TECHNICAL SPECIFICATIONS

Objective:
Supplying and installing quantity of (2) Microprocessor-controlled
air-cooled liquid chiller, including chilled water pumps, fan coils, chilled
water piping, and power panel. The work will be done in the two
Metrological Buildings of DGCA. All works related to this job should be
compliant with Ministry Of Public Works, and MEW regulations and codes.
The chiller should be compliant to ANSI/ASHRAE 15-2001, ARI, and tested
according to standard ANSI/ASHRAE 30-1995.
The present system is giving adequate cooling to the building, and it is the
DGCA intention to increase the capacity of cooling and it is the
responsibility of the contractor to design and install the new system to give
the best cooling to the Control Tower.

1. Chiller Specifications:
1.1. Genral:
1- Two Microprocessor-controlled Air cooled chiller each of capacity of
120 tons refrigerant (actual) at 115ºF ambient temperature to produce
44ºF chilled water at 300 GPM (based on 10ºF temperature drop).
2- One chiller will be working at all time while the other will be on
standby, and exchange operation on weekly basis whole the year 24-
hours a day at normal running conditions, and auto-changeover to the
standby one, incase of fault or failure of the duty one.
3- The two chillers should fit the existing chillers area of 10×7.46 m2
taking in consideration enough clearance for ease of maintenance of

1
 the chillers. Also, this area includes a shaded part for the chilled water
pumps.
4- Flow switches should be installed to prevent the chiller from start
when there is no flow of water. Also the necessary pressure gauges
and thermometers are required before inlet and outlet of each chiller.
5- Motorized water valves should be installed for automatic open/close
when the chiller is in start/stop mode, in addition to manual valves to
isolate the chiller for maintenance requirements.
6- Any related safeties for safe operation of the chillers, water pumps,
refrigerant circuits, all necessary auxiliaries such as starters, vibration
mounts, compressor protection, is appreciated by the DGCA engineer.

1.2. Compressors:
1- The chillers must contain at least two screw/scroll compressors with
low noise kit such as a silencer working on separate refrigerant circuit
using R-22 refrigerant.
2- Each compressor should adjust capacity using combination of Load/
Unload or ON/OFF compressor cycling of multiple compressors i.e.
the compressors can work on 10% of the load.
3- Hot gas bypass sized for minimum compressor loading to bypass hot
refrigerant gas to evaporator as appropriate.
4- The compressors and the cooler are mounted on the same base with
power and control panels mounted at each end of the unit.
5- A forced feed lubrication by reversible oil pump supplied to all
crankcase/bearings surfaces and filtered through a fine mesh stainless
steel oil strainer.

2
 6- Compressors should be outfitted with oil heaters to be activated
during compressor shutdown for simplicity of start.
7- Compressors shall be provided with protection devices against
irregular conditions. Minimal protection devices include:
a. High pressure protection as required by Underwriters
Laboratories and per ARI Standards and ASHRAE standard 15.
This may include:
i. A high pressure cutout.
ii. A high-to-low side internal relief valve, external relief
valve, or rupture member to comply with ASHRAE
standard 15.
b. High temperature control to protect against overheating and oil
breakdown.
c. Low pressure protection provided for:
i. Suction pressure.
ii. Compressor forced fed lubrication system.
d. Time delays or lockouts to prevent both compressor and
contactors from repetitive rapid-starting cycles.
e. Phase loss prevention.
8- Testing for compressor ratings must be in accordance to ASHRAE
standard 23.

1.3. Assembly:
1- Units are completely assembled with all interconnecting refrigerant
piping and internal wiring with clear marking ready for field
installation.

3
 2- The units are pressure-tested, evacuated and fully charged with
refrigerant and include an initial oil charge. After assembly, a full run
test is performed.
3- The units base and frame is of heavy-gauge, galvanized steel.

1.4. Microprocessor:
1- The Microprocessor should have the capability of multi-circuit
control to maintain chilled water temperature with a sequencer to
sequence the lead/lag for the compressors, and a mean to change-over
automatically between the two chillers according to weekly schedule
which can be programmed and set in the microprocessor software.
2- Compressor Start/Stop, Load/Unload decisions are performed by the
microprocessor to maintain leaving water temperature. These
decisions are a function of temperature deviation from the set point
and the rate of change of temperature.
3- The microprocessor display must be multi-line LCD display which
will read at a minimum:
a. Discharge and suction pressure for every compressor.
b. Outdoor air temperature.
c. Anti recycling timer status.
d. Compressor (run/stop/trip) status.
e. Inlet and leaving water temperature.
f. Automatic lead/lag status.
g. Compressor motor current.
h. Compressor oil temperature and pressure.
i. Status of liquid line solenoid valve.
j. Superheat temperature of the evaporator.

4
 4- Programming and entry: The buttons should include:
k. Status.
l. Time/set clock.
m. On/Off switch for each unit.
n. Numeric keypad.
o. History.
p. Set point.
q. Print.
r. Enter.
5- The Microprocessor should take the following commands:
s. Set point temperature settings with (Leaving/Return) water
temperature control.
t. High pressure, low pressure, for suction and discharge as well
as antifreeze cut-outs.
u. Remote (On/Off).
v. Running schedule for a week period.
w. Recording history of alerts/alarms, .etc.
x. Changing the units from IP-system to SI-system and vice versa.

1.5. Coolers:
The multi-circuit cooler is direct-expansion type with the refrigerant
in the tubes and chilled liquid flowing through the baffled shell. The water
baffles are constructed of galvanized steel to resist corrosion. The removable
heads allow access to the internally enhanced, seamless, copper tubes. Vent
and drain connections are included.
The cooler is covered with 19 mm (¾") flexible, closed-cell, foam
insulation. And each circuit is protected by a relief valve.

5
1.6. Condenser:
The condenser coils are seamless copper tubes, arranged in staggered
rows, mechanically expanded into ripple profile aluminum fins. Integral sub-
cooling is included.
The coil mounting frame, end sheets, tube supports and fan separation
plates of the coil mounting frames are constructed from unpainted
galvanized steel sheets.
The condenser fans are acoustically profiled, high efficiency, airfoil
type fan blades directly driven by independent motors, and positioned for
vertical discharge. The fan guards are constructed of heavy-gauge wire hot
dipped galvanized coated steel. All blades are dynamically and statically
balanced for vibration-free operation.
The condenser fan motors are totally enclosed Air-Over, squirrel-cage
type, current protected. They feature ball bearings that are double sealed and
permanently lubricated.
The condenser coil design should be designed to fit outdoor
conditions against sand storms and wind attack from sides. The condenser
should be horizontal style, taking the air from the bottom of the chiller and
discharge it upward and completely covered from sides with galvanized steel
sheets.

1.7. Refrigerant circuits:

Unit piping should be copper with brazed joints. The liquid line includes:
a. A shut off valve with charging port,
b. Sight glass with moisture-indicator,
c. Thermal expansion valve (direct acting, max-operating pressure),
d. Solenoid valve,

6
 e. Filter drier, and,
f. Service valves after/before compressors.
The entire suction line, the liquid line between the expansion valve and the
cooler, are insulated with flexible, UV stable color coordinated closed-cell,
foam insulation.

1.8. Pumps:
1. Two chilled water pumps are required, in which one pump will be
working and the other is standby.
2. Pumps capacity and head should be calculated according to the latest
standards and energy savings. Drawings and site visits will be arranged
for the contractor site survey. The final pump head will be calculated
based on the final pipe lengths and total pressure drop in different
fixtures in the system.
3. Two balance valves are also required with a flow metering device to
measure the flow for proper balancing. Also, a safety valve is required.
4. Two sets of service valves are also required, including pressure gages and
thermometers before and after the pumps.
5. The pumps specifications data and characteristic curves along with system
curve must be submitted to the DGCA Engineer for evaluation and
approval.
6. Pump operation and initial balancing will be the responsibility of the
contractor.

1.9. Chillers Power And Control Panel:

All controls and motor starting equipment necessary for full unit
operation is factory wired and functionally tested. The panel is divided into

7
sections; with separate power sections serving each refrigerant circuit, a
control section and a common input section.
Components are mounted on galvanized steel back plates, and
enclosed in the relevant section of the galvanized steel enclosure. Separate
doors are provided for each section. All doors are hinged, lockable with door
stays and are designed to IP55 weather protection.
The power section contains: compressor starting contactors, system
fuses, fan contactors, fan manual motor starters and control interface relays
(CE Compliant).
The common Input Section Contains: Non-fused disconnect switch for
customer single point power supply connection. Transformer and wiring to
allow control voltage to be internally derived (CE Compliant).
The Control Section Contains: Microprocessor, power supply and
relay boards. The relay board contains the control circuit serving
compressor solenoid, oil heater, compressor, and fan contactor coils.

2. Piping:
1. Supplying and installing chilled water piping from the chiller to the
two Metrological buildings including the interconnection with three
AHUs and pumps in the pumps yard, and the interconnection between
the risers and header in the chillers’ yard including the fan coil units’
connections. The piping includes the supply, return and drain water
piping.
2. The contractor will design the piping system using diversity for
different exposures to minimize pipe and pump sizes. The fan coil
system will be automatically controlled with three-way valve. It will
be fixed in Metrological building (2).

8
 3. All risers piping from the chiller till the top must be sh40, seamless
black steel piping conforming to ASTM 53 standard.
4. Two AHUs are required in Metrological building (1). One AHU will
be fixed on the roof of the building and the other one in the ground
floor. The third AHU will be fixed in the Hydrogen room. Also, the
fan coil units include valves and fittings.
5. Valves and fittings selection/characteristic sheets should be submitted
to the DGCA Engineer for approval.
6. Insulation of the pipes not exposed to the sun will be 1-inch 64 kg/m3
density fiber glass pipe insulation of entire piping.
7. Insulation of pipes exposed to sun will be 2-inch 96 Kg/m3 density
fiber glass pipe insulation for the entire chiller yard.
8. Aluminum cladding for the whole piping with 5mm Aluminum sheet.
9. The attached drawings elaborate the DGCA suggestion for piping
layout. The Contractor is free to present the best design which is cost
effective and high quality design.
10.A site visit will be conducted in the preliminary meeting and supply of
necessary drawings to achieve accurate calculation of head and losses
in pipes will be presented as required.

3. Fan Coils:
1. Supply and installing of 22 nos. of fan coil units complying with ARI
industry standard 440-98 for room fan coil units, and labeled and
listed by Underwriters Laboratories (UL), and complies with noise
generation standards.

9
 2. The units should be selected for the highest temperature difference
(not less than 12°F), and low cfm. The units should at least have 4-
rows of copper with Aluminum fins.
3. The contractor should make necessary modifications for the intake air
and discharge air openings’, including a washable aluminum filters for
each unit.
4. All fan coil units in the Metrological building (2) are ceiling type units
and it includes ceiling diffusers with necessary ducting from the units
to the diffusers.
5. Attached is a drawings showing the fan coil units distributions in
Metrological building (2), with the estimated total cooling and
sensible cooling capacities for the units based on our cooling load
estimation and the distribution based on the existing wall panel
decoration. The unit capacity reflects the cooling load estimate for the
room divided by the number of the units.
6. The contractor will be responsible for choosing the suitable fan coil
unit selection to achieve the loads and air distribution in the room.
7. Each unit must include:
a. Three-way control valve with robust electrical actuator: must be
globe-style with equal percentage plugs, and rated for pressure
drop service in excess of the highest differential pressure that
the pump can generates with digital control with accurate
precision. The valve will shut-off when the unit is switched off.
b. Strainer.
c. Two service gate valves.
d. Digital thermostat.
4. Power Supply Panel:

10
 A complete Electrical power panel in the chiller area, replacement of
the existing, is serving the two chillers. The panel will contain necessary
breakers in weather proof galvanized steel panel.
Earth system: All chillers, panels, and pumps shall be connected to
proper earth system made by the contractor.

5. Civil Works:
New base made of concrete should be made for each chiller according
to the manufacturer recommendation and Ministry of Public Works
Regulations. The unit should rest on the concrete base via spring assembly
and noise/vibration insulation according to the standards.

6. Documents:
Tenderer shall provide a complete technical, and performance data on
the equipment he is offering with his offer for evaluation.
The machine should have proper certification from the manufacturer
and labeled as per latest codes for pressure vessels, and heat exchangers.
Before starting the works, the contractor should present complete set
of technical data and material specifications for approval by DGCA
Engineers.
Upon commissioning, the contractor should supply a complete set of
documents, manuals, and as-built drawings for the whole system, printed
and saved on CD(s) as AutoCAD drawings.

7. Warranty:

11
 The supplier should guarantee the equipment for two year for the
machines and five years for the compressors.
The supplier should also guarantee the pumps and fan coil units for
one year.

8. Spare parts:
The contractor should supply with the equipment the recommended
spare parts for two years for the machine.

9. Tools:
Two complete tool kits for servicing the units and as recommended by
the manufacturer should be supplied by the contractor. A list of the tools
should be attached to the offer.

10. Training:
The Contractor should offer a training course on the machine at the
manufacturer facilities for at least two DGCA personnel including residence
air tickets, .etc.

12