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Design Objective:

to
to
to
to

maintain
maintain
maintain
maintain

specified temperature
specified humidity
indoor air quality within occupied area
positive indoor pressure to minimize outside air infiltration

Design Data
1.0 Outside Design conditions
Weather

Dry bulb
temperature

Wet bulb
temperature

Summer

44.4C

27.6C

Monsoon

36.1C

28.3C

Winter

12.2C

10.0C

Relative
Humidity

2.0 Inside Design condition :


22C 1C DBT and 50% 5% RH for critical areas
1.0 TG Building
Control Equipment Rooms for each unit
Common Control Room for two units
C & I Computer rooms for each unit
Shift in-charge room for two units
Record room for two units
UPS Panel room for each unit
3.0 Control room of ESP Control Building
4.0 Control room of common VFD Building
5.0 CHP Control room
6.0 AHP Control room
7.0 BCR room of Switch Yard Control Building
8.0 Control room of CW & ACW Pump house
9.0 Control room LDO Storage tank and pump house
10.0 Control room of Clarified water pump house
11.0 Control room, laboratories and offices of DM plant Building
12.0 Control room of Effluent Treatment Pump House
22C 1C DBT and RH not exceeding 65% for non critical areas

SWAS Rooms in TG Building


CPU Remote I/O cabinet rooms for each unit in TG Building

AC Plant Control rooms in TG Building


AC Areas in Technical Building
Dining hall and attached area of canteen building
Office areas of O&M Store Office building
Control room CW Chlorination Building
AC areas of Chemical laboratories
AC areas of Fire station building
AC areas of Ash Silo Utility building
Two nos. of Central chilled Water type air conditioning plants will be
provided to cater to the air conditioning requirement of the different
areas of the following buildings:
Turbine building ( Unit 1,2,3 & 4)
Technical building
ESP Control buildings
VFD Control buildings
CHP Control building
AHP Control building
A) One Central chilled water type air conditioning plant (AC
Plant#1) will cater the following areas
Control Equipment rooms for unit 1 & for unit 2
Common Control room for unit 1 & 2
C & I Computer rooms for unit 1 & for unit 2
Shift In-charge room for unit 1 & 2
Record room for unit 1 & 2
UPS Panel rooms for unit 1 & unit 2
SWAS Room (Dry panel area) for unit 1 & 2
CPU remote I/O Cabinet rooms for unit 1 & unit 2
Technical building
ESP Control rooms for unit 1 & unit 2
Common VFD Control room for unit 1 & 2
CHP Control room
AHP Control room
AC Plant # 1 control room
B) Another Central chilled water type air conditioning plant (AC
Plant #2) will cater the following areas
Control Equipment rooms for unit 3 & unit 4
Common control room for unit 3 & 4
C&I Computer rooms for unit 3 & unit 4
Shift in-charge room for unit 3 & 4
Record room for unit 3 & 4
UPS Panel room for unit 3 & unit 4
SWAS room ( Dry panel area) for unit 3 & 4
CPU remote I/O cabinet rooms for unit 3 & unit 4
ESP Control rooms for unit 3 & unit 4

Common VFD Control room for unit 3 & 4


AC Plant # 2 control room
C) Air conditioning of different Auxiliary building
1) Air cooled precision Air conditioner cater the following
areas
Switch yard control building BCR Room for unit 1,2,3 & 4
DM Plant building control room
Control room of CW & ACW pump house
Control room of clarified water pump house
Control room of LDO Storage tank and pump house
2) Air cooled ductable Split air conditioner cater the
following areas
Dining hall of canteen building
O & M Store office building
3) Air cooled non ductable split air conditioner cater the
following areas
Control room of CW Chlorination building
Fire station building
Control room of Ash utility building
ETP Control room

Building Construction Data


Following building constructional details should be considered for the airconditioning cooling load calculations:
a) Exposed walls
:
230mm thick brick wall + 12mm thick plaster inside +
20mm plaster outside
b) Partition walls
:
115mm thick brick wall + 12mm thick plaster on both
sides
c) Floor
: 150mm thick concrete block + 40mm thick cement
concrete + 12mm thick
kota stone/mosaic tiles
d) Roof
:
150mm thick concrete block + 20mm thick cement
mortar + 20mm thick

Terrazzo tiles.
To reduce the air-conditioning load, the exposed roof slabs of air-conditioning
areas, AHU room, precision air-conditioning room shall be insulated with
50mm thick TF quality expanded polystyrene(under deck) of density
16kg/cum or equivalent insulation.
Air-conditioning spaces shall be maintained at positive pressure to avoid any
infiltration of dust.
Cooling Load Margin:
Cooling load margin shall be 5% on room sensible heat and 5% on room
latent heat and overall margin around 10% on the total.
Fresh air shall be inducted to the air re-circulation system @ 34 CMH per
person for all areas and 12.75 CMH per person for Conference room or 1.5
ACH for control room area and 1 ACH for office and other areas, whichever is
higher.

Design Parameters and Details of Air-Conditioning System


Equipment
1.)

Air Handling Unit


Fan: Fan shall be DIDW backward/forward curved blade centrifugal
type. The impeller and scroll casing of fan shall be made of steel.
Fan shaft shall be of carbon steel.
Drive: Centrifugal fan shall be equipped with V-belt drive and belt
tensioning arrangement.
Dry Filter: The filter media shall be designed to hold dust and
prevent it from being dislodged by vibration. The filter shall be dry
panel type.
The face velocity of air across the filters shall not
exceed 2.5 m/s. Maximum pressure drop will be 6mm wg. Filter
thickness shall be at least 50mm. The efficiency of filter shall be
about 90% down to 10 microns particles size.

Cooling Coil: Cooling coil for chilled water shall consist of


seamless copper tubes with aluminum fins. The number of rows
shall be minimum 4 and shall follow even number.
The number of fins in the coils shall not exceed 13
per inch. Velocity of air across the coils shall be limited to 2.5
m/sec.

Casing: The casing shall be of double skin type GI with at least


25mm thick PUF insulation (density 35kg/m3) in between two
skins. Casing shall be complete with supply air outlets with

volume control damper and flexible connections. Outer skin of


AHU shall be powder coated.

2.)

Fan Coil Unit (FCU): FCU shall be complete with chilled water
cooling coil, one or more centrifugal fans and motors, cleanable HDPE
filters, double wall insulated condensate drain pan with 15 mm thick
expanded polystyrene insulation sandwiched between top and bottom
sheets of drain pan .
Cooling coil shall be standard three row staggered seamless
copper tube with aluminum plate fins mechanically bounded to cupper
tubes. All coils shall be factory tested at 21 kg/sq.cm. air pressure while
submerged in water. Fins spacing shall not be less than 10 fins per inch.
Fans shall be centrifugal, forward curved and direct driven.

3.)

Piping:

A) Refrigerant Piping: Refrigerant piping shall be M.S. Seamless (as


per IS-1239, Part-I heavy grade) or copper tube(IS-5493)
B) Water Piping: Condenser cooling water piping and chilled water
piping
Up to 150 NB: M.S. confirming IS-1239, part-I heavy grade (Class C)
Above 150NB: M.S Pipe confirming IS-1239 Part-I heavy grade.
Drain Pipe: GI Pipe heavy class

Piping shall be so designed that the water velocity through the


piping shall not exceed 2.5 m/sec. and piping friction drop shall
be limited to 4m per hundred meters of pipe length.
C.) Steam Piping: Steam piping shall be of ASTM-A Carbon
grade-B with 50mm thick fiberglass/mineral wool thermal
insulation covered with 30G sheet.
4.)

Air Filters:

A.)

Pre-filters: The filter media shall be designed to hold dust and

prevent it from being dislodged by vibration or other cause and


passing through filter.
The filter shall be of HDPE construction. The filter shall be GI
frame of adequate thickness not less than 20 SWG. The filters may be
in panels of sizes about 600mm X 600mm for easy handling.
The face velocity of air across the filters shall not exceed 2.5 m/sec
and maximum pressure drop will be 6 mm of WG. Filter thickness will
be at least 50mm. The efficiency shall 90% down to 10-microns
particles size.

B.)High Efficiency Filters: The filter shall be having efficiency 99%


down to 5 microns. The filter shall be of cleanable type construction of
reinforced glass fiber or cotton fabric sandwiched between two
galvanized wire netting.
The filter shall have G.I. frame of adequate thicknes.The
filters may be panels of size about 600mm X 600mm for easy handling.
Face velocity of air across the filters shall not exceed 1.5
m/s and maximum limitation pressure drop will be 15 mm of WG. Filter
thickness will be at least 250 mm.

5.)

Duct Work: Velocity of air in supply duct shall not exceed 8 m/s for
main duct and 6 m/s for branch duct.
Spacing of duct supports shall not exceed 3 m centers.

6.)

Dampers:

A.)Splitter Damper: Splitter dampers in branch take off shall be


provided.
B.)Fire Damper: Fire damper shall be motorized type operated by smoke
detectors of the zone fire fighting system. The fire dampers shall be
smoke-tight type and shall have 2 hours fire rating
Motorized fire dampers shall be rated for 240 V, 50 HZ, 1 ph,
AC supply. Damper shall close on de-energisation and open on
energisation of motor.

Fire dampers will be provided at the supply/exhaust duct for fire rated walls/floors

7.)

Diffusers, Grilles: Designed shall be such that to create desired


throw and spread of air.
All diffusers and grilles shall be made up of powder coated sheet steel
with finish painting. Each supply air diffuser shall be fitted with opposed
blade damper, built-in vanes and louvers
Velocity across the diffuser/grille should be limited to maximum 2
m/s.

8.)

Thermal Insulation:
a.) Refrigerant piping from the evaporator coil outlet up to the compressor
inlet shall be insulated with minimum 39mm aluminum foil faced Nitrile
rubber/XLPE for Screw chiller and 26mm Nitrile rubber/XLPE with 30G
aluminum sheet cladding for precision/split air conditioner.

Double skin casing of the cabinet type AHU with at least 25 mm thick Poly Urethane
Foam (PUF)/EPS sandwiched between them.

b.)Supply air duct and part of the return air duct passing through non
conditioned space: with at least 13 mm thick aluminum foil faced
Nitrile Rubber / XLPE insulation.
c.) Entire chilled water piping, valves, chilled water circulating pumps and
chillers: with 39 mm thick aluminum foil faced Nitrile Rubber/XLPE.
Portion of Chilled water piping exposed to atmosphere shall
be insulated with 50 mm thick expanded polystyrene(EPS) and finished
with chicken wire mesh, 12 mm thick sand-cement plaster and an
overall cladding of 30G aluminum sheet.
d.)Drain piping from AHU/Precision AC/Split AC/FCU and chiller shall be
insulated with 13 mm/ 6mm (for FCU and split unit) thick aluminum foil
faced Nitrile Rubber/XLPE.
e.) Chilled water Expansion Tank drain piping with 6 mm thick aluminum
foil faced nitrile rubber/XPLE.
f.) Steam piping and other hot surfaces shall be insulated with 50 mm
thick fibre-glass/mineral wool covered with 30G GI sheet.
g.)Condensate piping shall be insulated with 25 mm fibre-glass /mineral
wool covered with 30G GI sheet.
h.) Roof of AC spaces shall be insulated with 25 mm thick EPS (under deck)
for not exposed to sun and 50 mm thick EPS (Under deck) for exposed
sun.

9.)

Acoustic Insulation: All supply air ducts in the air conditioning


system shall be insulated acoustically up to a length 6 meter from the
AHU outlet with 25 mm thick fiber glass of density 48 kg/m3, insulation
from inside of duct.

10.) Water Pumps: Each pump shall be of horizontal split casing


centrifugal type, directly coupled to electric drive motor and mounted on a
common base plate. Pumps having motor of 5 HP capacities or below can
be of mono block construction.
Operating speed of the pump shall not be more than 15 rpm.

11.) Strip Heater: Heating equipment may be required for winter heating
as well as monsoon reheating.
Electrical heaters will be fin-tube type of specified KW rating with
fins permanently brazed to metal sheath. The metal sheath and fins will
be of G.I sheet material.
Wherever electric heaters are installed in the duct work, size of ducts
should be suitably increased to offset the additional resistance created by
the heaters.
An air stat is to installed such that in case there is no circulation of
air over the heater coils the heaters will be de-energized.

In case of reheating, the heater will be controlled by humidity


sensor & humidity transmitter and in case of winter heating, the heater
will be controlled by temperature sensor & temperature transmitter.

12.) Electrode Humidifier: Electrode humidifier consists of high


temperature polypropylene water tank, electrode, auto flash cycle
activated on demand from the microprocessor based control system with
humidity sensor, located in AHU/PAC room. Humidifier shall be controlled
by its own stand alone microprocessor based control panel.

13.) Non Chemical Water Treatment Equipment: This equipment shall


be fitted in the Condenser water header. The water treatment equipment
is a 1 meter long pipeline, which once installed, stops the formation of
scale in the heat exchanger zones completely. The water treatment
equipment consists of Metal Cell and Core and is installed on line after the
pumps and before the heat exchange zone. The distance of heat
exchange zone should not be more than 30 M and there should not be any
static area between the water treatment equipment and heat exchange
area.

Kay Design Assumptions and Constraints


1.)
Water cooled screw chilling machine
Temperature of chilled water entering chiller
Temperature of chilled water leaving chiller

11.4C
7C

Fouling factor for chiller


0.00013 Hr.M2C/K Cal
Refrigerant
(134a)
2.)

Air Handling Unit

HFC

Face velocity of air across filter

2.5 m/s

Face velocity across cooling coil

2.5 m/s

Fan outlet velocity for Fans

10 m/s

3.)

Design Parameter for selection of Centrifugal Fans

Fan speed for fans up to 450 mm dia


RPM
Fan speed for fans above 450 mm dia
RPM
4.)

1450

1000

Design Parameter for selection of pipe

Water Velocity
2.5 m/s
Maximum friction
0.04 m/m
5.)

Design Parameter for selection of Duct

Air velocity (Main supply duct)


m/s

Air velocity (Branch supply duct)


m/s

Friction
0.1
Velocity of air at supply air grilles/diffusers
m/s

2.0

The air Velocity through other elements of Ventilation system


will be as follows:

Supply air duct


Intake Louver
Discharge Louver
Supply air grill/ diffuser
Return air grill/ diffuser
Dampers
Back Draft Damper

12 m/s
4 m/s through free area
8 m/s through free area
3.75 m/s (max Neck velocity)
2.5 m/s (max Neck velocity)
10 m/s (max)
5 m/s (max)

Wall mounted axial flow fan


Axial fans shall be designed for:
a) Fan type:

Tube axial/propeller

b) The impeller shall have blades of an aerofoil design.


c) The speed of the fan shall be 1500 rpm for impeller diameter 450
mm or less and 1000 rpm for impeller diameter above 450 mm
The axial fans shall be complete with electric drive motor, grouting
framework, outlet cone (for tube axial), louvered shutter (for exhaust fan),
bird screen and supporting arrangement.
Axial fans will be of propeller type, for fans with 5 mmwc static pressure and
tube axial type for fans with static pressure above 5 mmwc.
Roof Extractor units
The roof exhauster shall be designed for:
a)

Fan type: Tube axial

b)

The impeller shall have blades of an aerofoil design.

c)

The speed of the fan shall be 1500 rpm for impeller diameter 450 mm
or less and 1000 rpm for impeller diameter above 450 mm

d)

Hood shall be hinged type

Each power roof extractor comprises of fan, fan motor, hood with disconnect
switch and supporting arrangement.

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