tender-specifications_hvac-_final-1_2023-03-28-16-07-21_776a7f8a221f5a63e0e7d256134297b0

TECHNICAL SPECIFICATIONS AND SCOPE OF WORK
– ANALYZER SHELTER HVAC
TECHNICAL SPECIFICATIONS
AND
SCOPE OF WORK -
ANALYZER SHELTER HVAC
Page 1 of 57
Contents
1. INTRODUCTION ....................................................................................................................................... 3
2. SITE CONDITIONS ..................................................................................................................................... 3
3. BRIEF DESCRIPTION OF THE REQUIREMENT ............................................................................................. 4
4. ORDER OF PRECEDENCE........................................................................................................................... 4
5. TECHNICAL REQUIREMENTS..................................................................................................................... 5
6. TECHNICAL DATASHEET ......................................................................................................................... 10
7. DESIGN AND CONSTRUCTION ................................................................................................................ 14
8. GENERAL SPECIFICATIONS ..................................................................................................................... 22
9. VENDOR’S SCOPE OF SUPPLY & WORK: .................................................................................................. 31
10. VENDOR’S SCOPE OF WORK ............................................................................................................... 32
11. CPCL SCOPE OF WORK ....................................................................................................................... 33
12. SPECIAL INSTRUCTIONS TO VENDOR (SIV) .......................................................................................... 33
13. VENDOR DOCUMENT REQUIREMENT ................................................................................................. 36
14. INSTALLATION AND COMMISSIOING: ................................................................................................. 39
15. SITE ACCEPTANCE TEST: ..................................................................................................................... 40
16. COMPLETION PERIOD ........................................................................................................................ 40
17. OPERATIONAL TRAINING AND FAMILIARIZATION ............................................................................... 40
18. WARRANTY ........................................................................................................................................ 40
19. WARRANTY AND POST WARRANTY MAINTENANCE SCOPE OF WORK ................................................ 41
20. LOGISTIC SUPPORT CERTIFICATE FORMAT.......................................................................................... 47
21. PROVEN TRACK RECORD (PTR) FORMAT............................................................................................. 48
Page 2 of 57
1. INTRODUCTION
The intent of this specification is to outline the Purchaser’s requirements under which the Bidder shall design,
engineer, procure, manufacture, inspect & test at works, shop-paint, pack & forward, transport, supply, install,
test and commission of the HVAC system for Analyser Shelter complete with all auxiliaries and features
required for efficient & satisfactory operation at Chennai Petroleum Corporation Limited (CPCL), Manali
Refinery, as per the specifications and data sheets attached.
The requirement is for replacement of the existing HVAC system of existing Analyser Shelters. The
specifications for HVAC System shall be suitable for Analyser Shelters located in hazardous area ZONE-1 Gas
Grp. IIA/IIB/IIC
Definitions
The following definition shall apply:
Purchaser/Owner : Chennai Petroleum Corporation Limited, Manali Refinery (CPCL)
Bidder/Vendor : The firm which quotes for the supply of HVAC
Site : Manali Refinery, Chennai. Tamil Nadu, India.
2. SITE CONDITIONS
The HVAC shall be suitable for unprotected installation in Hot, Humid and Corrosive environment having the
following ambient conditions. The site environmental conditions at CPCL, Chennai are as follows:
- Ambient temperature (Max/min.): 45 deg C /18 deg C.

- Relative Humidity: 80% (max) @45 deg C
- Rainfall data: 100 mm in 1 hour & 450mm 24 hours period.
The HVAC shall be suitable for continuous operation in hot, humid and tropical industrial climate in which the
corrosive gases and/or chemicals are present. The vendor’s attention is drawn, in particular, to the range of
Pressure and Temperatures, over which the instrument shall be designed to operate.
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3. BRIEF DESCRIPTION OF THE REQUIREMENT

This enquiry calls for the supply, installation, commissioning, warranty and post warranty annual maintenance
contract for 3 nos. of Analyzer shelter HVACs – flameproof with all required accessories as per specifications
and scope of work attached. The HVACs shall be installed in the following shelters:
 Single Flame proof HVAC for plant 214 – New HGU shelter – capacity 3 TR
 Single Flame proof HVAC for plant 211 – DHDT shelter – capacity 5 TR
 Single Flame proof HVAC for plant 206– CCR shelter – capacity 7.5 TR
The HVAC system shall be complete with required fresh air fans, recycle fan, heating and cooling unit, control
panel, low ventilation flow detection system and required fresh air ducts.
4. ORDER OF PRECEDENCE
In the event of any conflict between the standard specification, job specification/datasheets, statutory
regulations, related standards, codes etc the following order of priority shall govern:
a) Indian Government Statutory Regulations
b) Job Specifications / Data Sheets
c) Standard Specifications
d) Codes and Standards
Compliance with this requisition shall not relieve the Vendor of his responsibility to meet and guarantee all the
requirements specified on the latest issues and amendments of codes and standards and project documents.
In case of any deviation to any of the requirement, the same shall be brought to Purchaser’s notice for their
approval; however, the most stringent requirement shall generally apply. The supply of items, materials,
services and documentation shall be in accordance with the specific requirements. Any conflict between the
requisitions of this document and related specifications, standards and codes shall be submitted to purchaser
for clarification before proceeding with the manufacturing of affected parts.
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5. TECHNICAL REQUIREMENTS
5.1. The requirement is for replacement of one of the existing HVAC system of existing Analyser Shelters at
CPCL. The shelters are provided with dual redundant HVAC units at present. This tender, currently
envisages replacement of one of the two HVACs in each shelter.
5.2. Ventilation and air conditioning systems for analyser shelters shall comply with NFPA 496, Chapter 7 and
9 and the following requirements:
5.3. Ventilation (pressurization) system are installed in Analyser shelters, that continuously ventilates the
shelter with a flow of clean air in accordance with NFPA 496, Section 7.4.1 and an air conditioning system
that maintains indoor air temperature as specified.
5.4. Pressurisation system shall be provided for Analyser Shelter. Fresh air shall be taken from safe area.
Fresh air intake arrangement comprising of fresh air blower with drive (1 Working +1 Standby) & back
draft dampers, cleanable type filters (5+micron @ 95% efficiency) and bird screen etc shall be provided.
Relief dampers shall be used to exhaust room air at 5 mm WG over pressure. Shelter internal positive
pressure shall be maintained at 2.5mm WG minimum. Fresh air stack with rain cap shall be of carbon
steel, Welded in construction of minimum 2 mm thick. Fresh air shall be taken from nearest safe area
through fresh air stack or through horizontal/ vertical duct. The Ducts shall be completely leak proof
while passing through hazardous area. Loss of pressurization shall initiate an audio-visual alarm. In case
of failure of running fan, the standby fan will automatically start. A manual blower selector switch will
also be provided to alternate between the blowers. Intake of fresh air through the main HVAC blower is
not acceptable.
5.5. Each unit with 2 fresh air fan, 1 recycle fan, heating and cooling unit is to be offered.
5.6. Low ventilation flow detection system (Delta P) measurement across each fan (set to 60% of normal
flow) shall be provided. Analyser shelter HVAC system vibration shall not impact analyser operation.
5.7. All equipment manufactured abroad shall be certified by any approving authority like BASEEFA, FM, UL,
PTB, LCIE etc. In addition, certificate/endorsement by Indian Authorities – PESO/CCE, Nagpur, is
mandatory.
5.8. The compressor shall be of scroll / rotary screw type and the condensers shall be air cooled.
Page 5 of 57
5.9. The entire unit shall be self-containing HVAC

5.10. Fresh air make up requirements shall be calculated by the vendor based on the requirements as
specified in NFPA 496, (latest Edition), i.e where a release of flammable gas or vapour within an enclosure
can occur either in normal operation or under abnormal conditions, protection shall be provided b
diluting with air to maintain the concentration of flammable gas, vapour, or mixture to less than 25% of
its lower flammable limit (reference NFPA 496, 9.2.1 (2). of any individual flammable gas or vapour
entering the enclosure. However minimum 5 air changes shall be provided as per IEC61285 for
ventilation purpose. Inside temperature rise shall be limited to 5°C above ambient, by fresh air from
pressurization system, in case of failure of AC System.
5.11. Ventilation air shall be taken from a non-classified or Class 1, Division 2 (Class I, Zone 2) area.
5.12. Ventilation shall be based on a mechanical fresh air supply system with air escaping via pressure relief
outlets. The ventilation functions are:
5.13. Dilution ventilation (‘Closed’ shelter) – to dilute any gases or vapours that are released within the
shelter
5.14. Overpressure and dilution ventilation (‘Pressurised’ shelter) – to prevent gases entering from outside
5.15. Air intake filters for mechanically ventilated analyser shelters shall be 95 % efficiency, and fresh-air
supply fans shall be arranged as 2 × 100 % duty and standby such that one fan can be maintained whilst
the other continues to operate. Installed equipment shall be suitable to operate in moderately
contaminated air (IEC 60654-1, class 2).
5.16. Cooling shall be provided where it is not possible to do so by means of fresh air. Recirculation may be
used to provide cooling in hot climates in order to limit the energy required to cool and de-humidify
outside air, subject to obtaining minimum fresh air ventilation.
5.17. Fans shall comply with EN 14986 - Standard requirements for design, construction, testing and marking
of complete fan units intended for use in potentially explosive atmospheres in air containing gas, vapour,
mist and/or dusts.
5.18. FRESH AIR DUCT - Fresh Air Duct shall be of minimum 15 Meters length or as per existing shelter
requirements and of MOC - GI
5.19. The fresh air intake shall have gas detection.
Page 6 of 57
5.20. Gas detection, fire/gas dampers shall be provided.

5.21. HVAC operation and shut-down shall comply with Safety philosophy, Fire & Gas philosophy, and cause-
and-effect diagrams of the existing shelter.
5.22. Weight operated barometric louvers(existing) shall be used to maintain the internal pressure
5.23. All equipment shall be suitable for operation in their respective area classification.
5.24. Dust filters shall be located in the ventilation air intake. Filters shall be installed at an easily accessible
location.
5.25. Air flow shall ensure adequate cross ventilation. The existing shelter air discharge louver entries shall
be retained.
5.26. Air flow shall capture flammable vapours as close as possible to the source, taking into account that
vapours such as heavier-than-air hydrocarbon vapours shall be removed at floor level and lighter-than-
air gases such as hydrogen and methane shall be removed at the ceiling.
5.27. Ventilation or HVAC air handling unit fans shall be fabricated with spark resistant construction.
5.28. For analyser shelters located in classified area (Zone – 1, Gr. IIA/IIB/IIC), HVAC unit is required to be
explosion-proof in construction. All flame proof equipment manufactured locally (Within India), the
testing shall be carried out by any of the approved testing houses – CMRI/ERTL etc. the item shall, in
addition, bear the valid certification from PESO/CCE and also the manufacturer shall hold a valid BIS
license.
5.29. A flow switch shall be provided within the air duct of each HVAC air handling unit to give a low-flow
alarm in the control room (or other constantly attended location) and to initiate a white beacon mounted
outside the analyser shelter door upon low-flow condition (recommend 60% of design flow). The two
flow switches shall be voted (2-out-of-2) to alarm only upon loss of air flow through both the primary
and the backup HVAC systems. A time delay of up to 1 minute may be used to prevent spurious alarms.
Flow switches shall be certified for a Class 1, Division 1, Group B, C or D (Class I, Zone 1, Group IIC, IIB, &
IIA) as necessary.
5.30. The Civil foundation work etc for grouting / erecting the HVAC system and interconnecting the dampers
/ ducts to the existing Analyser Shelters shall be in CPCL scope. All structural work for any supports for
the ducting, stack, etc will also been in the scope of the vendor.
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5.31. Because the interior of the shelter is classified as Class 1, Division 2 (Class I, Zone 2), all the equipment
inside the shelter is suitable for use in a "limited release" environment (under normal operating
conditions). Two failures are required to introduce a hazard inside the shelter (undetected pressurization
failure for sufficient time for an explosive mixture to accumulate and a fault in the Class I, Zone 2 certified
equipment). The design requirements are based on NFPA 496, 9.3.8 (3) that offers an exception to
automatic shutdown upon loss of pressurization if the anticipated release is "limited" and the analyser
room is classified as Class I, Zone 2.
5.32. The vendor shall also provide a suitable power supply board which shall be of approved flame proof
construction suitable for Zone-1 Gas Grp II1/IIB/IIC through which all the power supply connections for
the HVAC system shall be connected. The incoming cable for power source to the supply board will be
provided by CPCL.
5.33. Vendor shall design the self-containing HVACs strictly as per the available space and in co-relation to
the existing Analyser Shelters as indicated in the schematic drawings respectively.
5.34. Vendor shall submit in their offer, the complete technical details, ratings, drawings of all the major
equipment / component, as per Standard design, for the HVAC system i.e. Compressor, Fan, Condenser,
Safety devices, Alarms, Indications, etc.
5.35. INSIDE CONDITIONS TO BE MAINTAINED - Following inside conditions of the Analyser Shelter are to be
maintained and guaranteed by the Vendor throughout the year
REQUIRED TEMP 22 ± 2° C
PRESSURE 5 mm WC
SUITABLE FOR HAZARDOUS AREA LOCATION –Zone 1
EX 'd' GAS GR II A / II B / II C
Page 8 of 57
5.36. DESIGN DOCUMENTS
HVAC design documents shall include the following:

1) HVAC design philosophy
2) Ducting & Instrumentation Drawings (D&IDs)
a) D&IDs are single-line drawings that show all main equipment items on a schematic representation
of the duct system.
b) D&IDs shall include symbolic representation of all controls and electrical equipment and indication
of which systems they interface with, e.g., motor supplies from motor control centres, instrument
connections to HVAC control systems, installation control systems, Fire & Gas systems.
3) HVAC Flow sheets
a) Flow sheets show main HVAC equipment and ducts in single-line format with airflows for each area
and along each duct branch. For simple systems, flow sheets may be combined with D&IDs.
4) Equipment specifications, data sheets and schedules
a) The specification should cover all equipment and materials
b) Data sheets should be provided for major/complicated equipment
c) Schedules should be provided as a means of listing all equipment types.
d) Equipment specifications, data sheets and schedules
5) Calculations: heating and cooling requirements, heat dissipation, equipment sizing, building leakage,
system resistance (air and water systems), sound levels.
5.37. The layout along with dimensions of the 3 HVACs are attached as under-
Annexure -1 : HVAC for DHDT Analyser Shelter

Annexure -2 : HVAC for new HGU Analyser Shelter
Annexure-3 : HVAC for CCR Analyser Shelter
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6. TECHNICAL DATASHEET
S.No. Parameter Requirement Bidder’s
compliance
1. Application Shelter Air conditioning
2. Design As per NFPA 496
3. Operation 5 air changes per hour

to maintain 50 Pa overpressure
4. Max ambient condition 50degC without tripping
system designed
5. Shelter Condition (Max) 28degC
6. Shelter Design 22degC +/- 2degC

condition
7. Shelter Over Pressure +2.5 mmWC
8. Classification Gas group IIC, Zone 1, Temp class T3
9. Power supply 415V, 3 Ph., 50 Hz.
10. Refrigeration Capacity 3 TR – 1 NO.

5 TR -1 NO.
7.5 TR – 1 NO.
11. Compressor SCROLL TYPE Hermetically sealed certified for Gas group
IIC
Fully hermetically sealed reciprocating type compressor
operating on refrigerant gas.
Compressor with flameproof terminal box is certified up
to zone 1, IIC area.
Compressor - epoxy painted.
Make: Vendor to Specify
Model: Vendor to Specify
Power Consumption: Vendor to Specify
Page 10 of 57

compliance
12. Condenser Fan AXIAL TYPE

Static Fan MOC : GI housing & Aluminium impeller fan
assembly with alloy hub.
Make : Vendor to Specify
Model : Vendor to Specify
Air flow : Vendor to Specify
13. Condenser Motor Motor Certified for GAS group IIC

Epoxy painted.
Make : Vendor to Specify
14. Condenser Coil AIR COOLED, FIN TUBE TYPE CONDENSOR COIL
with Casing of G.I 2mm Thick painted with Corrosion
resistant coating
MOC : Copper Fins on Mechanically Expanded Copper
Tubes
Fabricated from refrigerant grade copper chromium zinc
alloy tubing with anti-corrosive blue aluminium fin and
end plates, fully compliance for long service life in
corrosive environments.
Make :
15. Condenser Air Entry / To be formed on the casings with removable intake and
Exit : side panels in the form of Square slot punched in the metal
giving a neat finish with adequate free air flow for
condenser air requirements.
16. Blower Centrifugal Ex Proof Blower with Direct Driven motor
MAKE : Vendor to Specify
Model: Vendor to Specify
Page 11 of 57

compliance
Air flow : Vendor to Specify
17. Blower Motor Designed for continuous operation.

Evaporator (Supply air) Galvanized Fan and housing, fully lined with Aluminium.
fans: Fans give adequate air flow and static pressure. Capacity
to cater for required air changes per hour and to
maintain room pressure.
Epoxy painted.
Motor Certified for GAS group IIC
Make: Vendor to Specify
18. Evaporator Coil DIRECT EXPANSION FIN TUBE TYPE EVAPORATOR COIL
MOC: Aluminium Fins on Mechanically Expanded Copper
Tubes with Casing of SS 2mm Thick painted with
Corrosion resistant Blue Fins
Fabricated from refrigerant grade copper chromium zinc
alloy tubing with anti-corrosive blue aluminium fin and
end plates, fully compliance for long service life in
corrosive environments.
Make :
19. Motors – Fans Certified flameproof zone 1 operation.
20. Refrigeration Gas Vendor to Specify
21. System Test Pressure 300psig (for 48 hours with nitrogen)
22. Suction Pressure 65 psig - 80psig

(operating)
23. Discharge Pressure 250 psig - 390 psig
(operating) :
24. Min Set Suction 45 psig
Pressure
25. Max Set Discharge 460 psig
Pressure
Page 12 of 57

compliance
26. Air filter Box type Air Pre filter Filter

MOC : 2 layers of HDPE with Non-woven Polyester with
Aluminium Frame
Size : Vendor to specify
Pressure Drop:5 mmWC
Filter efficiency : 95% for 10 micron
Make :
27. Structure Panel of 1.2 mm thk SS- SS 304 / SS316 / SS 316L grade
Stainless Steel, liquid paint
: Base frame of 2 mm thk.
SS sheets liquid painted colour RAL 7023 with more than
70-80-micron paint thickness
: Shearing, punching and bending by CNC machine.
: Total Evaporation Section is Insulated with FR
Chemically Cross linked Polyethylene insulation of 20mm
thick with Aluminium coating
28. System Controls Thermostatic Temperature control
HP/LP Control
Over load Trip
29. Air Heater Operates based on temperature and humidity control
Type: Electric Air Heater certified for Gas Group IIC
Make:
Capacity:
Power Supply
30. Control panel Ex proof control panel for HVAC control containing
- Power ON/OFF,
- Auto/Manual control
- Incoming Mains indication
- Alarm contact – For any alarm
31. Insulation Complete Unit is designed for excellent thermal and
acoustic performance using high density insulation with
good efficiency and low noise level.
Page 13 of 57

compliance
32. Service access Service access is required on both side of the unit by
means of removable covers to give full access to all major
components
7. DESIGN AND CONSTRUCTION
7.1. Evaporator coil
a. The heating/cooling medium shall be conveyed through a heat exchanger made from seamless
copper tubes expanded into copper fins having solid-drawn collars. Heat exchangers exposed to
outside air shall be protected from corrosion by means of electro tinning or other type of coating,
such as epoxy spray or proprietary anti-corrosion finish.
b. Cooling coils shall be sized to prevent moisture carry-over and shall also be provided with droplet
eliminators having blades manufactured from SS316 to avoid corrosion.
c. Heat exchangers shall be tested at the Manufacturer’s works by immersing in water and pressurising
with air. The test pressure shall be 18 barg and maintained for at least 30 mins.
7.2. Condenser coils
a. Condenser coils shall be as described above, except made from refrigerant grade copper in
accordance with EN 14276-2 or ANSI equivalent and tested to 36 barg minimum. The heat exchanger
tubes shall be connected to headers in groups that ensure adequate refrigerant distribution.
Condenser coils shall be sized to minimize moisture carry-over and shall also be provided with droplet
eliminators having blades manufactured from SS316 to avoid corrosion.
b. On completion of satisfactory testing, condenser coils shall be dehydrated, charged with an inert gas
and sealed.
7.3. Electric Heaters
a. Electric heaters for use in a hazardous area or which may be exposed to flammable gas shall comply
with ISO 15138. All electric heaters shall be designed so that temperature reset devices are easily
accessible and also to enable over-temperature devices to be replaced without having to remove the
whole heater unit.
Page 14 of 57
7.4. Fan general requirements

a. The type of fan to be used shall include consideration of functional requirements, efficiency, space
requirements, maintainability and life-cycle. Fans shall be non-stall and non-overloading.
b. For all fan types, selections shall be based on:
i. - Steep performance curves to minimize airflow change with changes in static pressures, e.g.,
due to adverse wind conditions (fresh air fans) or dirty filters.
ii. - Allowance for dirty filter condition: fan selections shall be based on filter ‘dirty’ resistance.
iii. - Fan duty point shall be at least 15 % below the fan’s maximum static pressure.
c. Where feasible, fans shall be direct-drive to eliminate belt maintenance requirements. Use of direct-
drive fans may require suitable capacity adjusting devices and allowances in system design to ensure
that minimum duty requirement can be obtained. Inlet guide vane dampers may be used if located
within an AHU.
d. Fans to be located externally in corrosive environments (e.g., coastal) or handling moist or corrosive
air shall have casings manufactured from stainless steel SS316 unless located within an enclosure.
Fans in other locations and not subject to moist or corrosive air shall be manufactured from
galvanized mild steel or with epoxy paint coating. For belt-drive fans the frame shall incorporate
facilities for drive belt tensioning and alignment of pulleys.
e. Fans for use in extract systems where there is a possibility of fouling by particulate matter shall have
motors outside the airstream and be designed to resist build-up of contaminants and to facilitate
cleaning.
f. Fans should not be selected to have excessive velocities and rotational speeds because this creates
excessive noise and may reduce operational life. This situation should be avoided by improving
system design to reduce fan duties. Discharge velocities should not exceed 15 m/s.
g. Fan shafts shall be of high-tensile steel and designed to withstand fatigue. The shaft’s first critical
speed should be at least 20 % in excess of the recommended maximum fan operating speed.
h. Fan impellers shall be keyed on to shafts and shall be dynamically balanced.
i. Fans shall have anti-vibration mountings that provide isolation efficiency of at least 95%.
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j. Connections to adjacent ductwork or components shall be by means of 150 mm long flexible

connections having flanges at both ends that are clamped by metal backing flanges.
k. Belt drives, if used, shall be rated for continuous duty, and when used on single fans they shall be
arranged to have spare capacity so that in the event of one belt breaking the remainder will be
capable of transmitting the full drive load.
l. Fan bearings shall be rated for a design life of at least 40,000 hours and have lubrication points
extended as required so that they are accessible from outside the fan casing. Industrial fans shall be
designed to comply with ISO-5801:2007.
m. Accessories
i. Casing Drain
ii. Inspection Doors
7.4.1. Centrifugal fans
a. Centrifugal fan casings shall be stiffened to prevent flexing and shall allow for impeller removal.
b. The casing shall be provided with a removable bolt-fixed access door and a plugged casing drain.
c. Impellers shall be backward-curved with single-skin or aerofoil section blades and shall be
fabricated from aluminum finished with epoxy paint. Welds shall be tested by dye-penetration.
d. Extra heavy duty bearings are required. All bearings are lubricated for life and maintenance-free.
If re lubrication is necessary, it is recommended to use lithium base grease suitable for all
temperatures within the operational limits. Balancing Quality All wheels are statically and
dynamically balanced to ISO1940 and AMCA 204 – G2.5 standards. All fans after assembly are trim-
balanced to ISO1940 and AMCA 204 – G2.5 standard.
7.4.2. Axial fans
a. Axial fans have limited pressure capability and must be selected so that the required performance
in adverse conditions is within their capacity and they will not stall.
b. Casings shall be fully welded with rolled flanges at each end and bolted access doors provided for
fans over 400 mm diameter.
c. Where possible, axial fans shall be of the long case type with guide vanes welded to the inside of
the casing to improve performance and efficiency.
Page 16 of 57
7.5. Fan motors

a) Electric motors shall be selected so that the design loading, including transmission allowance, does not
exceed 90 % of the motor nameplate rating. Fan power requirement at the lowest design air
temperature shall be checked to ensure that the motor is adequate.
7.6. Refrigeration Packages
a) Refrigerant gases shall comply with the Montreal Protocol, all local regulations and CPCL HSE policies.
CFC and HCFC refrigerant gases shall not be used.
b) The TEWI (Total Equivalent Warming Impact) methodology may be used to compare different
refrigeration system arrangements for global warming impact in terms of refrigerant loss and energy
consumption.
c) All refrigeration systems shall be designed and built to prevent leakage in accordance with latest
industry guideline and should also minimize the refrigerant inventory. Compressor connections shall
be designed to avoid failure from vibration or rubbing and shall not transmit vibration to other parts
of the refrigerant circuit.
d) Refrigerant pipework between evaporator and condenser sections shall be refrigerant grade copper
installed in accordance with the system Manufacturer’s recommendations.
e) Other materials may be used where permitted by the referenced standards. It shall be sized and
installed at gradients to ensure proper compressor lubrication and system function. The refrigerant
pipework shall be insulated to prevent heat gain, to prevent heat rejection in conditioned spaces and
to protect from contact by personnel. Insulation in accessible locations shall have mechanical protect
at heights of up to 2 m above walking surfaces, and all external insulation shall be protected from
degradation by ultra-violet light.
f) The nameplates attached to equipment containing refrigerant gas shall include details of the type and
quantity of refrigerant.
g) Air-cooled condensers shall be protected from dust and sand by the following:
- Protective coating applied to the coil and fins
- Enclosed header tubes

Page 17 of 57
- Enclosure with sand-trap louvres.
h) Refrigeration packages shall use Manufacturer’s standard control systems.

7.7. Actuated Fire/Gas Dampers
a) Gas-tight dampers shall prevent the transfer of smoke or gas and meet the leakage standard Class 3
(for blades) and Class B (for Case) in accordance with EN 1751.
b) Status indication shall be provided by means of integrated switch boxes attached to the actuator. The
switch boxes may be of proprietary design incorporating switches to provide indication of ‘open’ and
‘closed’ positions. The switch trigger shall be part of the switch box unit and shall enable trigger points
to be adjustable to achieve the correct switching points which shall be within 5 % of the open or closed
damper position. The switch box must provide clear indication of the damper’s position in conjunction
with ‘Open’ and ‘Closed’ labels on the controls cover box.
c) Actuators shall be designed for long service without requiring any maintenance and for the normal
mode of fire damper operation where the spring is fully compressed except during testing.
d) Pneumatic actuators shall have NAMUR standard details for the drive connection, actuator mounting
and fittings.
e) Actuator springs shall be made of spring steel with a flexible corrosion-resistant coating. Instruments
and electrical components fitted to gas-tight dampers shall be classified for use in a hazardous area
f) Actuated fire and gas-tight dampers shall be manufactured from GI and casings shall be flanged to
enable removal/replacement without disturbing adjacent ductwork.
7.8. Grilles And Diffusers
Where possible, grilles and diffusers shall have fixed blades, straight or angled, so that there is no
possibility of undesired movement or unauthorized adjustment.
7.9. HVAC Equipment Drainage
HVAC equipment that produces moisture, such as filters, moisture separators and cooling coils, shall be
provided with drain pans with manometric traps connected to permanent drains. Each drain trap shall
have sufficient depth of water seal to withstand the maximum differential pressure to which it could be
exposed, including abnormal system operation with dampers closed or filters blocked. All traps shall be
Page 18 of 57
of a type that can be removed and dismantled for cleaning. ‘Open’ traps may be used where located in
a non-hazardous area.
7.10. Ducts
a) The material and type of construction for ductwork shall be selected to be suitable for the operating
conditions and design life of the installation.
b) GI with angle flanges shall be used for external ductwork and any ductwork exposed to moisture.
c) Duct nominal sizes are based on internal dimensions for fabricated rectangular and circular ducts.
d) External duct supports shall be sufficiently strong and rigid to provide both vertical and lateral
support to deal with duct weight, wind loading, and may also have to consider blast loading.
Proprietary channel systems with bolted/clamped connections may be used where adequate for
smaller duct sizes.
7.11. Control And Alarms
a) Simple controls, such as on/off switching, relays and thermostat temperature control shall be used
where possible.
b) Manufacturer’s standard control panels shall be provided for packaged equipment
c) Control systems shall normally operate in automatic mode but shall include selectable facility for
manual operation. Automatic controls shall be provided for control of temperature and humidity.
d) Control signals coming from an HVAC control system cabinet and going to an HVAC motor control
center (power) cabinet shall pass via an interface box.
e) CONTROL FUNCTIONS
Controls shall generally include the following functions:
• On/Off/Auto control
• Change-over between duty and standby equipment
f) ALARMS AND MONITORING
HVAC alarms shall be indicated on local HVAC control panel
and the following alarm/status signals shall be passed on to the DCS either hardwired or via a serial
link:
a) Fault alarms
Page 19 of 57
b) Operational status of systems and main HVAC equipment

c) Temperature and humidity shall be monitored and controlled
7.12. Combustible and Toxic Gas Detection
a) General Requirements
b) If a source of combustible or toxic gas is present, a combustible gas and/or toxicity detection
instrument shall be installed in each shelter.
c) Detectors shall be located near the floor, ceiling, or both, depending upon the density of the gases
being handled. At least one sensor for every 14 m² of floor area shall be installed.
d) Upon detecting gas, the combustible gas and/or toxicity detection equipment shall actuate both an
alarm in the control room (or other constantly attended location) and a local alarm. The local alarm
shall be audible both inside and outside the shelter with doors closed. In addition, separate warning
light beacons mounted outside the shelter shall be provided; a blue beacon for high Hydrogen Sulfide
and a red beacon for combustible gas.
7.13. Special Tools
The bidder shall provide all special tools necessary for the installation, operation, maintenance and
dismantling of equipment.
7.14. Equipment Nameplates
All maintainable equipment shall be provided with a nameplate made of stainless steel or engraved
laminate material mechanically fixed to the equipment. Letters shall be a minimum of 3 mm high and of
contrasting colour to the background. Nameplates shall include provision for adding the weight of
equipment that has to be weighed after manufacture.
The following information shall be shown:
a) Equipment tag number

b) Purchase order number
c) Manufacturer's name, equipment model reference and serial number
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d) Year of manufacture
e) Certified weight
f) Air pressure, barg minimum and barg maximum (as applicable)
g) Electrical power requirements, voltage, current, frequency (as applicable)
h) Fire rating (as applicable)
i) Design duty: airflow, pressure, heating, cooling (as applicable)
j) Lubrication instructions: type, quantity and frequency of greasing (as applicable)
k) Hazardous area classification (where applicable) and marks of certification
l) For systems containing refrigerant, type and quantity of refrigerant
Page 21 of 57
8. GENERAL SPECIFICATIONS
VENTILATION/ PRESSURIZATION
SYSTEM
Page 22 of 57
8.1. General
This specification outlines the minimum retirements under which the manufacturer shall design,
manufacture, test and supply the ventilation/Pressurization system, complete with all accessories.
8.2. Code And Standards

8.2.1.Latest editions of the following codes and standards as on the date of enquiry shall govern:
IS:4894 : Centrifugal Fans
IS:3588 : Specification for Electrical Axial Flow Fans
IS:2312 : Propeller type A.C Ventilating Fans
IS:2494(Part-2) : V-belts - Endless V-Bells for industrial Purposes-Part 2 fire resistant and
Antistatic V-belts – Specification
IS:3142 : Pulleys-V-Grooved Pulleys for Endless V-Belts Sections Z, A, B, C, D and
E and Wedge Belts Sections SPZ, SPA, SPC – Specification
IS:3103 : Code of Practice for Industrial Ventilations
IS:277 : Galvanized Steel Sheets (Plain and Corrugated) – Specification
IS:2062 : Hot Rolled low, medium and high tensile structural steel
IS:655 : Air Ducts- Specification
BS EN 779 : Particulate air filters for general ventilation – Determination of the
filtration Performance.
AMCA-210 : Laboratory Methods of Testing Fans for Certified Aerodynamic ce
Performance Rating.
ASHRAE : Handbooks of:
- Fundamentals,
- HVAC System and Equipment.
- HVAC Applications.
8.2.2.Other international standards may also be acceptable subject to their being equivalent or
Superior to those listed above, with prior approval of purchaser.
8.2.3.For provisions not covered by the above codes & standards, applicable good engineering
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Practices and norms shall govern.

8.3. Technical Requirements
8.3.1.For hazardous area application, fans shall be of non – sparking construction.
8.3.2.Noise level shall not exceed 85 dB (A) at 1m distance from fan.
8.3.3.The extent of over pressure in pressurized room shall be minimum 3 mm water column, unless
Otherwise specified in data sheet/job specification.

8.4. Centrifugal Fan
8.4.1.Fan casing shall be of heavy gauge steel volute chamber, rigidly reinforced and supported by
Structural angles to prevent drumming. The joints shall be sealed airtight.
8.4.2.Larger sizes of fans shall have split casing for ease of maintenance of rotor as per manufacture
standard practice.
8.4.3.The fan impeller shall have die-formed backward curved blades welded to the rim and back plate
to have a smooth contour.
8.4.4.Fan inlet screen, shall be galvanized wire mesh of 10 mm square.
8.4.5.The rotor assembly shall be dynamically balanced.
8.4.6.Fan operating speed shall not be more 90% of the maximum permissible speed.
8.4.7.Bearings shall be sealed against ingress of dust. Bearings and Plummer block shall be of
SKF/FAG/NTN MAKE ONLY.
8.4.8.Bearings housed in Plummer blocks shall be grease lubricated and of air-cooled design. Nipple
for greasing shall be provided.
8.4.9.Fan & driver shall be bolted rigidly on a common steel structural base frame grouted on a pre-
Cast concrete block floating on neoprene vibration isolators.
8.4.10. All supports, brackets, gaskets, foundation & fixing bolts etc. shall be supplied by vendor.
8.4.11. Torque-speed characteristics of fan and motor shall be matched.
8.4.12. Volume control damper of multi louvered type & flame resistant canvas connection with
Metallic flanges shall be provided at fan outlet.
8.4.13. V grooved Taper lock pulleys shall be provided with antistatic belts for drive.
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8.4.14. Unless specified otherwise in data sheet, fan outlet velocity shall not exceed 10m/sec.
8.4.15. Electric motor drivers shall have a maximum continuous rating (MCR) (i.e., service factor equal
to 1) not lower than the following:
Centrifugal fan Rated BKW Motor MCR (% of Fan Rated BKW)
Less than 22 125%
22 to 55 115%
More than 55 110%
8.4.16. The motor rating shall also be adequate for operation of centrifugal fan at specified minimum
ambient conditions at rated speed in un-throttled conditions.
8.5. Axial Fan
8.5.1.Fan shall be heavy duty industrial type suitable for continuous operation.
8.5.2.Fan impeller shall be metallurgy suitable for the fluid being handled. High efficiency aerofoil
section multi bladed impeller shall be used.
8.5.3.Impeller shall be dynamically balanced on a precision machine to minimize noise and vibration.
8.5.4.Fan shall be suitable for mounting in duct/wall or as specified in job specifications/ data sheet
casing shall be all welded sheet metal construction with flanges on both sides.
8.6. Air Distribution ducting, Diffusers/Grilles
8.6.1.Air Intake each blower room shall be by provision of suitable opening in the wall through louvers
with bird protection screen.
8.6.2.All ducts shall be made of galvanized steel sheets conforming to at least grade 120 of IS 277.
8.6.3.Ducts shall be designed, fabricated and flanged as per IS: 655,
8.6.4.Duct flanges shall be supported with anchor fasteners in the roof. Anchor fasteners shall be
provided by vendor. Duct supporting hangers shall be used at a spacing not exceeding 2 meters.
8.6.5.All flanges joints shall have 6mm thick Neoprene packing as gasket stuck to the flanges with
adhesive (viz, resins like araldite or equivalent)
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8.6.6.The entire duct shall be made air tight with the help of sealant (Foster 32:17 or MIRACLE D 617
or equivalent)
8.6.7.Ductwork shall be provided with following accessories as a minimum
- Turning Guide Vanes.
Splitter Damper with control rod & locking device.
- Volume Control Damper (opposed bladed type with minimum 18 - Fire

resistant flexible connection between duct chute and supply air grill (if required)
- Access doors for fire dampers.
8.6.8. Supply air grilles shall be provided fitted with sponge foam tape. Volume control damper shall
be provided with each supply air grille, volume control damper shall be key operated from the
front of grille supply air shall be provided with vertical & horizontal adjustable louvers.
8.6.9.Grilles shall be of power coated steel / anodized aluminum construction with anodized aluminum
angle frame.
8.6.10. Both horizontal branch and low – pressure ducts shall be designed by the “equal Friction”
method with a pressure drop less than 2.5mm WG/30 m. Duct Velocity shall not exceed 9.2 m/sec
for main supply air duct. For branch ducts leading to grilles, velocity shall be restricted to 5.1
m/sec.
8.6.11. All outlets /Grilles shall be designed with a terminal velocity not exceeding 3.8 m/sec
Manufacturers published data shall be taken into account for proper air throw/distribution, noise
and pressure drop. Selection must be made to ensure sound levels below NC 40. Sound
attenuators shall be installed in ducts, as required.
8.6.12. Where a branch duct takes off from a main supply air duct, an extractor shall be installed. Each
extractor shall be adjustable to a fixed position to divert the required volume of air to each branch
duct.
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8.6.13. Transition sections should be constructed such that the included angle for converging section
is less than 15 degrees and for diverging section, less than 10 degrees. When space limitations
require transitions using larger angles, splitters shall be installed in the transition (expect for Fan
discharge). Duct transition through fire rated wall should not impair the rating of wall.
8.6.14. All damper linkages shall be of SS-3.04 material
8.7. Intake Louvers
8.7.1.Intake louvers shall be of 20G G.I. Sheet constructed in plain of about 120mm width and
maximum 1000mm length. The edges of the louvers shall be bent to provide lip to restrict
carryover of rainwater falling on louvers.
8.7.2.Louvers shall be riveted at ends and fitted in 18G G.I sheet channel framework to be fixed with
nuts and bolts on grouting frame in the wall opening
8.7.3.Intake louvers shall be selected considering maximum velocity across louvers as 2.54 m/sec.
8.8. Filters
8.8.1.Filter media shall be multi mesh (4/5 ply) high-density Polyethylene and crimped to form deep
folds with efficiency of 95% to particles of 10 microns unless specified otherwise in data sheet.
8.8.2.Filter shall be selected for a clean pressure drop of 6.5 mm WG maximum
8.8.3.Filters shall be suitable for mounting in carbon steel frame work bolted to grouting frame.
8.8.4.Each filter frame shall be fixed with suitable gaskets to ensure proper sealing.
8.8.5.Filter shall be selected considering maximum velocity across filter as 1.78 m/sec.
8.9. Relief Dampers
8.9.1.Relief dampers are required to release excessive positive pressure inside the room beyond design
over pressure.
8.9.2.Relief dampers shall be counter weight actuated louver type with angle iron frame work, louvers
shall be hinged/riveted on rods. Which are connected to common operating linkage system.
Operating mechanism should be free from all constraints and easy to get operated automatically.
Excessive air pressure should result in a horizontal force on louvers and torque created by the
force open the damper against counter weight and, when excessive air pressure is released, it
should close by action of counter weight,
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8.9.3.Dampers shall be fitted on angle iron frame work furnished by vendor complete with fixing frame.
Unless otherwise mentioned in Data sheet, Damper blades shall be 20 Gauge G.I sheet
8.10. Fire Dampers
8.10.1. A combination of Fire and smoke dampers shall installed in supply air path, these shall conform
to UL-555 and UL-555S for 1.5 hour fire rating and smoke leakage class-I with temperature
category 176’C type test certificate for fire dampers (equal or higher size of same design) shall be
furnished.
8.10.2. The fire dampers shall be provided with limit switches for indication of open/close position of
dampers on vendor’s local panel.
8.10.3. Fire dampers shall be electric motorized type with spring return unless otherwise specified by
purchaser. Fire damper shall be arranged in fail-safe configuration, i.e damper shall be in open
position when power is ON. In case of power failure, damper shall close by spring action. Signal
from the purchaser’s fire and gas panel shall be made available at vendor’s local control panel in
the form of potential free contact. Te wiring from the contact up to actuator motor shall be done
by vendor. The same signal shall be used for tripping the fans.
8.11. Water Manometer
8.11.1. Water manometer shall be of inclined tube manometer.
8.11.2. Vendor shall include all connections, tubes and stand.
8.11.3. One Water manometer is required for measuring over-pressure of room with respect to
outside and the other for measuring pressure drop across filter.
8.12. Air Pressure Switch
8.12.1. Air pressure switch will be provided, if specified in job specification. Air pressure switch will
actuate an alarm, in case of failure of pressurization.
8.13. Inspection And Testing
Equipment shall be subjected to stage wise expediting, inspection and testing at vendor’s/such-vendor’s
works by purchaser/its authorized inspection agency. Vendor shall submit Quality Assurance (QA) Plans
before commencement of fabrication. Approved QA Plans shall from the basis for equipment inspection.
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8.14. Testing at Works

8.14.1. Vendor shall perform tests and inspection necessary to ensure that the material and
workmanship conform to the equipment of this specification.
8.14.2. Inspection & identification of raw materials as per approved quality plan. Test certificates for
materials, shall be produced for EIL Inspection.
8.14.3. Dynamic balancing of rotating assembly of fans.
8.14.4. General mechanical checks on fan assembly trueness, alignment clearances etc. for fans.
8.14.5. Mechanical running of fans, for 1 hour and general check on mechanical operation including
noise and vibration limits.
8.14.6. Performance test of fans at Manufacturer’s Works/at Site as per applicable code depending on
availability of testing facility. However, for offshore application performance test at shop is
mandatory.
8.14.7. Type test certificate of fire damper as per UL-555 and UL-555S shall be furnished.
8.14.8. Visual and dimensional examination of various equipment components.
8.14.9. Any or all the tests may at EIL/Purchaser’s option be witnessed by CPCL/ Purchaser. However,
such inspections shall be regarded as check-up and in no way absolve the vendor of his
responsibility.
8.15. Testing at Site
8.15.1. Inspection of raw materials to be used for fabrication and assembly and inspection of
manufacturer’s test certificates.
8.15.2. Checking of calibration of controls & Instrumentation.
8.16. Performance Testing and Guarantees at Site.
8.16.1. A field performance test shall be conducted by the vendor to demonstrate the guaranteed
performance after commissioning in accordance with test procedure to be prepared as per EIL
Std. No. 7-76-0103.
8.16.2. The procedure of performance testing shall be submitted for purchaser’s review and shall be
mutually agreed between the purchaser and the vendor.
8.16.3. The following shall be guaranteed and demonstrated during the performance testing:
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1) Air flow rate across intake louvers & filters.

2) Pressure drop across filters.
3) Noise level in pressurized/ventilated room and fan noise.
4) Air flow rate through each SA grille.
5) Positive pressure within space.
6) Functioning of Pressure Relief Dampers.
8.16.4. Necessary instruments for the performance testing shall be arranged by the vendor, and shall
be tested and calibrated before undertaking the performance test.
8.16.5. The performance test shall be for the period of 4 hours of continuous operation.
8.17. Protection And Painting

8.17.1. Surface preparation and painting
8.17.2. Stainless steel surfaces, both inside and outside, shall be pickled and passivated.
8.17.3. Machined and bearing surfaces shall be protected with varnish or thick coat of grease.
8.18. Packaging And Identification
8.18.1. All packaging shall be done in such a manner as to reduce the volume. The equipment may be
dismantled into major components, suitable for shipment and shall be properly packed to
provide adequate protection during shipment. All assemblies shall be properly match marked for
site erection.
8.18.2. Attachments, spare parts of the equipment and small items shall be packed separately in
wooden-cases. Each item shall be appropriately tagged with identification of main equipment
item denomination and reference of the respective assembly drawing.
8.18.3. Detailed packing list in water-proof envelope shall be inserted in the package together with
equipment.
8.18.4. Each equipment shall have an identification plate giving salient equipment data, make year of
manufacture, equipment number, name of manufacturer etc.
8.18.5. Vendor shall furnish procedure for prolonged storage of supplied equipment/material at site.
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9. VENDOR’S SCOPE OF SUPPLY & WORK:
The scope of supply and work shall broadly cover the following. The intent of this brief scope of supply and work
as mentioned below is to provide minimum requirements as required by the Bidder and does not relieve the
Bidder from his responsibility regarding design, reliable, efficient and safe operation of the supplied HVAC
system. Any hardware or software not specifically mentioned but required to achieve full functionality as per
specifications and for the safe operation, shall be included in the Bidder’s scope of supply, installation &
commissioning.
S/N Material code CPCL Requirement Qty. UoM
1. 8431100024 ANALYZER SHELTER HVAC SYSTEM- FLP-3 TR 1 LOT
2. 8431100034 ANALYSER SHELTER HVAC SYSTEM - FLP - 5TR 1 LOT
3. 8431100044 ANALYSER SHELTER HVAC SYSTEM - FLP-7.5TR 1 LOT
4. Services Installation & Commissioning 3 LS
5. Services PWCAMC charges
1st year charges 1 LS
2nd year charges 1 LS
3rd year charges 1 LS
4th year charges 1 LS
5th year charges 1 LS
Any other item felt necessary for the completion and making the system functional as per the Scope of Work
and Technical Specifications shall also be supplied by bidder. Bidder shall clearly mention details of all such
additional items or quantity in their offer.
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10. VENDOR’S SCOPE OF WORK

Vendor’s scope of work shall include the following but not limited to the following:
a) Design, engineering, supply, erection, installation commissioning & maintenance of the complete
HVAC system along with all required accessories as per the tender specification document.
b) All resources in terms of materials & services may be required to successfully commission the supplied
systems.
c) Responsibility of vendor at site shall include all activities necessary to be performed to complete the
project to achieve the functional requirements and design specifications of the system.
d) Physical inspection of the material received in the presence of CPCL representative for checking transit
damages before commencing installation activities for the sites.
e) Installation of all the supplied items shall be in the scope of bidder.
f) Existing civil foundation available on the shelters shall be used for mounting the HVAC system.
g) Grouting/Erecting the HVAC System shall be in the scope of bidder.
h) Interconnecting the dampers/Ducts to existing shelters shall be in the scope of bidder
i) Provision of Structural supports for ducting shall be in the scope of bidder.
a) Powering- up of the system and checking as per technical specifications.
b) Make available all consumables, instruments and equipment necessary for testing and commissioning
of the system as required by the scope of work.
c) Provide installation tools, tackles and accessories, lugs, connectors, cables and any other installation
material required for integration and installation of the system.
d) Preparation of Engineering Drawing and Technical Documentation- the Vendor shall supply all the
documents as per attached VDR as minimum.
e) Testing, pre-commissioning and final Commissioning of the supplied system complete in all respects
f) Site Acceptance Test(SAT) of Complete System
g) Warranty maintenance
h) Post warranty maintenance for 5 years
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i) Any other item not listed/indicated but required to meet specification indicated elsewhere and for
proper functioning/operation of HVAC system shall also be vendor scope of supply.
11. CPCL SCOPE OF WORK
a) Internal Shifting of HVACs from Plant Store to field.
b) Dismantling and removal of existing HVACs, fresh air ducts, dampers, etc. and Shifting of old HVACs
to CPCL Scrap yard.
c) CPCL shall provide 415 V AC, 50Hz Power supply near the HVAC system.
d) Civil works related to HVAC installation.
12. SPECIAL INSTRUCTIONS TO VENDOR (SIV)
General
a) This Specification attached herewith, covers the minimum requirements for the Design, Materials
supply, Testing, Inspection, Shipping, Installation and Commissioning of HVAC system with all the
required accessories.
b) The intent of this specification is to provide minimum requirements as required by the Bidder and
does not relieve the Bidder from his responsibility regarding reliable, efficient design and safe
operation of the supplied HVAC system. Any omission in the specification (hardware and or
software) will not relieve the bidder from his obligation to supply the system for achieving full
functionality with the intent of this specification.
c) In case of any conflict between this scope of work, related codes and standards etc., bidder shall
refer the matter in writing to the CPCL and shall obtain clarification in writing before starting the
manufacturing. However, in general more stringent requirements will prevail.
d) The bidder is expected to examine the biding documents including all instructions, forms, terms,
specifications and drawings carefully. Failure to furnish the information that is required as per
tender document or submission of a bid not substantially responsive to the tender requirements
in every respect shall be liable for rejection.
e) All jobs are to be carried out in a manner so as not to cause any hindrance/ obstruction/
inconvenience/ damage to the surroundings/ nearby areas/ nearby working people/ contractors
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etc. If any damage is caused, the same is required to be rectified by the bidder at no extra cost to
CPCL.
f) The offer should be clear, unambiguous and as specified in properly bound volumes with page
numbering.
g) Bidder must state categorically whether or not their offer meets all the technical requirements
listed in the Tender Documents. Any deviation shall be listed clause wise in a separate sheet.
h) Offer shall be considered as complete only if accompanied by relevant technical catalogue.
i) Bidder shall bring out any hardware/ software limitation with respect to functional requirements.
j) Bidder to note that CPCL Engineers shall be associated in all phase of the job execution, detailed
design, development, testing, FAT, commissioning, SAT, post audit etc.
k) Bidder to ensure that the software/hardware supplied by the bidder shall not be damaged due to
blackout/ burn out. Further, Bidder to indicate steps to be taken for safe operation under
emergencies like power failure, voltage/ frequency fluctuation, AC failure etc.
l) All consumables, components having limited life-span/ shelf-life but integral to the proposed
system shall be supplied free of cost during the warranty period.
m) The equipment installed shall be certified suitably to cater to the requirement of electrical area
classification. All the items shall be provided with statutory certificates.
n) Bidder to note that items not indicated clearly in the Bill of Material, but required to complete the
functional requirement of the CPCL shall be considered as included in the Bidder’s scope. Such
items shall be considered to be completed by bidder on his full responsibility.
o) Bidder shall include all the accessories/ special cables/ fittings and any other items required for the
safe operation/ online maintenance/ smooth functioning/ installation of items supplied. Any such
item requirement discovered at a later date even after CPCL has reviewed the vendor documents
shall be to vendor’s account.
p) All the selected model no’s shall be completely suitable for the ambient conditions. Bidder shall
replace the selected instruments/ items at no extra charge, if found unsuitable at a later date or at
any stage of the project.
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q) Bidder shall clearly indicate the exact make and model of the various components offered.
Technical offer without exact make and model may be liable for rejection.
r) Bidder to submit drawings, documents, information as per Bidder data Requirement
s) Bidder to submit documents for approval after the placement of PO. Bidder to not proceed for
design, manufacturing/procurement from sub-vendors before the document approval from CPCL.
t) OEM shall give support letter to bidder.
u) All the models offered by bidder should not be End of Sale and End of Life and the latest datasheet
of the proposed model should be available on the OEM's Global website.
v) Vendor shall be totally responsible to supply all required materials and services for satisfying the
functional / operational requirements stated in this Requisition, its attachments and annexure
forming a part of this document.
w) The bid has to be made for the complete system as per scope of work defined for each item, no
exceptions or exemptions or reduction in scope, design, etc. in any part is acceptable.
x) In event of doubt or lack of clarity on any issue the bidder should indicate the same in writing, no
verbal claims or explanations shall be accepted at any stage.
y) It is advised that the bidder should visit the site to collect the residual information not specified in
the tender document, make himself familiar with the topographical requirements, assessments for
his cabling and other accessories requirement. Non familiarization with site conditions will not be
accepted at any stage and it is deemed that the bidder has submitted the offer only after making
the study and has fully understood the requirement of CPCL.
z) Bidder to note, attached Bill-Of-Quantity (BOQs) shall be used for tender evaluation purpose,
however any other material & services required for successful completion of job as per
specification given in tender document shall be in the scope of vendor. Detailed bill of material
shall be part of the detailed engineering with successful bidder.
aa) Bidder shall give compliance report/ comments against each point to our specification and data
sheet.
bb) Any changes / modifications at site, if required based on site conditions, has to be marked in a
mark-up copy of the engineering/installation drawings and 2 sets handed over to CPCL. After
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incorporation of changes, the drawings have to be submitted as As-built sets after successful
commissioning.
cc) Vendor to attach de codification sheet for all the quoted models & components.
dd) Offered flame-proof HVAC system shall be latest & proven model with minimum one-year PTR in
analyzer shelters in hazardous area in hazardous hydrocarbon industry like refinery in India. All
instruments shall be of field proven quality, both with respect to design and materials. Prototype
instruments or instruments of experimental nature shall not be offered or supplied. In general, all
the supplied items by supplier shall have well proven performance record of operating
satisfactorily in any industry for minimum of one year in similar analyzer shelters in hazardous area
in hazardous hydrocarbon industry like refinery in India. Bidder to provide purchase order copies,
approved data sheets, SAT reports and satisfactory performance certificate from the end user and
end user details with phone number and E-mail ID.PTR format is enclosed.
ee) The vendor shall include all special tools, tackles and devices necessary for the erection /
maintenance of the item / equipment. A list of such special tools etc. shall be submitted along with
the bid. Vendor shall submit a specific confirmation with the offer, if no specific tools / tackles and
devices are required.
ff) Vendor shall stand guarantee for all items supplied by them, including their bought-out items.
gg) Bidder to confirm the spare support for minimum 10 years for the offered model. Format is
attached as a part of this specification.
hh) Vendor to sign and stamp each page of specification sheet as a token of acceptance.
13. VENDOR DOCUMENT REQUIREMENT

Four sets of As-built documentation to be provided at final stage after completion of the site work and
commissioning. Two sets of soft copy of all type of documentations shall be provided on CD/DVDs for records.
Major documentation requirement is tabulated below:
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Post order Post order For After

Sl. Along with
Description For Review/Informati Inspection As Built
No. the offer
Approval on
1. Specifications sheet duly filled in X
as token of acceptance
2. Make and Model of the offered X X X
items along with DATASHEET
3. GAD , dimensional and layout X X X X

drawing of offered HVAC
4. Detailed BOM X X
5. Utility Consumption details X X X
6. Filled in deviation/compliance X
Statement (NIL statement in
case of no deviation)
7. Complete technical literature X X
and catalogues of the offered
items along with accessories
along with complete de
8. codification
Proven Tracksheet.
Record X
9. Statutory certificates X X X
10. Guarantee/Warranty X
Certificates
11. Other test certificates X X
12. Packing list X X
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13. HVAC D&IDs (ducting and X X X

instrumentation diagrams)
14. Design criteria and data X X X

summary
15. Calculations for ventilation X X X

rates, pressurization, normal
and abnormal cooling,
16. Control
heating and
load,alarm
etc schemes X X X
17. Electrical power supply and X X
distribution drawings
18. Hardware/software related X X
drawings for control, alarm and
19. shutdown functions
Technical data books and spare
parts listings;
20. Operation & Maintenance X
instruction manuals including
start-up, shutdown, trouble-
shooting and regular
21. Certificates
maintenanceofprocedures;
Conformity and X X X
Declarations of Conformity for
equipment that is
classified for use in hazardous
areas (where applicable)
22. Logistic Support Certificate X X
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14. INSTALLATION AND COMMISSIOING:

Site Mobilization:
The Vendor shall depute their commissioning personnel prior to receipt of the supplied items at site for carrying
out installation/ commissioning works and for inspection of materials.
1. Installation & commissioning of all the supplied items is in the scope of vendor.
2. All technical personnel’s assigned to the site by the vendor shall be fully conversant with the supplied
system and shall have both hardware and software expertise to bring the system on line quickly.
3. Vendor’s responsibility at site shall include all activities necessary to be performed to complete the job
as per Tender Specifications including:
a. Checking for completeness of supplies.
b. Installation of the supplied items complete in all aspects.
c. Interconnection, hardware configuration and overall checking of system functioning.
d. Commissioning of the complete system in total.
4. All the equipment shall be checked thoroughly after its receipt at site. Tests as a minimum, shall
include:
a. Visual and mechanical testing.
b. Complete system configuration testing.
c. Demonstration of all system functions.
d. Checking of correct functioning of HVAC system
f. Demonstration of proper operation of system at specified power supply
Any specialized tools and tackles required for successful installation & commissioning (required if any) of the
system will be in vendor’s scope. Bidder’s quote shall include all incidentals vis. travel expenses, boarding,
lodging, food etc. of bidder’s personnel.
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15. SITE ACCEPTANCE TEST:

a) The site acceptance test shall be carried out in the presence of CPCL representative and Engineer-in-
charge or his authorized representative.
b) Bidder shall carry out the following functional tests, as a part of site acceptance test as a minimum: -
 Hardware verification as per approved BOM, drawings.
 Visual and mechanical check-up for proper workmanship, identification, ferruling, nameplates
etc.
 Demonstration of HVAC system operation & diagnostics.
 Checking of proper functioning of HVAC system at various conditions.
c) CPCL shall take over the HVAC system after uninterrupted, satisfactory, trouble free, fully functional
performance test for a period of one month after successful commissioning of HAVC system in totality
& completion of all SAT punch points at the site. Minutes of meeting shall be made for recording the
date of handover of the HVAC system. Warranty of the system shall start from this date of handover.
d) During above test period, any malfunctioning of the HVAC system components shall be replaced /
repaired as required free of cost by the Bidder. Once the system failure is detected, the performance
test shall start as a fresh from the beginning.
16. COMPLETION PERIOD
Installation & Commissioning to be completed within 30 days with minimum 3 spells from the date of intimation
from the EIC.
17. OPERATIONAL TRAINING AND FAMILIARIZATION
Training to CPCL personnel at the site for operation, administration & maintenance of the equipment to be
provided. Vendor should impart training to CPCL personnel at site for complete operation of the equipment.
18. WARRANTY
Vendor shall provide 24 Months onsite warranty from the date of receipt of material at site.
Vendor shall be fully responsible for the manufacture in respect of proper design, quality workmanship &
operation of all the items including all bought out items supplied by the Vendor, under warranty period
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mentioned above. All the required consumable required for the operation of the HVAC system shall be in the
scope of the bidder for the entire Warranty period.
It will be obligatory on the part of the vendor to modify or replace any hardware/software free of cost in case
any malfunction is revealed during on line operation after taking over by the owner within the warranty
period. The necessary service shall be done within 3 days. Travel, boarding & lodging expenses of service
engineers during warranty shall be to vendor’s scope.
During warranty period bidder shall depute service personnel quarterly once for complete checking of the
system. During these visits, Vendor is specifically required to do the inspection of general healthiness of the
system, inspection of Analyzers, if any problem is reported, running of test programs, on-line servicing and
solving reported problems. Detailed scope of work is given below:
19. WARRANTY AND POST WARRANTY MAINTENANCE SCOPE OF WORK
The Bidder’s scope of work includes HVACs of analyser shelters installed in CPCL Refinery for which following
preventive & breakdown maintenance jobs are to be carried out on monthly, quarterly and annual basis. Bidder
shall depute service personnel monthly once for carrying out the maintenance activities. The visit shall be
minimum 3 days or as required for completion of all the below mentioned activities:
19.2. Monthly basis
a) Inspect Return & Fresh air dampers & set air velocity, if required;
b) Inspect air filters and clean/replace, if necessary;
c) Clean Condenser & Evaporator coils;
d) Check House Air Pressure, Temperature & Humidity;
e) Check 'system fault' Indicators/alarm conditions;
f) Put 'OFF' Main Supply & ensure no Power Supply in Exd. Enclosure;
g) Inspect refrigerant leak on pipe joints, valves and flare nuts for any oil stains;
h) Inspect for tightness of holds down nuts/bolts of Compressor & Motor, tightened if necessary;
i) Check for tightness & di-colorisation of electrical connections & inform CPCL if any components
found burnt out or overheated;
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j) Check all electrical components for normal operations i.e. Contactors, Overload relays,
Thermostat, Timers, Air Flow Switches, Barriers & relays;
k) Filters are to be cleaned & inform CPCL if any are required to be replaced;
l) Cleaning of condenser & evaporator fins/fan blade by compressed air or water pressure. Also
cleaning motors, blower. Check all fans, are free of obstruction and/or misalignment and are not
coming into contact with surrounding fan shrouds and/or housings. Air intake section is free of
foreign matter that could block the intake panel on the condenser;
m) Check for free flow of Condensate drain from P-trap section & if found choke clean the same;
n) Check pin position of the Schrader valve, if found improper correct the same;
o) Switch 'ON' Main Supply, check voltage and monitor sequence of controls operation, fan direction
& measure amperage;
p) Check for normal operating suction & discharge pressure by connecting gauge manifold on the
service valve of the compressor & if found improper pressures as undercharge, charge gas for the
normal rated pressures;
q) Check Dual Pressure/High pressure & Low pressure switch setting by simulating for perfect tripping
under abnormal conditions & if found malfunctioning inform CPCL of the same;
r) Check & Set Thermostat for desired temperature & monitor its Cut-Off & Cut-In sequence;
s) Check for Condensate Water whether drain smoothly;
t) Test run unit to inspect if any abnormal noise, vibration & current drawn by compressor & motors.
Check function air flow switch etc. Log temperature & humidity of house.
u) Balance air flows & set dampers to achieve house pressure & Air duct is fully sealed to prevent
ingress/ egress of air during system operation except from the air intake stack and house supply
air outlet;
v) Re-fixing of Exd enclosure, coils compartments, panels and fresh air duct;
w) w. Checking the unit for two hours satisfactory run & ensure no overheating or tripping of the
electrical components;
x) Complete test & reports.
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19.3. Annual basis (Jobs that are to be done on 4th quarter of each year)
All access panels will be removed and unit cleaned internally & externally;
a) Condenser & Evaporator coils to clean by compressed air or water pressure;
b) Clean condensate water drain trap, drip tray;
c) All holding down bolts will be checked for tension;
d) Check for any refrigerant leaks and rectify, if necessary;
e) Check Compressor- Vibration/Leakage/Sound & correct, if required;
f) Check motors shaft & NDE/DE bearings for wobbling or misalignment & correct the same if found
abnormal;
g) Megger test for electrical winding & earthing protection of all motors;
h) Inspection of filters in air duct & evaporator & clean/check the dampers;
i) All the access panels & spigots should be checked for air leaks and sealed up & replace rusted
screws / nuts with a new one;
j) All connections and terminals in the enclosure will be checked for tightness & de-colorization.
All cable glands will be checked for tension and the rubber shrouds/boots refitted;
k) Switch 'ON' Main Supply, check voltage and monitor sequence of controls operation, fan
direction & measure amperage of all components and record
i. All safety controls & failure indicators to be checked.
ii. Compressor & Motor Power Contactors & Overloads relay.
iii. HP/LP encapsulated Switch
iv. Airflow Switch
v. Lockout relay
vi. Monitor relay
vii. Remote Shutdown relay
viii. Intrinsically safe Barrier relay
ix. Selector Switches Operations
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l) Check Compressor for any Vibration/Overloading/Tripping/Sound or abnormal noise & correct if

required;
m) Connect Gauge Manifold to check the operating pressures and temperatures of refrigerant gas. The
'ON' & 'OFF' coils temperature will be measured and compared with the test data certificates;
n) Any abnormalities will be recorded & intimated to CPCL;
o) Every year painting of the HVAC unit – completely as required and as per EIC instructions.
p) Ensure all panels and assess covers have been refitted securely on the completion of the service work;
q) Checking the unit for two hours’ satisfactory run & ensure no overheating or tripping of the electrical
components.
19.4. BIDDER’S SCOPE OF SUPPLY DURING WARRANTY AND POST WARRANTY PERIOD:
a) All required spares shall be in bidders scope of supply during the warranty and post warranty period.
b) All the tools & tackles, testing equipment required to carry out the job shall be under bidder’s scope
i.e. Vacuum Pump, Multimeter, Megger etc;
c) Consumables like anti corrosive aerosol for chemical protection of evaporator & condenser coils
Copper Brazing Rod, Silver Brazing, Brazing set, hose pipe; Rod, Teflon, PVC insulation tape, Screws
(Assorted), Nuts & bolts (Assorted), Silver Flux, CRC 2 - 26, Lubricating Oil (both motor and compressor),
Grease, Sealant, Flare Nuts, Dead Nuts, Straight & Angle Clips, Lugs (Assorted), Terminal Blocks,
(Assorted),Wires, Paint, Thinner, Copper piping, Insulation materials, Miscellaneous items such as
cotton waste, emery paper, detergent etc shall be in the scope of bidder in addition to the requirement
of consumables indicated elsewhere;
d) Every month filter shall be cleaned and every 6 months once, the same, shall be replaced compulsorily
till the end of PWCAMC.
19.5. CPCL’s SCOPE OF SUPPLY
a. Compressed air for cleaning purposes;
b. Water & electricity at nearest point;
c. Issue of necessary Work Permit, Gate Passes for carrying out the job as per CPCL Refinery rules and
regulations;
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19.6. SPECIAL INSTRUCTIONS TO BIDDER

a. Bidder shall carry out the job/activity after obtaining the proper clearance from the production/operation
department;
b. During each visit, the bidder’s service engineer shall report to the site engineer/EIC for planning and doing
the job activities. The visit shall be considered complete only after acceptance of site engineer/EIC;
c. During each visit, bidder has to collect the key of shelter on daily basis and will return the keys on the same
date to the Engineer after completing the job;
d. All personal protective equipment, like safety helmet, safety shoes etc required for working inside battery
area shall be in Bidder’s Scope. Bidder shall follow all safety norms as per present HSE norms from time to time;
e. Bidder to do cleaning of site after doing the servicing/maintenance job to maintain the necessary ambience;
f. During each visit, bidder’s service engineer shall work in general shift duties of 08 hours duration;
g. During each visit, the service engineer shall put a service tag on each of the respective HVAC after completion
of the servicing. The service tag shall have the following details:
i. Tag no.
ii. Serial no.
iii. Date of checking
iv. Next due date of checking
v. Signature
The Bidder’s personnel will follow the CPCL duty calendar and leave pattern for general shift duty in normal
working. In event of exigencies or otherwise as per work load, bidder can work beyond scheduled duty hours
with consent of site engineer/EIC without any extra payment.
h. Bidder’s service engineer shall take utmost care while maintaining the HVACs in CPCL as per standard
engineering practices and ensure no damage of any equipment due to negligence.
i. In case of breakdown of HVAC system, bidder should be attended within 24 hr after receiving of complaint.
Emergency/Break down visits shall be considered 6 visits per year. Any unutilized visits shall be carried over to
next year and so on till the end of PWCAMC period. During any month if the breakdown/emergency visit falls
first, bidder shall club the same with the PM visits and complete the activities for the month.
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j. Service personnel to wear IFR during the warranty and post warranty period and all required PPE.
19.7. SPECIAL CONDITIONS OF THE CONTRACT
The Objective of the AMC is to maintain 100% availability of the HVAC systems.
1) Vendor shall depute Qualified/Certified HVAC Engineer and Technician with no less than 2 years of
experience in handling and maintaining HVAC units
2) Vendor shall carry out scheduled Monthly PM activities for ensuring healthy functioning of the HVAC
systems. Checklist of activities to be performed under PM to be prepared by the vendor and approved
by the EIC.
3) All tools and tackles, bracing tools, refrigerant cylinders, vehicle for movement and PPE’s in the scope
of the vendor.
4) Work at any unit to be started after proper permits have been obtained. CPCL will ensure work fronts
are made ready.
5) The service engineer shall maintain a service log book at the site indicating the activities carried out
during preventive and breakdown maintenance and also submit service/repaired/replaced along with
fault analysis.
6) Boarding and lodging for the visit in the scope of the vendor.
19.8. PAYMENT TERM

Monthly payment at the end of each month after completion of PM visits.
Page 46 of 57
20. LOGISTIC SUPPORT CERTIFICATE FORMAT
CERTIFICATE FOR LOGISTIC SUPPORT
(To be signed by vendor's principal corporate level signatory on company letterhead)
I, on behalf of M/s __________ confirm that the HVAC system quoted by us for CPCL, Chennai, India against
tender document no ___________ shall continue to be supported by us and quoted system shall not be
withdrawn from ‘’Indian’’ market as a matter of corporate policy
I, further confirm that in case of placement of order by M/s CPCL on us M/s______ shall be supported in
providing back-up engineering, maintenance support and spare part support for a period of not less than ten
(10) years
From the date of placement of order
(SIGNATURE WITH SEAL)
Page 47 of 57
21. PROVEN TRACK RECORD (PTR) FORMAT

S.NO. DESCRIPTION AS OFFERED FOR SYSTEM AS SYSTEM AS
THIS PROJECT INSTALLED @ SITE 1 INSTALLED @ SITE 2
1. NAME OF THE PLANT
2. Name, Address, Fax No., E-Mail & Telephone No. of contact person in the plant
3. Name, Address, Fax No., E-Mail of consultant
4. Month & year of supply
5. Any major breakdown till date
6. If yes, cause of breakdown
7. Details of offered HVAC system
8. SYSTEM USED FOR: End application – Name of the plant/unit
9. SCOPE OF VENDOR’S RESPONSIBILITY
a) Manufacturing of HVAC system
b) Design and supply
c) Factory testing/Factory Acceptance Test
d) Site installation, commissioning
10. SALIENT FEATURES OF OFFERED SYSTEM OVER EARLIER INSTALLED SYSTEMS
VENDOR’S STAMP AND SIGNATURE
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ANNEXURE -1 PLANT 211 SHELTER
DRAWINGS
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ANNEXURE-2 PLANT 214 SHELTER
DRAWINGS
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ANNEXURE- 3 - PLANT 206 SHELTER
DRAWINGS
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TECHNICAL SPECIFICATIONS AND SCOPE OF WORK

– ANALYZER SHELTER HVAC

ANALYZER SHELTER HVAC

The following definition shall apply:

Purchaser/Owner : Chennai Petroleum Corporation Limited, Manali Refinery (CPCL)

Bidder/Vendor : The firm which quotes for the supply of HVAC

Site : Manali Refinery, Chennai. Tamil Nadu, India.

- Ambient temperature (Max/min.): 45 deg C /18 deg C.

3. BRIEF DESCRIPTION OF THE REQUIREMENT

5.9. The entire unit shall be self-containing HVAC

5.20. Gas detection, fire/gas dampers shall be provided.

5.36. DESIGN DOCUMENTS

HVAC design documents shall include the following:

Annexure -1 : HVAC for DHDT Analyser Shelter

1. Application Shelter Air conditioning

2. Design As per NFPA 496

3. Operation 5 air changes per hour

5. Shelter Condition (Max) 28degC

6. Shelter Design 22degC +/- 2degC

7. Shelter Over Pressure +2.5 mmWC

8. Classification Gas group IIC, Zone 1, Temp class T3

9. Power supply 415V, 3 Ph., 50 Hz.

10. Refrigeration Capacity 3 TR – 1 NO.

Model: Vendor to Specify

Power Consumption: Vendor to Specify

S.No. Parameter Requirement Bidder’s

12. Condenser Fan AXIAL TYPE

Model : Vendor to Specify

Air flow : Vendor to Specify

13. Condenser Motor Motor Certified for GAS group IIC

Power Consumption: Vendor to Specify

MAKE : Vendor to Specify

Model: Vendor to Specify

S.No. Parameter Requirement Bidder’s

Air flow : Vendor to Specify

17. Blower Motor Designed for continuous operation.

Power Consumption: Vendor to Specify

19. Motors – Fans Certified flameproof zone 1 operation.

20. Refrigeration Gas Vendor to Specify

21. System Test Pressure 300psig (for 48 hours with nitrogen)

22. Suction Pressure 65 psig - 80psig

S.No. Parameter Requirement Bidder’s

26. Air filter Box type Air Pre filter Filter

S.No. Parameter Requirement Bidder’s

7.4. Fan general requirements

j. Connections to adjacent ductwork or components shall be by means of 150 mm long flexible

7.5. Fan motors

- Protective coating applied to the coil and fins

- Enclosed header tubes

- Enclosure with sand-trap louvres.

h) Refrigeration packages shall use Manufacturer’s standard control systems.

7.9. HVAC Equipment Drainage

b) Operational status of systems and main HVAC equipment

7.14. Equipment Nameplates

The following information shall be shown:

a) Equipment tag number

8.2. Code And Standards

Practices and norms shall govern.

Otherwise specified in data sheet/job specification.

Centrifugal fan Rated BKW Motor MCR (% of Fan Rated BKW)

Less than 22 125%

More than 55 110%

- Turning Guide Vanes.

Splitter Damper with control rod & locking device.