1905 401 00 00006 A4 001 - 1

Bayer Project No: A00KM-000158
Division: CROPSCIENCE APG Project No: 506111-1905

GDL Chapter No: 16.02
Location: VAPI, INDIA Doc No: 1905-401-00-00006-A4-001
Plant: EPRO Doc Title: Design Basis – HVAC
System
Date.-27/10/2017 Rev No. 1 PAGE NO. 3 of 14
REVISION HISTORY:
Rev. /
Date Change Description
Vers.
0 28/09/2017 Original issue
1 27/10/2017 Issued for Design – Revised as per Client’s comments
© Bayer Engineering & Technology
Confidential © 2017 Aker Solutions

PC1905009_R0
System
DOCUMENT REFERENCES:
Current Rev. / Vers. of this Document 0
Referenced Documents
Document Document
Revision / Version
Name number
A00KM-
HVAC Design description 000165-MAN- 0
120-001

PC1905009_R0
System
TABLE OF CONTENTS
1. Project Title and General Information ...............................................................................................6
2. Design Codes and Standards ..........................................................................................................6
3. Units of Measurement ......................................................................................................................7
4. Site, Climatic and Utility Data ...........................................................................................................7
5. Other Project Specific requirement: nil .............................................................................................8
6. Outdoor Design Conditions ..............................................................................................................8
7. Indoor Design Conditions.................................................................................................................8
8. System Description..........................................................................................................................9
9. Equipment & system details ........................................................................................................... 10
10. Control Philosophy ........................................................................................................................ 13

PC1905009_R0
System
1. Project Title and General Information
1.1. Name of the Project : EPRO
1.2. Owner : Bayer Vapi Pvt.Ltd.
1.3. Client : Bayer Vapi Pvt.Ltd.
1.4. Location : Vapi, Gujarat, India
1.5. Process Licensor : -
1.6. PMC : -
2. Design Codes and Standards
2.1. Design Codes and Standards

The following are the major design codes used :
IS 277 : 2003 (AMD 5) : Galvanised steel sheets (plain and corrugated) -

specification
IS 655 : 2006 : Air ducts specifications
IS 659 : 1964 (AMD 1) : Safety code for Air conditioning
IS 660 : 1963 : Safety code for mechanical Refrigeration
IS : 4894-1987 : Centrifugal Fans
IS : 5111-1993 : Code of Practice and Measurement Procedure for

Testing Refrigerant Compressors
IS : 7613-1975 : Method of Testing Panel Type Air Filters for Air-

conditioning and Ventilation Purposes
IS : 3588-1987 : Specifications for Electrical Axial Flow Fan
IS : 2312-1967 (AMD 8) : Propeller type A/C Ventilation fans
SMACNA-2006 : HVAC Duct construction standard – Metal &

Flexible.
DW 143 – 1982 : Testing of Leakages in ducting.

PC1905009_R0
System
ASHRAE 62.1 (2013) : Ventilation for acceptable Indoor Air Quality
AMCA 210 ( 2016) : Laboratory methods of testing fans for certified

aerodynamic performance rating
ISHRAE (Second edition, 2014) : Indian Society of Heating, Refrigeration, and Air
Conditioning Engineer’s Hand Book
NBC (2nd Revision- 2005) : National Building Code of India
(R1)
IS 5572 (2009) : Classification of Hazardous area (other than
mines) having flammable gases and vapours for
Electrical Installation.
2.2. Statutory Requirements : The Gujarat lifts and escalators rules, 2001
2.3. Job specific Standards and Specifications / Aker Powergas Specifications
A00KM-000165-MAN-120-001 : HVAC Design Description
2.4. In case of any conflict amongst various documents, the order of precedence shall be as
follows:
Statutory Regulations
Job Specifications
Design Basis
Standard specifications, installation standards etc.
3. Units of Measurement
SI units / MKS units
4. Site, Climatic and Utility Data
4.1. Site Data

0 0
Geographic Location : 20.24 N, 72.90 E
Altitude : 27.5 M
4.2. Climatic conditions : Coastal & corrosive
4.3. Process design data for water : N.A.
4.4. Fouling factor for various services : N.A.
4.5. Distribution levels for electric power

PC1905009_R0
System
3 Phase - 415 VAC ±10% & 50Hz ± 3%
1 phase- 240 VAC ±10% & 50Hz ±3%
5. Other Project Specific requirement: nil
6. Outdoor Design Conditions
Dry Bulb Temperature Wet Bulb Temperature Relative Humidity,

(DBT) °C (WBT) °C (%RH)
SUMMER 43 25.6 24
MONSOON 31.1 26.1 68
WINTER 10 6.1 58
7. Indoor Design Conditions
7.1. Air Conditioning Areas
Indoor Conditions Ventilation

Air changes Remarks
Area Temperature % Relative Fresh air
per hour
(0C) Humidity /Exhaust
(ACPH)
40-85 Slight
MCC, VFD/UPS,
23+2 (no Fresh air 1.5 pressurisation
Battery room,
control)
23+2 40-85 Slight
IRR rooms,
(no Fresh air 1.5 pressurisation
Control rooms
control)
Plant Management
Team office, Engg.
As per
Offices, Record 23+2 40-85 Min. 1 ACPH for
Fresh air ASHRAE
room, Engg. Spare (no control) slight
62.1
room, Instrument pressurisation
spare room etc.

PC1905009_R0
System
7.2. Ventilation Areas
Sr. Indoor Conditions Ventilation

no Area Temperature % Relative Fresh air ACPH Remarks
(°C) Humidity /Exhaust
A. ANNEX BUILDING
1. Toilets, Pantry, Ambient No control Exhaust 10
2. Battery room - - Exhaust 1
3. Lift shaft Ambient No control Fresh air - 50 Pa
4. Air Lock Ambient No control Fresh air 12
B. PLANT BUILDING
Natural
1 Plant Building - - - - ventilation
50 Pa
pressurization
Ambient +
2 Lift Shaft No control Fresh air 12 or ACPH
5
whichever
governs
8. System Description
8.1. General
a) Annex Building - Air conditioning system
Direct expansion refrigeration (DX) system shall be provided which consists of Indoor
units & outdoor condensing units inter connected with refrigerant piping/cabling.
HCFC free refrigerant such as R407c & R410a shall be used for all AC system.
Indoor DX units shall either be floor mounted Package type/ Hi sensible Package /
Ductable Ceiling suspended / Cassette / Hi-wall Split AC Unit as per the requirement.
VRF (Variable Refrigerant Flow) system shall be provided for few rooms such as Plant
Maintenance Offices, Engg. Offices, Control room etc.
Fresh air shall be distributed to each air conditioned room to maintain the room under
slight positive pressure and/or to meet the fresh air requirement of occupants.
Fresh air for IRR & Control room shall be provided through Chemical Filter unit to
improve the life of their equipment & maintain the rooms at slight positive pressure.
Fresh air for balance air conditioned areas shall be provided with the help of Fan Filter
units to maintain the rooms under slight positive pressure.
b) Annex Building- Lift shaft pressurisation
Lift shaft of Annex building shall be pressurised only in case of fire.

The shaft shall be pressurised to around 50Pa with the help of fresh air using Fan filter
unit.

PC1905009_R0
System
c) Annex Building - Air locks pressurisation
Air locks provided for entry from Annex building to Plant building shall be continuously
ventilated. This is required because this passage connects the Safe area (Annex
building) to Hazardous area (Plant building).
The air locks shall be adequately ventilated at a rate of minimum 12 air changes per
hour.
Provision for overpressure control of air lock shall be provided.
Audio-visual alarm shall be provided for loss of ventilation.
d) Plant Building – Lift shaft pressurisation
Lift shaft of Plant building shall be continuously ventilated as it is located in hazardous

area and is enclosed from all sides.
The lift shaft shall be adequately ventilated at a rate of minimum 12 air changes per
hour.
The ventilation system shall continue to operate during fire scenario in order to protect
the area from ingress of smoke. It shall be designed to pressurise the lift shaft to
around 50Pa or to maintain 12 ACPH, whichever governs.
Audio-visual alarm shall be provided for loss of ventilation.
e) Plant Building – Ventilation system
Plant building shall be well ventilated as it is classified as hazardous area.

(R1) As per Bayer min. 4 Air changes per hour, are to be provided. The system shall be
designed for 12 Air changes per hour of natural ventilation as required to achieve
adequate ventilation as per IS 5572.
Plant building shall be naturally ventilated by considering louvers on all sides and with
minimum wind speed of 0.5m/s.
Ground floor of Plant building may provide hindrance for natural ventilation. Hence
(R1) mechanical ventilation shall be proposed using exhaust fans, as required to achieve the
desired air changes.
These fans shall draw exhaust from lower levels and discharge the air outside to
ambient.
9. Equipment & system details
9.1. Annex Building - MCC rooms & VFD/UPS/Battery room
a) Above areas shall be catered by dedicated Package type/ Hi sensible Package units.
b) 2 nos. x 50% capacity (i.e. 2 Working + 0 Stand-by) AC units shall be provided for
MCC room.

PC1905009_R0
System
c) 2 nos. x 100% capacity (i.e. 1 Working + 1 Stand-by) AC units shall be provided for
VFD/UPS room and Battery room.
d) These units shall be mounted on the floor inside the rooms which are air conditioned.
Cooled and de-humidified air shall be distributed in the room through ducting.
e) Fresh air shall be supplied from the common Fan filter unit located on the roof of the
building.
f) Fresh air duct entering each room from the shaft shall be protected with the help of
Fusible link type Fire dampers.
9.2. Annex Building - IRR rooms
a) IRR rooms shall be catered by dedicated Ceiling suspended Ductable AC units.
b) 2 nos. x 100% capacity (i.e. 1 Working + 1 Stand-by) AC units shall be provided.
c) The indoor units shall be suspended above the false ceiling inside the IRR room. Cooled
and de-humidified air shall be distributed in the room through ducting. Return air shall be
collected above false ceiling and routed back to the AC unit.
d) Fresh air shall be supplied from the common Chemical Filter unit located on the roof of
the building.
e) Fresh air duct entering each room from the shaft shall be protected with the help of
9.3. Annex Building - Control room & offices
a) Control room, Plant Management office, Engineering office Engineering Spares Room,
Instruments Spares Room & Record room shall be provided with a common VRF
(Variable Refrigerant flow) system.
b) 2 nos. x 50% capacity (i.e. 2 Working + 0 Stand-by) VRF system shall be provided.
Control room shall be partially catered from both the VRF systems.
c) Indoor units for Control room & offices shall be cassette type, whereas for few rooms
such as Record room, spare room etc. indoor units shall be hi-wall type.
d) Fresh air is supplied to the individual indoor units from the common Fan filter unit
located on the roof of the building. In case of Control room, fresh air shall be supplied
from a common Chemical Filter unit located on the roof of the building.
e) Fresh air duct entering each room from the shaft shall be protected with the help of

PC1905009_R0
System
9.4. Annex Building - Lift shaft Pressurization
a) The pressurisation unit shall be located on the roof of the building which shall supply
fresh air to the lift shaft through ducting.
b) 1 nos. x 100% capacity fan filter unit shall be provided.
c) The pressurisation unit shall be provided with G4 filters.
9.5. Annex Building - Air lock ventilation
a) Dedicated Fan filter units shall be provided on the roof of the building which shall supply
fresh air to the Air locks through ducting.
b) 2 nos. x 100% capacity (i.e. 1 Working + 1 Stand-by) dedicated fan filter units shall be
provided.
c) These shall be operating continuously with auto sequencing provision.
d) The pressurisation unit shall be provided with G4 filters.
9.6. Plant Building – Lift shaft pressurisation
a) Dedicated Fan filter unit shall be provided on the roof of the building which shall supply
fresh air to the lift shaft through ducting.
b) 2 nos. x 100% capacity (i.e. 1 Working + 1 Stand-by) dedicated fan filter units shall be
provided.
c) These shall be operating continuously with auto sequencing provision.
d) The pressurisation unit shall be provided with G4 filters.
9.7. Summary
Air Conditioning System
Working (W)+
Area Served Proposed System
Standby (S)
MCC rooms Package Unit
2W+ 0S
(Floor Mounted)
VFD/ UPS & Battery Room Package Unit
1W+1S
(Floor Mounted)
IRR rooms Ductable Split AC unit
1W+1S
(Ceiling suspended)

PC1905009_R0
System
Working (W)+
Standby (S)
Control Room, Plant Management offices,
Engineering Office, Engineering Spares VRF unit 2W+ 0S
Room, Instrument Spares Room, Spare
Room, Record Room etc.
9.8. Ventilation System
Working (W)+
Standby (S)
Fresh air for AC areas Fan Filter units 2W+0S
Fresh Air for Control room Chemical filter unit (with 2 x 100 % supply
1W+0S
& IRR rooms air fans)
Exhaust Air with wall mounted propeller
Battery Room 1W+1S
fans
1W+0S,
Toilets/ Pantries In-line/ wall mounted exhaust fans
each
Lift shaft– Annex Building Fan Filter unit 1W+0S
Air locks – Annex Building Fan Filter units 1W+1S
Lift shaft– Plant Building Fan Filter units 1W+1S
10. Control Philosophy
10.1. Air conditioning System
a) Individual AC system shall be controlled by their in-built temperature control system.
b) Each AC system shall be provided with an electrical panel. This panel shall have
provision to trip the HVAC equipment on receipt of fire signal from Fire Alarm panel.
10.2. Ventilation System
a) Lift shaft pressurisation unit (Annex building)
It shall automatically start on receipt of fire signal.
b) Air lock ventilation unit (Annex building)
It shall have auto changeover & sequencing provision for equal run of fresh air
units.
These units shall stop on receipt of fire signal.
Loss of ventilation shall be communicated to DCS with an audio-visual alarm.

PC1905009_R0
System
c) Lift shaft pressurisation unit (Plant Building)
It shall have auto changeover & sequencing provision for equal run of fresh air
units.
These units shall continue to pressurise the lift shaft even during fire scenario.
Loss of ventilation shall be communicated to DCS with an audio-visual alarm.

PC1905009_R0

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Bayer Project No: A00KM-000158

Division: CROPSCIENCE APG Project No: 506111-1905

© Bayer Engineering & Technology

Confidential © 2017 Aker Solutions

© Bayer Engineering & Technology

Confidential © 2017 Aker Solutions

1. Project Title and General Information ...............................................................................................6

2. Design Codes and Standards ..........................................................................................................6

3. Units of Measurement ......................................................................................................................7

4. Site, Climatic and Utility Data ...........................................................................................................7

5. Other Project Specific requirement: nil .............................................................................................8

6. Outdoor Design Conditions ..............................................................................................................8

7. Indoor Design Conditions.................................................................................................................8

9. Equipment & system details ........................................................................................................... 10

10. Control Philosophy ........................................................................................................................ 13

© Bayer Engineering & Technology

Confidential © 2017 Aker Solutions

1. Project Title and General Information

1.1. Name of the Project : EPRO

1.2. Owner : Bayer Vapi Pvt.Ltd.

1.3. Client : Bayer Vapi Pvt.Ltd.

1.4. Location : Vapi, Gujarat, India

1.5. Process Licensor : -

2. Design Codes and Standards

2.1. Design Codes and Standards

IS 277 : 2003 (AMD 5) : Galvanised steel sheets (plain and corrugated) -

IS 655 : 2006 : Air ducts specifications

IS 659 : 1964 (AMD 1) : Safety code for Air conditioning

IS 660 : 1963 : Safety code for mechanical Refrigeration

IS : 4894-1987 : Centrifugal Fans

IS : 5111-1993 : Code of Practice and Measurement Procedure for

IS : 7613-1975 : Method of Testing Panel Type Air Filters for Air-

IS : 3588-1987 : Specifications for Electrical Axial Flow Fan

IS : 2312-1967 (AMD 8) : Propeller type A/C Ventilation fans

SMACNA-2006 : HVAC Duct construction standard – Metal &

DW 143 – 1982 : Testing of Leakages in ducting.

© Bayer Engineering & Technology

Confidential © 2017 Aker Solutions

ASHRAE 62.1 (2013) : Ventilation for acceptable Indoor Air Quality

AMCA 210 ( 2016) : Laboratory methods of testing fans for certified

NBC (2nd Revision- 2005) : National Building Code of India

2.3. Job specific Standards and Specifications / Aker Powergas Specifications

A00KM-000165-MAN-120-001 : HVAC Design Description

SI units / MKS units

4. Site, Climatic and Utility Data

4.1. Site Data

4.2. Climatic conditions : Coastal & corrosive

4.3. Process design data for water : N.A.

4.4. Fouling factor for various services : N.A.

4.5. Distribution levels for electric power

© Bayer Engineering & Technology

Confidential © 2017 Aker Solutions

3 Phase - 415 VAC ±10% & 50Hz ± 3%

1 phase- 240 VAC ±10% & 50Hz ±3%

5. Other Project Specific requirement: nil

6. Outdoor Design Conditions

Dry Bulb Temperature Wet Bulb Temperature Relative Humidity,

MONSOON 31.1 26.1 68

7. Indoor Design Conditions

7.1. Air Conditioning Areas

Indoor Conditions Ventilation

© Bayer Engineering & Technology