Professional Documents
Culture Documents
Basis of Design
Basis of Design
Aeronautical Components
Riyadh, Kingdom of Saudi Arabia
Table of contents
1. INTRODUCTION. PROJECT BACKGROUND AND SCOPE .................................... 4
1.1. Background ................................................................................................. 4
1.1.1. WP1. Proposal for the Aeronautical Components Manufacturing Process .......... 4
1.1.2. WP2. Implementation of the Layout for the Large Plant ................................. 4
1.1.3. WP3. Sizing of the Plant, Offices and other Services ..................................... 4
1.2. Scope of the Concept Design (WP4) ............................................................ 6
2. OCCUPANCY ESTIMATION ............................................................................... 6
3. LAYOUT CONSIDERATIONS ............................................................................. 8
3.1. Plant Layout ................................................................................................ 8
3.2. Office Layout ............................................................................................... 8
4. URBANIZATION .............................................................................................. 9
4.1. Access and Traffic Roads ............................................................................. 9
4.2. Parking Lanes .............................................................................................. 9
4.3. Sidewalk Areas ............................................................................................ 9
4.4. External Lighting ....................................................................................... 10
4.5. Green Areas ............................................................................................... 10
5. FOUNDATIONS .............................................................................................. 10
5.1. Foundations. Office Building. ..................................................................... 11
5.2. Foundations. Plant Area............................................................................. 12
5.3. Special Foundations ................................................................................... 13
5.3.1. Plates Inserted and Levelled over Slab .......................................................15
6. STRUCTURES ................................................................................................ 16
6.1. Office Building ........................................................................................... 16
6.2. Plant Area .................................................................................................. 17
7. ARCHITECTURE ............................................................................................. 20
7.1. Roofs and Water-proofing.......................................................................... 20
7.2. Enclosure, Partitions and Linings ............................................................... 22
7.2.1. Partitions and Linings ...............................................................................22
7.2.2. Clean Areas Walls and Partitions ...............................................................23
7.3. Pavement and False Ceiling ....................................................................... 24
7.3.1. Pavement ...............................................................................................24
7.3.2. False Ceiling ...........................................................................................24
ANNEXES:
1.1. Background
• A report that includes the study, definition and proposal of alternatives to the
manufacturing process for the various small components in question.
• A report that includes the study, definition and proposal of alternatives to the
manufacturing process for the various large components in question.
o Number of investigators.
• Architecture/Structure requirements:
o Transport. The need for aerial transport, bridge cranes and specific handling
and transport systems.
o Lighting requirements.
o Air conditioning project: work conditions in the clean area will require
22ºC+/- 2ºC; to be decided for outside the clean area (using the following as
a reference: 24ºC +/-4ºC).
o Water supply.
o Access control.
• A complete layout of the large plant, including the area dedicated to production
and the rest of the services and offices.
• This report that contains, at least, the solutions to each of the requirements listed
for the large plant.
It must be studied and read together with the specifications and drawings.
2. OCCUPANCY ESTIMATION
Dimensioning of offices and other areas for personnel shall be based on the personnel
requirements shown in the following list:
PERSONNEL NEEDS.
OFFICE PERSONNEL
DIRECTOR 1
HHRR 3
FINANCE 2
SALES 2
PURCHASE 2
IT SUPPORT 2
PLANT MANAGER 1
SECRETARY 1
MANUFACTURING ENG. 4
TOOLING ENG. 1
CNC ENG. 2
PROCESS ENG. 2
LOGISTICS ENG. 1
PLANT PERSONNEL
RESPONSIBLES OF AREA 2
MOLD PREPARATION 4
US TRIMMING 1
HOT FORMING 2
ASSEMBLY T
2
STRINGERS' INTEGRATION
VACUUM BAGGING 4
CURING 1
DEMOLDING 2
MOULD CLEANING 2
TRIMMING + INSPECTION 1
GEOMETRICAL INSPECTION 2
NON-DESTRUCTIVE INSPECTION 1
FINISHING 2
EXPEDITIONS 2
QUALITY INSPECTORS 2
LOGISTIC/WAREHOUSE 4
MAINTENANCE 2
3. LAYOUT CONSIDERATIONS
The plant consists basically of a central logistic corridor for movements of AGVs,
personnel and other logistic vehicles (e.g. forklifts) with lateral operation areas, in which
the manufacturing and testing processes are carried out. The manufacturing areas can be
subdivided into a clean area and a production area.
A warehouse area has been foreseen for delivery and storage of the composite prepeg (in
freezer), auxiliary material and tools. Offices, lockers, rest rooms and meeting areas shall
be also provided for the plant personnel.
Finally, an offices module inside the production area is planned for the heads of the
different areas, inspectors and engineers the working inside the plant.
The core of all utilities associated with the plant, such as: electrical transformers and
panels, chiller production, data center, compressed air, vacuum and water pumps, etc.
shall be also located in the office building. The office building and plant building shall be
connected through a direct access in the ground floor.
The following distribution has been considered for the office building:
Ground Floor: Technical rooms for utilities, reception hall, medical services and access to
plant.
4. URBANIZATION
The planned urbanization mainly includes the construction of 4 access points to the plant,
roads, parking spaces, sidewalks, green areas, and the access control system.
The access from the main vials of the industrial area is carried out through four points of
entry. Three of them are located on the west side of the plant, and the fourth is located
on the southeast corner of the plant.
It is also planned a total of 120 parking spaces that will be covered with precast shelter.
The roads will have a slope of 2% from the axis of the vial to both sides. The outer
perimeter of the road will be terminated with a precast concrete curb incorporating a
ditch-shaped element for longitudinal drainage.
In the parking sections, a line of valley gutters will be placed on the outside line of the
road. The parking lane will be executed with a slope of 2% towards the axis of the vials.
The pavement planned for the parking lanes is the same as to the roads.
The sidewalks areas will have a 2% transverse slope for drainage of rainwater towards
the catchbasin network located on the road.
The width of the sidewalks areas is variable according to the area of the urbanization. In
the perimeter of the plant the width is of 2 meters of the side east and south and 4
meters in the east and north side. In the perimeter of the roads, the width is of 1 meter.
In each luminaire a precast concrete manhole of 0,40 x 0,40 m will be placed for the
connection to the projected electrical network.
The electrical wiring will be installed in PVC pipes placed in a trench along the perimeter
of the plant and the urbanization. The lighting system also comprises the awnings of the
parking lanes. Two 56 W LED lights will be installed on each park position.
The species has been chosen for its ability to adapt to arid and desert areas with a dry
summer and temperatures of more than 50 degrees. The water needs of the species and
the projected irrigation system has been defined in the annexes of hydrology and
drainage, and irrigation.
5. FOUNDATIONS
A geotechnical and geological survey war carried out on the site proposed for location of
the King Abdul-Aziz City of Science and Technology (KACST) project, consisting mainly
of:
• 9 boreholes.
• 6 test pits.
The main conclusion of the report of this investigation was the feasibility and suitability of
shallow foundations for hangar type buildings, water tanks and other small buildings with
no special requirements.
Given the results of the geo-technical report mentioned above and in the absence of
restrictive requirements for deformations or anticipation of large loads, the proposal is for
a superficial foundation consisting of isolated reinforced concrete footings under the
planned pillars.
To ensure support by a layer of terrain with enough load capacity, wells will be dug to an
approximate depth of 1.50 metres and filled with concrete and large rocks to the base of
the footings.
These footings will be joined by tie beams along their entire perimeter, which will serve
as the support of the façade enclosure. The interior footings will be completely isolated
since the low seismic properties of the area do not require more tie requirements.
All the footings must be used to embed the planned pillars and will be calculated for this
purpose to absorb the stresses obtained by calculating the structures.
The ground floor of the office building will have a composite slab resting on the pillars, as
described in Section 1.5.
The loads of equipment that may transmit vibrations, such as air conditioning pumps and
compression equipment, will rest on isolated benches placed over the composite slab
using silent-block damping systems.
Deep foundations are not considered necessary for the offices, initially.
Given the results of the geotechnical report mentioned above and in the absence of
restrictive requirements for deformations, the proposal is for a superficial foundation
consisting of isolated reinforced concrete footings under the planned pillars.
To ensure support by a layer of terrain with enough load capacity, wells will be dug to an
approximate depth of 2.00 metres and filled with concrete and large rocks to the base of
the footings.
These footings will be joined by tie beams along their entire perimeter, which will serve
as the support of the façade enclosure. The interior footings will be completely isolated
since the low seismic properties of the area do not require more tie requirements.
All the footings must be used to embed the planned pillars and will be calculated for this
purpose to absorb the stresses obtained by calculating the structures. Given the
considerable distance between pillars in the centre of the plants that is necessary to allow
movement of equipment and machinery inside the manufacturing area, the deep
foundation option may be studied if the results of initial sizing of the footings are too
large. In this case, the criteria set forth in Section 4.3 of this document, on Special
Foundations, will be followed.
The ground floor of the plant will have reinforced concrete flooring that will rest on a
subbase excavated previously to a depth of 1.50 meters and then filled with appropriate
granular soil, levelled and compacted, as shown in the following drawing.
The geotechnical parameters used to size the foundations are a conservative estimate
considering that the plants are located in any position on the plot.
Figure 3. Soil parameters for shallow foundations. Extract from the Geotechnical
Report.
It is understood that these are surface parameters, and it is accepted according to geo-
technical literature that the subgrade reaction modulus k30 can be considered to be
approximately 40,000 kN/m3 for medium density sands under a depth of 1.50 m.
There is still the risk that in the exact location of any of these foundations, the bearing
capacity or deformability of soil would be even worse than the assumed parameter
values. These risks can only be avoided through a more intense geotechnical campaign in
the exact foundation locations. The availability of accurate geotechnical data for the
exact foundation coordinates would probably result in an optimization of the foundations.
The available geotechnical report omits a suitability analysis for the special foundations
that shall support the high technology machines of the plants (e.g. ATL, AFP, Milling
machine), that demand very strict deflection tolerances.
A concept analysis was carried out to establish the most adequate foundation type based
on the available data, concluding that the safest and more economical option would be a
deep foundation system consisting of a concrete slab supported on micropiles.
A list with the foundation requirements specification and layout drawings for the
machinery delivered by M. Torres follows:
Layout Drawing
Code Machine Spec. no.
no.
The foundation requirements for the other machines, not provided by M. Torres, shall be
designed in accordance to the manufacturers’ specifications, once this machinery is
accurately defined.
The main Codes, Guides and Norms that affect the foundation design are listed below:
o ASCE 7-10 “Minimum Design Loads for Buildings and Other Structures”
It is then recommended to prepare foundation with plates inserted and levelled to the
right height between all of them.
Attached some pictures. For a better positioning, one plate can have a Positioning point
and 3 plates tear holes.
Layup moulds should be also prepared with corresponding adaption to every plate.
This project does not included Plates on the AFP and ATL machine as parts to be layup
are not defined. Although it is not the best solution, those plates could be done later on.
In that case, holes have to be done in a control area as machines are inside a clean
room.
6. STRUCTURES
The steel structure will be made up of beams (IPE or HEB type) and HEB-type columns to
be able to support and give global stability to all of the elements and machines on the
roof. In accordance with the following diagrams, the majority of the beams will be from
the IPE range, because as there is no depth limit imposed for the beams, we can achieve
the same inertia with a considerably smaller waste in kilos of rolled steel.
On the roof, the metal profiles, due to their versatility, will be arranged in the required
places to correctly support the various machines that will be installed on the composite
slab.
All of the columns for the office building will be embedded in their bases on a grid
arranged between them.
The three aforementioned composite slabs are made from a composite slab with a total
depth of 70 mm, a thickness of 1 mm and a 90 mm layer of concrete. It will have
negative and positive reinforcement of φ10c/21 and an electrowelded mesh φ6 150x150.
(The slab will function via lost formwork, as we will also reinforce it lower down on each
one of its grooves). We will try to ensure that these slabs do not exceed a span of 2.5
metres. This is for two reasons: to avoid the need for bracing during the building phase
and to guarantee proper safety conditions under final serviceability conditions.
Mesh
Heights in mm
The final selection of the total slab depth is always made on the premise that the
deflection of the structure in service must be compatible with the perfect working
condition of the building.
Characteristics:
• In order not to interfere with the workstations and to provide regular availability,
the optimal distance between frames is 6.3 metres. A good separation is therefore
created that complies with all modulation values imposed for the positioning of the
columns. Likewise, the purlins are not an influencing factor in the design of the
plants, as these are rolled profiles IPE220
• There is a total number of two structural joints (J-J’ and N-N’ axes). There will be
three sections with the following lengths:
• The floor dimensions between the axes of the end columns are 254.9 metres x
142.8 metres.
• To cover the space, three gantries are created (one for each working area, plus
the space of the corridor) with floor dimensions between axes of 51.5 + 39.8 +
51.5 metres. The corridor has the necessary width to have a foyer so that the
largest parts to be made (35 x 7 metres) can be moved from the industrial area
to the clean area.
Figure 8. Gantries.
• For the clean area, which represents the remaining 100 metres of the plant,
everything will be on the same level. The lower chords will have the necessary
profiles to create an internal cubicle, and just as with the external columns, it will
house a maintenance corridor.
• Each of these trusses will in turn be supported on a truss that incorporates them
and transfers the load to the columns.
There will be a total of 3 overhead cranes. In the production area there will be two, one
with a lifting capacity of 8 t and another of 16 t. In the clean area there will be a third
with a lifting capacity of 10 t. The overhead cranes will be suspended, via rail beams
under the lower chord of the trusses. In addition, the span of the overhead crane will not
under any circumstances reach the distance between the gantries. In the case of the
Large Plant, the following is proposed:
Figure 9. Cranes.
7. ARCHITECTURE
This system provides the shell with the necessary mechanical, thermal and acoustic
features.
On the ends of the roof, perpendicular to the line of maximum slope, are placed the
interior gutters that collection the water from the entire roof surface, equipped with
the corresponding bowls to channel the water to the downspouts.
Dynamic joints are proposed between the gutter and the roof panel; these will allow
expansion of the roof panel and guarantee system water tightness, all of which will
be located behind the apron of the main building facade.
2. An INVERTED WALKING ROOF FOR PEDESTRIANS with ceramic tile is proposed. The
slope will be 1%. This roof is consists of the following elements:
o Slope.
o Asphaltic primer.
2. The partitions of toilets and showers, both on the ground floor and first floor, are
projected through a compact phenolic panel 13 mm thick, moisture resistant, with
polished and bevelled edges, color to choose from by the facultative address, and
bar superior stabilizer of 25x25 mm of aluminum.
3. Demountable partition with visible profiling type M-82, or equivalent, stained glass
with blind base of 880.5mm height of plasterboard panel, with profile in lacquered
steel, double glazed 5/6mm.
4. The outer fence will be a system of free-standing sandwich panels, providing easy
assembly and architectural homogeneity, as well as the necessary thermal and
acoustic characteristics.
• An outer galvanized steel sheet, with a minimum prelacquer 0.6 mm thick, special
quality and UV protection.
5. The outer plate of the facade is extended at the top, forming the roof apron and
making it continuous.
6. The partitions of toilets and showers, both on the ground floor and first floor, are
projected through a compact phenolic panel 13 mm thick, moisture resistant, with
polished and bevelled edges, color to choose from by the facultative address, and
bar superior stabilizer of 25x25 mm of aluminum.
7. 100mm thickness internal plasterboard wall is used to the small reception hall
located in production area.
• Internal smooth sheet with a minimum prelacquer thickness of 0.6mm and plastisol
finish.
• External smooth sheet with a minimum prelacquer thickness of 0.6mm and plastisol
finish.
2. The horizontal enclosure, made of continuous panels with hidden profiles, will hang
from the main shell of the plant, acting as a false ceiling. This will make it easy to
access for maintenance purpose.
3. The proposal for the pavement is a self-leveling epoxy resin with a very smooth and
bright surface that impedes adherence and accumulation of dirt particles or dust
and favours easy detection of dirty surfaces. Very resistant to the cleaning agents.
7.3.1. Pavement
1. The more used pavement in the project is a system of a three-layer resin floor-
coating for concrete and similar substrates.
2. For wet rooms, both in the ground floor and in the first floor, the pavement is
projected by means of dry pressed earthenware tiles, 20x20cm, for dense traffic,
color to be chosen by the facultative management, received with cement mortar
CEM II / BP 32.5N and M-5 river sand.
The external doors will be a system of doors industry with specifications for durability and
tightness. The doors have a steel plate substructure and insulation similar to that of the
solution proposed for the facade. They will also have UV protection.
Taking advantage of the height difference between the roofs, fixed windows will be
placed in the central span for the entry of sunlight.
The principal door for this clean area for the special parts will be hangar doors, with a
double door system. The minimum width will be 38.00 meters and 5.00 meters height.
The Warehouse access doors will be high-speed roll up doors. Width 3.60 meters and
height 3.00 meters.
The personal doors will be door especially for clean room, flush on both sides of the
panel, allow easy cleaning, durability and high resistance to impacts. Width 1.00 meters
and height 2.10 meters.
7.4.4. Windows
Secondly, windows are not prominent figures due to the location and environment. Most
part of them are reserved to the office building but always projected trying to avoid solar
radiation. In addition, glazing shall always be reinforced to thermal insulation and solar
protection. That consist of two glasses separated by a hollow metal spacer filled with
desiccant. The assembly shall be sealed with a double flexible silicone structural seal that
has been approved by the silicone manufacturer, the metal profile manufacturer of the
chassis and the insulating glass manufacturer.
The window scheme will be 6+6/12/5+5 with double glass panes, acoustic and solar
glass protection and a reinforced thermal insulation chamber.
7.5. Stairs
We propose to place an exterior stairs (see schema, color blue) with metallic structure for
the maintenance of the machines over the roof. This stairs will connect the patio located
over the roof of the ground floor office building with the principal roof of the large plant.
The course of the stairs to access to the roof of the first floor office building and the large
plant for maintenance of the machines over the roof clean areas.
There are three more stairs that connects ground and first floor (see schema, color
orange) and another that is necessary for evacuation (see schema, color yellow).
8. UTILITIES
The utility drawings included the proposed location of utility main connections to take
account during the urban development design.
8.2. Plumbing
The design of the potable water supply will be done so as to comply with the
requirements included in the following standards:
The water supply would be provided from a main supply connection for a general
distribution pipeline located as shown in the figure.
This main distribution pipeline should be at least of 110 mm and 30 m.c.a. This general
will be on a ring for the factory and the offices. The demand for general use will be
determined using this table according with the Saudi Building Code Part 701.
Urinal 0.900 -
HVAC 2.350 -
NDI 0.850 -
The hot water supply system will be designed based on the use of Electrical Water
Heaters for each zone that requires hot water.
The pipe material will be PE for cold water and PE for hot water. Water hammer arrestors
will be provided at desired location on both cold and hot water lines to absorb eventual
shock preventing damaged on pipe, especially on pipe joints.
The designed drainage system includes the necessary elements for the reception,
transport, pumping, storage of rainwater collected on the surface of the plant and the
urbanization zone.
The system has been designed with the objective of maximizing the use of rainwater, so
that the plant can independently cover the total irrigation water needs of the
urbanization.
With this objective has been projected a tank of reinforced concrete of 1,275 cubic
meters of capacity and an interior dimensions of 15 x 25 x 3.4 meters. To this tank will
be pumped a certain amount of the collected rainwater, to be used as water of irrigation
in the urbanization.
The building object of the project consists in the longitudinal sense of 3 modules
constructed by means of metallic structure. The 3 modules have been designed with a
gable deck with a slope of 7%. The total surface area of the deck is approximately
36,664 square meters.
The water coming from the leaders will be led to 12 manhole of 0.50 x 0.50 m located in
the outer perimeter of the plant. From there you will be led through some PVC DN 250
SN 8 collectors to four 1.0 x 1.0 x 3.0 m reinforced concrete manhole located in the
corner of the plant. From there, rainwater will be pumped to the storage tank located on
the east side of the plant.
water up to the four pump manhole of the plant. The collectors will be located in trenches
on the perimeter sidewalk of the plant.
The estimated irrigation water requirements for trees are initially estimated. The number
and class of trees provided is:
The irrigation system consists of a pump equipment with a power of 1.5 KW, which
supplies a flow of 8 m3/h to the different areas of palm trees in the urbanization. The
irrigation network consists of a system of PEHD pipes buried in trenches and divided into
several sectors according to the location of the groups of palm trees.
The design of the drainage system is in accordance with the Saudi Building Code, 701
sanitary chapter 4. The math method is the drainage fixture unit value of table 4.9.1. The
minimum size of trap will use to connect the fixture to the branch.
The pipe size is according the table 4.10.1 (1) and 4.10.1 (2).
The vent system is designed following the Saudi Building Code, 701 sanitary chapter 5.
The drainage system design was done to minimize the building drain slope at 1%
The vent system design was done to have a stack from the building drain to the open air.
The compressed air system generation is formed by two air compressors, filter, oil and
water separator, a vessel, and the pipe distribution system.
The system has two similar air compressor with variable frequency drive. The air cooler
and air dryer are incorporated to air compressor.
Al the manual tool intake or machine intake are provided with pressure redactor to
control the pressure inlet supply.
The next table show the demand conditions of the different intake:
The vacuum system is formed by two vacuum pumps, two filters, a vessel and the pipe
distribution system.
The system has two similar vacuum pumps with variable frequency drive.
All the vacuum intake all for manual tool with a demand of: -0.8 bar, 800 LN/min, 1/2''
8.8. HVAC
This document establishes the mechanical design criteria for the plant. It includes the
chilled water production station, ventilating and air conditioning mechanical equipment
and systems.
- Save energy.
The main following codes and standards have been used in the present discipline:
- Ashrae. Applications
U values.
The coefficients of heat transfer (U) taken into consideration are as follows:
For the peak outside ambient conditions, the HVAC system has been designed to achieve
the following indoor conditions:
Infiltration.
Infiltration Total
Production room Dimensions (m) Units rate infiltration
(m3/h·m2) rate (m3/h)
Loading dock
5x5 1 0,68 17
doors
Table 6. Infiltrations.
Ventilation requirements.
For the offices module and the sanitary area, the following fresh air ventilation rates have
been considered according the Saudi Code:
Air filtration shall meet, as a minimum, the requirements listed in ASHRAE Applications
and ASHRAE Systems and Equipment Handbooks.
In case of outside air equal to or greater than 30% of total supply air or having an
outside air flow rate of 2400 l/s or greater, an approved sand trap filter shall be provided
and located ahead of all ductwork.
Plant
The main heat gains are coming from the equipment used in the composite fabrication
processes. It has been considered 25 W/m2.
Offices
- Cooling load: 5%
- Heating load: 5%
8.8.2. Solution
The results obtained from the load calculations are listed in the HVAC Annex.
AHUS.
The air-handling units planned in the different spaces are the following:
- Clean area: AHU-CL1, AHU-CL2, AHU-CL3, AHU-CL4, AHU-CL5, AHU-CL6, AHU-
CL7 and AHU-CL8
- Production area: AHU-PR9, AHU-PR10, AHU-PR11, AHU-PR12, AHU-PR13 and
AHU-PR14
- Warehouse : AHU-WH1
- Ventilation for offices module : AHU-FA1
- Sanitary area : AHU-FA2
- Ventilation for offices building : AHU-FA3 and AHU-FA4.
Fresh air shall be filtered to remove sand and dust particulate materials, through sand
trap louvers before entering the AHU. Fresh airwill be treated by AHU’s with heat
recovery wheel or cross flow plate. The AHUs supplying the clean area shall be equipped
with HEPA filter H13.
These AHUs shall be full modulating 2-way valves in order to reduce energy
consumption.
Motors of the components shall be with variable speed/frequency drive (VSD/VFD).
THERMAL POWER PLANT.
The thermal load required in the plant taking into account the cooling and heating
capacities of the AHUs in the previous table is the following:
The thermal plant that supplying the clean area is equipped by the elements listed below:
- 6 heat pumps (one of them planned for redundant operation in case of failure of
any of the units). Primary circuit works with constant flow rate. These pumps are
contained in the heat pumps
- 3 heat pumps. Primary circuit works with constant flow rate. These pumps are
contained in the heat pumps
Minimum
Maximum Maximum
pipework velocity Maximum
pipework pipework
pipework
velocity in plant velocity in false
To Φ From Φ pressure drop
rooms ceilings
50mm 50mm
0,75 1,25
2,5 m/s 1,5 m/s 40 mmca/m
m/s m/s
- Valves:
Shut-off valves: ball valves will be used for diameters up to 1 1/2”;
for diameters over 1 1/2” they will be butterfly valves with a
stainless steel disc; for diameters up to 5” they will be of the
scissors type and wheel valves will be used for diameters larger
than 5”, to facilitate manual rotation.
Filters: Y-shaped with a stainless steel basket. These are installed
upstream from the pumps.
Axial expansion compensator.
Air vents: they will be installed at the highest points of the circuits.
They will be automatic and adjustable.
Finally, the air will be distributed through round or rectangular air supply and return
ductwork made of galvanised steel plate.
The maximum drop of pressure considered in the ducting system is 0,8 Pa/m and the
maximum velocity considered is as follows:
Offices building and offices module are provided with a VRV system in order to adjust the
amount of refrigerant flowing to the multiple evaporators (indoor units), enabling the use
of many evaporators of differing capacities connected to a single condensing unit.
The following three different VRV are planned:
Offices building
Offices
Electrical module
Left area Right area
rooms
Cooling capacity (KW) 66,76 60,32 150,0 33,5
Heating capacity (KW) 75,25 67,64 - 37,5
Consumption 21,2 18,6 44,1 10,2
The set of condenser and evaporator units are designed for the single offices listed
below:
- Reception production area
- Testing area
- Production control area
- Logistic warehouse and maintenance
- Centralized data processing (inside the offices building)
• Automatic sprinkler system, except in low voltage power room, generator room
and medium voltage power room.
• Potable fire extinguisher, only in special hazard rooms of office area (business
group B).
• Clean agent fire extinguishing system, only in centralized data processing room.
• Automatic smoke detection only in low voltage power room, generator room and
medium voltage power room.
• Clean agent fire extinguishing system, only in limited lifetime material warehouse.
Production building.
Painting building.
• Frequency: 60 (Hz)
• Established voltage drop: <4% between the source of the installation and the
receivers
• Lighting
• Power
In order to supply this load value, the electrical substation shall be equipped with 4
The connection between these transformers and the new Main Distribution Board
(hereinafter, MDB) will be made using prefabricated busbar trunking. The illustration
below provides a detailed view of the proposed solution.
The MDB supplies the various DBs distributed throughout the plant and at the base of the
main loads.
DBs will be provided for each of the main work stations in the plant, as well as main
boards used to supply the services in the main work areas: clean area, production and
offices.
The interconnection between the MDB and the DBs will be done using a prefabricated
busbar trunking systems. Specifically, six busbar trunking systems shall be installed in
order to supply the loads located in the clean and production areas. Four units shall be
use for power loads (Busbars 1, 2, 3 and 4), and 2 units shall be use for lighting loads
(busbar 5 and 6).
After reaching the DB or receiver, a perforated cable tray will drop to the unit. The
illustration below provides a detailed view of the proposed solution.
A circuit breaker will be installed between the prefabricated busbar trunking and the drop
to the receiver, as shown in the illustration below. These breakers will be motorized in
order to can control its state in remoted way.
The electrical supply or circuit lines will be channelled from the DBs to the various
receivers. This will pass through trenches, trays or pipes, depending on each case.
• Conductor: Copper
• Insulation: XLPE
• Flame retardant.
The trays will be metallic, perforated and galvanized in sendzimir. Solid metallic trays will
be used to supply external equipment; these will be have covers to close the duct.
In the case of the offices the levels of work lighting will be as follows:
Figure 19. Industrial light fixtures for areas with high ceilings.
The lighting system will be switched on and off by areas and uses, as follows:
• Rest rooms, corridors and common areas: Presence detection lighting system.
• Clean area and production area: On/Off switching from the central control post
On/Off switching will be managed from a control system that can be easily integrated
with the building management system.
• Ground connection systems for neutral cables from the transformer in the new
transformation centre.
• A general and structural ground connection protection system in the new building.
The general ground connections will consists of a perimeter mesh network comprised by
a bare copper conductor 50 mm2 buried at a depth of 0.8 metres and copper-plated steel
pikes measuring 2 m, with shunts on the various ducts for subsequent grounding of
metal parts. Cadweld type exothermic welding will be used for attachment to the pillars.
A rectangular low voltage ground connection with a bare copper conductor and will be
placed in the new transformation centre for the neutral cabling of the transformer and a
separate medium voltage rectangular ground connection will be placed for medium
voltage fittings.
The grounding network of the lightning rods will be connected to the general grounding
system of the building to prevent generation of hazardous sparks and through currents.
A ground connection will be placed for each downspout, protecting the last three metres
with a metal pipe equipped with a system to disconnect the ground connection to
measure resistance.
The proposed data network shall provide a complete functional LAN system including but
not limited to Data cabinets, switches, Fiber/UTP patch panels and all other data
equipment.
The Category 6A / Class E portion of the cabling system shall comply with the proposed
channel performance requirements of the latest revision of ISO/IEC 11801 2nd Edition,
Amendment 2.2:2010 “Performance Specifications for 4-pair 100 Ohm Category 6A /
Class E Cabling”.
The Voice and Data system will comprise the following subsystems:
• Telecommunication rooms.
• Backbone cabling.
• Cableways.
Telecommunications room.
Telecommunications rooms provide a common access point for backbone and building
pathways and may contain cabling used for cross-connection.
The main telecommunication room (MER) is located in the Centralized Data Processing
Room, in the second floor of the offices. MER will be the main Data room, where the main
data cabinets will be located.
The provider telecommunication room (PTR) will be also located in the same Centralized
Data Processing Room. The external data/voice networks and Internet connection will be
connected here.
These communication cabinets will be 42U racks, dimensions 800x800 mm, with glass
door anchored by screws, back door profiles 19" front and rear lock by key, removable
side panels, lids vertical. These racks will have strips 19 " with 2 x 8 schuko sockets
without switch 1U and grommets 19" 1U. Patch panels consist of 24 RJ-45 ports, Cat.6A.
The patch cords are UTP Cat6A, flexible with removable protective of 3 meters.
Due to distances, other 5 wallmount 12U 19” rack cabinets are installed:
MER RACKS
TELEPHONE PANEL
Telephone Panel 50RJ45 cat3 1U
1 5 9 13 17 21 1 5 9 13 17 21
4 8 12 16 20 24 4 8 12 16 20 24
1
4
4
5
5
8
8
9
9
13
12
13
12
17
16
17
16
21
20
21
20
24
24
1
1
4
4
5
5
8
8
9
9
13
12
13
12
17
16
17
16
21
20
21
20
24
24
24 RJ-45 cat6A patchpanel
Wireless controller
- 2 x PDU
- 9 x cable distribution
- 2 x fiber patchpanel
- 6 x patchpanel
- 6 x switches
SER D2
TELEPHONE PANEL
Telephone Panel 50RJ45 cat3 1U
1 5 9 13 17 21
4 8 12 16 20 24
- 2 x PDU
- 8 x cable distribution
- 1 x fiber patchpanel
- 5 x patchpanel
- 5 x switches
SER D3
TELEPHONE PANEL
Telephone Panel 50RJ45 cat3 1U
1 5 9 13 17 21
4 8 12 16 20 24
- 2 x PDU
- 4 x cable distribution
- 1 x fiber patchpanel
- 2 x patchpanel
- 2 x switches
1
4
5
5
8
9
9
13
12
13
17
16
17
21
20
21
24
24 RJ-45 cat6A patchpanel
4 8 12 16 20 24
- 1 x PDU
- 4 x cable distribution
- 1 x fiber patchpanel
- 1 x patchpanel
- 1 x switches
Access D5
1 5 9 13 17 21
4 8 12 16 20 24
4x 10giga fiber
- 1 x PDU
- 4 x cable distribution
- 1 x fiber patchpanel
- 2 x patchpanel
- 2 x switches
Backbone cabling.
Between the MER and each SER (including MER/SER) a telephony backbone is provided.
The copper backbone shall be built up with category 3 multipair cabling. Each SER needs
to be provided with a 50 pair backbone, mounted on both sides on 50-fold RJ-45 patch
panels. Per patch panel one cable management panel needs to be taken into account.
Plant
D4 2 x 12FO D6
D2 2 x 12FO
access access
SER
Offices
2 x 12FO
D1 D1 50 pairs 2 x 12FO
PROVIDER MER 2 x 12FO
IT provider
50 pairs
D5 D7
2 x 12FO D3 2 x 12FO
access access
SER
2 x 12FO
D8
access
The horizontal cable length extends from the rack cabinet to the telecommunications
outlet/connector in the work area. The maximum horizontal cable length shall be 90 m
(295 ft). The length of the jumpers and patch cords that connect horizontal cabling with
equipment or backbone cabling, should not exceed 5 m (16 ft).
All cabling shall conform the Category 6A standard. All cables shall be UTP or F/UTP.
Telecommunications outlets shall consist in RJ-45 connector category 6A at least.
Offices where offices desks are defined 2 outlets per office desk (voice and
data)
Cableways.
Cable trays shall be installed along the sides of the plant at a proper height to not
interfere with the works to be done in the plant.
Cable trays shall be placed inside the false ceiling in offices areas.
Telephone system.
In addition, it is proposed a 50 pairs telephone cable between data cabinets for dedicated
telephone lines, i.e. lift, fire alarm panel, etc.
Switches.
Stackable switches are provided considering that the data room will have switches level
4, Gigabit Ethernet link with 4 x 10Gigabit fiber optics links.
The design has been based on standard Ethernet switches providing 10/100/1000Base-T
ports for servers and high end users. The switches shall be linked together with a fibre-
optic link cable allowing a through put of 10Gbps between the core switches.
The office building is provided with a WIFI network that coverages all desks and meeting
rooms. The solution is managed by a wireless gigabit controller installed in MER.
Wireless access point (AP) are dual band (2,4 and 5Ghz) with a maximum throughput of
1300Mbps. All AC are installed in the ceiling in the indicated locations:
WLAN controller
Switches
Gigabit
AP AP AP AP AP AP
The doors that will be dedicated for staff Access to plant and offices are shown in the
image below:
• Access Controller.
ACS controller shall be connected to LAN using data outlets and cat6A cables.
Emergency door shall be equiped with a magnetic door sensor in order to detect any door
opening. An alarm shall be generated in case a door opening without fire alarm active.
CCTV System.
• IP-CCTV Cameras.
IP cameras shall cover entrances to the plant and offices, technical rooms and corridors
and provide a general view of clean and production areas and specific locals or machines
as required.
IP Cameras shall be connected to LAN using data outlets and cat 6A cables.
Images of cameras shall be recorded in digital HD format (for example mpeg4, H.264)
and saved on hard disk recorders for configurable time. These network video recorders
shall be located in data cabinets in the MER.
CCTV Control and Monitoring will be done in the Control Room located in the second floor
of offices. The video surveillance system shall be fully integrated with the access control
system opening the opportunity to set predefined camera positions on access controlled
doors to detect an unauthorized access.
All controlled doors and emergency door shall have a CCTV camera.
• Air pressure: control of the status of pressurization equipment, alarms and faults.
• Firefighting (water and clean agent): control of tank levels, state control of
pumping units, alarms and faults.
The SCADA server is located in the same rack than the security system in the centralized
processing data room. A client is installed in the control room.
D1
SECURITY RACK
MODBUS RTU
MODBUS
SCADA CLIENT RTU TO ETHERNET ELECTRICAL CONTROL LINES
GATEWAY
NVR
ACCESS CONTROL
SERVER
LAN ACS 1 to 10
CCTV
SERVER Sensors/actuators
SCADA
ACS
CONTROLLER
... ACS
CONTROLLER
SERVER
MODBUS RTU
AUTOMATION
HVAC PRODUCTION SERVER WITH I/O
CONTROL BOARD MODULES
DAMPER1 DAMPER2 DAMPER3
CONTROLLER CONTROLLER CONTROLLER
FREEZER
MODBUS
GATEWAY
ACS 11 to 19
ACS
CONTROLLER
... ACS
CONTROLLER
PRODUCTION
UNIT GATEWAY
MODBUS RTU
PRODUCTION
CLEAN ROOM DATA ROOM
ROOM
CONTROLLER CONTROLLER
CONTROLLER
The system shall be manual and automatic public broadcast. The public address system
will have different types of inputs with different type of priority and shall be interfaced
with fire alarm system to play pre-recorded fire alarm emergency message in case of
fire.
The system shall have the following architecture and contain following components:
• Network Controller.
• Power amplifiers.
• Call stations.
• Speakers, which will be ceiling mounted in office areas and wall mounted in wide
areas or corridors. Speakers will be for indoor or outdoor.
• CD Player/Recorder.
The PA system will divide the hangar in several zones and different power amplifier types
are used to meet the specific power requirements of each zone. The proposed zones are:
• Zone 1 – Offices.
Amplifiers will have 2 outputs and 250W power each output suitable for powering all
speakers connected to them.
The public address rack shall be located inside in the Centralized Data Processing Room,
in the second floor of the offices. The rack will contain network controller, power
amplifiers, power units, etc. Rack cabinet should be powered from external
uninterruptable power supply.
The PA system shall use 70 volts distribution system. Speaker lines shall be supervised.
Cabling for speakers lines shall have a section of 2x2,5mm2. Cables will be routed from
the PAS rack to the speakers using the main communication trays.