply air duct will maintain a
preset adjustable air temperature by modulating the two-way control valve
in the summer or by controlling the multi-step electrical heater during
winter to provide a 10 degrees F differential for cooling or heating
operation.
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In case of fire or heavy smoke (as detected by two area smoke/heat
detectors), an alarm signal will be sent by the fire alarm control panel
(FACP) to the BMS to shutdown the AHUs. Smoke/heat detectors are
installed in the supply and return ducts.

Other accessories of AHU such as differential pressure switch installed

across the air filters will monitor the filter status and will send signal to the
BMS for acceptable or clogged filters. The heater temperature sensor will
turn off the heater in case of temperature rise above the preset value.

2.9.5 Fan Coil Units

Fan coil unit placed at its respective area will be energized/de-energized

by its room temperature controller or thermostat as preset or define by
end-user. FCUs are interlock with exhaust fans serving the same area and
will be shutdown during emergency cases like fire or smoke.

2.9.6 Exhaust Fans

Exhaust fans can either be energized manually or through the BMS and
are interlock with the FCU serving the same area. When smoke is detected
by two area smoke detectors installed in the served area or installed in the
main exhaust duct, an alarm will be sent to the fire alarm control panel and
to the BMS to operate the related exhaust fans continuously until the
smoke is cleared while the FCU is shutdown.

EMERGENCY CASES

During emergency cases like fire, an alarm signal from fire alarm control
panel (FACP) will be sent to BMS to shutdown all HVAC related
equipment and accessories. Smoke extract fans will be energized to relieve
the building from heavy smoke.

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