MS-xxx/Code1
ST/CV00000LHC-U-CI-0000Group Code:ST/CV / IT-2937/ST/ATLASThe Large Hadron Collider ProjectAugust 2001IT-2937/ST/ATLAS
Annex 1: Technical Requirements
Abstract
The purpose of this annex is to define the technical requirements for the construction and for the fitting of the various components of the installations.
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Table of Contents
1AHU: AIR HANDLING UNIT......
1.1Identification system......
1.2Construction of the Air Handling Units (AHU)......
1.2.1Panels of the AHU’s......
1.2.2Structure, sections, and support......
1.2.3Assembly of the panels......
1.2.4Air-tightness......
1.2.5Sections of the AHU forming a box......
1.2.6Inside AHU lighting......
1.2.7Sight window......
1.2.8Fire resistance......
1.2.9Earthing......
1.2.10Handling......
1.3Fans (UU)......
1.3.1General characteristics......
1.3.2Fan type UUDC......
1.4Motor of fan (UM)......
1.4.1General characteristics......
1.4.2Types of motors......
1.5Servo-motors......
1.6Heat exchangers (UE)......
1.6.1Characteristics shared by all the types of heat exchanger......
1.6.2Characteristics shared by the water coils......
1.6.3Chilled water coil UEGZ......
1.6.4Electric heaters UEEZ......
1.6.5Humidification system......
1.7Air filters (UF)......
1.7.1General......
1.7.2Metal pre-filters UFPZ......
1.7.3Multi-V pleated filters UFFM (multidiedral)......
1.7.4Absolute filters UFAM......
1.7.5Filter classification......
2VENTILATION DUCTS......
2.1Construction......
2.2Duct supports......
2.3Access traps......
2.4Manual adjusting dampers UVMM......
2.5Measuring stations......
2.6Thermal insulation......
2.7Balance......
2.8Sheet thickness......
2.9Textile ducts: UGTX......
2.10Construction criteria and operating conditions......
3ACCESSORIES......
3.1Return air grille: UQGA......
3.2Jalousie grille......
3.3Air displacement terminal: UQUD......
3.4Motorised damper UVUM (fresh air) and UQCM (return air)......
3.5Three way valve: UVMB (with flange and counter flange)......
4MARKING......
4.1Equipment identification......
4.2Duct identification......
4.2.1Location of the identification......
4.2.2CERN colour code......
4.2.3Air flow direction......
4.2.4Circuit designation......
4.2.5Example of identification symbol......
4.2.6Application of the symbols......
4.3Identification of the electric components......
5ACOUSTIC......
5.1Acoustic baffles......
5.2Acoustic insulation......
5.3Air handling units......
6METAL STRUCTURES......
7ELECTRICAL WORK......
7.1Basis for calculations......
7.1.1Circuit-breaking capacity......
7.1.2Mechanical strength......
7.1.3Equipment selection......
7.1.4Environment......
7.2Electric cubicles......
7.2.1Overall design of the electric cubicles (Contractor’s supply)......
7.2.2UIAC: power cubicle (Contractor supply)......
7.2.3UIAO: Control cubicle (Contractor supply)......
7.2.4UIMG: Thyristor cubicle (Contractor supply)......
7.2.5UIMV: variable speed drive for motors (Contractor supply)......
7.3Electric boxes......
7.3.1UICP : Proximity command cubicle......
7.3.2UICN : Fire Brigade control cubicle......
7.4Electric components......
7.5Cables......
7.6Cable trays......
7.7Electric connections......
7.8Electrical drawings......
7.8.1Specification......
7.8.2Electrical components......
8INSTRUMENTATION......
8.1Description of the sensors:......
8.2Description of the actuators......
9REGULATION AND MONITORING......
9.1Programmable Logic Controllers (PLC)......
Vocabulary
Term / DefinitionAHU / Air Handling Unit
CAMM / Computer assisted Maintenance Management.
CDD / CERN Drawing Directory
CIT / «Power Supply Cubicle Intelligent Control»
DQE / Description and Quantities Estimate
EDMS / Engineering Data Management System.
EJP / Reduce power operation mode.
FMECA / Failure Mode Effects and Criticallity Analysis
HPGL / Hewlett Packard Graphics Languages
ISO / International Standardisation Organisation
PDF / Portable Document File
PLC / Programmable Logic Controller
QAP / Quality Assurance Plan
TCP/IP / Transmission Control Protocol / Internet Protocol
TCR / Technical Control Room
TDS / Technical Data Server
TF / Tender Form document
TQ / Technical Questionnaire
UIAC / Electric power cubicle « NormalPower»
UIAO / Electric control cubicle « NormalPower»
UICN / Firemen control cubicle
VSD / Variable speed drive
Warning
All the equipment and components installed by the Contractor shall comply to the present annex. The specific technical parameters are given in the Technical Specification, in the Description Quantities Estimate and in the Technical Questionnaire.
With respect the existing standardisation in the spare parts stock at CERN, certain components shall be chosen according to specific makes and type. In this case, makes and types are not followed in the present annex by the above mention : “or equivalent”.
Annex 1: Technical Requirements
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IT-2937/ST/ATLAS
1AHU: AIR HANDLING UNIT
1.1Identification system
CERN has developed an alphanumeric identification system for organising the installation and the maintenance of the various components of the LHC Project. This identification system is described in Annex 7 and used in the various documents of this Invitation to Tenders.
The Bidder should become familiar with this system. Each component is described in this document by the four alphanumeric characters forming the first group of its identification code.
1.2Construction of the Air Handling Units (AHU)
1.2.1Panels of the AHU’s
The panels shall be double-skinned, insulated made with at least 1 mm gauge galvanised, hot-dip or electro coated, steel sheet. The insulation shall be halogen-free, made of rockwool (minimum 70 kg/m3). The panels shall guarantee the required acoustic properties. The panels may be fitted inside the structure or secured to the outside and laid flush, with the smallest possible gap between them. The thermal bridges shall be treated according to the class mentioned below.
Table 1: Class of AHU’s panels according to EN 1886 rule
Heat transfer coefficient / Class T2* / 0,5 < U 1 W / m2 / KAssembly / Class TB2* / 0,6 < Kd 0,75
* if no other specific requirement in the technical specification
For AHUs having two independent air streams (with a lower and a upper cross-section) the separating panel shall be designed in the same way as the other panels. A diagram of the AHU components is given in the Technical Specification.
1.2.2Structure, sections, and support
Each component (coil, filter, measuring station crate, etc) shall be fitted in a modular structure forming a section with its panels. Several sections shall be put together to form a sub-assembly of suitable size for transport, handling and access to the premises. The complete AHU, placed on a support chassis, shall comprise the sub-assemblies joined together. The structure shall consist of a rigid hot-dip galvanised steel frame. The brazed or welded parts shall be cleaned and brushed and then coated with a galvanising paint or equivalent. This structure shall be designed to support the load of the components corresponding to the various sections without transmitting mechanical forces to the panels. Reinforcements shall be fitted to the inner and upper surfaces to increase the rigidity of the structure and resist handling forces without deformation or other damage. There shall be uprights in front of each section so that removable panels may be fitted and the components mounted and removed. Once the access panel removed, it shall be possible to remove the component completely from the AHU by means of slide-rails. If the panels do not adjoin, the section forming the structure shall be filled with an insulating material meeting the specifications and ensure the same heat transmission coefficient as the panels.
The support chassis corresponding to the access sections shall be suitably reinforced. The sections shall be fitted with internal separators around the components to prevent short-circuits in the air-flow. The sub-assemblies shall be delivered fully fitted and protected and finally assembled on site.
The support chassis shall consist of 2 parallel rails of the same length as the AHU and ensure the planeness of the assembly. The Contractor shall be responsible for levelling by means of adjustment devices.
1.2.3Assembly of the panels
All the panels and other components shall be secured to the structure by cadmium-plated mild steel nuts, bolts and washers. The sub-assemblies shall have enough drilled feet to the structure for screwed assembly. The system shall allow alignment and rapid assembly with the minimum of standard tooling. The lower structure of each sub-assembly shall previously have been fitted with attachment points so that each one can be firmly secured to the support chassis. Once assembled, the unit shall resist the operating pressures and withstand the under and overpressures caused by the complete closure of the upstream and downstream dampers.
1.2.4Air-tightness
Table 2: The permissible leakage rates (shall be tested to the manufacturer)
Static pressure limitP / Leakage limit (litre’s per second per square metre of the outside surface of an assembly)
0 < p 500 Pa / 0.027 x p 0,65
600 < p 1000 Pa / 0.009 x p 0,65
1100 < p 2000 Pa / 0.003 x p 0,65
2000 < p / 0.001 x p 0,65
p is the differential pressure in Pa
The sealing between panels and structure shall be provided by shaped seals of halogen-free material. The cable and pipe passages inside the AHU and through the outer panels shall be sealed by means of packing glands or, for control cables, by smooth passages injected with a silicone compound.
1.2.5Sections of the AHU forming a box
1.2.5.1Sealing box UQCS
The boxes are intended to provide the connection between two sections on either side of a wall. 50mm of rockwool insulation shall be secured around this section.
1.2.5.2Mixing box
These are of three types:
- casing with removable panel and damper (UQCN),
- casing with door and damper (UQCM),
- casing with door and damper (UQCU), 400°C/2h fire resistance rating.
1.2.5.3Access box
Access casings shall comprise doors with double internal and external halogen free handles. They shall be sealed by shaped halogen-free rubber sections. The positions are shown in the schematics. Besides the reinforced basic structure, the casings shall comprise a walkway grating capable of bearing a concentrated load of 100 kg and an additional landing for double air-passage AHU’s. The access panels for water coils shall be easily removable and have cut-outs for the connecting pipework. These cut-outs shall be fitted with insulating seals and a hot-dip galvanised steel packing glands secured to the outside of the panels. On one side the AHU’s shall consist of casings with access via removable panels (UQCA) and casings with access doors (UQCL and UQCM) and on the other of screwed panels. The cross-sectional width of the UQCL and of the UQCM shall not be less than 600 mm. In the 400°C/2h fire rating version, the UQCW access casings shall be fitted with a door and cut-out having the same fire rating.
1.2.5.4Rack box for measuring instruments UQCE
These shall comprise a rigid U-section frame of suitable width for the size of the measuring sensor and allowing for its securing over the whole of the air path cross-section, for which uprights shall be fitted. This frame shall be capable of travelling on upper and lower slides once the side panel has been removed and be easily removable from the structure. The cross-sectional width of the UQCE shall be no less than 200 mm. If there are two air streams, two independent measuring racks shall be fitted.
1.2.5.5Intermediate box UQCO
Consisting of fixed panels, they shall provide the connection between various sections.
1.2.5.6Fan access doors UQCV
The door faces shall be of the same type as those of the panels. For motor weights above 40 kg, the casing itself may have a slide rail with a hook for handling the motor (the approval of CERN's TIS Division must be obtained for all the handling devices provided by the Contractor). Two doors (one per air stream) will be required for double air-stream AHU’s.
1.2.6Inside AHU lighting
The Contractor shall be fully responsible for the electric lighting installation inside the AHU.
The equipment shall essentially comprise:
- the 230 V internal lighting system of the AHU with a tightly sealed port in each section with facilities for inspection and overhaul,
- control by a single switch with light indicator,
- the lighting cubicle shall comprise the separate terminal blocks (power supply, the protective devices and the fuses, differential switches, … ); this cubicle shall be independent of the electric ventilation cubicle,
- the cables shall run on cable trays or in galvanised tubes. The installation specifications for the electric wiring shall be the same as those for the ventilation system.
1.2.7Sight window
Each lighted section of AHU shall be designed with a air proof double glass window, halogen free.
1.2.8Fire resistance
All the materials used in the AHU’s shall be non-combustible. If an AHU is designed to operate at 400°C for 2 hours, all the components shall be suitably selected.
1.2.9Earthing
Each section of an AHU comprising electrical components at risk (heaters, motors, fans, etc.) shall be fitted with an earth terminal directly connected to a metal part of the structure. The connections between the earth terminals and the internal electrical components shall be made by using suitable insulated cables, the colours of which shall comply with the specifications of CERN's code. The Contractor shall be responsible for the proper fitting of these earthings.
1.2.10Handling
Each AHU shall be provided with its own handling system (holes in the base with handling system included), to move the unit after installation. All faces shall be easily removable (panels with one quarter round handle on access and hydraulic connection side, and screwed panels on the other side), to permit the handling of all components of the AHU. In order to let the dismantling in case of need and for the purposes of handling and removal of each ventilation section for maintenance (turbine, motor, etc.), the Contractor will supply a complete range of lifting and handling equipment (telescopically retractable monorail, lift truck, lifting beam, hook, hook assembly, etc) customised to deal with the load to be handled (approval to be obtained from CERN TIS Division) . The access doors to the internal constituents of the ventilation units, must be wide enough to allow these items to pass through.
1.3Fans (UU)
The abbreviation (UU) covers the fan, its motor and, where appropriate, its casing.
1.3.1General characteristics
The fan and its fixings shall be entirely of non-corroding metal. The overall design shall be of the industrial type. The efficiency of the fan shall be 80 %. The motor-fan set shall be fitted on a shared frame with anti-vibration blocks. The intake (single port) and the outlet (single and double port) of the fan shall be fitted with flexible halogen-free sleeves.
Important: most of fans at CERN are working continuous all day long and all year long, without any interruption except the annual shut down.
For this project, the maximum speed of the new fans shall be 1400 rpm/mn.
1.3.1.1Volute
The volute shall either be made of galvanised sheet steel or be a mechanically welded structure of continuously welded painted sheet steel, with reinforcing frames. It shall be fitted with a door for inspection and bleeding of the casing. The intake apertures shall be fitted with protective grilles.
1.3.1.2Impeller
The impeller shall be of the rearward-inclined flat-blade type to ensure a stable flow rate, maximum effectiveness and minimum noise. Its peripheral speed shall be 40 m/s.
1.3.1.3Spindle
The end of the spindle opposite the transmission shall be extended by at least 25 mm so that a proximity detector may be fitted to monitor the fan's rotation. The fans shall be fitted with lubricated-for-life single-row ball bearings with securing ring. The large fans shall be fitted with cast steel spherical roller bearings.
1.3.1.4Selection
Each fan shall be selected to ensure the mass air flow rate (plus 5%) specified for each AHU in order to guarantee a specified flow rate at the forced-air points, in line with operational values. The overall flow rate loss to be taken into account shall be the sum of the flow rates of the AHU with moderately-clogged filters (the mean of the flow rate loss of the filters when clean and when due for changing) and the air circuits upstream and downstream of the unit.
1.3.1.5Transmission
The pulleys shall be V-grooved with removable conical hubs (taper-lock type). The distance between pulley centres shall make it possible for the belts adequately to surround them. The screw belt tensioners shall ensure proper belt alignment. The shapes of the belts shall be suitable for the pulley system and the whole transmission system shall be capable of withstanding frequent switching on and off. The types of belt shapes shall be selected from the upper section of the calculated range and they shall be N+1 in number (calculated number + 1), i.e. at least 2 belts. The front of the protective transmission casing shall be of perforated sheet steel so that the belts are clearly visible and it shall be removable for checking. The motor shall always be fitted on slide rails to maintain belt tension and adjustment shall be possible via a single screw on each rail, with a lock nut keeping the base in position.
1.3.1.6Accessories
Each fan section will be fitted with pressure measuring points (fan intake and outlet pressure) to measure the total fan pressure.
1.3.2Fan type UUDC
Centrifugal fan, double port, belt transmission.
The fans shall have twin intake ports, with shaped blades curved backwards towards the rear (reaction). The impeller shall be keyed to the transmission spindle and removable by releasing screwed flanges. The outlet aperture shall be connected to the AHU by a non flammable material flexible sleeve.
1.3.3Fan type UUZC (option)
Centrifugal fan, single port, belt transmission, designed for gas extraction.
All the components shall be designed for the operating conditions (aluminium impeller, anti static belts, thermal and acoustic insulation of the AHU casing).
The spindle passages shall be fitted with leak recovery systems on the packing glands.
1.4Motor of fan (UM)
1.4.1General characteristics
Before despatch, the motors shall be protected against water vapour infiltration and remain so protected until they are operational. The motors shall be built to the European standards (IEC). A 10% margin shall be provided over the maximum mechanical power absorbed at the fan spindle.
- Rotor cage type, three phases,
- operating voltage: 3 x 400 V, 50 Hz,
- protective index: IP54 (except for special applications),
- insulation class: F (except for special applications),
- service type: S1,
- starting type: < 25 kW, direct,
> 25 kW, electronic motor-starter, suitable for the operation of the fan with limited starting current (ID/IN < 5),
- fitted with ball bearings.
The electrical connection box shall be accessible and fitted with packing glands matching the diameters of the power supply cables. Earth terminal on the motor casing.
If the fan drive motors are within the heat radiation zone of the electric heaters, they shall be protected by reflective metal sheets. "Equipment" Emergency stops shall be fitted in compliance with safety instruction N°5. All the motor shall bear an engraved identification plate. All electric motors shall feature a thermal overheating protection (by means of thermistance) embedded in windings, as well as by means of magnetic–thermal protection, cutting off the supply, stopping the fan and delivering a “default” signal. The subsequent start-up of the motor shall require a manual command.