Emaar Business Park, GGN Particular Conditions & Technical Specification

HVAC System

The contractor shall refer the following annexure while bidding and will read them in conjunction
with specifications as well as bill of quantity

Annexure - I : Particular Conditions of contract.

Annexure - II : Codes and Standards
Annexure - III : List of approved makes
Annexure - IV : Technical Specifications

Annexure-I
PARTICULAR CONDITIONS OF CONTRACT

These Particular Conditions are to be read in conjunction with other documents issued along with
tender. In case of any discrepancy between Design drawings, General conditions or Bill of quantity,
more stringent of the same shall be applicable.

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1. WORK DESCRIPTION

The work shall be strictly carried out as per the scope listed in this document and in
accordance with the specifications. The equipment & material supplied at site will also be
selected from the list of approved makes. Bill of quantity provided with the document is for
contractor guidance. It is expected that after award of work, contractor shall prepare shop
drawings for approval by the Consultant & Client representative and also submit
Technical documentation duly identifying shortlisted make of material/equipment along
with its data sheets. Actual ordering shall be based on approved shop drawings &
documents.

The work at site shall comply with the approved shop drawings and will meet the
satisfaction of Client representative. The contractor shall be required to demonstrate
satisfactory operation of entire system (including client supplied equipment installed by
contractor) and furnish the required labour, material & tools to install & commission the
system.

The broad scope of work for proposed HVAC system covered under this contract shall
include supply, installation, testing & commissioning of the following:

 Replacement of Valves & Fittings

 Air side Balancing
 Replacement of Coils
 Mechanical ventilation systems.
 Chilled, Condenser and Drain water piping with associated fittings, valves etc.
 Air distribution system.
 Associated electrical works.
 Water Balancing

2. SITE MANAGEMENT

The Contractor shall be required to provide following staffing for the project:

a. Design Engineer who will work with Consultant for getting shop drawings, technical
submittal and variation in quantity statement approved.

b. Procurement team.

c. Full time dedicated Engineer (minimum 10 year experience) & one supervisor posted
at site.

The contractor shall submit organization chart and CV prior to starting work at site.

The Contractor shall have required stores, tools & plant, security and facility to transport
materials to place of installation for speedy execution of work.

3. REGULATIONS & PERMITS

Prior to starting work at site, the contractor shall obtain required permits/ licenses required
for satisfactory execution and operation of the installation. All receipted amounts shall be
reimbursed by Client on production of proof of payment by the contractor.

The executed work shall strictly confirm to applicable laws, regulations and Indian
Standards which become applicable. In case the specifications and drawings contained in
this document call for higher standard than those required by prevailing regulations, then
these specifications & drawings shall become applicable. However, in case of any conflict
or violation between the document/drawings and BOQ, then the applicable laws &
regulations shall be governing & binding.

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4. TECHNICAL DOCUMENTATION

The contractor prior to supplying material at site, will submit the following documentation
to Consultant/Client representative for approval:

 Manufacturers drawings, catalogues, pamphlets, Technical Data Sheets and other

documents in triplicate. Each item shall be properly labeled, indicating the specific
services for which material or equipment is to be used, giving reference to the
governing section and clause number and clearly identifying in ink the items and the
operating characteristics. Data of general nature shall not be accepted.

 Samples of all materials shall be submitted to the Client’s site representative prior to
procurement. These will be submitted in two sets for approval and retention by Client’s
representative and shall be kept in their site office for reference and verification till the
completion of the Project. Wherever directed, a mockup or sample installation shall be
carried out for approval before proceeding for further installation.

 Where the contractor proposes to use an alternate make or model of equipment other
than that specified, then contractor will take approval from the client & consultants and
also provide cost benefit to the company, if any. all new drawings and detailing
required thereafter shall be prepared by the contractor at his own expense including
any re-design required for other discipline/trade. Any delay on such account shall also
be at the cost of and consequence of the Contractor.

Contractor to refer Annexure –III for list of approved makes & materials for this project.
5. VARIATION IN QUANTITY STATEMENT

After approval of major & relevant shop drawings, the contractor shall submit four
copies of a comprehensive variation in quantity statement. This statement must be
submitted prior to completing ordering of equipment and should identify imported/local
materials in this contract as well as proposed spares/tools. The Consultant shall
provide recommendation to Client representative for acceptance of anticipated
variation in contract amounts and also advise Client to initiate action for procurement
of spare parts and tools at the completion of project.
Quantity shall be verified by the project incharge and shall be paid on the actual basis
after approval.

7. QUALITY ASSURANCE
The contractor to ensure that all materials and equipment supplied shall be new and of
best available quality conforming to the relevant Indian Standard Specifications and to
these specifications. Makes shall be strictly in conformity with list of approved
manufacturers as per Annexure -III.Owners reserve the right to reject any item which
in their assessment is second hand

Any deviations from above shall be clearly highlighted prior to supply and shall be
brought to the notice of the Client representative/Consultant for further instructions in
the matter.

Prior to starting execution work at site, the Contractor shall verify the sufficiency of the
size of the shaft openings, clearances and ceiling spaces for proper installation.
Failure to communicate insufficiency of any of the above, shall constitute Contractor
acceptance of the same. The Contractor shall locate all equipment in fully accessible
locations which can be easily serviced, operated or maintained. The exact location
and size of access panels, required for each concealed, valve or other devices
requiring attendance shall be finalized and communicated in sufficient time. Failing
this, the Contractor shall make all the necessary repairs and changes at own expense.
Access panel shall be marked.

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8. WORKS NOT COVERED UNDER THIS CONTRACT

Following works are excluded from the scope under this contract. These shall be
executed by respective contractor in accordance with approved shop drawings where
these details must be highlighted. However, contractor shall be responsible for
providing details and thereafter supervision to ensure satisfactory & timely execution
of these associated items as they have a bearing on this contract.

9. OTHER SCOPE OF WORK

ASSOCIATED CIVIL WORKS

Following civil works associated with HVAC installation are Included In the scope of this
contract. These shall be executed by agencies in accordance with approved shop
drawings of and under direct supervision of the Project In charge

For Civil Scope of work refer BOQ.

ELECTRICAL SERVICES WORKS

All associated ELECTRICAL WORKS listed below shall be in the scope of

Contactor. These shall be installed by Contractor in accordance with approved
shop drawings of, and under direct supervision of the Project In charge/
Maintenance Team.

i. Providing power supply with earthing at the incoming of control panel in

VRV outdoors.

10. TESTING, ADJUSTING AND BALANCING

Air and water balancing shall be carried out by the contractor through a specialist team
(different than erection team) as per Specifications and ASHRAE Guide lines.
Performance test shall consist of three days of 10 hour each operation of system for
each season. The results for each season shall be submitted to Client
representative/Consultant. The submittal shall include operational parameters marked
on performance curves for each equipment along with test certificates and
safety/control settings.

The installation shall be tested again after removal of defects and shall be
commissioned only after approval by the Client’s site representative. All tests shall be
carried out in the presence of the representatives of the Construction Manager /
Architect /Consultant and Client’s site representative. After commissioning, the results
shall be submitted for scrutiny in quadruplicate.

All equipment The installation shall operate under all conditions of load without any
sound or vibration which is objectionable in the opinion of the Client’s site
representative. In case of rotating machinery sound or vibration noticeable outside the
room in which it is installed, or annoyingly noticeable inside its own room, shall be
considered objectionable. Such conditions shall be corrected by the Contractor at his
own expense. The contractor shall guarantee that the equipment installed shall
maintain the specified Noise Control levels.

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11. COMPLETION CERTIFICATE

On completion of the installation, a certificate shall be furnished by the contractor,

counter signed by the licensed supervisor, under whose direct supervision the
installation was carried out. This certificate shall be in the prescribed form as required
by the local authority.

The contractor shall be responsible for getting the entire installation duly approved by
the local authorities concerned, and shall bear expenses if any, in connection with the
same.

12. AS-BUILT DRAWINGS

Contractor shall submit following as-built drawings as and when work is completed:

 Six set of hard copies of all as-built drawings duly corrected and incorporating
any modifications during execution.
 Two set of pen drive containing the drawings.

The drawings shall provide plant room layouts, piping layouts, location of all concealed
accessories/piping, wiring diagram, control diagram, Single line diagram, control
schematic with detailed bill of materials, showing makes, types & description of all
components & accessories and sequencing of automatic controls and other services.

13. MAINTENANCE MANUAL

Upon completion and commissioning of works, the contractor shall submit a draft copy
of comprehensive operating instructions, maintenance schedule and log sheets for all
systems and equipment included in this contract. This shall be supplementary to
manufacturer’s operating and maintenance manuals. Upon approval of the draft, the
contractor shall submit four (4) complete bound sets of typewritten operating
instructions and maintenance manuals; one each for retention by Consultant and
Client’s site representative and two for Clients Operating Personnel. These manuals
shall also include basis of design, detailed technical data for each piece of equipment
as installed, spare parts manual and recommended spares for 4 year period of
maintenance of each equipment. The manuals shall include:

i. Description of the work carried out / installed.

ii. Operating instructions.
iii. Maintenance instructions including procedures for preventive maintenance.
iv. Manufacturers catalogues.
v. Spare parts list.
vi. Trouble shooting charts.
vii. Drawings
viii. Type and routine test certificates of major items.

Details of all the bought out item should be part of this maintenance manual.

14. ON SITE TRAINING

Upon completion of all work and all tests, the Contractor shall furnish necessary
operators, labor and helpers for operating the entire installation for such periods so as
to enable the Client’s staff to get acquainted with the operation of the system. During
this period, the contractor shall train the Client’s personnel in the operation,
adjustment and maintenance of all equipment installed.

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15. DEFECTS LIABILITY PERIOD

DLP shall be of 12 months as specified in the contract.

Complaints

The Contractor shall receive calls for any and all problems experienced in the
operation of the system under this contract, attend to these within 10 hours of
receiving the complaints and shall take steps to immediately correct any deficiencies
that may exist.

Repairs

All equipment that requires repairing shall be immediately serviced and repaired.
Since the period of Mechanical Maintenance runs concurrently with the defects liability
period, all replacement parts and labour shall be supplied promptly free-of-charge to
the Client.

16. UPTIME GUARANTEE

The contractor shall guarantee for the installed system an uptime of 98%. In case of
shortfall in any month during the defects liability period, the Defects Liability period
shall get extended by a month for every month having shortfall and no reimbursement
shall be made for the extended period.

17. OPERATION & MAINTENACE CONTRACT

Contractor may be required to carry out the operation of the installation during and
after the defects liability period. Further, it may also be required to carry out all-
inclusive maintenance of the entire system for a period of four years beyond the
defects liability period.

Operation Contract:

It will involve round the clock operation for 24 hours a day wherein work will include
but not limited to operation of installation, maintaining log books, complain register and
summary of operation.

The terms of payment shall be monthly at the end of each month on pro-rata basis.

All Inclusive Maintenance Contract:

The work will involve routine preventive maintenance with monthly status report. Entire
installation shall be painted every two years. 98% uptime of all systems is expected
under this contract wherein up time shall be assessed every month and in case of
shortfall during any month the contract shall be extended by a month. No
reimbursement shall be payable for the extended period.

Adequate number of persons to the satisfaction of the Client representative shall be

provided including relievers wherein statutory compliances such as of EPF, ESIC and
other applicable labour legislations shall be to contractor account. No overtime shall
be payable. Routine shut downs shall be permitted with prior permission of the Owner.

Payment shall be Quarterly at the beginning of each quarter on pro-rata basis.

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ANNEXURE- II
PART LIST OF CODES & STANDARDS

The installation in entirety shall comply with latest codes/standards published by Bureau of Indian
Standards (BIS) as well as local regulations from departments like Pollution Control Board,
Electrical inspectorate, Fire Authorities, Airport Authority of India (AAI), High rise committee, Indian
Electricity rules etc. Some of the standards are mentioned here below for reference:

ASHRAE Hand Books Systems & Equipment 2016.

Fundamentals 2017.
Refrigeration 2018.
Application 2019.

ASHRAE Standard 62.1-2019.

ASHRAE Standard 90.1-2019
ASHRAE Standard 55-2017
ASHRAE Standard 52.1 and 52.2

IEC
Energy Conservation Building code of
India -2017 (BEE)

IS : 277 - 2003 Galvanized steel sheet (Plain &

Corrugated) wire for fencing.

IS : 554 - 1985 (Reaffirmed 1999) Dimensions for pipe threads where

pressure tight joints are required on the
threads.

IS : 655 - 1963 (Reaffirmed 2006) Metal air ducts.

IS : 659 – 1964 (Reaffirmed 2012) Air conditioning (Safety Code)

IS : 660 – 1963 (Reaffirmed 2017) Mechanical Refrigeration (Safety Code)

IS : 694 - 1990 (Reaffirmed 2015) PVC insulated (HD) electric cables for
working voltage up to and including 1100
volts.

IS : 732 - 1989 (Reaffirmed 2019) Code of practice for electrical wiring.

IS : 780 - 1984 (Reaffirmed 1995) Sluice valves for water works purposes.

IS : 822-1970 (Reaffirmed 2003) Code of procedure for inspection of

welds.

IS : 1239 (Part - I) - 1990 (R2004) Mild steel tube

IS : 1239 (Part - II) - 1992 (R2011) Mild steel Tubular and other wrought
steel pipe fittings.

IS : 1255 – 1983 (R2016) Code of Practice for installation and

maintenance of Power Cables upto and
including 33 KV rating (Second Revision)

IS : 1554 - 1988 (Part – I) (R2012) PVC insulated ( Heavy Duty) electric cables
for working voltages pto and including
1100 volts.

IS : 1897 – 1983 (Reaffirmed 2016) Copper bus bar / strip for electrical purposes

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IS : 2379 – 1990 (R2006) Colour code for the identification of

pipelines.

IS : 2551 – 1982 (R2005) Danger notice plate

IS : 3043 – 1987 (R2018) Code of practice for earthing.

IS : 3103 – 1975 (Reaffirmed 2008) Code of practice for Industrial Ventilation.

IS : 3837 – 1976 (Reaffirmed 2017) Accessories for rigid steel conduit for
electrical wiring.

IS : 4736 – 1986 (Reaffirmed 1998) Hot-dip zinc coatings on steel tubes.

IS : 4894 - 1987 (R1999) Centrifugal Fan.

IS : 5133 - 1969 (Part-I) (Reaffirmed 1990) Boxes for the enclosure of electrical
accessories.

IS : 14772 - 2000 Guide for safety procedure and practices

in electrical work.

IS : 5312 (Part-I) - 1984 (Reaffirmed 2004) Swing - check type reflux Non
return valves for water works

IS : 15652 – 2006 Rubber mats for electrical purposes.

IS : 5578-1984 (R2016) Marking and identification of conductors

IS : 11353-1985 (R2017) Marking and identification of conductors

IS : 6392 – 1971 (Reaffirmed 2003) Steel pipe flanges.

IS : 8623 Part 01 – 1993 (R2004) Low voltage switchgear and control gear
Assemblies (Requirement for type / partly
type tested assemblies)

IS : 8623 Part 02 - 1993 Bus Bar trunking system

IS : 8828 – 1996 (R2006) Circuit Breakers for over current protection

For house hold and similar installation.

IS : 9537 Part 02 – 1981 (R2003) Conduit for Electrical Installation

IS : 10810 - 1988 Methods of test for cables.

IS : 13947-1993 (Part-I) (R2004) General rules for low voltage switch gears
and control gears.

IS : 13947-1993 (Part-II) (R2004) Circuit Breakers

IEC 947 - 2

IS : 13947 - 1993 (Part-III) (R2004) Switches, disconnectors and fuse

for low voltage switch gear and control gear.

IS : 13947 - 1993 (Part-IV) (R2004) Low voltage switch gear and control gear
for contactors and motor starters

IS : 13947 – 1993 (Part-V) (R2004) Control Circuit Devices.

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Annexure-III
(List of Approved Makes)

S. No Equipment/Material Approved Manufacturer Name

1. VRV ODU & RCBO Panel Daikin
Mitsubishi
LG
Samsung
2. AHRI Certified CHW/DX Coils Zeco
Edgetech
Systemair
3. Copper Piping Mandev
RR shramik
Rajco
Totalline.
4. Tube/Duct Nitrile Rubber Insulation Armacell
ALP Aeroflex
Superlon

5. GI Sheets Bhushan
Jindal
SAIL
TATA
6. MS Piping APL Apollo
Jindal Hissar
Prakash Surya
Tata Steel

7. Butterfly Valve/ Balancing Audco

VTM
Advance
Castle
8. Pressure Independent Balancing Belimo
Valves Flowcon
Danfoss
Siemens
9. Pressure Gauge/Air Vent Emerald
Fiebig
H Guru
10. Thermometer Emerald
Fiebig
H Guru
11. Volume Control Dampers System air
Greenheck

12 Modular Support for VRV ODU Hilti

Fischer
Walraven
13. Vibration Isolator Hilti
Fischer
Walraven
14. Anchor Fasteners Hilti
Fischer
Walraven

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15. MCB/RCCB/ MCCB/ MPCB Siemens

Schneider
L&T
ABB
Hager
16. Indicating Lamps LED type and Push Schneider
Button Siemens
ESBEE
Teknik Vaishno

17 Cables Polycab
KEI
Havell’s
Bonton
RR Kabel
18 Termination kits 3M
Raychem
19 Double Compression Cable Glands Dowells
with earthing links Comet
20 Bimetallic Cable Lugs Dowells
Comet
Cosmos
21 PVC Insulated FRLS Wires Polycab
KEI
Havell’s
Bonton
RR Kabel
22 Cable Trays & Raceways Ricco
MEM
Profab
23 Metal Conduit & Accessories BEC
AKG

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ANNEXURE-IV
TECHNICAL SPECIFICATIONS

1. VARIABLE REFRIGERANT VOLUME SYSTEM (VRF)

1.1 Scope

The scope of this section comprises the supply, erection testing and commissioning of
Variable Refrigerant Volume System conforming to these specifications and in accordance
with the requirements Schedule of Quantities.

1.2 Type

Compressor installed in outdoor unit shall be equipped with inverter controller, and capable
of changing the rotating speed to follow variations in cooling and heating load.

Outdoor unit shall be suitable for mix match connection of all type of indoor units.

The refrigerant piping between indoor units and outdoor unit shall be extended up to 150m
with maximum 50m level difference without any oil traps.

Both indoor units and outdoor unit shall be factory assembled, tested and filled with first
charge of refrigerant before delivering at site.

1.3 Outdoor Unit

The outdoor unit shall be factory assembled, weather proof casing, constructed from heavy
gauge mild steel panels and coated with baked enamel finish. The unit should be
completely factory wired , tested with all necessary controls and switch gears:

All outdoor units shall have 100% Inverter compressors with minimum COP of 3.7 and be
able to operate even in case one of compressor is out of order.

In case of outdoor units with multiple compressors, the operation shall not be disrupted
with failure of any compressor.

It should also be provided with duty cycling for switching starting sequence of multiple
outdoor units.

The noise level shall not be more than 65 dB(A) at normal operation measured horizontally
1m away and 1.5m above ground level.

The outdoor unit shall be modular in design and should be allowed for side by side
installation

The unit shall be provided with its own microprocessor control panel.

The outdoor unit should be fitted with low noise, aero spiral design fan with large airflow
and should be designed to operate compressor linking technology. The unit should also be
capable to deliver 55 Pa external static pressure to meet long exhaust duct connection
requirement.

1.4 Compressor

The compressor shall be highly efficient scroll type and capable of inverter control. It shall
change the speed in accordance to the variation in cooling or heating load requirement:

The inverter shall be IGBT type for efficient and quiet operation.

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All outdoor units shall have at least 10 steps of capacity control to meet load fluctuation
and indoor unit individual control. All parts of compressor shall be sufficiently lubricated
stock. Forced lubrication may also be employed.

Oil heater shall be provided in the compressor casing.

1.5 Refrigerant circuit

The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid valves at
condenser end.

1.6 Safety Services

All necessary safety devices shall be provided to ensure safe operation of the system.

Following safety devices shall be part of outdoor unit; high pressure switch, fuse,
crankcase heater, fusible plug, over load relay, protection for inverter, and short recycling
guard timer.

1.7 Oil Recovery System

Unit shall be equipped with an oil recovery system to ensure stable operation with long
refrigeration piping lengths.

2. Coil Chilled/DX Coil.

The Chilled water/ DX coils shall be selected complying with following parameters:

a. Material of coil : Copper or Aluminum tubes

b. Dia of coil : Ranging from 12.5 to 15 mm (O.D)
c. Minimum thickness of coil : 0.4 mm.
d. Material of Fins : Aluminum
e. Fin spacing : 4 - 5 fins per cm
f. Maximum air velocity across the coil : 150 meters per minute (500 fpm)
g. Water pressure drop in coil : Not exceeding 10 PSIG (0.70 kg/sq cm)
h. Material of Coil frame : Stainless Steel
i. Test Pressure of Coil : Hydraulically tested @ 21 kg/sqcm air pressure.
j. Certification : AHRI/Eurovent

The material of header shall be copper and both supply & return connections shall be with
dielectric coupling or adapter for connection with MS pipes. For air purge, a purge valve
shall be provided and discharge shall be routed to the condensate drain pan by means of
flexible PVC tubing. Purge valve shall be easily accessible.

The row depth for coils shall be as follows until unless specified otherwise in drawings/bill
of quantity.

S.No Application Coil Row Depth

1. Ceiling mounted AHU with pre-cooled ventilation air 4

2. Ceiling mounted AHU with untreated ventilation air 6

3. Floor Mounted AHU 6

4. Treated Fresh Air Units 8

5. Hot Water /Reheat Coil 2

Computerized cooling coil selection output shall be provided at the Technical submittal
stage.

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3. PIPING

3.1 Scope

The scope of this section comprises the supply and laying of pipes, pipe fittings and
valves, testing and balancing of all water and refrigerant piping required for the complete
installation as shown on the Drawings. All piping inclusive of fittings and valves shall
follow the applicable Indian Standards.

3.2 Pipe Sizes

Pipe sizes shall be as required for the individual fluid flows. Various pipe sizes have
been indicated on the Drawings, these are for Contractor’s guidance only and shall not
relieve contractor of responsibility for providing smooth noiseless balanced circulation of
fluids.

3.3 Chilled, Hot and Condensing Water Piping

Following material shall be used for pipes and fittings.

Pipes Nominal size (mm) Material Specification

<150 IS 1239 Part-1
200 and above IS 3589 Gr. FE 410 (8mm thick)
Fittings Nominal size (mm) Material Specification
<40 Socket welded, ASTM A105 construction as per ANSI
B16.11
50-150 Butt welded, ASTM A234 Gr. WPB as per ANSI B16.11
>200 Site fabricated from IS 3589 Gr. FE 410 (8mm thick)
Flanges Nominal size (mm) Material Specification
< 150 IS 2062 Gr.A construction as per ANSI B16.5
> 200 IS 2062 Gr.A, construction as per ANSI B16.5

a. All jointing in the pipe system shall generally be by welding, unless

otherwise mentioned, or directed at site. All welding shall be done by qualified
welders and shall strictly conform to BIS Code of practice for manual metal arc,
welding of Mild Steel.

Out of three weld one butt weld of each welder shall be fully radiographed for
testing purposes. Upon approval of welding joints the concerned welder shall be
allowed to carry further welding of pipes. Rest of the welds shall have 100% visual
inspection.

b. All welded joints (except pipe welded end-to-end) shall be made by use of one-
piece welding flanges, caps, nozzles, elbows, branch outlets and tees of approved
make. Cut samples shall be submitted for approval, if directed. All such fittings
etc., shall be of a type which maintain full wall-thickness at all points, simple
radius and fillets, and proper bevels or shoulders at ends. All job welding shall be
done by the electric arc welding process in accordance with the following:

 All joints shall have 45 degree bevel type, pipe mill-bevelled or machine-
bevelled by the contractor.

 All scale and oxide shall be removed with hammer, chisel or file and bevel left
smooth and clean.

 Pipe lengths shall line up straight with abutting pipe ends concentric.

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 Both conductors from the welding machine shall be extended to locations at

which welding work is being done. The leads from welding machine to location
of welding work shall be held together with tape or other approved means so as
to prevent induced current in structural steel, in piping or in other metals within
the building. The ground lead shall be connected to length of pipe through
joints in pipe, structural steel of building or steel pipe supports.

c. All pipes and their steel supports shall be thoroughly cleaned and given one
primary coat of red oxide paint before being installed. For vibration isolators
pre-molded polyurethane pipe sections of 160 Kg/m3 density with adhesive shall
be fixed between pipe and MS support. 10 mm thick MS ‘U’ clamp with resistoflex
shall be fixed on the pipe so that the pipe is kept in position. All welded piping
shall be subject to the approval at site. All supports exposed to ambient shall be
painted with two coats of epoxy. For condenser water piping running exposed to
ambient, 2 coats of Epoxy paint shall be applied over piping . Then One coat of
zinc chromate primer shall be applied. Finally color painting shall be provided as
per specification in identification of services.

d. Fittings shall be malleable casting of pressure rating suitable for the piping
system. Fittings used on welded piping shall be of the weldable type. These shall
form part of piping and are not separately identified in Schedule of Quantities.

e. Tee-off connections shall be through equal or reducing tees, otherwise ferrules

welded to the main pipe shall be used. Drilling and tapping of the walls of the main
pipe shall not be resorted to.

3.4 Cold Water and Drain Piping

a. All pipes to be used for cold water (makeup), drain, condensate drain and
fittings shall be GI / U-PVC as indicated in SOQ.

b. All jointing in the pipe system shall be by screwed joints and/or by

screwed flanges using 3 mm 3 ply rubber insertion gaskets. Pipe threads and
flanges shall be as per relevant BIS Codes.

c. All pipes supports shall be mild steel, thoroughly cleaned and given one
primary coat of red oxide paint before being installed.

d. Fittings shall be galvanized steel `medium class’ malleable casting of

pressure rating suitable for the piping system. Supply of flanges shall include
bolts, nuts, gaskets as required. Sufficient number of flanges and unions shall
be provided for future cleaning and servicing of piping. Tee-off connection shall
be through equal or reducing tees. All equipment and valve connections, or
connections to any other mating pipes shall be through flanges required for
the mating connections. Fittings & flanges shall form part of piping and are not
separately identified in Schedule of Quantities.

e. Gate valves, globe valves, check valves and strainers shall be similar to
those specified for chilled, condensing and hot water piping.

f. For proper drainage of AHU Condensate, ‘U’ trap shall be provided in the drain
piping.

g. All condensate drain piping shall be insulated and painted as per the section
“Insulation” as indicated in Schedule of Quantities.

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3.5 Refrigerant Piping

a. All refrigerant pipes and fittings shall be hard drawn copper tubes and wrought
copper / brass fittings suitable for connection with silver solder / phos-copper.

b. All joints in copper piping shall be sweat joints using low temperature brazing
and / or silver solder. Before joining any copper pipe or fittings, its interiors shall be
thoroughly cleaned by passing a clean cloth via wire or cable through its entire
length. The piping shall be continuously kept clean of dirt etc. while constructing
the joints. Subsequently, it shall be thoroughly blown out using carbon dioxide /
nitrogen.

c. Refrigerant lines shall be sized to limit pressure drop between the evaporator
and condensing unit to less than 0.2 kg per sq.cm.

d. Sight glass with moisture indicator and removable type combination dryer cum
filter with MS housing and brass wire mesh / punched brass sheet shall be
installed in liquid line of the refrigeration system incorporating a three valve by
pass. After ninety days of operation, liquid line drier cartridges shall be replaced.

e. Heat exchanger shall be MS heavy duty pipe in pipe type and without any joint in
the inner pipe.

f. Horizontal suction line shall be pitched towards the compressor and no reducers
shall be provided for proper oil return.

g. After the refrigerant piping installation has been completed, the refrigerant
piping system shall be pressure tested using Freon mixed with nitrogen /
carbon dioxide at a pressure of 20 kg per sq. cm (high side) and 10 kg per sq.
cm (low side). Pressure shall be maintained in the system for a minimum of 12
hours. The system shall then be evacuated to a minimum vacuum of 70 cm of
mercury and held for 24 hours. Vacuum shall be checked with a vacuum gage.

h. All refrigeration piping shall be installed strictly as per the instructions and
recommendations of air conditioning equipment manufacturer.

3.6 Piping Installation

a. Design Drawings indicate schematically the size and location of pipes. The
Contractor, on award of the work, shall prepare detailed shop drawings, showing
the cross-section, longitudinal sections, details of fittings, locations of isolating
and control valves, drain and air valves, and all pipe supports. He must keep in
view the specific openings in the building through which pipes are designed to
pass.

Pipe shall be cut only with hack saw blades and welding rods shall not be used for
this purpose. All the pipes shall be cleaned and applied with one coat of Zinc
chromate primer.

b. Piping shall be properly supported on, or suspended from, stands, clamps,

hangers as specified and as required. The Contractor shall adequately design all
the brackets, saddles, anchors, clamps and hangers and be responsible for their
structural sufficiency.

All pipes in HVAC plant room shall be supported with pipes and channels from
floor only with necessary PUF pipe supports and Resistoflex sheet.
c. Pipe supports shall be of steel, adjustable for height and Zinc chromate primer
coated and finish coated black. Where pipe and clamps are of dissimilar
materials, a gasket shall be provided in between.

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Spacing of pipe supports shall not exceed the following :

__________________________________________________________
Pipe size Spacing between supports Rod Size
___________________________________________________________

Upto 12 mm 1.5 Meter 10 mm

15 to 25 mm 2.0 meter 10 mm

30 to 150 mm 2.0 meter 10 mm

Over 150 mm 2.5 meter 12.5 mm

d. Vertical pipes passing through floors shall be plumb and parallel to wall. Pipes
shall be supported on alternate floor. MS cleats shall be welded on pipes and rest
on MS channel placed on the floor with 15 mm thick Resistoflex pads between the
cleat and channel. U clamps with Resistoflex sheet shall be provided to keep the
pipe in position.

e. Bull heading in water/refrigerant piping shall be avoided.

f. Pipe sleeves at least 3 mm thick, 50 mm / 100 mm larger in diameter than

condenser / chilled water pipes respectively shall be provided wherever
pipes pass through retaining wall and slab. Annular space shall be filled with
fiber glass and finished with retainer rings welded on the ends of the sleeve.

g. Wherever pipes pass through the brick or masonry / slab openings, the gaps shall
be sealed with fire sealant such as fire barrier caulks.

h. Insulated piping shall be supported in such a manner as not to put undue

pressure on the insulation. 20 gage metal sheet shall be provided between the
insulation and the clamp, saddle or roller, extending at least 15 cm on both sides
of the clamp, saddles or roller.

j. All piping work shall be carried out in a workmen like manner, causing minimum
disturbance to the existing services, buildings and structure. The entire piping
work shall be organized, in consultation with other agencies work, so that
laying of pipes, supports, and pressure testing for each area shall be carried out
in one stretch.

k. Cut-outs in the floor slabs for installing the various pipes are indicated in the
Drawings. Contractor shall carefully examine the cut-outs provided and clearly
point out where the cut-outs shown in the Drawings do not meet with the
requirements.

l. The Contractor shall make sure that the clamps, brackets, clamp saddles and
hangers provided for pipe supports are adequate. Piping layout shall take due
care for expansion and contraction in pipes and include expansion joints where
required.

m. All pipes shall be accurately cut to the required size in accordance with relevant
BIS Codes, edges beveled and burrs removed before laying. Open ends of the
piping shall be closed as the pipe is installed to avoid entrance of foreign
matter. Where reducers are to be made in horizontal runs, eccentric reducers shall
be used for the piping to drain freely. In other locations, concentric reducers
may be used.

n. Flanged inspection pieces 1.5 meters long, with bolted flanges on both ends, shall
be provided no more than 30 meters centers, or where-ever shown in
Approved-for-Construction shop drawings, to facilitate future cleaning of all welded
pipes.

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o. All buried pipes shall be cleaned and coated with zinc chromate primer and
bitumen paint, and placed on concrete blocks with PUF saddles dipped in
bitumen at every 2 meters and wrapped with three layers of fiber glass tissue,
each layer laid in bitumen.

q. Auto purge valves shall be provided at all highest points in the piping system for
venting air. Air valves shall be 15 mm pipe size with screwed joints.

Discharge from the air valves shall be piped through an equal sized mild steel or
galvanized steel pipe to the nearest drain or sump. These pipes shall be
pitched towards drain points.

r. Whenever services like piping, ducting and cabling are passing through floor slab,
shaft or fire zone wall, opening around services shall be closed with fire retardant
material. Contractor shall use either fire compound or fire barriers for this purpose.
Fire compound shall be in form of powder and shall be mixed with water in
proportion suggested by OEM. Mixed compound shall be poured in shuttering and
grid of 30 x 30 x 1.2mm angles placed as 150mm center to center. Minimum
thickness of pour shall be 100mm and shall be for fire integrity of 120minutes.
Angles shall be securely welded to building re-bars ( if left during construction) or
fastened to concrete floor.

Fire barrier shall be in form of high density rock wool slabs with surface treated for
fire retardation. Minimum thickness of the slab shall be 100mm and shall be for fire
integrity of 120 minutes. Slabs shall be tightly friction fitted in the shaft to cover all
open spaces.

Measurement will be on area basis of applied projected area (in m2 / ft2).

3.7 Pressure Gauges and Thermometers

a. Pressure gages shall be stainless steel and shall be provided at suction and at
discharge of each pump, at chilled water supply and return at each air handling
unit, at each chillers and condenser, and as shown on the Drawings and
included in Schedule of Quantities. Care shall be taken to protect pressure
gages during testing.

Pressure gage sockets on insulated pipes and accessories shall be extended upto
insulation to avoid damage of insulation for replacement of gages. Pressure
gauges shall be provided with ball valve and syphon tube.

b. Thermometers shall be stainless steel and shall be provided at chilled water

supply and return at each air handling unit, at each chiller and condenser, and
as shown on Drawings and included in Schedule of Quantities.

c. Thermometers on CHW lines shall be with long stem. Thermometer socket shall
be extended up to insulation thickness so that the thermometer shall be removable
without damaging the insulation.

3.8 Valves

a. Ball and butterfly valves conforming to the following specifications shall be

provided as shown on Drawings :

-------------------------------------------------------------------------------------------------------
Size Construction Ends Type
-------------------------------------------------------------------------------------------------------
15 to 40 mm Forged Brass Screwed Ball

50 mm and over Body Cast iron, Wafer Butterfly

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Type and requirements shall be as indicated in Schedule of Quantities. Valves

shall have non-rising spindles unless specified otherwise and shall be suitable
for PN 16 (unless specified otherwise in SOQ) rating. Butterfly valve should be of
wafer type long neck construction single stem design with center lugs to ensure
proper alignment of pipe flanges. Mount valve onto flanges only after flanges have
been welded to pipes using a tool piece and cooled down to room temperature to
prevent damage to resilient seat. The rubber liner should be fully supported by the
valve flanges. Appropriate dimensions and thickness of Flanges and Bolts, as per
the Flange Tables ANSI B16.5 should be used. The flanges should be properly
aligned with each other so that bolts are exactly perpendicular to the flanges.
Evenly tighten the flange bolts to secure the valves. Counter flanges with nut-bolts
and gaskets shall be provided by valve manufacturer.

b. Butterfly valves shall perform the function of isolating valves and shall be suitable
for PN 16 (unless specified otherwise in SOQ) rating. Butterfly valves shall have
Epoxy Coated cast iron body with Integrally molded EPDM liner of replaceable
type. The liner shall be integrally molded on hard backup ring and shall be suitable
for PN 16 (unless specified otherwise in SOQ) rating. All butterfly valves shall be
provided with locking devices. Valves 250 mm and above dia shall be gear
driven.

c. Automatic balancing valves shall automatically control flow rates within ± 5%

accuracy. Valve control mechanism shall consist of a stainless steel cartridge with
a ported cup and coil / helical spring to avoid corrosion. Four operating ranges
shall be available with the minimum range requiring less than 14 kPa to actuate
the mechanism. Manufacturer shall provide independent laboratory tests verifying
assurance of performance.

d. Balancing cum control valves shall be sized based on flow rates and pressure
drops across cooling coil.

e. Manual double regulating balancing valves shall be provided at chiller, condenser,

various tap-offs and each AHU outlet line as indicated in Schedule of Quantities.
These valves shall have built-in pressure-drop measuring facility to compute flow
rate across the valve. The test cocks shall be long enough to protrude out of
pipe insulation. To enable accurate and practical operation, measurement of flow
and differential pressure shall be made with a computerized balancing instrument
which shall enable the operator to read the flow directly without the use of
diagrams or tables. In addition to measuring flow rate, differential pressure and
temperature, computerized balancing instrument shall have a computer
Programme to provide the following functions:

i. To balance the HVAC installation and calculate the necessary valve

settings, based on system measurements.

ii. To store the results of balancing.

iii. To log measured values from a valve (differential pressure, flowrate or

temperature).

i. To printout saved data in computerized measurement protocol (CMP)

consisting of :

- Name and size of Balancing Valve (BV)

- Presetting position of BV
- P at BV
- Flow at BV
- Design Flow

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f. The supply of flanges shall form part of piping (not separately identified in
Schedule of Quantities) and shall also include supply of bolts, washers, nuts and
suitable asbestos fiber / rubber insertion gaskets (minimum 3 mm thick). Flanges
shall be as per ANSI B16.5.

g. All ball valves and ball valves with Y strainer shall be brass forged body
construction with chrome plated brass ball and handle of stainless steel
constructions. These are separately identified in Schedule of Quantities.

h. Non return valves shall be dual plate check valve provided as shown on the
Drawings, and identified in Schedule of Quantities conforming to relevant Codes
and in accordance with the following Specifications :

------------------------------------------------------------------------------------------------------
Size Construction Ends
------------------------------------------------------------------------------------------------------

40 to 300 mm Body: Grey Cast iron Flanged

(Epoxy Coated),
CI IS 210 Gr. FG 260
Plates: CF-8 (SS-304),
Hinge/Stop Pin: SS-410
Spring(s): SS-316.
Seal: EPDM

350 mm to 500 mm Body: Grey Cast iron Flanged

(Epoxy Coated),
CI IS 210 Gr. FG 260
Plates: SS-409.
Hinge/Stop Pin: SS-410
Spring(s): SS-316.
Seal: EPDM

The bearing shall be PTFE material. Valves shall be PN 16 (unless specified

otherwise in SOQ) rating.

3.10 Pressure Independent Balancing cum Control Valves

The Self balancing flow control valves that are pressure independent, 2-way, modulating to
accept Input signals from the control system. Each Air Handling Unit / Fan Coil Unit shall
be provided with a 2Way Pressure Independent Balancing and Control Valve integrated in
a single Body. Pressure Drop across the valve must not exceed 20 Kpa up to DN 32 and
30 Kpa in bigger Sizes. The valve should be a Globe Type. Diaphragm (not cartridge)
based delta p controller should ensure 100% valve authority & linear characteristics at all
loads and all settings. Regarding Control - Valve should be equipped with electronic
modulating gear type (not rotary /thermal or Wax) actuator which can accept either “4(0)-
20 mA / 2(0)-10V DC signals. Operating voltage for actuator shall be 24V AC.

All Valve actuators should be microprocessor based with self-calibrating feature.

Valve Actuator combination should be able to give logarithmic control characteristics to
achieve linear control. Actuator shall be able to work against pump head or maximum
closing pressure. Manual Override Flow Balancing should only be done in Valve, not in
actuator and should not involve opening of actuator Body.

Regarding Balancing – Each Valve should have a step less adjustable maximum flow
limitation as per the designed flow rate of coils. The balancing should be done only in the
valve not in the actuator so that in case of actuator failure the balancing is not lost and
easily accessible.

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Valve specifications :

Description For 15 to 32 mm For 40 to 250 mm

Diff Pressure (P1-P3) 16 To 400 kPa 30 To 400 kPa
Media Temperature -10 ° to 120 °C, to 248 °F -10 ° to 120 °C, to 248 °F
Body Material Brass (CuZn40Pb2 - CW 617N) Grey iron EN-GJL-250(GG25)
Test Ports Needle measuring nipple Needle measuring nipple
Leakage acc. to standard
No visible leakage (at 100N) max.0,01 - 0.05% of kv at 650N
IEC 534
Stem Seals EPDM - CuZn40Pb2 - CW 617N EPDM -NBR
Maximum Close Off Pr 1600 kPa, 1600 kPa,
Pressure rating PN16 PN16
Control Range Standard IEC 534 Since CV Characteristic is Linear Control Range is Infinity
Control Valve Character Valve Actuator combination should be able to give logarithmic control
characteristics to achieve linear control

Actuator specifications :
For Valve Sizes 15- 32mm 40- 100mm 125-150mm
Actuator Type Modulating Modulating Modulating
Supply Voltage 24Volt AC 24Volt AC/DC 24Volt AC
Frequency 50Hz/60 Hz 50Hz/60 Hz 50Hz/60 Hz
Power Consumption 2VA 4.5 VA 9VA
Close of Force 130N 400N 2000N
Maximum Stroke 5mm 20mm 40mm
Speed 24 Seconds/mm 15Seconds/mm 8Seconds/mm
Protection IP42 IP54 IP54
Body Non Corrosive Actuator Body
Weight 0.1Kg 0.45Kg 3.8Kg

3.11 Testing

a. During construction , the contractor shall properly cap all lines, so as to prevent the
entrance of sand, dirt, etc. Each system of piping shall be flushed thoroughly after
completion (for the purpose of removing dirt, grit, sand etc. from the piping and
fittings) for as long a time as is required to thoroughly clean the system.

b. All piping shall be tested to hydrostatic test pressure of at least two times the
maximum operating pressure, but not less than 10 kg per sq. cm gage for a
period of not less than 24 hours. All leaks and defects in joints revealed during
the testing shall be rectified, retested and gotten approved

c. Piping repaired subsequent to the above pressure test shall be re-tested in the
same manner.

d. Piping may be tested in sections and such sections shall be securely capped,
then re-tested for the entire system.

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e. The Contractor shall give sufficient notice to all other agencies at site, of his
intention to test a section or sections of piping and all testing shall be witnessed
and recorded by Owner’s site representative.

f. The contractors shall provide temporary pipe connections to initially by-pass

condenser/chiller and circulate water through condenser/chilled water pipe lines
for minimum 8 hours. Water should be drained out from the lowest point. The
temporary lines shall be removed and blanked with dead flanges. Pot strainers
and Y strainers shall be cleaned and fresh water filled in the circuits.

g. After regular flushing, as per ‘f’ above, all systems shall be chemically cleaned.
Chemical cleaning shall be carried out in 3 stages. In first stage biological cleaning
shall be done to remove algae, bacteria, SRB etc. which produces slimes. Second
stage is pre-cleaning in which loose rust, oil, and debris are removed. Chemical
addition and hold up time shall be as per chemical supply agencies
recommendations. Third stage is passivation, in which chemicals will be added
and passivation film will be formed over inside surfaces of piping system. Type of
chemical used and quantity of the same along with detailed method statement
shall be submitted by contractor for consultants’ approval before starting this
activity.

Before handover Owner’s site representative shall be provided with certificate of

cleaning of pipe systems, signed by the contractor.

h. After the piping has been installed, tested and run for at least three days of
eight hours each, all insulated exposed piping in plant room shall be given
two finish coats, 3 mils each of approved color, conforming to relevant BIS Codes.
The direction of flow of fluid in the pipes shall be visibly marked with identifying
arrows. For painting of insulated and clad pipes refer to Insulation section.

j. The Contractor shall make sure that proper noiseless circulation of fluid is
achieved through all coils and other heat exchange equipment in the system
concerned. If proper circulation is not achieved due to air bound connection,
the Contractor shall rectify the defective connections. He shall bear all expenses
for carrying out the above rectifications including the tearing up and re-finishing of
floors and walls if required.

k. The Contractor shall provide all materials, tools, equipment, instruments,

services and labour required to perform the test and to remove water resulting
from cleaning and after testing.

3.12 Balancing

a. After completion of the installation, all water system shall be adjusted and
balanced to deliver the water quantities as specified, quoted, or as directed.

b. All balancing valves, Automatic control valves and two-way diverting valves shall
be set for full flow condition during balancing procedure. Each water circuit
shall be adjusted thru balancing valves provided for this purpose; these shall be
permanently marked after balancing is completed, so that they can be restored to
their correct positions, if disturbed.

c. Complete certified balancing report shall be submitted for evaluation and

approval by Owner’s site representative. Upon approval, four copies of the
balancing report shall be submitted with the as-installed drawings and completion
documents.

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3.13 Valve Identification

Provide 30 mm dia brass valve tag, with embossed letters and number for each valve and
attach the tag to valve handle by “S” hook or by suitable means. Contractor shall provide
valve tag schedule and valve chart for each piping system, consisting of schematic
drawing of piping layout, along with a valve list, showing and identifying each valve by
number, service and location and describing its function.

The contractor shall frame under glass in the air-conditioning plant room or as directed by
Owner’s site representative two copies of valve chart. Two additional unmounted copies
shall be supplied to the Owner’s site representative.

Tags shall correspond with the valve schedule and record drawings. In back of house
areas, where ceilings are installed and the valve or valve tag is not visible, a self-adhering
tag with the valve number shall be installed on the wall or directly under the ceiling. For
public area ceiling valves, these tags are to be installed in the service corridor, leading to
the public areas.

3.14 Measurement for Piping

Unless specified otherwise, measurement for piping for the project shall be on the basis
of center line measurements described herewith.

Piping shall be measured in units of length along the center line of installed pipes
including all pipe fittings, flanges (with gaskets, nuts, and bolts for jointing), unions,
bends, elbows, tees, concentric and / or eccentric reducers, inspection pieces,
expansion loops etc. The above accessories shall be measured as part of piping length
along the center line of installed pipes, and no special multiples of pipe lengths for
accessories shall be permitted.

The quoted rates for center line linear measurements of piping shall include all
wastage allowances, pipe supports including hangers, MS channel, PUF supports, nuts,
check nuts, vibration isolator suspension where specified or required, and any other
item required to complete the piping installation as per the Specifications. None of these
items will be separately measured nor paid for.

However, all valves (gate / globe / check / balancing / purge / butterfly / drain etc.),
strainers, thermometers, pressure gages shall be separately counted and paid as per
their individual unit rates, which shall also include their insulation as per
Specifications. Piping measurements shall be taken before application of the insulation.

Contractor shall get pressure testing of pipes/measurements etc. verified by the Owners
representative at site.

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4.0 G.I DUCTING ( FACTORY/ SITE FABRICATED )

4.1 Raw Materials

Galvanized steel sheets with Class - VIII Galvanizing – light coating of zinc (Zinc coating
shall be Lead free), nominal 120gm/sq.m surface area and Lock Forming Quality prime
material along with mill test certificates. In addition, if deemed necessary, samples of raw
material, selected at random by owner’s site representative shall be subject to approval
and tested for thickness and zinc coating at contractor's expense.

4.2 Factory Fabricated Ducts

All ducts shall be factory fabricated from galvanized steel of the following thickness, as
indicated below : For Ducts with External SP up to 250 Pa

Rectangular External Pressure 250 Pa

Ducts G. S. Duct Section Length 1.2 m (4 ft)
Maximum Duct Size Gauge Joint Type Bracing Spacing
1–500 mm 26 C&S Connector Nil
501 – 750 mm 26 C&S Connector Nil
751 – 900 mm 26 TDF Flange Nil
901 – 1200 mm 24 TDF Flange Nil
1201 – 1500 mm 22 TDF Flange Nil
1501 – 1800 mm 22 TDF Flange JTR or ZEE BAR
1801 – 2100 mm 20 TDF Flange JTR or ZEE BAR
2101 – above 18 TDF Flange JTR or ZEE BAR

4.3 Site Fabricated Ducts

Rectangular Ducts G. S. External Pressure 250 Pa

Maximum Duct Size Gauge

1–75 cm 24

76 – 150 cm 22

151 – 225 cm 20

225 – above 18

FOR ALUMINUM DUCTS MATERIAL SHALL BE ONE COMMERCIAL GAUGE

HIGHER WITH 22 G AS MINIMUM

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4.5 Duct Construction

7.4.1 All ducts shall be fabricated and installed in workmanlike manner, conforming to
relevant SMACNA codes.

a) Ducts so identified on the Drawings shall be acoustically lined and insulated from
outside as described in the section “Insulation” and as indicated in schedule of
Quantities. Duct dimensions shown on drawings, are overall sheet metal
dimensions inclusive of the acoustic lining where required and indicated in
Schedule of quantities. The fabricated duct dimensions should be as per
approved drawings and care should be taken to ensure that all connecting
sections are dimensionally matched to avoid any gaps.

b) Ducts shall be straight and smooth on the inside with longitudinal seams shall be
airtight and at corners only which shall be either Pittsburgh or snap button as per
SMACNA practice, to ensure air tightness.

c) All ducts up to 75cms width within conditioned spaces shall have C&S connector.
The internal ends of slip joints shall be in the direction of airflow. Care should be
taken to ensure that Cleats are mounted on the longer side of the duct and Cleats
on the shorter side. Ducts and accessories within ceiling spaces, visible from air-
conditioned areas shall be provided with two coats of mat black finish paint.

d) Changes in dimensions and shape of ducts shall be gradual (between 1:4 and
1:7). Air-turns (vanes) shall be installed in all bends and duct collars designed to
permit the air to make the turn without appreciable turbulence.

e) Ducts shall be fabricated as per details shown on Drawings. All ducts shall be
rigid and shall be adequately supported and braced where required with standing
seams, tees, or angles, of ample size to keep the ducts true to shape and to
prevent buckling, vibration or breathing.

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f) All sheet metal connection, partitions and plenums, required to confine the flow of
air to and through the filters and fans, shall be constructed of 18 gauge GSS /
16gauge aluminum, thoroughly stiffened with 25mm x 25mm x 3mm galvanized
steel angle braces and fitted with all necessary inspection doors as required, to
give access to all parts of the apparatus. Access doors shall be not less than
45cm x 45cm in size.

g) Plenums shall be shop/factory fabricated panel type and assembled at site. Fixing
of galvanized angle flanges on duct pieces shall be with rivets heads inside i.e.
towards GS sheet and riveting shall be done from outside.

h) Self-adhesive Neoprene rubber / UV resistant PVC foam lining 5mm nominal

thickness instead of felt, shall be used between duct flanges and between duct
supports in all ducting installation.

i) All fire rated duct, smoke exhaust ducts shall be quoted with flame bar BWII or
equivalent to achieve the required fire rating also all the related accessories
gaskets shall be suitable for the required fire rating.

5. AIR DISTRIBUTION

5.1 Dampers

a. Dampers: All duct dampers shall be opposed blade louver dampers of robust 16
G GSS construction and tight fitting. The design, method of handling and control
shall be suitable for the location and service required.

b. Dampers shall be provided with suitable links levers and quadrants as required for
their proper operation. Control or setting device shall be made robust, easily
operable and accessible through suitable access door in the duct. Every
damper shall have an indicating device clearly showing the damper position at
all times.

c. Dampers shall be placed in ducts at every branch supply or return air duct
connection, whether or not indicated on the Drawings, for the proper volume
control and balancing of the air distribution system.

d. Pressure relief dampers: Pressure relief dampers shall be constructed with 18G
Aluminum construction with parallel blade construction. Leaf’s shall be 100% air
tight upon closure. Leaf’s shall be loaded with spring pressure of stiffness (k value)
corresponding to set point pressure.

Constant volume regulator shall be made of PVC. The range covers an air flow
range from 15 up to 1200 m³/h within a pressure range from 50 up to 600 Pa.

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6. INSULATION

6.1 Scope

The scope of this section comprises the supply and application of insulation
conforming to these specifications. The insulation material shall be Closed Cell
Elastomeric Nitrile Rubber or Polyethylene Foam XLPE.

6.2 Material

Thermal insulation material for Duct insulation shall be with factory laminated black fiber
glass cloth closed cell Nitrile rubber. Density of the nitrile rubber shall be 40-60 Kg/m3
or
Al foil faced polyethylene material (XLPE). Density of the polyethylene material shall be
25-30 Kg/m3

Thermal conductivity as per BS 874 part 2 – 86 (DIN 52613, 52612) / DIN EN 12667 / EN
ISO8497 of the insulation material shall not exceed 0.038 W/moK or 0.212 BTU / (Hr-ft2-
oF/inch) at an average temperature of 30oC. The product shall have temperature range of

–40 oC to 105oC. The insulation material shall be fire rated for Class 0 as per BS 476 Part
6 : 1989 for fire propagation test and for Class 1 as per BS 476 Part 7, 1987 for surface
spread of flame test. Water vapour permeability shall be not less than 0.024 per inch (2.48
x 10-13 Kg/m.s.Pa i.e. µ>7000: Water vapour diffusion resistance) as per DIN 53122 part 2,
DIN 52615 / EN 12086 & EN13469.

In addition to above properties the insulation material for ducts shall be anti-microbial.
Microbiological growth on insulation surface shall be in accordance with ASTM G-21 and
bacterial resistance to ASTM2180/ ISO22196.

The Material shall comply to ISO 5659 / BS 6853 / ABD 0031 for smoke density and
toxicity values. The thermal conductivity of insulation material shall not be effected by
aging as per DIN 52616 standard.

Thickness of the insulation shall be as specified for the individual application. Each lot of
insulation material delivered at site shall be accompanied with manufacturer’s test
certificate for density and thickness. Adhesive used for sealing the insulation shall be
non-flammable and with low VOC content (maximum 850 gm/l less water) as per IGBC
guide lines) strictly as per manufacturer’s recommendations. Adhesive shall be externally
applied by contractor on site.

Ducting insulation thickness shall be as per table below.

Ducting position Thk. for non-coastal places

SA duct in RA path 13 mm

Ducted return air system SA duct: 19 mm

RA duct: 13 mm
Both SA & RA exposed Both 25 mm

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6.3 Duct Insulation

External thermal insulation shall be provided as follows :

The thickness of insulation material shall be as shown on drawings or identified in the

schedule of quantity. Following procedure shall be adhered to:

Duct surfaces shall be cleaned to remove all grease, oil, dirt, etc. prior to carrying out
insulation work.
Measurement of surface dimensions shall be taken properly to cut closed cell insulation to
size with sufficient allowance in dimension. Cutting of insulation sheets shall be done with
adjustable blade to make 900 cut in thickness of sheet. Hacksaw or blades are not
acceptable tools for cutting the insulation.

Material shall be fitted under compression and no stretching of material shall be permitted.
All longitudinal and transverse joints shall be sealed by providing 50 mm wide Fibre glass
cloth laminated tape as per manufacturer recommendations. The insulation installers shall
be certified by manufacture.

Where ducts/pipes penetrates walls / floor it shall be insulated with intumescent

properties insulation material for fire protection. The treatment shall be minimum
500 mm extended on both sides.

6.4 Chilled water pipe insulation

Thermal insulation material for Pipe insulation shall be Elastomeric Nitrile Rubber with
factory laminated Non Metallic cladding system made up of double layer laminate of
Aluminum, coated with special UV protection and PVC backing. Thermal conductivity as
per DIN EN 12667 of the insulation material shall not exceed 0.038 W/moK or 0.212 BTU
/ (Hr-ft2-oF/inch) at an average temperature of 30oC. Density of the nitrile rubber shall be
40-55 Kg/m3,. The product shall have temperature range of –40 oC to 105oC. The
insulation material shall be fire rated for Class 0 as per BS 476 Part 6 : 1989 for fire
propagation test and for Class 1 as per BS 476 Part 7, 1987 for surface spread of flame
test. Water vapour diffusion resistance of the system i.e. µ value shall be greater than or
equal to 60000 as per EN 12086

Wherever double layered insulation is used, first layer shall be plain nitrile rubber and final
layer shall be factory laminated cladding system

Thickness of the insulation shall be as specified for the individual application. Each lot of
insulation material delivered at site shall be accompanied with manufacturer’s test
certificate for density and thickness. Samples of insulation material from each lot
delivered at site may be selected by Owner’s site representative and gotten tested for
thermal conductivity and density at Contractor’s cost. Adhesive used for sealing shall be
strictly as per manufacturer’s recommendations.

All chilled water, refrigerant, and condensate drain piping shall be insulated in the
manner specified herein. Before applying insulation, all pipe shall be brushed and
cleaned. All MS pipes shall be provided with a coat of zinc chromate primer. Thermal
insulation shall be applied as follows or as specified in drawings or schedule of quantity:

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Piping Insulation thickness shall be as follows;

Pipe nominal bore Thk. for non-coastal places Thk. for coastal places

15 mm – 25 mm 19 mm 25 mm

32 mm – 80 mm 25 mm 32 mm

100 mm – 400 mm 32 mm 38 mm

Above 400 mm 45 mm 45 mm

For the pipe sizes up to 100NB, insulation material in sleeve forms shall be used. These
sleeves shall have self-adhesive type longitudinal precut, throughout the length of the tube.
The top cladding layer shall have self-adhesive overlapping flap. Butt joints shall be
properly sealed with manufacturers adhesive and finally concealed with 50mm wide Silver
tape

Wherever flat sheets shall be used it shall also be factory laminated cladding type, and cut
out in correct dimension using correct tools. Scissors or Hacksaw-blade shall not be
allowed. All longitudinal and transverse joints shall be sealed by providing 50 mm wide
Silver tape as per manufacturer recommendations. The adhesive shall be strictly as
recommended by the manufacturer. The insulation shall be continuous over the entire run
of piping, fittings and valves. All valves, fittings, joints, strainers etc. in chilled water piping
shall be insulated to the same thickness as specified for the main run of piping and
application shall be same as above. Valves bonnet, yokes and spindles shall be insulated
strictly as per manufacturer’s application procedure. Cladding for the Bends, T Section,
Strainers and other pipe accessories shall be with the same cladding material in loose
form.

6.5 Refrigerant pipe insulation

Base insulation material for Refrigerant pipe shall be same as that of CHW pipe. The
factory lamination on the base material shall be of chemically treated blue colored glass
cloth of 7 mil thickness tested for UV resistance as per EN ISO 4892-2 Method-A.
Thickness of refrigerant piping insulation shall be 13mm and 19mm unless specified
separately.

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7.0 QUALITY ASSURANCE,INSPECTION, TESTING AND COMMISSIONING

7.1 SCOPE

The following quality assurance, inspection, testing and commissioning procedures shall
be required to be carried out upon award of work.

I. Provide quality assurance program (QAP), works quality assurance program

(WQAP), field quality assurance program (FQAP) and quality plan.

II. Tests at manufacturer’s works.

III. Perform site tests and commissioning.

7.2 SUBMITTALS

I. After award of work following information shall be submitted.

a. Quality Assurance Program (QAP)

b. Works Quality Assurance Programme (WQAP)
c. Field Quality Assurance Programme (FQAP)
d. Method Statement.

II. For inspection and testing, submit inspection and testing procedures, Programme,
record sheets applicable at each hold point.

III. After completion of testing, submit test records, packaging, transportation and
storage instructions and methods.

IV. For site installation and commissioning, submit installation methods or procedures,
notification and procedures for precommission and commissioning.

V. After commissioning, submit site test records, as-built drawings, manufacturer’s

operation maintenance manuals and list of recommended spares and tools.

7.3 QUALITY ASSURANCE CONCEPT AND CONTROL

I. Minimum requirements for establishing and implementing a quality assurance

Programme shall be applied to all aspects of the work necessary for carrying out
the contract. Quality assurance shall extend to material parts, components,
systems and services as a means of obtaining and sustaining the reliability of
critical items, operating performance, maintenance and safety.

II. Acceptance of the Contractor’s quality assurance Programme does not relieve the
Contractor’s obligation to comply with the requirement of the contract document. If
the Programme is found to be ineffective, then the Owner’s site representative
reserves the right to request for necessary revisions of the Programme.

III. The Contractor is required to produce readily identifiable documentary evidence

covering the extent and details of both his own and his sub contractor’s quality
assurances system as follows :

a. Quality Assurance Program (QAP)

b. Works Quality Assurance Programme (WQAP)
c. Field Quality Assurance Programme (FQAP)
d. Quality Plan.

IV. These documents shall be prepared separately and submitted to the Owner’s site
representative at the time of starting the work.

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V. Quality Plan and Manual shall be prepared by the Contractor for all items and
services to be supplied, after the contract has been placed, but before
commencement of fabrication, and shall be subject to evaluation and acceptance
by the Owner’s site representative before start of work.

7.4 QUALITY ASSURANCE MANUAL (QAM)

I. The QAM shall be a general comprehensive document outlining the Contractor’s

basic organization, policies and procedures. The information to be given in the
QAM shall include but not limited to :

a. Quality Policy.

b. Quality Assurance Programme

c. Organization Structure showing inter relationships.

d. Functional responsibilities and levels of authority.

e. Lines of communication.

f. Customer relations.

g. Laboratory Facilities.

7.5 WORKS QUALITY ASSURANCE PROGRAMME (WQAP)

I. The WQAP shall identify the Contractor’s Quality Assurance Programme at works
applicable throughout all phases of Contract performance, including design,
procurement, manufacture, inspection and testing. It shall identify each of the
Programme elements to be designed, developed, executed and maintained by the
Contractor for the purpose of ensuring that all supplies and services comply with
this specifications.

II. The information to be given under this Programme shall include but not limited to :

a. Organization and Responsibility.

b. Contract Review.

c. Design and Document Control.

d. Procurement Control.

e. Production Control.

f. Control on Sub-contractors.

g. In-process Quality Control and Traceability.

h. Inspection and Testing.

j. Control of Non-conformances.

k. Corrective Action.

l. Control of Inspection, Measuring and Test Equipment.

m. Handling, Storage, Packaging and Delivery.

n. Records.

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p. Quality Audits.
q. After - Sales Servicing.

7.6 FIELD QUALITY ASSURANCE PROGRAMME (FQAP)

I. This Programme shall identify the Contractor’s Quality Assurance Programme at

site applicable throughout site construction, erection and commissioning. It is the
underlying philosophy that the quality built into the product at works shall be
maintained throughout the construction and commissioning stages.

II. While, in principle, the FQAP shall include the items discussed in WQAP, it shall,
however, be approached differently to take into account site conditions.

III. The FQAP shall include, but not limited to the following information :

a. Organization and responsibility.

b. Control of Drawings and Documentation.

c. Product Checklist.

d. Control and Traceability of Purchased materials and services.

e. Receipt Inspection of materials at site.

f. Material Storage Control.

g. Inspection and Examination Procedures.

h. Control of Painting and Insulation Works.

j. Pre-commissioning.

k. Commissioning.

l. Control of Non-conformances.

m. Corrective Action.

n. Control of Inspection, Measuring and Test Equipment.

p. Records.

q. Complétion Documents.

r. List of recommended spares and tools.

s. Personal Training.

t. Servicing during Defects Liability Period.

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7.7 QUALITY PLAN

I. The contractor shall be required to prepare manufacturing and

construction/erection quality plans for all equipment items and services. The
quality plan shall also define the involvement of Owner’s site representative in the
inspection and test programs.

II. The Quality Plan shall incorporate as appropriate :

a. Charts indicating flow of materials, parts and components through

manufacturing quality control inspection and test to delivery and erection.

b. The charts shall indicate the location of hold points for quality control,
inspection and test beyond which manufacture shall not continue until the
action required by the hold point is met, and the documentation required is
generated.

c. The control documents associated with each hold point, i.e. drawings,
material, specification, Works Process Schedule (WPS), Process Quality
Records (PQR), quality control methods and procedures and acceptance
standards.

7.8 SITE QUALITY CONTROL SECTION

I. The Contractor’s Quality Control (Q.C.) section shall be headed by an experienced

Quality Control Engineer. He shall be assisted by other supervisors. The section
shall be an independent one, reporting to the contractor’s Site Manager only on
administrative matters, but otherwise under full control by the Contractor’s
Corporate Quality System Management.

II. The Contractor’s Q.C. Section shall liaise closely with the Owner’s site
representative in charge of Quality Assurance/Quality Control, and to whom it shall
give fullest cooperation. It is the underlying principle of this contract document that
while the Contractor’s Q.C. Engineer implements the Contractor’s Quality
Programme, the adequacy and effectiveness of that implementation shall be
audited by the Owner’s site representative whose recommendations on improving
or maintaining quality shall be acted upon promptly by the Contractor’s Q.C.
Section.

7.9 INSPECTION AND TESTING

I. All equipment and components supplied may be subjected to inspection and tests
by the Consultant/ Owner’s site representative during manufacture,
erection/installation and after completion. The inspection and tests shall include
but not be limited by the requirements of this contract document. Prior to
inspection and testing, the equipment shall undergo pre-service cleaning and
protection.

II. Tenderers shall state and guarantee the technical particulars listed in the
Schedule of Technical Data. These guarantees and particulars shall be binding
and shall not be varied without the written permission of the Owner’s site
representative.

III. No tolerances shall be allowed other than the tolerances specified or permitted in
the relevant approved Standards, unless otherwise stated.

IV. If the guaranteed performance of any item of equipment is not met and / or if any
item fails to comply with the specification requirement in any respect whatsoever at
any stage of manufacture, test or erection, the Owner’s site representative may
reject the item, or defective component thereof, whichever he considers
necessary; and after adjustment or modification as directed by the Owner’s site

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representative, the contractor shall submit the item for further inspection and /or
test.

V. The approval of the Owner’s site representative of inspection and/or test results
shall not prejudice the right of the Owner’s site representative to reject an item of
equipment if it does not comply with the contract document when erected, does
not or prove completely satisfactory in service.

VI. The Contractor shall be responsible for the timely transmission of the relevant and
appropriate sections of the contract document to manufacturers and sub-
contractors for the proper execution of all tests at their works as per contract
specifications.

7.10 TESTS AT MANUFACTURER’S WORKS

I. All tests to be performed during manufacture, fabrication and inspection shall be

agreed with the Consultant/ Owner’s site representative prior to commencement of
the work. The Contractor shall prepare the details of the schedule and submit
these to the Consultant/ Owner’s site representative for approval. It must be
ensured that adequate relevant information on the design code/standard
employed, the manufacture /fabrication/assembly procedure and the attendant
quality control steps proposed are made available to the Consultant/Owner’s site
representative who will mark in the appropriate spaces his intention to attend or
waive the invited tests, or inspections. Contractor shall arrange inspection and
factory witness test for centrifugal, screw chiller and vapor absorption chiller.

II. A minimum of twenty-one days’ notice of the readiness of equipment for test or
inspection shall be provided to the Owner’s site representative by the Contractor
(whether the tests be held at the Contractor’s of Sub-contractor’s works). The
subject items should remain available for Owner’s site representative inspection
and test up to a minimum 10 days beyond the agreed date of witnessing the test.
Every facility in respect of access, drawings, instruments and manpower shall be
provided by the Contractor and sub-contractor to enable the Owner’s site
representative to carry out the necessary inspection and testing of the Plant.

III. No plant shall be packed, prepared for shipment, or dismantled for the purpose of
packing for shipment, unless it has been satisfactorily inspected, all tests called for
have been successfully carried out in the presence of the Owner’s site
representative or approved for shipment, or alternatively inspection has been
waived.

IV. Functional electrical, mechanical and hydraulic tests shall be carried out on
completed assemblies in the works. The extent of these tests and method of
recording the results shall be submitted to, and agreed by, the Owner’s site
representative in sufficient time to enable the tests to be satisfactorily witnesses, or
if necessary for any changes required to the proposed Programme of tests to be
agreed.

V. The Consultant/Owner’s site representative reserves the right to visit the

Manufacturer’s works at any reasonable time during fabrication of equipment and
to familiarize himself with the progress made and the quantity of the work to date.

VI. Within 30 days of completion of any tests, triplicate sets of all principal test
records, test certificates and correction and performance curves shall be supplied
to the Owner’s site representative.

VII. These test records, certificates and performance curves shall be supplied for all
tests, whether or not they have been witnessed by the Owner’s site representative
or not. The information given on such test certificates and curves shall be sufficient
to identify the material or equipment to which the certificate refers and should also
bear the Contract reference title.

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VIII. When all equipment has been tested, the test certificates from all works and site
tests shall be compiled by the Contractor into volumes and bound in an approved
from complete with index and four copies of each volume shall be supplied to
Consultant/ Owner’s site representative.

IX. Stage wise inspection of equipment in factory in waived.

7.11 PERFORMANCE TESTS AT MANUFACTURER’S WOKS

I. All equipment may be subjected to routine performance tests at the Manufacturer’s

Works in accordance with the relevant ANSI, ASME, ASTM, BIS standard
including operating tests of complete assemblies to ensure correct operation of
apparatus and components.

II. Pumps, fans, compressor, and other rotating equipment shall be given full load
tests, and run to 15% over speed for 5 minutes to check vibration. Main and
auxiliary gear boxes shall be subjected to shock load tests and a six-hour
endurance run at rated speed and maximum torque.

III. The Contractor shall submit single line diagrams including the layout of the Plant
together with the location of test instrumentation and the principal dimensions of
the layout. All calculations to derive performance data shall be made strictly in
accordance with format given in the approved standards. Any alterations or
deviations from the approved standard test layout or formulae shall be subjected
to the prior approval of the Owner’s Site Representative.

IV. The performance test shall be conducted over the full operating range of the pump
to a closed valve condition and a minimum of five measurement points covering
the full range shall be taken. Curves indicating Quality vs. Head, Quantity vs.
Power absorbed, and Quantity vs. Pump efficiency shall be provided. In addition a
curve of the NPSH required vs. Quantity shall be provided except when the
suction conditions do not require this test. Any proposal for the omission of this
test shall be to the approval of the Consultant/ Owner’s site representative.

V. On completion of the tests the Contractor shall submit a report showing the test
results obtained together with the curves corrected to the site operating conditions.

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8.0 TESTING, ADJUSTING AND BALANCING

8.1 SCOPE

a. Testing, adjusting and balancing of air-conditioning systems at site.

b. Testing, adjusting and balancing of HVAC Hydronic system at site.

Comply with current editions of all applicable practices, codes, methods of

standards prepared by technical societies and associations including :

ASHRAE : 2011 HVAC Application.

SMACNA : Manual for the Balancing and Adjustment of air

distribution system.

8.2 PERFORMANCE

a. Verify design conformity.

b. Establish fluid flow rates, volumes and operating pressures.

c. Take electrical power readings for each motor.

d. Establish operating sound and vibration levels.

e. Adjust and balance to design parameters.

f. Record and report results as per the formats specified.

8.3 DEFINITIONS

a. Test : To determine quantitative performance of

equipment.

b. Adjust : To regulate for specified fluid flow rates and air

patterns at terminal equipment (e.g. reduce fan speed,
throttling etc.)

b. Balance : To proportion within distribution system

(submains, branches and terminals) in accordance with design
quantities.

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