PROVISION OF CENTRAL AIR CONDITIONING PLANT FOR BUILDING NO P-154 AND P-194 AT NAVAL DOCKYARD MUMBAI

Amount

Dismantling the existing AC Plant, 3x60TR (02 Running + standby ) including all connected items such as pump, cooling tower, duct, electric connection, compressor, control panel Air handling Unit, condenser, cooling tower ducting and other items etc. & handing over to user department within Naval Dockyard complete all as specified and as directed.

Material and labour for supply, installation, commissioning and testing of Chilled water type Air Conditioning plant duly designed by the bidder as per the technical bid submitted by the firm in Stage 1 and the correspondence with the relevant bidder as mentioned in this office letter No 8498/231 dated 08 Oct 2020 complete with all accessories all as specified in building No P-154 and P-194 for area hatched in the drawing and marked as AC to meet design parameters given in Annexure ‘I’ comprising of the following :-

(A) CHILLER UNIT- Water cooled screw Chillers meeting ECBC norms and AHRI certified having a capacity of 310 TR (min) with VFD (Variable frequency drive) starters of OEM make only with refrigerant circuit, having automatic capacity control, HP/LP and oil pressure cutouts, necessary insulation to chiller and refrigerant pipe and Squirrel cage induction motor of adequate capacity for operation on 3-phase, 415 +/- 10% Volts, 50 Hz A.C, supply and drive arrangement as per manufacturer's design and standard specifications with shell and tube type water cooled Condenser with MS shell and copper tubes with integral fins complete with safety valve to match the capacity of compressor and insulated shell and tube type water cooled flooded evaporator with MS shell and seamless copper tubes, differential pressure switch at condenser and chiller outlet, compact refrigeration system including refrigerant piping, Refrigerant and oil ready for use on connecting electric power and cooling tower using zero ozone depleting potential and energy efficient as refrigerant preferably such as 'R 134 a'

with all accessories, display/gauge panel of various parameters including microprocessor based control panel for controlling various chiller operating parameters all as per manufacturer's design and specification etc. complete of makes - Carrier /Blue star/ Trane/York /Daikin -02 Nos (01 No working & 01 No Standby). Notes :- (i) VFD Shall be air cooled unit mounted. (ii) IPLV ≥ 9.0(Rated as per AHRI 550/590 Standard) (iii) Pressure drop shall not exceed 6.5 mtr of water column in both evaporator and condenser. (iv) COP shall not be less than 5.75

(B) CONDENSOR WATER STORAGE AND CIRCULATING SYSTEM : Comprising of following based on undermentioned parameters :- Condensor water inlet Temp - 32.22 Deg C Condensor water outlet Temp - 36.39 Deg C Condensor water flow - near 3.79 gpm/Ton at design condition

(i) Supply, installation, testing and commissioning of Horizontal split casing condenser water centrifugal pump sets with bronze impeller for condenser water recirculation complete with TEFC, 3 phase squirrel cage induction motor with class "F" insulation working on 415 volts, 50 Hz, AC supply, base plate, coupling guard, vibration isolators, SS shaft, factory fitted mechanical seal, flexible pipe connector at inlet and outlet etc. conforming to technical specification and compatible with above chiller unit of suitable H.P. & flow rate (with min efficiency 80 %) - 03 Nos (02 No. working + 01 No as standby) Make-Kirloskar/ KSB/ Beacon/ Crompton

(iii) One water softening plant with DMF (Dual Media Filter) having FRP body of minimum capacity 4 Cum/hr suitable for not less than 350 ppm hardness all as per water hardness being used complete all as directed. Make : Thermax/ Ion exchange

(iv) FRP Induced draft type cooling tower Cross /counter flow, twin/four cell, direct/gear driven, site erected cooling tower of 120 % capacity based on the parameters given below and complete with PVC fill/louvers, Drift eliminator, TEFC motor, propeller fan, FRP sump and steel ladder etc., the cooling tower shall conform to technical specification given in the tender, The max allowable sound power at a distance of one mtr from the cooling tower shall be less than 75 db. The cooling tower model shall be to suit site condition. Make-Mihir/Advance/Paharpur Duty Parameters : Water flow - near 3 gpm/ton/as per manufacturer recommendations Designed wet bulb temp - 28.3 deg C Water Inlet Temp -36.39 deg C Water Outlet Temp -32.22 deg C

(v) HDPE water tank of suitable capacity not less than 5000 ltr, ISI marked complete with inlet, outlet and overflow connection and float valves etc. including GI pipe medium grade complete with fitting valves etc. for connecting cooling tower sump and storage tank all as required and specified.- 01 No. Make of water tank-Syntex/Polycab Make of GI pipe -Tata/Jindal/Sail NOTE - Necessary platform for make up water tank and connected pipes to be included in the rate quoted against above item.

(C) CHILLED WATER DISTRIBUTION SYSTEM ; comprising of following based on under mentioned parameters Chilled water inlet Temp - 12.22 deg C Chilled water outlet Temp - 6.67 deg C Chilled water flow - near 2.4 gpm/ton at design condition

(i) Horizontal split casing water centrifugal pump sets with bronze impeller for chilled water recirculation complete with TEFC 3 phase Squirrel cage induction motor with class "F" insulation working on 415 Volts AC base plate, coupling guard, vibration isolators, SS shaft factory fitted mechanical seal, flexible pipe connector at inlet and outlet etc. conforming to technical specification and compatible with above chiller unit of suitable H.P. considering flow rate nearly 2 gpm /TR & min efficiency 80%) - 03 Nos (each of 50% capacity, 02 Nos working & 01 No as standby). The Chilled water pumps shall also include the cost of thermal insulation.

(ii) Chilled water piping and fitting of MS class C insulated with Rigid perforated sections of expanded polystyrene of uniform density of 24 Kgs/m3, 50 mm thick finished with chicken wire mesh and 10 mm thick cement sand plaster for interconnection and recirculating water between chiller unit, chilled water pump, expansion tank and AHUs - one lot of different sizes and length as required at site. Note : The piping shall be so designed that the water velocity through the piping shall not exceed max 8 fps and also the piping friction drop shall be limited to 4 m per hundred metres of pipe length. (Pipe laid inside the building shall be covered by Aluminium Cladding 26 gauge).

(iii) Supply, installation, testing and commissioning of chilled water expansion tank of capacity 1000 Ltr made of PVC/HDPE, insulated with EPS/fiber glass wool 50 mm thick (min) covered with chicken wire mesh and 10 mm cement sand plaster duly covered with aluminium sheet of 24 SWG complete with suitable inlet, outlet fitting over flow connection and control valve to be placed at the highest point i.e. on the roof of the building. (iv) Supply and install NRV of suitable size and capacity on discharge side of each chiller pump.

(v) Condensate drain piping suitable for the system as required at site.

(D) HOT WATER DISTRIBUTION SYSTEM : Comprising of following : (i) Supply, installation, testing and commissioning of Hot water Generator of capacity not less than 100 kw in multiple bank complete with controls, electrical panels etc. confirming to standard technical specifications. Inlet water Temp - not less than 30 Deg C Outlet water Temp - not less than 50 Deg C 01 No. Make- Rapidcool/ Reynold/ Rapid Control.

(ii) Supply, installation, testing and commissioning of Monoblock hot water centrifugal pump sets with bronze impeller for hot water recirculation complete with TEFC Squirrel Cage induction motor with class "F" insulation, base plate, vibration isolators etc. conforming to standard technical specification, the Hot water pumps shall include thermal insulation, the Capacity of motor shall be decided as per design conditions - 02 Nos of 100 % capacity (01 working + 01 stand by).

(iii) Supply, Installation, testing and commissioning hot water piping of MS class C complete with fitting like elbows, tees, reducers, bents, MS flanges, Supports, welding, painting etc. including insulation with Rigid performed sections of expanded polysterene of uniform density of 24 Kgs/m³, 50 mm thick finished with chicken wire mesh and 10 mm thick cement sand plaster duly covered with aluminium sheet of 24 SWG for interconnection and recirculating water in Hot water circuit - One lot of different sizes and length all required at site.

(iv) Supply, installation, testing and commissioning of expansion tank for hot water circuit of size 1.0 m x 1.0 m x1.0 m made out of 5 mm M S Sheet duly epoxy coated and insulated with EPS/Fibre glass wool 50 mm thick (min) covered with chicken wire mesh and 10 mm cement sand plaster complete with suitable inlet, outlet fitting over flow connection and control valve etc. -01 No.

(E) Double Skin floor mounted AHU with fine filters and heating coil : Supply, installation, testing and commissioning Factory made Double Skin chilled water Air Handling Unit floor mounted fabricated out of extruded aluminium section with 0.6 mm pre-plasticized /pre-coated galvanized steel sheet outside and 0.6 mm galvanized steel sheet inside with DIDW forward curved centrifugal blower in MS Construction, blower section, fan and fan section, fan motor TEFC type suitable for operation on 415 volts, 50 Hz +5% AC supply 6 row (design to be got approved from accepting officer before placing order) cooling coil and 2 row heating coil made of aluminium finned copper tube copper header with coil section, pre filter section with non woven synthetic media of 10 micron particle size with an efficiency of 90 % polished stainless steel drain pan made out of 22 G sheet duly insulated complete with motor, belt drive packaged, guard etc. without face and bypass dampers, the AHU Panels shall be insulated with 25 mm thick and 40 Kg/M³ density PU foam, the motor and blower assembly shall be mounted on Aluminium extruded section only, the face velocity across cooling/heating coil shall be limited to 152 MPM max face velocity across pre filters 137 MPM, max fan outlet velocity- 487 MPM, max fan speed -800 RPM, max fan motor speed -1500 RPM,

F) AIR CIRCULATING SYSTEM : Entire work for air circulation from AHUs to entire space to be air conditioned shall be done as under : (i) GI DUCTING WORK ( FACTORY MADE/ SITE FABRICATED) : Designing, supplying, fabrication, installation and testing of GSS sheet metal ducting complete with splitter damper, duct damper, vanes etc. fabricated out of galvanized sheet class VIII conforming to IS 277- 1965 all as required and as per IS specification and as per approved drawings for supply and return air based on following parameters : Max flow velocity (SA duct) - 365 m/min Max flow velocity (RA duct) - 243 m/min Max Friction drop - 1 cm wg/100 m run (ii) The duct fabrication and installation shall confirm to IS 655-1963 all dampers, splitters shall be fabricated out of GS Sheet of two gauges higher than the duct piece having these fittings-01 lot as required at site.

(iii) Supplying and fixing of external thermal insulation on ducts with Nitrile Foam insulation in metalized finish, tape and adhesive (pidilite SR-998) of suitable thickness min 25 mm thick with class O fire rating when tested under BS 476 Part 6 & BS 476 Part 7 all as required at site for supply air duct passing through conditioned/ unconditioned space and for return air duct passing through unconditioned space all as per standard practice - 01 lot as required at site. Note : The thickness of insulation shall be sufficient to prevent condensation under specified condition, the material shall be CFC & HCFC free, the material shall incorporate microban anti microbial protection to actively inbuilt the growth or mould, the exposed ducts shall be insulated with elastomeric nitrile rubber with aluminium tail facing.

(iv) Supply installation and testing of powder coated aluminium extruded grills/diffusers ceiling/wall mounting type of size as required at site as per standard norms. The supply air grills/diffusers shall be provided with screw operated opposed blade volume control device made of extruded aluminium in black anodized finish, all grills/diffusers shall have soft continuous rubber/foam gasket between the periphery of the grills/diffusers and surface on which it has to be mounted, the return air grills shall have fixed horizontal bars, the thickness of the fixed hole louvers shall be 5 mm in front and the flange shall be 20 mm wide with round edges. the register shall be suitable for concealed fixing and horizontal bars of the grills shall be mechanically crimb from the back to hold them, the square/rectangular ceiling diffusers shall be flush fixed pattern for air flow direction - 01 lot as required at site.

(v) Supply and fixing fresh/exhaust air louvers min 50 mm deep made of powder coated extruded aluminium construction with bird/insect screen having blades inclined at 45 degree on a 40 mm blade pitch - 01 lot as required at site.

(vi) Supplying and fixing of acoustic lining of duct with 50 mm thick resin bounded fiber glass having a density of 33 kg/m³ or 12 mm thick fibre glass rigid board of density 48 kg/m³ and covered with 0.5 mm thick perforated aluminium sheet all as specified and directed upto five metres of duct from the canvas connection of AHU - 01 lot as required at site.

Note :- Air handling units shall be connected to duct work by inserting at air inlet and air outlet a double canvas sleeve, each sleeve shall be minimum 4" long securely bounded and bolted to duct and units, each sleeve shall be made smooth and the connecting duct work rigidly held in line with unit inlet or outlet.

(vii) Supplying and fixing of necessary motorized type fire damper with spring return type actuator for supply air duct and fusible link type fire damper as per UL 555 for return air path for fire protection including mapping necessary electrical interlocking arrangement with fire damper and evaporation fan motor to shut down the AC fan on detection of fire.

(G) INSTRUMENTS AND VARIOUS CONTROLS Instrument and various controls for refrigeration system and water line like comprising of water pressure gauge industrial stem type thermometer, dry and wet bulb thermometer humidistat, thermostat, Y strainer, non return valve, butterfly valve, ball valve, 3 way valve, balancing valve, air vent etc. as required including fixing complete.

(H) Complete oil and refrigerant required up to successful completion of Phase-II test.

(J) Microcomputer based Controller Controls at Plant Room as per manufacturer design consisting of following :- (i) Adoptive control Micro Processor with unit control panels to ensure and implement compressor protective system based on temperature and pressure criteria and to perform unit control functions, limit functions, sequence of operation, compressor motor control, compressor motor protection, and the starter functions. The system shall have adequate pre-programmed reports for compressor, refrigerant, chillers and should be able to accept external inputs from sensors etc. with display facility in both English and Hindi (this shall be composite unit of chiller unit).

(ii) Unit control module capable of sensing and controlling variables that govern the operation of chillers, motor current, evaporator temperature etc. with tracer system for identification of locations all from the control having Intelligent add-ons to monitor and diagnose failures based on various parameters including its corrections and display .

(K) ELECTRIC WORKS COMPRISING OF :- (i) Supply, installation, testing and commissioning of free floor mounted Indoor type CPRI approved confirming to IS-8623 Part-I 1993 factory fabricated cubical panel board made out of 2 mm thick CRCA sheet duly compartmentalized to accommodate incomer MCCB and TPN copper bus bar of rating not less than 1.5 times the rated capacity of the incomer MCCB, the TPN bus bar shall be insulated with colour coated heat shrinkable sleeve and shall be mounted on DMC/EPOXY insulators of size not less than 50x50 mm conical type at a maximum interval of 500 mm through out the length of the TPN bus bar, the cubical incomer MCCB as well as outgoing MCCB/MCB shall have copper TPN extension links of current carrying capacity not less than 1.5 times the rated capacity of individual feeders, the extension links shall not be less than 300mm long supported on DMC/EPOXY insulators having provision for termination of incomer and outgoing cables, all interconnections between the main bus bar as well as

outgoing feeders shall be carried out with TPN copper bus bar of rating not less than 1.5 times the rated capacity of individual outgoing feeders, all bus bar should be insulated with heat shrinkable PVC sleeves, all control wires shall be with 4 sqmm multi stranded copper conductors and shall be properly bunched, tied, ferruled for proper identification and crimped with adequate size of lugs, the cubical panel shall have a bottom channel of size 75x40mm duly coated with zinc metal coating having thickness not less than 100 microns, a detachable pre-drilled gland plate of thickness not less than 3mm zinc metal coated should be used at the bottom for entry of armoured cable of adequate size with glands. The panel should be front open able /lockable and shall have louvers and air vent gasket for natural flow of air, 3mm XLPE adhesive gasket shall be used to make panel board completely vermin proof. The panel should be powder coated complete and consisting of the following items mounted in separate compartment shelves.

Note : Wherever required ladder type 16 G, GI perforated U shaped channel 40 mm x 20 mm cable tray of required size shall be provided without any extra cost. (iii) Material and Labour for providing earthing grid including earthing work suitable for local soil conditions as per IS for achieving desired earth resistance and marking necessary earth connections 2 Nos of each electrical eqpts with GI strip/GI wire/Aluminium Strip of suitable size all as per relevant IS. (iv) Supplying, laying, testing and commissioning of control cabling PVC insulated copper conductor of 1100 volts grade armoured /unarmoured of suitable size and core for operation of various controls, associated with microcomputer based control of chilled water AC plant all as required at site - 01 lot.

(2) The main electric supply will be provided in A/C Plant room by the department through cable which shall be connected to the incomer MCCB of the main panel by the contractor. (3) All MCCB's provided shall be compatible to SCADA system.

(j) CIVIL WORKS COMPRISING OF:- (i) Foundation to equipment such as chillers AHUs, HWG LT Panel board, Pump sets, cooling tower, pipeline, common headers etc. including any other masonry work connected with the installation of equipments.

(ii) Excavation and earth work for pipe work, cable work, foundation support etc.

(iii) Opening in walls for duct work, grills/diffusers/ blanking plates etc., finishing of openings including painting/whitewash work to match the interior decoration existing work all as specified.

(iv) Modification / refixing of false ceiling for fixing ducts/grills/diffusers and ensure no leakage of conditioned air etc. as required.

(v) Beadings of standard make and quality as directed by GE on all doors and windows to avoid air losses if required.

(vi) Making good any surface modified or disturbed on account of laying pipe lines of all kind cables or ducts all to the full satisfaction of GE.

Notes :- (1) Any work like boxing/false ceiling/partition required for air return air passage or supply air duct through corridor/ lobby/ room shall be provided by the contractor. Any kind of false ceiling wood paneling, boxing and frame work for fixing of grills, diffuser shall be part of scope of work to be executed by firm and cost of same shall be deemed to be included in the quoted rates.

(2) Contractor shall submit design of plant and working drawing for equipment layout, schematic condenser water piping, chilled water piping, AHU layout and ducting within 02 weeks after acceptance of offer and shall got it approved from Accepting Officer by detailing his rep who is well conversant with all details of drawing and layout so that all doubts about the details submitted by the firm can be clarified on spot.

(3) All the materials and equipment shall be provided as per make specified in the contract documents after getting it approved from the GE. In case for any materials/equipments, if make are not specified in CA the same shall be provided all as per direction and written approval of GE.

(4) Guarantee for the equipments provided by the firm shall be valid for any manufacturing defects and workmanship till completion of defects liability period i.e. for a period of 24 months after satisfactory completion of PH-II tests. Consumable item like gas, oil, filter and electrical hardware shall also be provided by firm till defect liability period. The rate quoted by firm shall be deemed to inclusive of these provisions.

(5) Routine and preventive maintenance shall be covered under defect liability period also i.e. for a period of 24 Months from the satisfactory completion of Phase-II tests. The cost of the same shall be deemed to be inclusive in the rates quoted by firm.

(6) Any work required for making the conditioned space air tight so that undue infiltration of unconditioned air into the conditioned space can be avoided, shall be carried out by the firm to achieve the desired condition and the cost of same shall be deemed to be included in the rates quoted by the firm .

(7) Any other works/ equipment which are not specified in this Schedule but the same are required to be executed /provided for achieving the desired room condition and for complying the standard practice including for micro computer control system the same shall be provided/executed by firm without any extra cost and the cost of the same shall be deemed to be included in the rates quoted by the firm.

(8) The codes regulation to be followed for executing the work are attached as Annexure -II.

(9) The schedule of makes for various equipments and materials to be incorporated in the work are attached as Annexure -III

(10) Acoustic insulation of AHU room shall be carried out by firm as per standard norms.

(11) Overall COP of the plant ≥ 3.7

(12) Under duck insulation, if the shall above false ceiling being used as return air duct, shall be provided all as per standard norms by firm without any extra cost.

(13) Following work will be executed by department:-

(i) Provision of water supply to the inlet of makeup water tank. (ii) Construction of plant room and AHU room.

Shree Ayyappa Engineering

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