Standard Operating Procedures

The HVAC Process at GENPACT, Uppal is divided into four circuits.

1. Air Handling Circuit
2. Chilled Water Circuit
3. Refrigerant Circuit
4. Condenser Water Circuit or Air (as the case may be).

They are as under:

The HVAC System is integrated with the BMS Software wherein it is possible to observe &
log the events like the system parameters, abnormalities etc & generate the reports.
Design Consideration:
The Air Conditioning System is designed to provide comfort conditions of 24 1 C
and Less than 65 % RH in the entire building area during the peak summer when the outside
conditions would be around 41O C. The service areas like car parking, Substation, Electrical
Room, Plant Room & Toilets are provided with ventilation systems with 15 to 20 air changes
per hour and Kitchen with 40 air changes per hour as required.
The air conditioning & BMS system combinely has been provided to take care of system
reliability as well ass energy efficiency and flexibility to address to the varying the load
pattern. The operating hours of processing block would be 24 hours with full occupancy
during nights. The learning centre would mostly be in operation during the daytime for 8-10
hours and the residential block load would be peak during the night.
The Equipment are as under.:
Water Cooled Chiller
Air Cooled Chiller
Refrigerant Used
Condenser pumps
Cooling Towers
Chilled Primary Water Pumps
Chilled Secondary Water Pumps
Flow Rate (Chilled Water)
Flow Rate (Condenser)

TRANE Make 2 X 400 TR

TRANE Make 2 X 350TR
R 134a
(HFC 134a)
3 Nos each 30HP, 960 USGPM
2 Nos Induced Draft FRP 450TR
5 Nos of 12.5 HP, 800 USGPM
3 Nos of 20 HP, 1844 USGPM
800 USGPM
960 USGPM

Parameter of the Plant as per the design calculations assumed as follows:

1. Maximum Demand
2. Minimum rated Latent Energy Storage:
3. Nominal Cool Storage Capacity:
(To take care of the emergency circumstances.)

1500 TR

4. Total Space to be Air-conditioned:

63569 Sq.m

5.

Total proposed capacity of Chilled Brine System

Not less than 3000 TR Capacity

With Latent Heat Storage system

Chilling Unit + 24000TR TES.

b. Default Chillers, Direct Cooling capacity

100 % of nominal;

c. Default Chillers (TES-Latent Heat)

67 % of nominal (Assumed).

20000 TR Hour

24000 TR Hours

The maximum demand value of 5000 TR indicated above is based on installation of Heat Recovery
Ventilator for the Centralized Fresh Air System designed to take care of fresh air requirements in this
project & also includes a 10% of spare capacity to take care of future additional requirements of Ac
by the multi-national end users.

Note: Highlighted Items need to be checked again.

AHU Line Diagram:

The AHU Circuit is a closed loop feedback system in which AHU pumps in cool air into the
floor & keep the floor temperature within the set readings & thereby maintaining the Cooling
Comfort across the floor.

18o C
SUPPLY AIR

14o C @ 2.8 Kg/Cm2

FAN

To Chiller
AIR CONDITIONING SPACE

AHU
From Chiller
23 1O C

10 C @ 3.0 Kg/Cm2
FILTERS

RETURN AIR
24 O C

The BMS Sensor at AHU Module detects the temperature of return air from the floor
& The motorised valve is either fully opened or partially opened or fully closed as per the
parameters of the return air & the set point in the BMS.
The air distribution system consists of Double skin air handling Units with Pre filter, Cooling coil &
DIDW centrifugal fan section. The AHU motors are also provided with VFDs and the speed is
regulated according to the load. The supply air is distributed through fabricated ducts and return is
collected above the false ceiling back to the AHU rooms. The supply air plenum and initial 4 M of
supply duct is acoustic insulated with 25 mm fiberglass matt finished with Aluminium perforated
sheet. The complete supply air duct is 100% thermally insulated externally with aluminium faced
fiber- glass matt of 25 mm thick to avoid any cooling loss.
The supply distribution would be through aluminium grid diffuser and return air through diffusers
and grilles. The supply air to high occupancy areas like conference rooms & Training rooms are
through are through Variable air volume thermo fusers to regulate the air quantity as per the
occupancy with in the space. The supply and return air ducts with in each AHU room is provided
with motorized valve damper and would be actuated on receiving signal from fire alarm system.

The AHU Rooms in processing area in A& C Blocks of Ground, First & Second floors are provided
with manual & motorized fresh air dampers and the air is automatically adjusted as per the CO 2 Level
in the area.
Totally there are 30 Nos of floor mounted AHUs of variable capacities located at different locations
in the building provided to maintain a sufficient temperature in the building.
There are 6 Nos. of ceiling mounted AHUs located in the battery rooms to provide enough cooling in
the battery rooms located in Ground Floor, Second Floor Core-2 & Core-3 & Fourth Floor.
There are 15 nos of PAHUs are provided in all UPS Rooms & Server room for 24 hours of operation.
Precession AHUs are to control the temperature and humidity.
All the AHUs can run in Auto Mode by BMS or in Manual Mode.

The AHU consists of chilled water pipe lines & blower. The chilled water from the secondary
pumps outlet enters the AHU where the heat exchange takes place from the return air of the
air conditioning space. Thereby cooling takes place for the air and the chilled water
temperature rises. The water at the outlet of the AHU is transferred to the chillers through
primary pumps for cooling.

Chilled Water Line Circuit

The Chilled Water from the AHU, PAHU, and FCU is transferred to the Chiller through
Primary Pumps. The chilled water parameters are maintained as per the Return Air Handled
by the AHU Units. Under normal conditions the inlet chilled water parameters are 16o C &
3.6 kg/cm2. In the chiller the water is cooled by the refrigerant (R 134a) and the temperature
at the outlet of the chiller is maintained at 8o C & 3.2 kg/cm2. The outlet of the chiller is
transferred to AHUs through the Secondary Pumps where the pressure is increased to 4.2
Kg/Cm2 at the same temperature. At the inlet of AHUs the temperature is around 10o C at a
pressure of 3.0 Kg/ Cm2. At the outlet of the AHU depending up on the load, the temperature
of the chilled water is around at a temperature of 16o C & at a pressure of 2.4 kg/Cm2. The
Chilled water from AHUs is transferred to the air separator where any air in the system is
being released from the air vent. From the air separator the water is transferred to the primary
pump where the water pressure is increased to 3.8 kg/ cm2 and transferred to the chiller inlet.
8o C @ 3.2 kg/Cm2

16o C @ 3.6 Kg/Cm2

CHILLER

3.6 Kg/Cm2
Primary
Pump

Secondary
Pump
3.0 Kg/Cm2

4.2 Kg/Cm2
10o C @ 3.0 Kg/Cm2

A
S
AHU LOAD
14o C @ 2.8 Kg/Cm2

Chiller Refrigerant Circuit:

Condenser Water Out (36o C)

Condenser Water In (32O C)

Condenser
EXV
Refrigerant

Liquid
Refrigerant

Oil Separator

Drier
Vapour Refrigerant

LVS
Liquid
Refrigerant

CHW Out (8O C )

CHW In (16O C ) Shell & Tube Evaporator
Comp

The refrigerant (R 134a) is compressed to a high temperature of xxx & high pressure of yyy
in the compressor & hence the refrigerant turns into vapour form (& contains oil traces)
which is otherwise is in liquid form at ambient temp. From the compressor refrigerant is in
the form of vapour mixes with oil (lube oil)& goes to the oil separator, where the oil is
separated & the separated oil is sent back to the compressor (for bearings). The compressed
refrigerant alone will be moving to the condenser where it is cooled by the water from the
cooling tower in case of Water Cooled Chiller and by air in case of Air Cooled Chiller.
From the condenser, the liquid refrigerant goes to the drier where the refrigerant is dried &
then to expansion valve, which is operated by a servomotor depending upon the pressure
inside the LVS.
Liquid Vapour Separator will separate the vapour refrigerant from liquid refrigerant &
vapour refrigerant is again sent back to the suction of the compressor.
Liquid Refrigerant is sent to the evaporator.
The water from the AHU rooms entering into the evaporator is cooled by the refrigerant and
sent back to the secondary pumps.

CONDENSER WATER LINE CIRCUIT:

The water from the condenser of the chiller is transferred to the cooling tower, where in the
water is cooled by forced draft by means of a cooling fan and the cooled water is transferred
to the condenser inlet through condenser pumps. At the inlet of the cooling tower the
temperature of condensate is 38o C at a pressure of 2.0 kg/cm2 while at the outlet of the
cooling towers the parameters are maintained at 32oC, 2.0 kg/cm2 at an ambient temperature
of 28o C.

38O C @ 2.0 kg/cm2

FAN
COOLING
TOWER

32O C @ 2.0 kg/cm2

1.4 kg/cm2
CDP
3.2 kg/cm2

CONDENSER
O

32 C @ 2.6 kg/cm

38O C @ 2.0 kg/cm2

Control System: The Entire system is controlled either by remote mode from BMS or by manual
mode.
The system basically comprises of the follow:
1. Chillers
To meet the load the chilling Plant Consists of 2 Nos of Water Cooled Centrifugal Chillers of Trane
make of 400 TR capacity each located in the ground Floor Plant Room & 2 Nos of Air Cooled Screw
Chiller of Trane make of 350 TR capacity each located in the Terrace. All the four chillers are
connected by common water Head so that there is flexibility of operation of chillers to cater to all the
areas as required. The chillers are provided with motorised butterfly valve sot that the particular valve
is automatically closed whichever chiller is not in operation through BMS Operation. The feeder
panel for the air cooled chiller is located in the terrace electrical room and whereas for The water
cooled chiller and all the pumps & Cooling towers is served by the MCC Panel located in the Ground
Floor Plant Room.
2 Pumps:
The Chilled water circulation Consists of 5 Nos of Primary pumps and 5 Nos Of Secondary Pumps.
Primary Pumps are used to circulate the chilled water from the AHUs to the chiller and whereas the
Secondary water pumps are used to recirculate the water from the chiller to the load i.e. AHUs.
a. Primary Pumps
There are 5 Nos of Primary Chilled water pumps (4 Working & 1 Std By) of Beacon make,
Vertically split back pullout type located in the plant room. Each pump is designed for 3040 LPM
flows against 12 mtrs Head. One pump each catering to each of the chiller. The primary pumps
are of Constant Speed. Inlet side provided with a butterfly valve with a Y- Strainer and outlet side
consists of NRV and balancing Valve. This pumps are driven by 9.3 kW /12.5 HP motors.
b. Secondary Pumps
The Secondary water pumps are used for the water circulation from the Chiller to AHU Loads.
The secondary chilled water pump system is divided into tow parts with 3 Nos (2W + 1 Stdby)
catering for the processing Block and 2 Nos (1 W + 1 Stdby) for the learning cum residential
Block. These pumps are of Variable speed type. Depending upon the load the two way valve in
the AHUs regulate the water flow to coil & this causes in an increase / decrease in the line
pressure. Accordingly the pressure transmitter send signal to the secondary pump controller
which in turn controls the speed of the motor through VFD thus saving the power. The excess
water from secondary circuit goes back to the primary circuit through the bypass line.
The entire system is provided with reverse return & balancing valves at various locations to
balance the load properly.

All the pumps are of ITT BELL & GOSSETT Make of end suction back pull out type.
Each pump in processing block is designed for 922US GPM Flows at a 18 M head and
whereas each pump in the residential block is designed for 707 US GPM Flows at a 21M

Head. Each pump is driven by 15 KW/ 20 HP motor. All of these pumps are located in the
pump room. Inlet side provided with a butterfly valve and Y- Strainer and outlet side
consists of NRV and balancing valve. These pumps are driven by 45 Kw /60 HP motors

c. Pumps (Chilled water)

The water cooled chiller is catered by 3 nos of condenser water pumps which circulate the
Condensed water through the condenser and induced draft FRP Cooling tower located on the
terrace. All the pumps are of BEACON make, vertically split casing Centrifugal pumps are
located in the pump room. Inlet side provided with a butterfly valve and Y- Strainer and outlet
side consists of NRV and balancing valve. Each pump is designed for 3850 LPM Flows against
24 Mtrs Head. 30 HP/ 22 KW motors drive these pumps.
3. Water Cooling system
There are 2 Nos of cooling towers, of BELL Make and a capacity of 400 TR (1 each for each
water cooled chiller) are located on the terrace. The Condensed water from the condenser pump
flows through the cooling tower from the top and cooled by the fan and the cooled water flows
back to the Chiller Condenser through a Basket Strainer.
The cooling Tower fan motor has a VFD & the speed is adjusted according to the sump
temperature to save the power in the winter / man soon seasons.
To compensate the vaporization losses in the line, there is a continuous supply of soft water in
the tank through make up valve. For fast filling direct ball valve is also provided in the line.
All chilled water piping and piping accessories are insulated. Piping accessories consists of
Various types of control valves with actuators, butterfly valves, Check valves, Strainers etc..
Brief Description about the Building Air-conditioning Layouts.
The building structure is divided into three blocks A, B, C. Block A and C consisting of workstations
and Block B consists of server room, UPS room, and Atrium & Corridor areas. The building is again
divided into the left wing and right wing.
The chilled water is supplied to the AHUs through the risers. Totally there are 8 nos of Shafts located
at the end of the each block, which will supply the chilled water to the AHUs, CAHUs & PAHUs
located there.

Ventilation systems
1) Staircase pressurization 6 nos
Each staircase equipped with stair case pressurisation fans. Totally there are 6 nos of
pressurisation fans located at the roof level connected to all floors through fresh air ducts.
In case of fire, these fans will work pressurising the staircase.
This is mainly to prevent smoke NOT to enter into the Stair Cases - so that the trapped occupants
& Fire Fighting personnel can freely use Stairs as escape route during emergency.
These fans are coupled with motors of 1.5 KW/ 2HP

2) Lift well pressurisation - 4 nos

There are 4 nos of lift well pressurisation fans. 2 For Passenger Lifts, 1 each for service lifts
located at the roof level. These units will run only during Emergency (Fire)
Normally these units are under off position.
In Each floor near the lift entrance, fresh air grilles are provided. The shaft core equipped with
a set of fresh air fan to pressurise the core. In Each shaft core the Grilles are connected to the
fresh air duct in each & every floors. Ducts are connected to electrically operated fire dampers. In
case of fire, these dampers will be opened along with the fire alarm systems and fan will
AUTOMATICALLY start & act as AIR CURTAINS to prevent Fire NOT to enter LIFT WELL
& as well as protect the Passenger in the Passenger Carriage.
- 4 Nos of 20400 CMH / 12,000 Cfm against 450 Pa / 1.8 inches of WG & 7.5KW are installed
for this operation.
3) Toilet exhaust systems 6 Nos
These systems comprises of 1Nos each of core 1, 2, 3, 4 having capacity of 20400 CMH / 12,000
CFM against 360 Pa / 1.44 Inches of WG with load of 7.5 KW to create a negative pressure
located at the roof level for each Core toilet.
Thus the foul smell is exhausted through the main exhaust duct, which is connected to the blower
(under negative pressure).
4) Server Room Inergen Gas Exhaust- 2 nos.
There are 2 nos of exhaust fans provided at the roof level in both the Service Lift Rooms. These
fans are generally in off condition. In case of any emergency (Fire) Inergen gas will dump into
the server rooms. These fans have to be switched on to create a negative pressure and to exhaust
the Inergen gas in the server room.
5) Basement ventilation 8Nos (Axial Flow Fans) fresh air fans & 8 nos extract /exhaust fans
Ground Floor Electrical Panel room is equipped with Fresh air fan. This fan is located at the roof
level to give fresh air in the electrical panel room. Instead of that the exhaust fans are provided at
the roof level for plant room, pump room. 4 Nos of exhaust fans are provided in the car parking
area and 1 no in Ground Floor Kitchen area. 2 Nos of Blowers are also provided in the car
parking area.

Preventive Maintenance Schedule

Chillers
Monthly
Check refrigerant charge, pressure and temperatures.
Check oil level and pressure.
Check pressure cut out points and safety set points
Check operation and safety control of micro processor
Perform control test on chillers
Check electrical loose connections
Check abnormal function of the chiller
Check chilled water pressure and temperature drop cross the chiller
Check the noise level of the chiller
Cleaning of condenser coil.
Quarterly
Check for leakage of refrigerant
Check all rotating part for abnormal noise
Check refrigerant drier core
Check compressor motor starter and interlocks
Check electrical components of the chillers
Check condition of the condenser coil.
Check oil level
Check for Acid Moisture test for Refrigerant oil
Yearly
Check the oil quality and replace.
Thorough check of microprocessor
Check FSM
Check performance of the chillers.

Chilled Water Pumps, Motors and Actuators

Monthly
Lubrication of the bearing for pump and motor
Lubrication of actuators
Function of actuators
Checking of water quality
Checking of motor temperature
Check for pump bearing heating and noise.
Half Yearly
Check the alignment of the drive assembly.
Check all the fasteners.
Check for loose cable termination
Check the electrical inter locks
Check for water quality.
Check for abnormal noise or heating of pump and motors.
Check the strainers.
Yearly
Overhaul the pumps and replace the gland packing
Check all the electrical interlocks
Check all cable termination
Check all the actuators electrical controls and termination
Check all the electrical panels
Check all the valve and replace the gland packing

Air Handling Units

Monthly
Clean the filters
Check the belt tension
Check for abnormal sound
Check the damper is 100% open
Check the functioning of 3 way mixing valve.
Check the thermostat setting
Check the proportionate thermostat setting
Check the humidistat setting
Check the inlet and outlet temperature and pressure.
Half Yearly
Check and adjust the belt tension
Check the air flow through the unit
Check the drain piping
Check and clean the coils
Check for leakage of valves
Check for corrosion in fitting and valves.
Check for gland leakage in valve.
Yearly
Check for balancing of fan
Check for air leakage in ducts
Check all the electrical controls and termination
Check all pressure and temperature gauges.
Check all motor condition
Check the fan bearing condition.
Check and clean the drain piping
Check all the fasteners.

Ventilation
Monthly
Clean the fans
Check the lubrication of the bearing
Check the belt tension
Check the damper position
Half Yearly
Check all the fasteners
Check the alignment
Check for abnormal noise.
Check the bearings
Check the motor for over heating
Yearly
Check all the controls and termination of the system
Clean all the fans and ducts
Check the filter condition
Check all the fasteners
Check the balancing of fans
Check the bearing condition
Check for abnormality in the equipment
Overhaul the fans & Fan Motors (including Stator & Rotor Windings for Insulation).

Routine Maintenance
Daily Checks
Check the operational parameters of the chillers are working with- in the permitted limits
Check the operational parameters of pumps are with in its limit.
Check the make up water to expansion tank is available
Check for abnormal noise in chillers
Check for abnormal noise in pumps
Check for abnormal noise in fans
Check for leaks in the piping near the pumps, expansion tanks and chillers
Check for overheating of motors
Check for overheating of fan bearing
Check for module temperatures are in limits
Check the valve position near the pumps and chillers are in proper position
Check the damper position of ventilation fan are in proper position
Check the cleanliness of the equipments

Log Books Maintained for A/C: AC LOG BOOKS

1. Water Cooled Chiller Log Book 2 Nos. ( 1 For Each Chiller) For Every 2 hours.
2. Air Cooled Chiller Log Book 2 Nos. (1 For each Chiller) for every 2 Hours.
3. PAHU Log Book 1 No For Every 4 Hours.
4. Pump Log Book 1 No for Every 4 Hours.
5. VFD Meter Reading Book..once in each shift
6. Log Sheets for the temperature in the floors at various locations Twice in the shift.
7. A/C Technician Log book