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Marafeqs Design Guidelines for the Connection of ETS(s) to the District Cooling System
IFI
09-08-2011 - Clause # 3.2 - Clause # 3.7 - Document number and report format changed
IFI
12-04-2012
REASON FOR ISSUE: IFR IFI IFA IFT IFC Issued for Review/Comment(s) Issued for Information Issued for Approval Issued for Tender Issued for Construction
Marafeq Qatar L.L.C/ Capital QR 30 000 000 P.O. Box 5651 Doha - Qatar T: 974 40120120 F: 974 40120121
LUSAIL DEVELOPMENT
CONTENTS
1
1.1 1.2 1.3
INTRODUCTION
The District Cooling System General Definitions
5
5 5 6
2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
8
8 8 8 8 8 9 9 9
3
3.1 3.2 3.3 3.4 3.5 3.6 3.7
10
11 11 12 12 13 13 14
4
4.1 4.2 4.3
15
15 15 16
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4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 ETS Room Conditions Room Ventilation Primary Interconnecting Pipes Protection Make-up Water and Chemical Water Treatment on the Secondary Systems Water Quality on the Secondary Systems Plumbing / Evacuations Power Outlet / Lighting Fibre Optic 16 16 17 17 17 18 18 18
5
5.1 5.2
ENERGY METERS
General PLC Requirements
19
19 19
6
6.1 6.1.1 6.1.2 6.2 6.2.1 6.2.2 6.2.3 6.3 6.4 6.4.1 6.4.2 6.5 6.6 6.7 6.8 6.9
21
21 21 21 21 21 22 22 22 22 22 23 23 23 23 24 24
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6.10 6.11 Metering Place Venting Valves and Drain Valves 24 24
7
7.1 7.2 7.3
INSTALLATION
Jointing Insulation Tagging
25
25 25 25
26 27
APPENDICES
Appendix 1: Application for Design Conformance Certificate Appendix 2: ETS Examination summary for ETS Conformance Certificate Appendix 3: PI&D - Schematic of ETS installation
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1
1.1
1.2
General
This document describes the Technical Requirements for connecting to MARAFEQ District Cooling Systems. The document should be used for planning, preparation of specifications and procurement during initial design phases in advance of the formal agreement between MARAFEQ and developers/sub-developer/end-users. All technical requirements that applies for connecting to the District Cooling Network are specified in this MARAFEQ Technical Requirements for the connection of ETS(s) to the District Cooling System This document replaces the previously provisional MARAFEQ Booklet 1 to instead be used as a design guideline and for technical requirements of the ETS. Any description statements in the provisional Booklet 1, will no longer apply.
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1.3
Definitions
ETS The Energy Transfer Station (ETS) is the point where the energy from the district cooling system is transferred to the buildings (water) cooling system. An ETS consist of pipes, valves, filter(s), metering and heat exchanger(s)s. Client Contractor Customer Engineer Marafeq Mega-Developer Sub-Developer Vendor PHE or HEX PLC Point of Delivery The master developer - Lusail Real Estate Development Company (LREDC) or its appointed representative. The organization or its appointed representative, responsible for execution of the works. The owner / sub-developer in-charge of the building. Marafeqs supervision engineer or its appointed representative. The utility company which provides District Cooling, Gas Supply and Waste Management services. The owner of the district. The owner of the building. Any invited companies being fully eligible to submit the Tender. The successful Vendor will be the contractor/Supplier. Plate Heat Exchanger, component separating the primary water system from the secondary water system. Definition used can sometimes also be Heat Exchanger (HEX). PLC (Programmable Logic Controller) a programmable microprocessor used to automate monitoring and control of industrial plant. The point of delivery is defined as where MARAFEQ scope of works for the primary pipe system ends, whereas: Inside wall penetration on the buildings connected from utility tunnels. Primary 1m into the plot set-back for buildings connected by directly buried pipes. For both cases above MARAFEQ will install extra isolation valves, in the outside main pipe system.
"Primary" refers to the (Supply and Return) pipe network circulating chilled water produced in District Cooling Plants through the MARAFEQ distribution network. The Secondary are the CUSTOMER's cooling water circuits (Supply and Return) on the building side systems of the heat exchangers. The Primary Service Line run from the Point of Delivery on the main District Cooling pipe system located outside in the street to the individual building interior wall. A set of isolation valves shall be installed where the service line penetrates the building wall. The Primary Interconnecting Pipes run from the main isolation valves inside the building wall to the ETS PHE(s) located in the ETS Plant Room. These ETS are pre-fabricated in the factory, installed and tested. They are mounted on a steel frame, and are possible to transport assembled, which makes installation of a high quality and with a minimum time on site. However conditions and restrictions on transportation openings may lead to that the ETS must be disassembled, shipped and reassembled on site. The ETS can therefore be built in modules or with assembly parts on site. These ETS can be designed with 1, 2, 3 or more PHE units, depending on the scope of the cooling load demand and desired DC delivery availability.
Non-Standard ETS
ETS generally with 3 or more PHE, for CUSTOMERs with higher cooling load requirements. (With pre-fabricated ETS it would require a very large foot-print for numerous PHE. Then large PHE is used instead and assembled with the plates on site). District Cooling Distribution System Marafeqs Design Guidelines for the Connection of ETS to the DC System V.2
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These ETS must be built on site. All components are shipped as separate parts and assembled on site. Trial Operation Commencement of Operation Service Commercial Operation Testing period of the ETS functions before commercial operations, where Marafeq performs test runs and checking the ETS performance. Tollgate marking the end of installation work to be done by the contractor and chilled water is then available for use by the CUSTOMER. This is the contractual date registered in the Cooling Supply Agreement. Tollgate marking the approval from MARAFEQ of the installation and after final adjustments, once the work to be done by the CUSTOMER is terminated and has been inspected, approved and put into service. Note: Operation start-up and putting into service may be combined into a single operation if the CUSTOMERs installations are operational at the time of putting to service.
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2.1
2.2
2.3
2.4
ETS
The CUSTOMERs scope of works includes complete ETS(s) as described in these MARAFEQ Technical Requirements for the connection of ETS(s) to the District Cooling System specifications. The ETS(s) belongs to the Customer, and has no rotating & moving parts. District Cooling will therefore, compared to Chillers located in each building, have no or very limited disturbing noise or vibrations. The metering equipment is excluded from the CUSTOMERs scope of works, and will be supplied and owned by MARAFEQ.
2.5
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2.6
2.7
2.8
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3
TECHNICAL REQUIREMENTS AND RECOMMENDATIONS
MARAFEQ reserves the right to review and approve the design of the ETS and secondary side of the cooling system to make sure it will work and operate together with the District Cooling Network. The schematic of an ETS installation and the components is shown in the following figure. (Can also be found in Appendix 3 where also the symbols are easier to read.)
MARAFEQ recommendations: For high quality and short installation time on site MARAFEQ recommend the use of prefabricated standardized ETS. The installation can depend on needed cooling demand be divided up with 1, 2 or 3 standard PHE. This applies for standard ETS installations for subscribed cooling demands between 70 and 2900 TR. Cooling demand over 2900 TR will need special attention, since standard concept normally can not be used. When high availability of cooling is of special importance at least two 50% PHE is recommended instead of only one 100% PHE. Higher availability might be requested for Commercial use than for Residential buildings. A good redundancy can also be achieved with two 60% PHE. In case of a failure on one PHE, it is still possible to supply 60% of the demand. Each PHE should have a 20% extra space for capacity expansion possibility on the frame. Redundancy PHE is normally not required.
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3.1
Design Criteria
Table 3.1: Design Criteria
Design pressure, primary side Test pressure, primary side Maximum pressure difference over ETS (P) Design ambient temperature for installation, primary side Maximum allowed pressure drop at nominal flow and subscribed load between incoming isolation valves at the wall penetration. NOTE 1) Maximum HEX pressure drop at design flow Cooling Capacity: Available differential pressure. NOTE 2) Supply chilled water temperature, DC Side (t DCS): Return chilled water temperature, DC Side (tDCR): Supply cooling water temperature, CUSTOMER Side (tCCS): Return cooling water temperature, CUSTOMER Side (tCCR): Maximum chilled water flow per ton cooling load (design):
16 23 To be provided 50 150
NOTE 1): Actual available differential pressure depends on the ETS location in the District Cooling Network and can be much higher. The maximum pressure drop shall be used when designing connecting pipes and components assuming the control valves to be fully open. NOTE 2): The actual available differential pressure for the ETS depends on the location in the District Cooling Network and may also change over time as the District Cooling Network develops. To be provided by MARAFEQ. Notes: - It is critical that all air handling units, fan coils units etc are designed for the stated Customer Side temperatures in the table above to provide at least a +14C primary return temperature. This means that the maximum flow required for 1 ton of cooling load is 0.095 l/s (1.5 USGPM). If the building cannot meet this requirement, MARAFEQ cannot guarantee a supply chilled water temperature of +6.5C on the Customer Side at peak load conditions. - Pipe pressure drop calculations and pumps flow-head diagrams and differential pressure set at circuit end of the Customers chilled water circuit (secondary side) are to be coordinated with MARAFEQ during design stage.
3.2
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Directive 2006/42/EC on machinery Kahramaa Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment (applicable parts) QCS Qatar Construction Specifications QCD Qatar Civil Defense Local standards All applicable standards, specifications and regulations issued and/or referred to by Authorities, City Council, Civil Services department or other parties.
3.3
3.4
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Installation of two thermowells on both the primary side and the secondary side, to be used for temperature transmitters (TT). MARAFEQ requires the usage of pressure independent control valves for highest possible T, minimum energy use and reduced labour cost. For highest possible availability one control valve for each PHE is recommended, and then naturally separate termowells for each control valve. A strainer is required at the inlet of the heat exchanger(s) with a pressure gauge arranged so that it is possible to measure the pressure upstream / downstream the strainer and in the supply pipe as per attached PI&D schematic, s ee Appendix 3.
3.5
MARAFEQ recommendations: As indicated on PI&D Appendix 3 it is recommended for low flow control for FVD pumps to add a 2-way control bypass valve around the pump. The 2-way control bypass valve shall correspond to a maximum secondary side chilled water flow of 5% of the full design flow.
3.6
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3.7
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4
4.1
4.2
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Table 4.2: ETS scope of equipment Space for ETS Lighting Electrical supply Meter place Floor drain Flushing possibility ETS primary side Connection Valves Strainer(s) Pressure gauges Temperature indicators Heat exchanger(s) Control valve(s) DC Differential pressure regulator (if necessary, connection shall be included) Dummy pipe / flow sensors Metering equipment Venting valves Drain valves CIP connections ETS secondary side Circulation pumps Expansion vessel Temperature transmitters Pressure indicators and transmitters Safety valve Filling valve Strainer(s) Drain valves CIP connections Note1: See also table 5.1 Should be included CUSTOMERs scope C C C C C Provided from MARAFEQ
C C C C C C M C M (Note 1) C C C
C C C C C C C C C
4.3 4.3.1
4.3.2
Room Ventilation
Mechanical ventilation of the ETS room shall provide continuous refreshment of the air, to prevent condensation that will eventually cause corrosion on equipment. Ventilation air into the room shall be filtered and cooled as required to meet the operating requirements/limits for all ETS equipment. See conditions 4.3.1. Minimum fresh air ventilation ration 0.5 volumes per hour and keeping a positive pressure level in the ETS room.
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4.3.3 Primary Interconnecting Pipes Protection
The network shall be protected from the weather, water splashes, shocks and in general any risk of degradation along the path of the primary network in rooms through which it passes. Pipe protectors should be added to any piping within garbage rooms, parking ramps or other highly trafficked areas where piping could get damaged.
4.3.4
4.3.5
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4.3.6 Plumbing / Evacuations
A floor drain or a sump (with lifting pump) shall be provided to evacuate drain water, washing water and various drips. Open gutters are preferred. Vents shall be provided in high points and drains in low points with outlet conduits located along the path of the primary pipes as far as the special connection to the sewer at the penetration point into the building. It must be possible to discharge water effluents to nearby drains, after specific maintenance operations. The details of each should be specified on construction drawings and on detail drawings. Venting and drain points should remain accessible for network maintenance.
4.3.7
4.3.8
Fibre Optic
To be decided.
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5
5.1
ETS Control and Instrument Item Description Supply By C M M M M C C C Installed By C C C C M C C C Cable Trays and ladders N/A N/A C
(Note 1)
1 2 3 4 5 6 7 8
Threadolets for Instruments Thermowells for temperature transmitters Instruments (PT/PDT/TT/PS) Flow Meter (FM) Energy Meter Control Valve PLC-Panel Wiring for controls
C C C C N/A
Note 1. Instrument and sensors will be free issued including cables. M = MARAFEQ C = CUSTOMER or his appointed Designer or Contractor
5.2
PLC Requirements
No data from the CUSTOMER Building Automation System (BAS) is required for PLC monitoring. MARAFEQ can however export data points used to calculate billing from the district cooling PLC to the BAS. Wiring between the BAS panel and the PLC and any necessary additions to the PLC programme shall be by the CUSTOMER and according to MARAFEQ requirements. MARAFEQ Requirements: The CUSTOMER shall provide, at no cost to MARAFEQ, all control wiring linking between the CUSTOMERs building automation system (BAS) to PLC in the ETS.
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The data points used to calculate billing are: - District Cooling Supply Temperature - District Cooling Return Temperature - District Cooling Flow
Outputs will be powered by the PLC and shall be 24 VDC sinking at the CUSTOMERs BAS.
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6.1
6.1.1
Components
Components for the primary district cooling side should be of the following materials with at least the quality defined for each material type in: Pressure vessel steel Stainless steel P295 GH or corresponding AISI 316 or corresponding
6.1.2
Pipes
Pipes can be made of stainless steel or black steel and should respect the requirements of existing materials and meet pipe standards. Further information can be found in Euroheat&Power Technical Recommendations for District Cooling Pipes at www.euroheat.org . Usually the pipes are of ordinary carbon steel. The disadvantage of the carbon steel cooling pipes is the risk of corrosion attacks, especially from the outside. At low temperatures, below +5C, brittle fracture can occur in welds for the low grade materials. Therefore must so-called killed steel be used in order to prevent brittle fracture. In order to av oid corrosion attack, it has become common to use alloy stainless steel material in cooling systems. Stainless steel requires special skills of welders.
6.2 6.2.1
Valves
Isolation Valves
Main isolation valves shall be located directly inside the building as close as possible to the walls. Connection to the district cooling network should be by welding.
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Isolation valves must be provided in the supply and return pipe around the heat exchanger(s) to allow for maintenance and cleaning. All isolating valves shall be of type welded ball valves. Caution is needed so that the seals in the valves will not be damaged during the welding process. All valves shall be easily accessible and tagged.
6.2.2
Manual Ball Valves for Drain and Vent of the Heat Exchanger(S)
Two ball valves (DN50) for manual air vent and drain shall be provided for each heat exchanger as shown in the P&ID schematic, Appendix 3. These connections will also be used for future chemical injection and periodic flushing of each heat exchanger while the isolation valves are closed. Provide hose connection and cap for each valve. Body, disc and seat rated for a zero leakage shut off at not less pressure class than the heat exchanger(s) design pressure. Provide lever handle with metallic extended stem for insulation.
6.2.3
6.3
Strainers
A strainer is required at the inlet of the heat exchanger(s) to protect it from any suspended particles and debris. The strainer element shall allow for cleaning without being dismantled. The connections shall be flanged or welded. Strainer shall be Y-pattern with blow off drain valve. Screen shall be made of stainless steel with max perforation mesh size 0.6 - 1.0 mm. Screen shall be accessed by way of threaded or bolted cover.
6.4 6.4.1
Indicators
Pressure Indicators
Pressure Gauge for manual reading of the primary side pressure should be included. The scale should be from 0-25 bar. Industrial grade pressure gauge shall be provided and arranged so that it is possible to measure the pressure upstream/downstream of the strainer plus in the supply pipe. The pressure gauge shall be bourdon tube type, phenolic or stainless steel case with plastic lens, black letters on white surface, solid front and blow out back style.
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Stainless steel movement and wetted parts Gauges dial should be 100 mm diameter
6.4.2
Temperature Indicators
In case of more than one heat exchanger required for a single ETS, industrial grade thermometers must be provided in the supply and return line of each heat exchanger Thermometers shall be Bi-metal type thermometers with 125mm diameter stainless steel dial and shatter proof glass, black letters on white surface, external pointer adjustment and rear angle adjustable with connection to thermowell. Thermowells shall be 316 stainless steel bar stock construction, step type. The thermowell shall protrude 1/3 1/2 pipe diameter inside the pipe and lagging extension suitable for the insulated pipe.
6.5
Temperature Transmitters
Temperature transmitetrs can be done directly with thermometers or transmitters connected to surveillance equipment. They should have a range that covers at least the maximum temperature variation. Pockets for the temperature transmitters must not be isolated over. It should at O&M be possible to see if the transmitters are mounted in pockets. The temperature range should be adapted for cooling purposes and positioned so that it is easy to read. For each control valve two temperature transmitters with thermowells for the CUSTOMER cooling water system shall be installed by the CUSTOMERs contractor. Thermowells shall be 316 stainless steel bar stock construction, step type with 3/4 NPT process connection. Thermowells shall protrude 1/3 1/2 pipe diameter inside the pipe and lagging extension suitable for the insulated pipe.
6.6
Heat Exchanger
The material of the Heat Exchangers (PHE) must withstand both systems liquid media. Nameplate should be visible and readable. For chemical cleaning, the manufacturer shall be consulted. PHE shall be located on a drip tray. PHE shall be designed, built and marked in full compliance to AHRI-400 Liquid-to-Liquid Plate Heat Exchangers with ZERO tolerances. Manufacturers of heat exchangers should be able to show that heat exchangers meet the test program described in the standard EN 1148 or equal. The control also includes the manufacturer's data design programs are consistent with product performance. Always use the latest version of the design program.
6.7
CIP Connection
In order to make CIP (Cleaning In Place) of PHE plates possible, the ETS shall have connections installed. CIP is done without dismounting the PHE. In order to save CIP chemicals, the water volume shall be reduced to a minimum. For this the isolating valves should be located closely to the PHE.
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6.8
PLC System
The system consists of control valves and actuators, sensors and PLC cabinet. Ability to manual adjustment of control valve shall be possible. The PLC cabinet is set so that stable control is obtained. The values are recorded and documented in the PLC cabinet during commissioning. Control valves shall operate without disturbing noise at a differential pressure of up to 0.6 MPa (6 bar) at a pressure of at least 0.1 MPa (1 bar) after the valve. There must be readable sign on the valve showing type, DN, pressure class and kvs-value.
6.9
6.10
Metering Place
The metering place includes the supply pipe temperature sensor and the return pipe flow sensor and temperature sensor. In addition, a place for integrator and power supply should be arranged for. The installation must be done according to MARAFEQ instructions. Flow sensor; temperature sensor and integrator should be installed so they are easy to read and replace. In cases where temperature sensors are mounted without pockets it should clearly be labeled on the sensors. Temperature sensors should, for best performance, be connected to integrator with 4-wire connection. (Not possible on small pipe DN.) The energy meter is MARAFEQ property and will be provided for the installation. MARAFEQ should have the possibility to connect the metering devices to a PLC system for metering values transmission. Connected metering devices must not be disconnected by anyone other than MARAFEQ staff.
6.11
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7
7.1
INSTALLATION Jointing
Works on the primary district cooling side (and also on the secondary cooling system if direct connection is used) should be carried out by the company with welding license and certified welders who carried out the approved welder qualification test in accordance with EN287-1 or passed brazing tests according to Qualification on Copper pipes as with BS 1724 or equal. Installation of valves in primary district cooling system must use a welding method that will not cause damage to the valve seal. Therefore it requires electric fusion welding if the weld is located at shorter distances than 0.5 m away from the valve house. In addition the valve suppliers recommendations shall be followed.
7.2
Insulation
In order to avoid condensation of moisture from the air on the pipes, valves and other components, shall be insulated. In order to avoid condensation water from drip, the facility should be equipped with drip trays and isolated with vapor barrier. Pipes should preferably be pre-insulated according to EN253 pipes or EN244 fittings. Isolation can also be of cellular rubber which is glued together, edge to edge. The montage must be airtight. Insulation thickness shall be based on no condensation with an ambient air temperature of 28C and 75% relative humidity. Polyurethane foam with the top layer of Aluminum is used for high requirements on vapor barrier and resistance against mechanical impact. Insulation for heat exchangers are recommended to be provided from the PHE manufacturer. Generally insulation work shall be carried out by an approved specialist for thermal insulation contractor.
7.3
Tagging
Pipes, valves and equipment shall be tagged according BS 1710 or equal. Each item of equipment shall be identified by using white non-corroding shatterproof laminated plastic labels engraved with black letters, 6mm high, the function and number of each piece of equipment, i.e. primary chilled water pump, pump numbers, etc. All labels shall be fixed with screwed, riveted or glued to equipment cover. Where a piece of equipment is insulated the identification label shall be fixed to the external surface of the insulation. Valves shall be tagged with identification discs attached with a split ring, S-hook or brass chain, whichever is the most appropriate. All primary and secondary chilled water pipe work shall have self-coloured, self-adhesive PVC tape bands colour coded in accordance with BS 1710 so far as this is applicable and at suitable intervals.
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APPENDICES
Appendix 1: Application for Design Conformance Certificate Appendix 2: ETS Examination summary for ETS Conformance Certificate Appendix 3: PI&D - Schematic of ETS installation
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Appendix1
ApplicationforDesignConformanceCertificate
(DesigninformationthatshallbeincludedontheETSplantPID) Address PlotID.. GrossFloorArea(GFA)..m2 NetFloorArea(NFA)CooledAream2 AHU(AirhandlingUnits)..TR(kW) FCU(FanCoilUnits)...TR(kW) Processcooling..TR(kW) Others..TR(kW) ERU(EnergyRecoveryUnits)...TR(kW) Districtcoolingsystem(Primary) PHEsupplier Type/numberofplates Designflowm3/h PressurelosskPa DesigntemperatureoC
Buildingcoolingwatersystem(Secondary) Designflowm3/h PressurelosskPa DesigntemperatureoC Controlvalves/actuatorssupplier(Primaryside) Typeofcontrolunit/programversion Typeofcontrolvalve 3 Flowm /h PressurelosskPa CalculationofvalveDN/kvvalue ChosenvalveDN/kvsvalue Regulatingrange Actuatortimeotoc,ctoo
Appendix2
ETSExaminationsummary
Date: Customer/Company: Executedby: Typeofcontrol:
ETSID:
DISTRICTCOOLINGSYSTEM
2Volumem Pressure 3Supply,beforestrainerMPa/kPa 4Supply,afterstrainerMPa/kPa 5ReturnMPa/kPa Pos System/component
3
BUILDINGCOOLINGSYSTEM
Secondaryside o 8Temperaturesupply C 9Temperaturereturn C Other 10Outsidetemperature C
o o o
Status 14
Proposed action
Districtcoolingsystem
Isolatingvalves Strainer Pressuresensors Temperaturesensors Flowtransmitter Calculationunit Temperaturetransmitter Others PHE Controlunit Controlvalve
Buildingscoolingsystem
Strainer Pressuresensors Temperaturesensors Pumps Expansiontank/safetyvalve Valves Others
Otherequipment