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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

lR;eso t;rs
SPECIFICATION FOR CENTRALIZED AIR VENTILATION WITH AIR COOLERS OF WAITING ROOM AND DEPARTURE LOUNGE AT THE STATIONS

Specification No. RDSO/2009/EM/SPEC/0001, (Rev.0)Amdt.1

S N 1. Amendment No. Date 08.11.2010 1 Revision No. Date Reason Clause Nos. 13.0 (Guarantee), 14.0 (After sales service) and 16.0 (ISO 9000 Accreditation) Deleted as per Railway Boards letter No. 2006/ Elect.(G)/150/9/Pt. dated 10.09.2010

ISSUED BY -

ELECTRICAL ENERGY MANAGEMENT DIRECTORATE RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW 226 011

Approved by

Executive Director / EEM

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INDEX Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 Description Foreword Reference Standards General Requirement of Air Ventilation Design & General Construction Installation & Operation General & Safety Requirement Noise Protection Tests Marking Instruction & Maintenance Manual Training Guarantee : Deleted After Sales Service : Deleted Infringement of Patent Rights ISO Accreditation : Deleted Page 3 3 3 4 8 8 9 9 10 12 12 13 13 13 13 13

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SPECIFICATIONS FOR CENTRALIZED AIR VENTILATION WITH AIR COOLERS OF WAITING ROOM & DEPARTURE LOUNGE AT THE STATIONS 1.0 Foreword: This specification defines the objective, guidelines and requirement for the design, manufacture, supply. Installation, testing and commissioning of centralized air ventilation with air cooler at waiting room, passenger halls etc at stations of Indian Railways. 2.0 Reference Standards IS:694 :1990: IS:325 :1970: IS:4691 :1985: PVC Insulated Cables for working voltages up to & including 1100V Three phase induction motor. Degree of protection provided by enclosure for rotating electrical machines

IS:6272 : 1987: Cooling fan. IS:302: 1979: General & safety appliances. requirements for electrical

IEC 60529:2001: Degree of protections provided on enclosures (IP Code) IS:2184: 1968: Flame proof enclosures for electricals apparatus. IS:4722: 1968: Rotating electrical machines IS:2992: 1965: Insulation resistance testers. IS:4728: 1975: Terminal marking & direction of rotation electrical machinery. IS:3615: Various technical terms used in air conditioning. IS:9542: Horizontal centrifugal mono block pump. ASHRAE Standard 62.1-2001 Note: Latest version of the above specifications shall be referred to.

3.0

General Requirement of Air Ventilation The total minimum out side fresh air introduced into an enclosure by positive ventilation method shall be related to the numbers of occupants in the enclosure at any time. The national consensus standard for out side air ventilation is ASHRAE Standard 62.12001. Calculation for ventilation required can be done as shown below :-

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No. of person per 10 sq. meter of floor area : 15 (assumed) Ventilation required per person : 25.5 CMH Total ventilation required : 25.5X15 =382.5 CMH per 10 sq. meter floor area Therefore, depending on the floor area and occupancy of that area, requirement of fresh air can be calculated for designing of ventilation system. It shall be possible to control the humidity of individual location through suitable control such as regulation of circulation of cool water. To determine volumetric flow rate, the average measured air velocity is multiplied by the cross sectional area of a duct. For example, if a duct is 0.61 meter by 0.61 meter (cross-sectional area- 0.3721 square meter) and the average measured air velocity is 2741 meter per hour. The resulting volumetric flow rate is 2741 meter / hr x 0.3721 square meter or 1020 CMH. 4.0 Design & General Construction In this system cooling is due to adiabatic exchange of heat between air & water spray or wetted surface. A good indicator of proper ventilation is the level of carbon dioxide present in a space. Carbon dioxide is a normal by product of respiration, combustion and other process. Elevated level of Carbon dioxide may indicate that additional ventilation is required. ASHRAE Standard 62 recommends an indoor level not to exceed about 700 ppm above outdoor ambient air which is typically about 300 to 400 ppm. Such system comprises of Air handling unit, Ducting and water circulation system. The tenderer shall also take into account the level of humidity prevailing in different regions while designing the system. 4.1 Air Handling Unit (AHU) AHU shall be double skin horizontal floor mounted, low noise, sturdy, screw-less cabinet construction and better thermally insulated. All components shall be mounted on an integral base frame and be designed to prevent condensation on the exterior skin. Alternatively, AHU can be vertical type to occupy lesser floor space or ceiling suspended type requiring no floor space. Selection of the type of AHU shall be based on the rating and the site condition. 4.1.1 (i) Casing The AHU base frame shall be of 14G galvanized steel sheet.

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(ii) (iii)

Frame of AHU shall be made of smooth rounded extruded aluminum anodized profiles with fiber glass corner joints. Insulated panel shall be fixed on the aluminum frame using overlap design wedges to achieve screw less construction for easy assembly. 3.0mm thick special gasket shall be fixed on frame below the panels for improved air tightness of the cabinet and better thermal and acoustic performance. These double skin sandwiched panels shall be made of Outer skin: Inner skin: 0.6mm, 23G pre-painted galvanized sheet with PVC guard film. 0.6mm, 23G plain galvanized sheet.

(iv)

(v)

Panel shall be 25mm thick, pressure injected with polyurethane foam using CFC-Free, R-141b blowing agent. Uniform PUF density of 38+/-2kg/m3. The casing shall be designed in such a way that humidification section is fitted inside in a modular way. Pre-Filter Section

(vi)

4.1.2 (i)

The main purpose of the filtration system is to remove larger particles and to protect the cooling system from dirt build-up. Pre-filter provided shall be of synthetic non woven type washable HDPE and supported with aluminum frame. Filter efficiency shall be 90% for 20 micron (Eurovent class EU-3 as per EN799). Humidification Section. Humidification section consists of cellulose pad, water circulation pump and sump for water storage. This section shall be modular for easy fitment inside the AHU Cellulose pad Humidification section shall be double skin with 0.6mm, 23G stainless steel, 304 grade for inner skin & 0.6mm, 23G prepainted GI sheet for outer skin. Cellulose pads on side/sides of the humidification section shall be provided for the purpose of water circulation. Designing of pads shall be done for air inlet velocity not exceeding 10058 meter/hour. Desired efficiency of the cooling pads shall not be less than 90% and thickness shall not be less than 200mm(8).

(ii)

(iii)

4.1.3

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Sump Water sump shall be fabricated of 1.2mm 18G thick stainless steel grade304. Pump (i) Water circulating pump shall be monoblock type with IP-55 protection. Water level switch to be provided for safety against wet run of pump. Size & material of float valve 20mm dia, heavy duty brass PVC droplet eliminator to be provided. Fan & Motor A fan is an air moving device comprising a wheel or blades and housing. (i) Fan and motor shall be mounted on aluminum extruded slide rail base frame to adjust belt tension without disturbing motor alignment. Fan section shall be provided with an access for easy in servicing. View port shall be provided at fan door panel which would help monitoring fan & motor status. Door limit switch shall be provided to automatically trip fan with the door is open. Factory fitted opposed blade aerofoil aluminum volume control damper to facilitate balancing. Aluminum die cast powder coated hinges shall be provided. The forward curved double inlet double width (DIDW) centrifugal fan shall be AMCA (Air movement & control association) certified.

(ii)

(iii) (iv) 4.1.4

(ii) (iii)

(iv)

(v)

(vi) (vii)

(viii) Fan & motor assemblies shall be mounted on anti-vibration pads to prevent noise/vibration transmission. Spring isolators to be provided at fan-motor for anti vibration. (ix) The fan blade shall be designed for maximum efficiency and quiet operation.

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(x)

The fan shall be statically dynamically balanced. Whole fan assembly shall be trim-balanced to ISO-1940 and AMCA 204-G 2.5 standard. No readily flammable material shall be used in the construction of fan. Molded parts, if used, shall be of such materials as will withstand the maximum temperature attained in the adjacent component parts. The impeller and scroll shall be made of galvanized steel sheet.

(xi)

(xii)

(xiii) Motor shall be standard frame with open drip-proof enclosure and shall be suitable to operate at 415V +/- 10%, three phases. (xiv) (xv) Fan motors are to have a maximum rotating speed of 1500 rpm. Motor shall be 4-pole, TEFC with class F insulation and IP-55 degree of protection. Fan rotating speed is to be in accordance with air flow amounts and fans are to be belt driven where speed differentials exist between motor and fan.

(xvi)

(xvii) Driven set of V-belt and pulley (statically and dynamically balanced) to be provided 4.2 Air Ducting A passageway made of GSS complete with necessary support hanger, nut bolts and gaskets etc, used for conveying air at low pressure. Air velocity is seldom uniform across any section of an air duct. The shape of a duct, its turn and branches and friction all effect the movement of air. In general air tends to move slower toward the edges or corners and faster in the center of a duct. All metal duct work shall confirm to the requirement of IS : 644. Duct size and GSS sheet thickness shall be designed as per the following table:Type of duct Main Duct Main branch Duct Branch Duct Air Velocity inside duct 4 - 7 m/s 3 - 5 m/s 1 - 3 m/s GSS sheet thickness 18G 20G 22G

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4.2.1

Air Grills Powder coated extruded section aluminum grills, with GI volume control dampers shall be provided with the duct as fresh air inlet in ventilated area.

4.2.2

Air Outlets: Provision of air outlet of capacity at least 80% of inlet air shall be provided in the ventilated area. It may include windows, ventilator, exhaust port etc. If room is covered from all side duct of suitable size with 22G GSS sheet shall be provided as air outlet.

4.3

Control Panel Control panel shall be provided with powder coated control box to house isolator single phasing preventor and contactors for starting of the motor. Control panel shall be compatible with BMS. On-off trip indications and luminous push buttons shall be provided. Provision shall also be made to connect control value, fire dampers, modulating motor and door switch.

5.0

Installation and operation All ventilation equipment works such as fan & motor, filter and duct work etc, shall be located at convenient places to facilitate periodical inspection, cleaning and maintenance. Duct-work shall conform to IS: 655 (specification for metal air ducts). The system with acceptable noise level or below should be designed. Suitable noise damping method shall be applied.

6.0 6.1

General and Safety Requirement Protection against Electric Shock In the assembled fan motor & monoblock pump, live parts shall not be accessible to the standard test finger. This requirement is applicable for all positions in normal use.

6.2

Electric Insulation The electric insulation of the fans motor & mono-block pump shall be adequate and the leakage current in normal use shall not be excessive. The insulation resistance shall be not less than 10 M .

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There shall be no breakdown of the insulation when the both is subjected to high voltage test or flash test, as the case may be. 6.3 Finish All the surface of both fan motor and blades shall be of corrosion resisting material or shall be suitably and durably protected against corrosion. 6.4 Interchangeability The motor of the fan & mono-block pump of a particular size and model shall be interchangeable such that the performance of the fan & pump keeps with in limits specified in this standard. 6.5 Silent Operation Precautions shall be taken in the manufacture of fan, motor and pump to ensure a reasonable degree of silence at all speeds. 7.0 Noise Careful consideration must be given to preventing noise transmission via the duct work system, through phonic insulation and construction devices, to limit the level of acoustic pressure to the requirement. The extent of noise levels should not exceed 60 db generated by the ventilation equipments. Noise measurement should be done 1 metre away from the end wall and 1.4 meter above the floor level as per relevant standard. Velocity of air from the grill / diffuser should be 3.0 m/sec. in SDCL condition at the height of 1.6 meters from the floor. 8.0 Protection Following protections shall be provided Transient voltage protection Over current protection Short circuit protection Thermal protection The protect the equipment against over load, facility for automatic tripping and disconnecting within 5 seconds shall be provided in case the load current goes beyond 120% of the rated capacity. Metal oxide varistors (MOVs) shall be provided against high potential transient voltage spikes. MCCBs/MCBs of appropriate rating shall be provided along with HRC fuses of suitable capacity, to isolate internal/external faults.

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9.0

Tests In respect of tests for which testing facility is not available with the manufacturer, the same may be carried out at NABL accredited test house/laboratory

9.1

Type Test Type test of the complete system shall be witnessed and cleared by RDSO. The successful tenderer shall prepare detailed test plan and get it approved by RDSO prior to commencement of the tests.

(a) (i)

Air delivery Air delivery measurement at suction end Air velocity shall be measured at different points on suction end. Its average value should be multiplied by suction area to calculate air delivery. Air delivery measurement at delivery end -In this test, air velocity shall be measurement at all diffusers / grills fitted inside ventilation area very closely at three points on each grill. Average value of this velocity should be multiplied by grills area and then number of grills provided in a ventilation area to calculate air delivery. Air delivery measured at delivery end shall not be less than the designed air delivery.. Pressure drop in the air duct The pressure drop shall be measured across the full length of the ventilated area at diffuser grill. Pressure drop at farthest point may be kept within permissible limits by suitable design of ducting. Pressure drop measurement should be done with differential pressure transducers. During measurement of Pressure Drop in the air duct. Following points should be kept into mind. (i) Same length of the sensor should be inserted into the grill during all measurement Sensor of the Pressure meter should be kept in the same direction during all measurement No obstacle / baffle should be there inside the duct/between sensor and air flow during measurement of Pressure drop.

(ii)

(b)

(ii)

(iii)

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(c)

Noise Measurement Noise measurement should be done 1 meter away from the end wall and 1.4 meter above the floor level. In above condition, noise level should not exceed 60 db.

(d)

The fan motor shall be required to pass the tests CL. 23.1, 23.2, 23.4, 23.5, 14.0, 13.1,25.0, 24.0, 15.0, 16.0, 26.0 of IS:325 (Latest version). The mono-block pump shall be required to pass the tests CL.23.2, 27.0 of IS: 325, CL.10.0 of IS: 8418 and IP-55 protection test as per IS: 4691. Fan & Motor efficiency Most efficient fan & motor and pump shall be used by the manufacturer. Efficiency of the fan & motor and pump shall be proved by the manufacturer. Fan Speed The speed of rotation of the fan shall be determined by running the motor and pulley PCD. The speed of rotation also shall be determined by the test voltage and its rated frequency. The method of measurement shall be such that the speed of the fan is not appreciably affected. Leakage Current Test- This test shall be carried out in accordance with 13.2 of IS : 302-1979 . No design change shall be undertaken by manufacturer after type test without prior approval of RDSO.

(e)

(f)

(f)

(h)

9.2

Acceptance Test These are the tests which are being conducted before acceptance. (a) (b) (c) Air delivery Fan speed The motor shall be required to pass the tests CL.23.1, 23.2, 23.4, 14.0, 25.0, 24.0, 16.0, 26.0 of IS: 325. The mono-block pump shall be required to pass the test CL.22.3.2 of IS: 325 except para f & g of CL.22.3.2. Routine test Those tests which are being conducted on each and every ventilation system before supplying to the user.

(d) 9.3

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(a) (b) (c)

Air delivery Fan speed The motor shall be required to pass the tests CL.23.1, 23.2, 23.4, 24.0, 25.0 of IS: 325 The mono-block pump shall be required to pass the test CL.22.3.2 of IS: 325 except para f of CL. 22.3.2. Marking: Each centralized ventilation system shall be provided with a rating plate of weatherproof material fitted on the front panel in a visible position; containing the following information

(d)

10.0

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Type Specification No. Serial No. Month and year of manufacture Air delivery Rated speed Make of the all equipments Power consumption in KW Impeller diameter Weight of the Unit. All markings/indications shall be placed in the vicinity of the components to which they refer & shall not be placed on removable parts. The content of the rating plate shall be indelibly marked by etching or engraving.

11.0

Instruction / Maintenance Manual Three copies of instruction manual containing the following information, shall be supplied along with each centralized ventilation system.: Instructions for installation Wiring diagram indicating the components & their rating. Drawing showing general mounting arrangement of centralized ventilation system and its various components. Bill of material containing list of components, their ratings and make. Step by step maintenance & trouble shooting procedure.

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12.0

Training Training shall be arranged to railway operating & maintenance staff without extra cost after functionally completion of the unit. Training shall include a discussion on equipment design and layout, demonstration on routine operation, maintenance & trouble-shooting procedure.

13.0 14.0 15.0 15.1

Guarantee : Deleted After Sales Service : Deleted Infringement of patent rights Indian Railways shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, use of similar components in the design & development of this item and any other factor not mentioned herein which may cause such a dispute. The entire responsibility to settle any such disputes/matters lies with the manufacturer/supplier. ISO 9000 accreditation : Deleted

16.0