Annexure -2

SPECIFICATIONS, TERMS, CONDITIONS AND COMPLIANCE SHEET

Spray Painting Booth with 100% Fresh Air Year Round Air Conditioning System

Sr. No. Description Specifications

Party’s Specification / Compliance

1.0 SPRAY PAINTING BOOTH 1 No 1.01 Type Positive pressurized, Side draft, Dry back painting booth 1.02 Working space of spray paint booth 3100 (W) X 3300 (D) X 2600 (H) mm 1.03 Spray paint booth overall dimensions Compact and shall be accommodated in the existing room of size

7200 mm (L) x 6200 mm (W) x 4000 mm (Ht)

1.04 Structure of booth wall & ceiling panels Panel material PUF insulated SS-304;

Panel sheet SS-304; 18-gauge sheet; Plain inside & ribbed outside

Panel insulation 60 ± 2 mm thick PUF insulated wall panel

PUF density 38 ± 2 kg/m3 PUF thermal conductivity ≤ 0.021 w/mK

1.05 Entry / Exit Door Dimensions 1600(w) x 2100(h) mm Type Manual sliding with D-handle No of leaves Single leaf Door material PUF insulated SS-304;

Door sheet SS-304; 18 gauge sheet; plain on both inside & outside

Door insulation ≥ 60 mm thick PUF insulated panel PUF density 38 ± 2 Kg/m3 PUF thermal conductivity ≤ 0.021 w/mK

Vision glass Double glazed tempered glass on both sides; Properly sealed; Ergonomically placed.

Vision glass size 800 mm (L) x 600 mm (Ht) Vision glass height 1200 mm from the ground Tempered glass thickness 5 - 6 mm Make Metaflex / MTH

1.06 SS-304 Supporting Structure of Booth C-channel, Angle, Flat and other sections of SS-304 1.07 Intake Air Filters Filter Media Area 3300 X 2600 mm (Approx.)

Filter Media Construction Pleated Individual Filter Module 610 x 610 mm Pleated Filter Depth ≥ 150 mm Filter Module Holder SS-304 Frame; Detachable Filter Rating 5µ; EU5 Filters Mounting Washable and Replaceable

Filter monitoring

Using differential pressure across filters. Differential pressure transmitter as

per Sr. No. 1.11

Make AAF/Aerisol/Spectrum or equivalent 1.08 Paint Arrester Filter Stage-1 Filter Type Pleated & Perforated cardboard filter

No of pleats per meter 25 Thickness of Filter 50 mm Filter Efficiency ≥ 91% Filter Media Area 3300 X 2600 mm (Approx.) Filter Module 900 x 900 mm Filter Module Holder SS-304 Frame; Detachable Filters Mounting Replaceable Make AAF/Aerisol/Spectrum or equivalent

Quantity 1 set with Frame + 2 sets of Filter element as spare

1.09 Paint Arrester Filter Stage-2; (backside of Stage-1 Filter)

Filter Type Disposable Non-Woven Fiber Glass Type Filter

No of pleats per meter 25 Thickness of Filter 50 mm Filter Efficiency ≥ 96% Filter Media Area 3300 X 2600 mm (Approx.) Filter Module 900 x 900 mm

Filter Module Holder SS-304 Frame with retaining grids; Detachable

Filters Mounting Replaceable Make AAF/Aerisol/Spectrum or equivalent

Quantity 1 set with Frame + 2 sets of Filter element as spare

1.10 Differential Pressure inside the booth; Settable

0-25 Pascal Differential Pressure Transmitter as per Sr. No 1.11 Supply and Exhaust Blowers shall be configured to control/

maintain the set differential pressure inside the painting booth

1.11 Differential Pressure Transmitter Medium Air & non-combustible gases Field selectable Ranges ± 0.1˝, 0.25˝,0.5˝ W.C Units Selectable SI or British Display 4 digits LCD Accuracy ±1% Power Requirements 10 to 35 VDC (2-wire) Output Signals 4 to 20 mA (2-wire) Response Time Adjustable 0.5 to 15 sec Zero & Span Adjustments Digital push button Enclosure Rating IP65

Quantity 2 Nos. 1 No for Intake air filters (1.07) 1 No for Booth Pressure (1.10)

Make Dwyer / GE / ABB Model Please Specify

1.12 Booth Illumination Illumination

≥ 1500 lumens/Sq. meter; uniformly distributed

Type Chemical fume proof Mounting Concealed in Ceiling No of Tubes per set ≥ 2 No of Sets in the booth ≥ 6 MCBs for lighting Single Pole MCBs for each set Electrical Supply 230±10 % VAC, 50 HZ, 1 Phase Make Philips / Crompton / Bajaj

1.13 Flooring Type ESD Tiles or ESD Coating Floor Area 3100 mm X 3300 mm Thickness of ESD Tiles / Coating

≥ 3 mm

Surface Resistance 106 To 108 Ohm/Square

Color Light Gray 1.14 Acceptable Noise Level in the Booth ≤ 78 dBA 1.15 Spray Paint Booth Environment

Conditions Temperature inside the booth

23 °C ± 3°C PT-100 Sensor as per Sr. No 1.16

Relative Humidity of Booth

50% ± 10 % RH Transmitter as per Sr. No 1.17

Water Chilling Plant and Air Handling Unit shall be Fabricated and Supplied to meet Spray Paint Booth environment conditions.

Specifications of Water Chilling Plant as per Sr. No 2.0 Specifications of Air Handling Unit as per Sr. No 3.0

1.16 Booth Temperature sensor Type PT-100 Signal Connection 3-wire Accuracy Class Class B (IEC 60571)

1.17 RH Transmitter with LCD display Service

Humidity, Temperature and Dew point in air

RH Range 0-100% RH Accuracy ±2% Humidity sensor Capacitance Polymer Display Resolution 1% Temperature & Dew Point 0-60 °C Temperature Accuracy ± 0.3 °C Probe 5/16˝ x 10˝ stainless steel Display Resolution 0.1 °C Power Requirements 10-35 VDC Output Signal 4-20 mA – 2 channel Display LCD Display Display Selection Switch for RH or Dew Point Mounting Wall Mount Quantity 1 No. Make Dwyer/ GE / Omega Model Please Specify

1.18 Compressed Air Line Piping Size of the line 1/2 inch Operating pressure 7 bar Pressure rating of piping 20 bar

No of service points in the spray paint booth after filter system

2 Nos.

Material of Piping Seamless Copper / SS Approx. Length of piping 15 meter No of Valves 2 Nos.

1.19 Compressed Air Filters & Regulator setup

Body of Regulator & Filter housing

Metal body with transparent bowl and pressure gauge

Body of Filters housing Transparent plastic / Aluminum Grade of Filtration stage-1 5µ Grade of Filtration stage-2 1µ Connection Size 1/4 inch Operating Pressure ≤ 10 bar

Pressure gauge

2 inch dial; 0-200 psi scale; Liquid Filled; Stainless steel; connection size compatible to Air Regulator; Wika or equivalent make

Make Festo / 3M / Bullows 1.20 Compressed Air Pressure Transmitter Range 0 to 16 bar Absolute

Input Power 10-35 VDC Output signal 4-20 mA; 2-wire Sensor connection 1/4 inch Signal connection 2 - wire; DIN Connector Media compatibility Air Make Honeywell / Kevilco / Juma / Dwyer

1.21 Spray Gun Holders Mounting Wall Mounted Spray Gun Compatibility HVLP; Devilbiss / Binks Quantity 2 Nos.

1.22 Suspended Arm System for HMI Compatible for HMI

Suitable for offered HMI As per Sr. No 4.5

Arm movement 200 mm; both vertical & Horizontal Make Rittal / Pentair / Eldon

1.23 Turntable Diameter of Turntable 2 feet

Table top SS 304; Adjustable height 600- 900 mm

Load Lifting capacity ≥ 200 Kg MOC of Supporting Structure

MS with power coating / Epoxy Coated

1.24 For Booth illumination, electrical power will be supplied separately independent of common PLC based control panel.

1.25 All other required power input supply and output signals shall be connected, with suitable cables, from and to common PLC based control panel. The cable shall be run through cable protecting PVC conduit pipe and PVC/SS tray with cover.

2.0 30 TR WATER CHILLING PLANT 1 No 2.1 Total Refrigeration Capacity; TR 30 TR

Shall be accommodatable in the space designated for AHU and Chilling Plant of size 8300 mm x 5000 mm x 4000 mm (Ht)

2.2 No of Refrigerant Circuit Units 3 Nos (Independent Circuits) 2.3 Capacity of Each Independent

Refrigeration Circuit 10 TR

2.4 Design Conditions 30 TR at 2 °C Saturated Suction Temperature (SST) and 52 °C Saturated Discharge Temperature (SDT) to cool down water from 12 °C to 7 °C.

2.5 Media to cool Water 2.6 Power Supply 415±10 % VAC, 50 HZ, 3 Phase

The supplier shall provide the required suitable electrical cable with proper earthing for connecting the chilling plant to main PLC based control panel. The cable shall be run through cable protecting PVC conduit pipe and PVC/SS tray with cover.

2.7 Refrigerant R-134a 2.8 Refrigeration Compressors Type Hermetic Scroll Compressor

Cooling Capacity 10 TR @ 2 °C S|ST & 52 °C SDT Refrigerant R-134a Power Supply 415±10 % VAC, 50 Hz, 3 Ph Acceptable Noise Level ≤ 78 dBA

Service Valves Individual Suction and Discharge Stop Valves on each Compressor

No of Compressors 3 Working & 1 Spare Total : 4 Nos.

Make Copeland/Danfoss/Blitzer

Model Number

Please specify. Software Output for the selection

of Scroll Compressor shall be submitted along with technical bid

2.9 Condensers Type Air Cooled Size 90 in x 30 in x 4 rows No of Circuits 15 Circuits Size of Copper tube 3/8 in; 27 gauge grooved tube Fan Type, Quantity & Make

Axial Fans; 3 Nos for each condenser GEC/ Alstom/ Khaitan/ Almonard

No of Condensers 3 Nos.

Standard Accessories Receiver, Purge Valve, Safety Valve, Drain Plug etc.

Location of Air Condensers Shall be installed in the wall cut-outs as designated in the building layout plan.

2.10 Liquid Line Solenoid Valves Type Direct Acting

Quantity 3 Working & 1 Spare Total : 4 Nos.

Coil operating voltage 24 VDC Make Danfoss / Alco / Sporlon Model No. Please specify

2.11 Catch-All Driers Size 5/8-inch; No. 305

Quantity

2 Nos installed in parallel for each circuit with 7/8-inch liquid line header; 6 Working & 2 Spare Total : 8 Nos.

Make Danfoss / Alco / Sporlon Model No. Please specify

2.12 Liquid Line Sight Glass Quantity 3 Nos Make Danfoss / Alco / Sporlon Model No. Please specify

2.13 Expansion Valves Type

Electronic Expansion Valves With Stepper Motor

No of Steps ≥ 3000

Accessories Suitable Driver kit Comprising Of Controller, Temperature Sensor, Pressure Transducer etc.

Quantity 3 Nos. Make Danfoss/ Alco/ Sporlon/ Carel Model No. Please specify

2.14 Evaporators Type

Direct Expansion (DX); Copper Brazed Plate Heat Exchanger (BPHE)

Capacity 10 TR Quantity 3 Nos. Make Alfa Lavel/ GEA/ Tranter Model Please specify

2.15 Suction Filter Capacity 10 TR each Make Danfoss/ Alco/ Sporlon Model No. Please specify Quantity 3 Nos.

2.16 Suction and Discharge Pressure Transmitters for Refrigerant

Range 0 to 25 bar Absolute Media compatibility R-134a Sensor Connection 1/4 inch Signal Connection 2 Wire; Din Connector Output Signal 4-20 mA

Quantity 6 installed + 2 Spare Total 8 Nos.

Make Kevilco/ Jumo/ Emerson/ AST/ Burkert/ Prignitz

Model No. Please specify 2.17 Chiller Pump Capacity 22.5 M3 / hr @ 26 Meter Head

MOC Stainless Steel Make Grundfoss / Wilo / ITT Lowara Model Please Specify Drive Variable Frequency Drive

VFD Supply Voltage 380 To 480 Vac ± 10 % VFD Input Frequency 50 to 60 Hz VFD Output Frequency Variable VFD Enclosure Rating IP55 VFD Efficiency 98% VFD Make ABB/ Danfoss/ Siemens

Quantity 1 Working + 1 Spare Total Quantity : 2 Nos.

2.18 Strainer for Chiller Pump Inlet Material Brass / SS Size As per Chiller pump inlet size

2.19 Water Flow Switch for Chiller Pump Function Dry Run Trip MOC For Contact Parts Stainless Steel Supply Voltage 24 VDC Control Output On – Off Type Make Honeywell / Flowtec / Sagonomiya Model Please Specify Quantity 1 No.

2.20 3-Way Modulating Valve Media Water Coil Operating Voltage 24 VDC

Input Signal for Modulation

0-10V / 4-20 mA 0-10V / 4-20 mA signal from

Digital Temperature Controller installed after Air Handling Unit Cooling Coil.

Connection 50 NB Quantity 1 No. Make Belimo / Danfoss Model No. Please specify

2.21 Chilled Water Tank with Lid Capacity ≥1500 Liters MOC of Tank PUF Insulated SS-304 or PP/PE PUF Thickness ≥ 22 mm Insulation PUF

Standard Provisions 1. Ball Valve Connection at the

bottom of a side for connection to Chiller Pump.

2. Make-up water connection at the top.

3. Drain Valve Connection at the bottom of a side.

4. BPHEs (3 Nos.) shall be placed inside the tank with flange/threaded connections.

5. Level Sensor; side mounted 6. Make up water solenoid valve; 24

VDC coil Quantity 1 No.

2.22 Chilled Water Temperature sensor Type PT-100 Signal Connection 3-wire Accuracy Class Class B (IEC 60571)

2.23 Refrigerant Piping Piping Layout Compact MOC of Piping / Tubing Seamless Copper

Discharge Line 1-3/8 inch ID; 16/18-gauge seamless copper tube

Liquid Line 7/8 inch ID; 16/18-gauge seamless copper tube

Suction Line 1-5/8 inch ID; 16/18-gauge seamless copper tube

2.24 First Charge of Refrigerant & Oil First Charge of R-134a refrigerant gas and recommended refrigeration lubricating oil shall be provided by the supplier.

2.25 Refrigerant Line Insulation Refrigerant suction lines shall be insulated with expanded butyl rubber/ or equivalent and aluminum cladded of required thickness.

2.26 Chilled Water Line Piping PP-R (Polypropylene – Random) of PN-10 pressure rating pipes and fittings shall be used for chilled water pipe line.

Chilled water from Chilled water tank shall be connected to Air Handling Unit Cooling coil through 3-way modulation by-pass valve and chiller pump with proper insulation by expanded butyl rubber/ or equivalent and aluminum cladded of required thickness.

The return water from Air Handling Unit cooling coil shall be connected to three BPHEs water inputs by a common header.

The BPHEs water outlets shall be opened freely into the chilled water tank at half of the height of BPHEs.

2.27 Plant Structure The total unit shall be placed on Epoxy / PU coated MS structural stand made from MS channels for the above equipment and internal gas piping.

The complete unit shall be accommodatable in the space designated for Air Handling Unit and Chilling Plant of size 8300 mm x 5000 mm x 4000 mm (Ht).

3.0 AIR HANDLING UNIT WITH DUCTING, EXHAUST AIR BLOWER WITH CHIMNEY FOR PAINT BOOTH

3.1 Scope of Supply of Air Handling Unit with Ducting

Horizontal Air Handling Unit shall be composed of Fresh air Supply Filter, Fresh Air Supply Damper, Mixing Plenum, Supply Air Blower, Preheater, Cooling Coil, After Heater, Humidifier, Return Air Duct with Damper and Conditioned Air Supply Duct with Damper.

AMCA (Air Movement & Control Association) Certified. The complete unit shall be accommodatable in the space designated for Air Handling Unit and Chilling Plant of size 8300 mm x 5000 mm x 4000 mm (Ht).

3.2 Requirement To maintain Spray Paint booth at 23 ±3°C temperature & RH 50% ±10% using chilled water of 30 TR Chilling plant.

3.3 AHU Mounting Horizontal Floor Mounted 3.4 AHU Frame Work Extruded Aluminum Profile Frame 3.5 Structure Of AHU Panels Panel Material PUF insulated GI sheet

Panel sheet GI sheet; 0.63 mm plain on both inside & outside

Panel Insulation 43 ± 2 mm thick PUF Insulated Wall Panel

PUF Density 38 ± 2 Kg/m3 PUF Thermal Conductivity ≤ 0.021 w/mK

3.6 AHU Supply Air Filter Type Pleated filter; washable/ cleanable efficiency ≥ 90% Filter class 10 µ; EU4 Filter depth ≥ 100 mm

3.7 Supply Air Mixing Plenum To mix fresh supply air & return air and mixed air shall be supplied to Supply air blower

3.8 Volume Control Dampers with actuators Requirement

Air volume control and balancing the system

Damper locations

1. Fresh Air Intake volume control damper (VCD-1) between Filters and Mixing plenum

2. Return air volume control damper (VCD-2) before mixing plenum.

3. Conditioned Air supply damper (VCD-3) after return air duct.

MOC Aluminum; Robust construction with louvers; Tightly fitted

Type Spring return with suitable torque Quantity 3 Nos. Control Modulating Input signal 0-10 VDC / 4-20 mA Supply Voltage 24VDC Make Belimo / Siemens / Danfoss Model Please specify

3.9 Digital Temperature controller with Auto tune PID with Pt-100 Sensors

Requirement For controlling Volume control Dampers and Chilling Pump.

DTC locations 1. After cooling Coil 2. Before Conditioned Air supply

damper.

Input RTD; Pt-100 Sensor; 3-wire; class B Temperature setting 0 – 60 °C Controller Power Supply 100-240 VAC, 50 Hz Control Signal Output 4-20 mA

Process Value setting Setting range shall be decimal and non-decimal

Standard Functions Self-tuning PID function; ON/OFF function; Timer function, Digital PV filter; PID over shoot protection.

Display of Values Process Value (PV) and Set Value (SV) shall be different in color

Size 48 x 48 mm Quantity 2 No. Make Toho / Omron / Fuji / Athena

3.10 Supply Air Blower Capacity 10,000 CFM at 80 mm WC

Software Output for the selection of Blower capacity with head shall be submitted along with technical bid.

Make Kruger / Punker/ Nicotra/ Osberg Drive VFD VFD Supply Voltage 380 To 480 Vac ± 10 % VFD Input Frequency 50 to 60 Hz VFD Output Frequency Variable VFD Enclosure Rating IP55 VFD Efficiency 98% VFD Make ABB/ Danfoss/ Siemens Motor TEFC / IP-56 Electrical Supply 415±10 % VAC, 50 HZ, 3 Ph Motor make ABB/ Crompton/ Siemens

3.11 Pre-Heater Type Finned strip air heater Capacity 18 kW

Quantity 3 No; 6 kW each Total Capacity : 18 kW

3.12 Chilled Water Cooling Coil Size

5 Feet Length X 4 Feet Height X 8 Row Deep Cooling Coil

Coil Tubes & Header 1/2 Inch OD X 0.36 mm (27 Gauge) thick Copper tubes with 2-in dia. chilled water header.

Coil Fins 0.15 mm thick; 12-13 Aluminum fins per inch

water inlet temperature 7 °C water outlet temperature 12 °C Air-on Temperature ≤20 °C Ambient Temperature 44 °C

3.13 Drain Pan with Auto Drain Valve Drain Pan

20 gauge, SS-304 drain pan with 20 mm thick insulation on outside

Auto drain valve 1/2 inch; Settable interval time and ON time

3.14 After-Heater Type Finned strip air heater

Capacity 18 kW

Quantity 3 No; 6 kW each Total Capacity : 18 kW

3.15 Steam Humidifier Type

Sealed SS Tank with Immersion Heater

MOC of Tank SS-304 SS Tank Dimension 1200 (L) x 300 (W) x 200 (Ht) mm

Immersion Heater Rating 6 kW 2 Nos; 3 kW each

Valve for Steam Injection Solenoid Valve; Normally Closed; 24 VDC coil operation

Steam Injection Uniformly distributed Spray nozzles; 5 Nos.

Make-up water Solenoid Valve; Normally Closed; 24 VDC coil operation

Standard features Level sensor; Pressure Relief plug; Over Temperature cut off.; Drain Valve

Quantity 1 No. 3.16 Temperature Sensors Type PT-100

Signal Connection 3-wire Accuracy Class Class B (IEC 60571)

Locations

1. Ambient; outside AHU 2. Before Cooling Coil 3. After cooling Coil 4. Before Conditioned Air supply

damper.

Quantity 4 No 3.17 RH Transmitters

Service Humidity, Temperature and Dew point in air

RH Range 0-100% RH Accuracy ±2% Humidity sensor Capacitance Polymer Display Resolution 1% Temperature & Dew Point 0-60 °C Temperature Accuracy ± 0.3 °C

Probe 5/16˝ x 10˝ stainless steel Display Resolution 0.1 °C Power Requirements 10-35 VDC Output Signal 4-20 mA – 2 channel Display LCD Display Display Selection Switch for RH or Dew Point Mounting Duct Mount

Mounting Locations

1. Ambient; outside AHU 2. Mixing plenum 3. Before conditioned Air supply

damper

Quantity 3 No. Make Dwyer/ GE / Omega Model Please Specify

3.18 Conditioned Air Supply Duct & Return Air Duct

Type GI duct with minimum suitable bends

Surface Area of Duct Approx. 500 Sq. feet (Intake + Return + Supply)

MOC of Duct GI Sheet; 22 gauge sheet for duct & 24 gauge sheet for bends.

Thermal Insulation

Thermal insulation over the ducting with 19 mm thick nitrile rubber with factory backed aluminum foils. The duct surface which is to be insulated shall be cleaned and applied with suitable adhesive. The gaps in the insulation shall be sealed with tape.

Acoustic Insulation Acoustic insulation for ducts shall be provided to meet the required noise level ≤ 78 dBA.

3.19 Access Doors Access doors shall be provided to areas of regular maintenance, wherever required.

3.20 Scope for Exhaust Air Blower with Ducting and Chimney.

Exhaust Air Blower unit shall be composed of exhaust air duct, Exhaust Air Blower and Chimney.

3.23 Exhaust Air Blower Capacity 6,000 CFM at 48 mm WC

Software Output for the selection of Blower capacity with head shall be submitted along with technical bid.

Make Kruger / Punker/ Nicotra/ Osberg Drive Variable Frequency Drive VFD Supply Voltage 380 To 480 Vac ± 10 % VFD Input Frequency 50 to 60 Hz VFD Output Frequency Variable VFD Enclosure Rating IP55 VFD Efficiency 98% VFD Make ABB/ Danfoss/ Siemens Motor TEFC / IP-56 Electrical Supply 415±10 % VAC, 50 HZ, 3 Ph Motor make ABB/ Crompton/ Siemens

3.24 Exhaust Air Duct Type GI duct with suitable bends

MOC of Duct GI Sheet; 22 gauge sheet for duct & 24 gauge sheet for bends.

Surface Area of Duct Approx. 300 Sq. feet

Thermal Insulation

Thermal insulation over the ducting with 19 mm thick nitrile rubber with factory backed aluminum foils. The duct surface which is to be insulated shall be cleaned and applied with suitable adhesive. The gaps in the insulation shall be sealed with tape.

Acoustic Insulation Acoustic insulation for ducts shall be provided to meet the required noise level ≤ 78 dBA.

3.25 Air Velocity Transmitter with LED display and mounting accessories

Media Air; Range ≥ 3000 fpm Accuracy ±3% Display 4-1/2 digit 1/2˝ red LED Temperature Limits 0 to 50°C Humidity Non condensing

Power Requirements 24 VDC +10% Output Signal 4 to 20 mA Mounting Orientation Shall not be sensitive to position Make Dwyer / Honeywell/Omega/ Wika Model Please specify

3.25 Chimney after Exhaust Blower Type Round duct with rainwater cap.

MOC of Chimney

Epoxy coated MS; with conical bottom section and round chimney. Mesh around rain water cap to prevent birds entry.

Reinforcement of Chimney Ribs, Reinforcement and support at every 2-meter length.

Conical bottom section ≥ Ø 600 x ≥ Ø 450 mm Diameter of Chimney ≥ 450 mm Height of Chimney 10 meter Thickness of sheet ≥ 5 mm

3.26 Electrical Supply & Cabling All other required power input supply to Fresh Air Supply Damper, Supply Air Blower, Preheater, After Heater, Steam Humidifier, Return Air Damper, Conditioned Air Supply Damper, Exhaust Air Blower, Digital Temperature controllers, RH Transmitters shall be from common PLC based control panel. The output signals of transmitters shall be connected to common PLC based control panel. The cable shall be run through cable protecting PVC conduit pipe and PVC/SS tray with cover.

4.0 PLC BASED CONTROL PANEL AND SCADA SYSTEM 4.1 PLC – Main CPU with Ethernet interface

for communication with other devices like HMI and SCADA

Programming memory ≥192 Kbyte

Expansion of I/Os Shall support additional analog I/Os, Digital I/Os, RTD pt-100 inputs

Connection method of add-on modules

Direct Snap-On modules without flexible wiring.

Protocols Shall support http, FTP, Sntp, Snmp, Smtp, Sql, Mysql

Integrated Options Integrated Web Server, FTP

Server Integrated Real time clock

Interface Ports Build-in Ethernet and serial ports Program Developing software

Latest PLC program software with license key

Programming interface cable between PC and PLC

Ethernet cable / interface cable

PLC program file

Original PLC program file along with password shall be supplied. This PLC program file shall be editable at user end for future needs. Password shall be submitted to SAC separately after warranty period is completed.

Software compatibility Windows 7 or higher Supply Voltage 24 ±10% VDC Quantity 1 No

Make Siemens / Phoenix Contact/ ABB/ Mitsubishi / GE Fanuc

Model Please specify 4.2 Add-on Temperature Modules No of RTD inputs 16 Nos.

RTD Sensor compatibility Pt-100 – 3 wire Accuracy ≤± 0.5 ⁰C Process Data update ≤6 ms

Resolution 16 bits +/- Sign bit + 15bits

Make Same make offered for Sr. No. 4.1 Model Please specify

4.3 Add-on Analog input Modules No of analog inputs 24 Nos. Supply Voltage 24 ±10% VDC Input signal 4-20 mA – 2 wire Process Data update ≤1 ms

Measured value Resolution 16 bits +/- Sign bit + 15bits

Make Same make offered for Sr. No. 4.1 Model Please specify

4.4 Add-on Digital Input Modules No of digital inputs 48 Nos.

Make Same make offered for Sr. No. 4.1 Model Please specify

4.5 Add-on Digital Output Modules No of digital Outputs 48 Nos. Make Same make offered for Sr. No. 4.1 Model Please specify

4.6 Human-Machine Interface with built in LAN port

Display size ≥10 inch Screen Programmable touch screen Resolution Minimum 800 x 480 dots Display device TFT Color LCD; Backlit LED Colors Minimum 65536 colors FROM ≥10 MB SRAM ≥128KB Data logging USB Pen drive Supply Voltage 24 ±10% VDC

External interface

RS-232– (1 No), RS-485 Modbus RTU (2 No) USB – Type A (1No); USB – Type B mini (1No) Ethernet port (1 No)

Program Developing software

Latest HMI programming software with license key

Programming interface cable between PC - HMI

Ethernet cable / interface cable

HMI program file

Original HMI program file along with password shall be supplied. This HMI program file shall be editable at user end for future needs. Password shall be submitted to SAC separately after warranty period is completed.

Software compatibility Windows 7 or higher Quantity 1 No

Make Fuji / Siemens / Phoenix Contact / Mitsubishi / GE Fanuc

Model Please specify 4.7 Industrial Ethernet Switch No of Ethernet Ports 5 Port (RJ 45)

Transmission Speed 10/100 Mbps

Mounting Din Rail Mountable Supply Voltage 24 ±10% VDC

Switching modes Auto Negotiation, Store And Forward Switching Mode

Status indicators Link Status And Diagnostic Indicators Per Port

Quantity 1 No Make Cisco/ Phoenix Contact/ Advantech Model Please specify

4.8 SMPS Input Voltage 230 VAC Out Put Voltage 24 VDC Output Current 5 A Mounting DIN rail mounting

Quantity 6 Nos. 3 working + 3 Spare

Make Siemens/ Phonix Contact/ Omron 4.9 Energy Meter Type Current, Voltage, pf. Hz, kW, kWh

Accuracy ± 0.5% Electrical Supply Type 3 Ph, 50 Hz Display Type Backlit LCD Display Color Monochrome Refresh Time Configurable from 1 To 60 min

Communication Port

RS 485 Modbus RTU. Parameters shall be data logged either communicating with PLC or HMI or SCADA.

Quantity 1 No

Make Schneider/ Siemens/ABB/ Phoenix Contact

Model Please specify 4.10 PLC Based Control and Power

Distribution Panels Designation of Panels There shall be 3 No. of sheet steel

electrical panel boxes. 1. Main SFU and Contactors Panel 2. VFDs Panel 3. PLC Control Panel

4.11 Main SFU and Contactors panel It shall house main 315 Amp Switch Fuse Unit (Siemens/ ABB/Schneider), Copper bus bar (Bussmann/ Siemens/ ABB), MCCBs, MPCBs, Electronic OLRs, Single phasing and reverse rotation preventers for each compressor individually (3 Nos), DOLs, Contactors, HRC fuses, I/O connectors, Cooling fans etc. Supply power shall be given from the top of control panel.

Control Panel Make Rittal/ Fibox/ Hoffman/ Eldon Model Please Specify

4.12 VFDs Panel It shall house 125 Amp SFU, Variable Frequency Drives, fast blowing semiconductor fuses, I/O connectors, high capacity cooling fans etc. Supply power shall be taken from main SFU Panel from the top of control panel.

Control Panel Make Rittal/ Fibox/ Hoffman/ Eldon Model Please Specify

4.13 PLC Control Panel It shall house 32 Amp SFU, SMPSs, PLC, I/O connectors, fast blowing semiconductor fuses, high capacity cooling fans etc. Supply power shall be taken from main SFU Panel from the top of control panel.

Control Panel Make Rittal/ Fibox / Hoffman/ Eldon Model Please Specify

4.14 Common Specifications of Control Panels Enclosure

Sheet Steel; ≥ 1.5 Mm Thick; Dip coat Primed, Powder Coated On Outside, Textured Paint

Door

Sheet Steel; ≥2.0 Mm Thickness; Dip coat Primed, Powder Coated On Outside, Textured Paint Door Hinged, Shall Be Swappable From Right To Left Or Vice Versa

Mounting Panel Zinc Plated Carbon Steel; 3.0 Mm Thick

Distance between Control Panels

Minimum 250 mm; for cooling fans air filters

Wires & Cables All internal cables and wires shall be of multi strand copper.

All external wires and cables shall be of multi strand armored

Finolex / Havells / Polycab

Cable Trays The cable shall be run through cable protecting PVC conduit pipe and PVC/SS tray with cover.

4.15 Data Acquisition and SCADA Graphical User Interface (GUI) based software on Windows platform.

OPC server support. Shall support minimum 50 word tags Data acquisition from the any make of meters / transducers over standard protocol.

Viewing Online Data on real time basis Viewing Historical Data Remote monitoring and control Data acquisition and management. Device configuration for data acquisition. Alarm and event management. 2D/3D Graphical and tabular display Trend display of historical data. Data Import, Export and Reporting The SCADA program along with the development software and Run Time software with full feature license shall be supplied. The SCADA program file shall also be supplied.

Make GE/ Siemens / Phoenix Contact / Mitsubishi

Model Please specify 4.16 Computer for SCADA Intel® Core™ I5; 7th Gen I5-7400 3 GHz processor or better, Intel

H110 chipset or better, Intel HD graphics, 1 TB HDD, 8 GB DDR4-SDRAM, Ethernet LAN (RJ-45), USB ports, DVD super multi, Keyboard, Mouse, 22" LED with 1366 x 768 pixels or better display with compatible OS for PLC, HMI and SCADA software

Quantity Make Make HP/ Dell/ Lenovo Model Please specify

4.17 Color Printer Color Laser Network Printer, A4, 16 BW and 4C ppm speed, 8 MB Memory, USB port with compatible drivers for installed OS in SCADA Computer

4.18 .

Programming For PLC, HMI, SCADA PLC, HMI & SCADA shall use TCP/IP communication protocol for interface.

The operation of complete system, i.e., Spray Paint Booth, Chilling Plant, Air Handling Unit and Exhaust system shall be operated from HMI installed near the Spray paint booth.

The operation shall be available in both manual and fully automatic modes without compromising safe operation of the system and components.

The fault alarm messages shall be displayed on HMI and SCADA The operation of the system from HMI shall be based on user levels with password.

The schematic diagram depicting parameters location and corresponding values shall be developed using SCADA.

Operation of SCADA shall be based on user levels with password. Programming software and Run Time software of PLC, HMI and SCADA shall be installed in the supplied computer along with license. The source files of PLC, HMI and SCADA program developing and Run time software with license for re-installing in case of computer OS corrupted.

The developed program files of PLC, HMI and SCADA shall also be supplied. The passwords of these program files shall be supplied to SAC after completion of 2-year warranty period. These program files shall be usable if the computer had to be reset and the PLC, HMI and SCADA software are reinstalled.

4.19 Safety interlocks All the compressors shall trip if the suction pressure drops below set value or discharge pressure raises above set value. The respective fault shall be displayed on HMI and SCADA.

All the refrigeration compressors, condenser fans, chiller pump, supply air blower, exhaust blower, shall trip on overload. The respective fault shall be displayed on HMI and SCADA.

Chiller pump shall trip if no water flow is there in water circuit (flow switch). This fault shall be displayed on HMI and SCADA.

Anti-freeze thermostat shall be provided in chiller water tank. This shall shut down the chilling plant if temperature reaches set temperature. This fault shall be displayed on HMI and SCADA

Short circuit protection for Pre-heater elements (3 Nos), After-heater elements (3 Nos.), Steam generator heating elements (2 Nos.), Refrigerant liquid line solenoid vales (3 Nos). The respective component fault shall be displayed on HMI and SCADA.

4.20 Data logging All parameters shall be data logged in SCADA. 4.21 Alarms All parameters overshoot and undershoot conditions shall activate

buzzer and the respective condition shall be displayed on HMI and SCADA.

5.0 GENERAL SPECIFICATIONS, TERMS & CONDITIONS 5.1 Pre- bid visit Vendors may visit our existing facility / plant through purchase

division before submitting their offer, if required.

5.2 Scope of the work and scope of supply The vendor shall dismantle and remove the existing units spray paint booth, AHU, chilling plant, supply & exhaust duct, exhaust blower, chimney, electrical panels and install new units in consultation with SAC engineer.

Vendor shall implement data logging and SCADA of the total integrated 100% fresh air year round air conditioning system

The required minor civil work for foundation and support shall be the scope of the vendor. Drilling holes into walls for cable passage, making holes for duct passage shall be the scope of vendor.

Compressed air line from compressor room shall be provided and connected to compressor air filter / regulator system. The layout of the rooms are shown in the building layout plan.

The vendor shall connect make-up water ports of Chiller tank and Steam generator from the existing facility DI / RO water lines.

The vendor shall carry out all required electrical wiring, control wiring and data logging wiring internally in a systematic layout and shall be run through cable trays with cover. Supply to main SFU panel will be given by SAC.

Installation and commissioning shall be carried out by the supplier at Space Applications Center (SAC), Ahmedabad.

5.3 Pre-delivery inspection Inspection will be at vendor’s premises at various stages of the fabrication of the system. The vendor shall deliver the system only after pre-dispatch inspection and certification for delivery.

5.4 Delivery, Installation & Commissioning Terms

Material Delivery at SAC 16 Weeks from the date of issue of Purchase Order.

Installation and Commissioning

Maximum 6 weeks from the date of shut down of existing plant and handing over to the vendor by SAC.

5.5 Criteria for performance evaluation The vendor shall demonstrate the specifications and features of the system.

The whole system should run continuously for 8 hours. SAC personal will perform the spray painting operation in the booth. The parameters like temperature, RH, pressure, illumination, noise level etc. shall meet the specifications throughout the operation.

The performance evaluation will be conducted in three seasons (Summer, Monsoon and Winter) for 2 days during each season in a year.

5.6 Operation & Service Manuals The vendor shall supply Operation and maintenance manuals, safety guide lines, electrical wiring schematics, calibration certificates, mechanical schematics, parts details etc., along with the system.

5.7 Training The supplier shall impart training to operators about the operation and features of SCADA.

The supplier shall impart training to maintenance personnel about trouble shooting the common faults of operation and rectifications of the same.

5.8 After sales support Service support and spare part support shall be available for minimum 8 years.

5.9 Warranty The whole system shall be guaranteed for Two Years against all manufacturing defects and performance from the date of successful installation and commissioning of the system at SAC.

5.10 Annual Maintenance Contract (Optional) Not included for price comparison

Vendor shall quote for 3-year AMC after completion of two-year standard warranty.