© DMR Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system © DELHI METRO RAIL CORPORATION LIMITED - DMRC ELECTRICAL STANDARDS & DESIGN WING (DESDW) SPECIFICATION NO. DMES-E/0004/ DMRC-E-E&M-VRF-01 SPECIFICATIONS FOR SUPPLY, INSTALLATION TESTING & COMMISSIONING OF VARIABLE REFRIGERANT FLOW SYSTEM Issued on: Date iaomee ‘Stage = 15" Oct 2014 I Draft-1 DELHI METRO RAIL CORPORATION LTD. 7" Floor, B-Wing, Metro Bhawan, Fire Brigade Lane, Barakhamba Road, New Delhi -—110 001. Page 1 of 12© MRC Electrical Standards & Design Wing specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system eae Previous Record of specification Stage Draft -1 Date 15/10/2014 Page 2 of 12 DMES-E/0004Ee DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system 3 Contents 1. Detailed Description and Application in DMRC 2. Governing Specifications 3. Requirement, \ 3.1 Environmental Conditions 3.2 Functional requirements. 3.2.1 VRF, [Link] Outdoor Unit © [Link] Indoor Unit [Link] Centralized system remote controller... 3.21.4 Refrigerant Pipework .. 3.21.5 Drain Piping 3.22 Noise Level 3.23 Input Voltage & Frequency. 4. Additional Requirements. Safety. © Oe ee®aNINVoaoe2nuan 5. 6. Energy Efficiency Maintenance and Life vo este 10 Special Condition. Testing....... meee creer 10 0. Training "1 a oon Page 3 of 12eS DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system 1. Detailed description and Application in DMRG 1.1 Variable Refrigerant Flow(VRF) type of Air- conditioning system is to be provided at the elevated stations(Rail Corridorand depots of DMRC, Generally, the following rooms of the stations shall be air- conditioned. Station Control Room Ticket Office EFO . Signal Maintenance Room Signal Equipment Room Telecom equipment Room UPS (S&T) Room UPS (Elect) Room Station Manager Room Crew Control Room at specified stations 1.2 The scope of work related to Variable Refrigerant Flow Air-conditioning System, shall generally comprise of but not limited to the following Manufacturing Testing at manufacturer's works ‘Supply and storage, Installation at station Site testing and commissioning Training of DMRC staff 1.3. The VRF type air-conditioning system shall generally consist of Outdoor and Indoor units along with refrigerant piping, its insulation and layout tray. Air distribution system when ducting is provided as per BOQ Drain Piping, Electrical works. Materials and components not specifically stated in the specifications and/or bill of materials or noted on the drawings but which are necessary for satisfactory installation and operation of the system. Page 4 of 12eS DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system aaae 2. Governing Specifications The VRF type air-conditioning system shall comply with standards mentioned particularly in the table below unless otherwise stipulated in the specifications. The latest version of standards shall be applicable. AHRI-1230 (or the latest) ASHRAE latest standard and guidelines, UL-94- VO 7 Indian Electricity Rules- 2005 3. Requirements : ‘The VRF system shall be designed to meet the following minimum requirements: 34 Design Parameters 3.1.1. The following parameters shall be considered for the design [Link] Outside Conditions DB ] WB ‘Summer 42 deg C 22.4 deg C | Winter 32.3degC 29.1 deg C [Link] Inside Conditions ‘Summer & Monsoon 24 T deg C (Relative humidity not exceeding 60%) o [Link] Fresh Air: As per ASHRAE, [Link] Lighting Load: 1.2 WiSq ft. [Link] Ducting(For Air conditioning) Maximum Air velocity ‘460 mtrs/min Maximum Friction Tom WG per 100 mirs run | Maximum velocity at exhaust air grille 15 mtrs/min Page 5 of 12eS DMRC Electrical Standards & Design Wing DMES-E/0004 ations For Supply, Installation, Testing & Commissioning of Variable Refrig int Flow system 3.2 Functional Requirements 3.2.1 VRE The Variable Refrigerant Flow (VRF) System should be air cooled, consisting of modular condensing outdoor units connected to multiple indoor units. Each indoor unit shall have the capability of individual set point control. Each modular condensing unit should incorporate at least one inverter base compressor to obtain 10% to 100% step less capacity control to match the air-conditioning load. The refrigerant used should be environmental friendly. The manufacturer shall take a note of the ambient air pollution prevailing in Delhi/NCR region and shall provide proven protection against corrosion to e all the components of VRF module. The VRF air conditioning system shall consist of the following sub-systems:- [Link] Outdoor unit The outdoor unit shall be a factory assembled unit housed in a sturdy weather proof casing constructed from rust-proofed mild steel panels coated with a baked enamel finish. There should be no scaling, corrosion or any other physical deformation on the body of Outdoor unit. The outdoor unit shall be modular in design and thickness of the sheet used for manufacturing the body shall be such that it shall not deform during handling and may use corrugation to strengthen the body structure. The Outdoor unit shall at least have the following sub-components:- + Compressor The compressor shall be of highly efficient capable of capacity modulation and shall have at least 1 No. variable compressor up to 20 HP and 2 Nos. up to 40 HP unit, + Heat Exchanger The Condenser fins must be coated with Anti-corrosive treatment. «Refrigerant Circuit The equipment must have inbuilt refrigerant stabilization control for proper refrigerant distribution. * Oil Recovery System Each unit shall be equipped, with an oil separator to ensure stable operation with : long refrigerant piping. The system should have inbuilt oll balancing circuit to Page 6 of 12Se DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system Bee avoid poor lubrication. In case if it is not required due to a specific design criteria, the same shall be submitted [Link] Indoor unit Indoor unit shall be Wall mounted with metallic body, or as per the BOQ. CFM shall be as per the approved design. It shall have electronic control valve to control refrigerant flow rate in response to load variations of the room. The indoor unit should be designed such that in case of failure/ trip of one indoor unit, the working of ODU and other indoor Units should not be affected. The indoor unit fan shall be direct driven. The indoor unit casing shall be fully insulated and sealed to prevent condensation. Each indoor unit shall have the capabilty of individual set point control ~ 3.2.1:3 Centralized system remote controller ‘A multifunctional compact centralized system remote controller shall be provided with the system. The System Controller shall provide proven air conditioning management system to give complete control of VRF air conditioning equipment, It should be user friendly It should be able to control all the indoor units connected at a station, with a provision for 25% future additional indoor units. The centralized system remote controller shall perform the following minimum functions: |. Starting /stopping of Air conditioners as a zone or group or individual unit. Il. Temperature setting for each indoor unit or zone. lll. Switching between temperature control modes, switching of fan speed. - IV. The address of the indoor unit shall be set automatically in case of individual and group control V. Monitoring of operation status such as operation mode & temperature setting of individual indoor units, maintenance information, trouble-shooting information. VI. Scheduling of both Indoor and Outdoor units as per the requirement. Vil. A provision of wiring the centralized system controller to the indoor unit, upto a distance of 1 km shall be made. [Link] Refrigerant pipework All interconnecting pipe-work between the condensing unit & indoor units shall have quality seamless copper tubes with brazed connections and the appropriate distribution Page 7 of 12© DNRC Electrical Standards & Design Wing DMES-E/0004 ‘Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system Bae joints and headers shall be used. The piping should be routed at site in such a manner, that brazed joints in the Refrigeration Piping are kept to a minimum. The refrigerant pipe shall be thermally insulated by proven materials having low thermal conductivity, high mechanical strength, non-combustible, resistance to Fungi, ozone, UV and any other environmental pollutant. Moulded tee joints of thermal insulating material shall be used at bends. The refrigerant piping shall be extendable minimum 165 m with 50 m level without any oil trap. Distribution refrigeration pipe joints and headers shall be installed in an appropriate orientation to enable correct distribution of refrigerant. The Distribution joints shall be factory insulated. All pipe-work must be kept clean and free from contamination to prevent breakdown of the system. All pipe ends shall be kept sealed until immediately prior to making a joint. [Link] Drain piping 3.22 ~~ 323 The indoor units shall be connected to vertical drainage GI pipe. The pipes shall be laid in proper slope for efficient drainage of condensate water. Drain pipes carrying condensate water shall be insulated. The joints shall be properly sealed with synthetic glue to ensure proper bonding of the ends. Noise Level The Noise level of outdoor unit shall not be more than 68 dB(A)at normal operation. The Noise Level of indoor unit shall not be more than 42 dB(A) for non ductable type and not more than 49dB(A) for ductable unit type. The noise level shall be measured at a distance of 1m away(horizontally) and 1.5m above ground, Input Voltage & Frequency All the outdoor unit shall be suitable for operation with 415 V #10%, 50+3% Hz, 3Ph 4 wire AC supply where as all indoor units should be with 220 Vt 10%, 50Hz +3 % Single Phase supply only. Additional Requirements The power/controV/communication cable between indoor and outdoor units shall run in GI conduits, The insulated refrigerant piping and cable between indoor and outdoor unit shall run in a Galvanized Steel raceway with proper supporting arrangement. There shall be proper securing arrangement of top cover with the bottom tray. Page 8 of 12© Owerc Electrical Standards & Design Wing Spe tions For Supply, Installation, Testing & Commissi 43 44 45 52 53 64 ing of V rant Flow system All galvanized support beams, galvanized legs, galvanized hangers, anchor bolts, vibration isolators, and ductworks shall be provided for the installation of the units, assembly and its sub-assembly. The VRF type air conditioning units shall be mounted on vibration isolators and installed in accordance with the manufacturer's recommendation such that no disturbing vibration or noise is being transmitted to the nearby structure, The centralise system controller shall be located in a properly sized box with lock and key facility along with its battery unit. The power supply cable for the controller shall be taken in a conduit from the nearest 230V socket. A guidance manual of the controller shall be located in this unit. Safety All necessary safety devices shall be provided in the indoor and outdoor units to ensure the safety operation of the system. The design of the safety system shall be such that the equipment is protected and defect of one unit shall not lead to consequential damage to any other units. The safety and protection design shall be submitted with the offer and shall be a part of the training course to DMRC official. The following safety devices shall be part of the outdoor unit: High Pressure Switch Low Pressure Switch Fan Motor Safety Thermostat Over Current Relay Fusible Plug Fuse Noneroene Overload protection including overload protection for inverter driven compresser. 8. Protection for indoor fan motor All the material used in the manufacturing of VRF system shall be fire retardant. The indoor unit shall be in conformance to UL-94 guidelines. The manufacturer shall submit UL compliance certificate with the offer. Energy ef ney Only the best manufacturing practices i.e. the units with maximum IEER as per AHRI- 1230 standard with addendum will be accepted. The contractor shall study the best available designs and offer the best IEER available in industry. However, the VRF unit Page 9 of 12, DMES-E/0004; ee a DMES-E/0004 should provide a minimum IEER of 16. The weightage system and formulas used for all calculations shall be as per AHRI 1230. 6.2 _ IEER shall not derate more then 10% at 43°C. 7. Maintenance and life 7.1 The service life of the VRF system shall be at least 20 years, with average 12 hours working per day during the year. \ 7.2 The manufacturer shall submit the list of those items whose life does not match with the service life of VRF. The life of such spares shall be advised with a certificate from the original manufacturer of the spares. The firm shall supply purchase specification of these items. 7.3 The manufacturer should also submit Annual Maintenance cost rates for the full service life of the system. 7.4 — The manufacturer shall provide free service and guarantee for 24 months from the date . of taking over the metro station by the purchaser. 8. Material and manufacturing . 81 Quality Assurance and Controls: The Contractor's Management Systems shall emphasize quality assurance and controls. The programme shall be adequate to ensure . an acceptable level of quality of the equipment supplied. The concept of total quality assurance shall be based on the principle that quality is a basic responsibility of the Contractor's organization, and shall be visible by: 1. Firm procurement and job performance specifications. 2. Firm procedures for transmission of information and data to their Subcontractors and . ensuring their compliance. 3. Adequate testing to ensure repetitive product conformity to design requirements and Total programme of surveillance and verification of physical performance and configuration accountability. 4, Adequate records shall be kept by the Contractor to provide evidence of quality and accountability. These records shall include results of inspections, tests, process controls, certification of processes and personnel, discrepant material, and other quality control requirements Complaint Handling and commitment towards customer satisfaction Page 10 of 12© DMRC Electrical Standards & Design Wing DMES-E/0004 82 The manufacturer shall ensure use of best manufacturing practice like quality of bends, no sharp comers, and no metallic parts with sharp edges, use of quality gasket at appropriate loss to damp vibrations and sealing etc. 83 The manufacturer shall study the environmental pollution data prevailing near the Metro Station where its equipment is going be installed. The manufacturer shall take adequate precaution either during manufacturing or installation to prevent any damage to the ‘equipment or loss of life arising due to prevailing pollution level. 9. Testing . 9.1 The unit shall be tested for capacity and IEER as per AHRI conditions at manufactures premises or at an accredited laboratory. Capacity at 43° C will also be tested. The r capacity of ODU and IDU’s shall be as per the BOQ. 100% capacity of ODU’s should be delivered at 35°C, as per the AHRI conditions and deration of capacity upto 43° C should not be more than 10%. 9.2 The manufacturer shall also submit the deration graph for different ambient conditions in the performance of their VRF system starting from the maximum ambient temperature conditions as specified in this specification. 9.3 Before delivery, owner/ their representative reserve the right to witness the test in presence of tenderers and manufacturers representative. 9.4 The manufacturer shall submit Installation guidelines duly approved by Engineer-in- charge. The manufacturer shall ensure compliance of installation guidelines and shall sign the installation certificate before commissioning of the plant to start. 9.4 After complete installation of refrigerant piping, it shall be pre-pressure tested and o repaired if necessary and further pressure tested to 3,800 Pa, to hold for a minimum 24 hours with dry nitrogen prior to insulating the joints 9.5 After satisfactory testing, the refrigerant pipe shall be evacuated and dehydrated to (- 755 MM HG) and held for one to four hours depending on the pipe length 9.6 The FAT plan for VRF equipment shall be as per Annexure-A. 10. Training 10.1 The contractor shall ensure training of DMRC staff as decided by DMRC at DMRC workplace or at his workplace as considered necessary. Page 11 of 12Qe DMRC Electrical Standards & Design Wing DMES-E/0004 Spe ications For Supply, Install ing of Variable Refrigerant Flow system As Built Drawings. * Do's and Don'ts for the maintenance and operating staff. + Working details of VRF system. ‘+ Operating manual. + Extracts of the warrant/DLP. ‘+ Details of service center. ‘* List of staff trained on the said design of the VRF, 7 ‘+The first page of the booklet shall be signed by the manufacture, contractor and DMRC Engineer. ‘+ Soft copy of the entire documents. Page 12 of 12Se DMRC Electrical Standards & Design Wing DMES-E/0004 ions For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system aa ANNEXURE: PHYSICAL PARAMETERS TO BE CHECKED COMPONENT PARAMETER _ | Requirement Remarks 7. | OUTDOOR UNIT | Casing Weather proof casing constructed | from rust-proofed mild steel panels coated with a baked 4 | enamel finish | Compressor | Minimum 1 no. 7 variable compressor | upto 20 HP capacity, 2 nos. variable compressors beyond 20 HP. 2. | INDOOR UNIT ‘Component Electronic Expansion Valve insulation fully insulated and sealed 3. | HEAT EXCHANGER | Construction | The Condenser fins ] must be coated with Anti-corrosive treatment, REFRIGERANT Component ‘Accumulator CIRCUIT Component Liquid and gas shut | off valve | ‘Component Solenoid valves 5. | OILRECOVERY | Component Oil Separator __| SYSTEM 7 6 | SAFETY DEVICES | Component High Pressure | ‘Switch | | ‘Component Low Pressure | ‘Switch | Component | Fan Motor Safety Thermostat ‘Component ‘Over Current Relay | ‘Component Fusible Plugs ‘Component FuseSpe © MRC Electrical Standards & Design Wing ations For Supply, Installation, ing & Commissioning of Variabl DMES-E/0004 i | FAN MOTOR ‘Component Thermal protection relay. CENTRALIZED SYSTEM TOUCH SCREEN REMOTE CONTROLLER ‘Component Provision of wiring the centralized controller to indoor unit upto a distance of 1 km. TECHNICAL PARAMETERS TO BE CHECKED Sr No. COMPONENT PARAMETER REQUIREMENT REMARK OUTDOOR UNIT Cooling capacity 100% cooling capacity at 35 Deg C ambient temperature and deration not more than 10% at 43 deg C. Noise level 68 dB(A)at normal operation measured horizontally 1m away and 1.5m above round. coP As per ARI Conditions INDOOR UNIT Noise level NOISE Level < 42dBA for non ductable type and <49qBA for ductable unit type. REFRIGERANT PIPING Length Extendable minimum165 m with 50 m level without any oil trap FAN MOTOR ‘Speed Control At least two speed operation to maintain constant head pressure control at all ambient temperatures.8 DMRC Electrical Standards & Design Wing DMES-E/0004 Specifications For Supply, Installation, Testing & Commissioning of Variable Refrigerant Flow system ae 5. | CENTRALIZED Operation ‘Starting/stopping of SYSTEM TOUCH | Air conditioners as a SCREEN REMOTE zone or group or CONTROLLER individual unit. Operation Temperature setting for each indoor unit or zone. Operation ‘Switching between \ temperature control modes Operation ‘Switching of fan speed Operation Control direction of airflow Operation Enabling/disabling of individual remote controller operation Operation Monitoring of operation status Operation Maintenance information Operation Trouble-shooting | information. Operation Temperature setting of individual indoor units Gowen le. suet hardly wer 5 ccs fr mens Hat be ab Hs, hoy ng Oe seul Creek for pacrcnge % ; rater prejersen of ot Cbieem tevminals . . unl, Lived Dn undoey Ue a. Fin