district cooling lusail -...

MARAFEQ 09-08-2011 DISTRICT COOLING – ETS Technical Requirements - 1 - Version 1

DISTRICTCOOLINGLUSAILEnergyTransferStations

MARAFEQTechnicalRequirementsfortheconnectionofETS(s)totheDistrict

CoolingSystem

BYMARAFEQ

No:MQ:001‐2011


Content

Appendixes 4

1 INTRODUCTION 5

1.1 TheDistrictCoolingSystem 5

1.2 General 5

1.3 Definitions 6

2 THECUSTOMERSCOPEOFWORK 8

2.1 ETSPlantRoomforDistrictCooling,general 8

2.2 PrimaryServiceLine 8

2.3 PrimaryInterconnectingPipes 8

2.4 ETS 8

2.5 CUSTOMERInternalChilledWaterSystem 8

2.6 PipeCleaningandCommissioning 9

2.7 PressureTests,InspectionsandQualityControl 9

2.8 ProceduresforConnectiontoDistrictCooling 9

3 TECHNICALREQUIREMENTSANDRECOMMENDATIONS 10

3.1 DesignCriteria 10

3.2 NormsandStandards 11

3.3 ETSPlantRoomforDistrictCooling,ParticularRequirements 11

3.4 ETSInstallationandComponentRequirements 12

3.5 SecondarySideChilledWaterSystem,PumpsandOperation 12

3.6 SecondarySideAirHandling‐,FanCoil‐andTerminalUnits 13

3.7 Electricalpowersupply 13

4 SPACEANDEQUIPMENT 14

4.1 Locationandsizes 14

4.2 ETSequipmentrequirements 14


4.3 ETSEnvironmentandConditions 15

4.3.1 ETSROOMCONDITIONS 15

4.3.2 ROOMVENTILATION 15

4.3.3 PRIMARYINTERCONNECTINGPIPESPROTECTION 15

4.3.4 MAKE‐UPWATERANDCHEMICALWATERTREATMENTONTHESECONDARYSYSTEMS 16

4.3.5 WATERQUALITYONTHESECONDARYSYSTEMS 16

4.3.6 PLUMBING/EVACUATIONS 16

4.3.7 POWEROUTLET/LIGHTING 17

4.3.8 FIBREOPTIC 17

5 ENERGYMETERS 18

5.1 General 18

5.2 PLCRequirements 18

6 DISTRICTCOOLINGSYSTEMCOMPONENTSANDMATERIALSDESCRIPTIONS 20

6.1 Pipesandfittings 20

6.1.1 COMPONENTS 20

6.1.2 PIPES 20

6.2 Valves 20

6.2.1 ISOLATIONVALVES 20

6.2.2 MANUALBALLVALVESFORDRAINANDVENTOFTHEHEATEXCHANGER(S) 21

6.2.3 SAFETYRELIEFVALVES 21

6.3 Strainers 21

6.4 Indicators 21

6.4.1 PRESSUREINDICATORS 21

6.4.2 TEMPERATUREINDICATORS 22

6.5 TemperatureTransmitters 22

6.6 HeatExchanger 22

6.7 CIPConnection 22

6.8 PLCSystem 22


6.9 DistrictCoolingMetering 23

6.10 MeteringPlace 23

6.11 VentingValvesandDrainValves 23

7 INSTALLATION 23

7.1 Jointing 23

7.2 Insulation 24

7.3 Tagging 24

8 CHANGESTOTHESYSTEM 25

AppendixesAppendix1:Applicationfor“DesignConformanceCertificate”Appendix2:ETSExaminationsummaryfor“ETSConformanceCertificate”Appendix3:PI&D‐SchematicofETSinstallation


1 INTRODUCTION

1.1 TheDistrictCoolingSystem

TheETS(EnergyTransferStation)istheCUSTOMER'spartofalargerpressuresystems,theDistrictCoolingsysteminLusailoperatedbyMARAFEQ.SincetheETSisapartoftheDistrictCoolingsystemitmustbebuilt,maintainedandoperatedinsuchawaythatitcomplieswiththese“MARAFEQTechnicalRequirementsfortheconnectionofETS’stotheDistrictCoolingSystem,MQ:001‐2011.

DistrictCoolingisanenvironmentalfriendlytechnologyforproducinganddistributingrefrigerationtorealestate.Foranefficientsystemallincludedpartsofthesupplychainneedtofunctionefficient.ADistrictCoolingsystemconsistofcentralizedproductionplant(s)adistributionnetworkandETS’s.MARAFEQheredescribesrequirementsfortheETSinordertooptimizetheDCsystemfunction.

Figure1:Districtcoolingsystem–generalschematics

1.2 General

This document describes the Technical Requirements for connecting to MARAFEQDistrict Cooling Systems. The document should be used for planning, preparation ofspecifications and procurement during initial design phases in advance of the formalagreementbetweenMARAFEQanddevelopers/sub‐developer/end‐users.

All technical requirements thatapplies forconnecting to theDistrictCoolingNetworkarespecifiedinthis“MARAFEQTechnicalRequirementsfortheconnectionofETS(s)totheDistrictCoolingSystem”

ThisdocumentreplacesthepreviouslyprovisionalMARAFEQ“Booklet1”toinsteadbeusedasadesignguidelineandfortechnicalrequirementsof theETS.AnydescriptionstatementsintheprovisionalBooklet1,willnolongerapply.


1.3 Definitions

ETS TheEnergyTransferStation(ETS)isthepointwheretheenergyfromthedistrict

coolingsystemistransferredtothebuildings(water)coolingsystem.AnETSconsist

ofpipes,valves,filter(s),meteringandheatexchanger(s)s.

MARAFEQ MARAFEQisasautilitycompanythesupplierofdistrictcoolingandresponsiblefor

theoperationoftheDistrictCoolingsystem.

LREDC LusailRealEstateDevelopmentCompany.IsthemasterDeveloper.

CUSTOMER CUSTOMERistheClient/Sub‐Developer/End‐userinchargeoftheconnected

building.

ItistheCUSTOMER’sresponsibilitythattheETSisdesignedaccordingtothisETS

TechnicalRequirements.

PHEor

HEX

PlateHeatExchanger,componentseparatingtheprimarywatersystemfromthe

secondarywatersystem.DefintionusedcansometimesalsobeHeatExchanger

(HEX).

PLC PLC–(ProgrammableLogicController)aprogrammablemicroprocessorusedto

automatemonitoringandcontrolofindustrialplant.

PointofDelivery ThepointofdeliveryisdefinedaswhereMARAFEQscopeofworksfortheprimary

pipesystemends,wheras:

‐ Insidewallpenetrationonthebuildingsconnectedfromutilitytunnels.

‐ 1mintotheplot“set‐back”forbuildingsconnectedbydirectlyburied

pipes.

‐ ForbothcasesaboveMARAFEQwillinstallextraisolationvalves,inthe

outsidemainpipesystem.

Primary "Primary"referstothe(«Supply»and«Return»)pipenetworkcirculatingchilled

waterproducedinDistrictCoolingPlantsthroughtheMARAFEQdistribution

network.

Secondary The“Secondary”aretheCUSTOMER'scoolingwatercircuits(«Supply»and

«Return»)onthebuildingsidesystemsoftheheatexchangers.

PrimaryService

Line

ThePrimaryServiceLinerunfromthe“PointofDelivery”onthemainDistrict

Coolingpipesystemlocatedoutsideinthestreettotheindividualbuildinginterior

wall.Asetofisolationvalvesshallbeinstalledwheretheservicelinepenetratesthe

buildingwall

PrimaryInter‐

connectingPipes

ThePrimaryInterconnectingPipesrunfromthemainisolationvalvesinsidethe

buildingwalltotheETSPHE(s)locatedintheETSPlantRoom.

StandardETS TheseETSarepre‐fabricatedinthefactory,installedandtested.Theyaremounted

onasteelframe,andarepossibletotransportassembled,whichmakesinstallation

ofahighqualityandwithaminimumtimeonsite.Howeverconditionsand

restrictionsontransportationopeningsmayleadtothattheETSmustbe

disassembled,shippedandreassembledonsite.TheETScanthereforebebuiltin

modulesorwithassemblypartsonsite.

TheseETScanbedesignedwith1,2,3ormorePHEunits,dependingonthescopeof

thecoolingloaddemandanddesiredDCdeliveryavailability.

Non‐StandardETS ETSgenerallywith3ormorePHE,forCUSTOMERswithhighercoolingload

requirements.(Withpre‐fabricatedETSitwouldrequireaverylargefoot‐printfor

numerousPHE.ThenlargePHEisusedinsteadandassembledwiththeplateson

site)

TheseETSmustbebuiltonsite.Allcomponentsareshippedasseparatepartsand

assembledonsite.

TrialOperation TestingperiodoftheETSfunctionsbeforecommercialoperations,whereMarafeq

performstestrunsandcheckingtheETSperformance.

Commencementof

OperationService

Tollgatemarkingtheendofinstallationworktobedonebythecontractorand

chilledwateristhenavailableforusebytheCUSTOMER.Thisisthecontractualdate


registeredintheCoolingSupplyAgreement.

Commercial

Operation

TollgatemarkingtheapprovalfromMARAFEQoftheinstallationandafterfinal

adjustments,oncetheworktobedonebytheCUSTOMERisterminatedandhas

beeninspected,approvedandputintoservice.

Note:Operationstart‐upandputtingintoservicemaybecombinedintoasingle

operationiftheCUSTOMER’sinstallationsareoperationalatthetimeofputtingto

service.


2 THECUSTOMERSCOPEOFWORK

MARAFEQ reserves the right to supervise, inspect andapprove the installationof theETSandprimarysidepiping,i.e.theequipmentthatwillbeoperatedbyMARAFEQ.

2.1 ETSPlantRoomforDistrictCooling,general

The CUSTOMER should provide, at suitable space for the installation of the DistrictCoolingsystemETSequipment,the“ETSPlantRoomforDistrictCooling”.Thisshouldincludespacefortheservicelines,interconnectingpipesaswellasfloordrainandfreshwaterpiping.

MARAFEQshallhave fullanddirectaccess to theETSPlantRoomforDistrictCooling24/7.

2.2 PrimaryServiceLine

IntheCUSTOMER’sscopeofworksisincludedprimarypipesfromthe“PointofDelivery”tothelocationofthemainisolationvalveslocatedinsidethebuildingswallpenetration.ThepipesshallbeofindustrialstandardofDistrictCoolingandbythequalityapprovedbyMARAFEQ.

2.3 PrimaryInterconnectingPipes

IntheCUSTOMER’sscopeofworksisincludedtheinterconnectingprimarypipesfromthemainisolationvalvesinsidethewallpenetrationtotheconnectionflangesoftheETSPHElocatedintheETSPlantRoomforDistrictCooling.ThepipesshallbeofindustrialstandardofDistrictCoolingsystemsandbythequalityapprovedbyMARAFEQ.

2.4 ETS

IntheCUSTOMER’sscopeofworksisincludedcompleteETS(s)asdescribedinthese“MARAFEQTechnicalRequirementsfortheconnectionofETS(s)totheDistrictCoolingSystem”specifications.TheETS(s)belongstotheCustomer,andhasnorotating&movingparts.DistrictCoolingwillthereforecomparedtoChillers,locatedineachbuilding,havenoorverylimiteddisturbingnoiseorvibrations.ThemeteringequipmentisexcludedfromtheCUSTOMER’sscopeofworks,andwillbesuppliedandownedbyMARAFEQ.

2.5 CUSTOMERInternalChilledWaterSystem

TheCUSTOMERortheirrepresentativeshalldesign,provide,operateandmaintainthesecondarysidechilledwatersysteminaccordancewiththetechnicalrequirements.

Variable speed chilled water pumps and two way control valves shall be used forvaryingtheCUSTOMER’schilledwaterflow.


2.6 PipeCleaningandCommissioning

The CUSTOMER shall prior to the commissioning perform a complete and thoroughpipecleaningoftheprimarysideandpipecleaningandchemicalwatertreatmentofthesecondary side chilledwaterpipingnetwork, so that at the timeof connection to theETS PHE, the CUSTOMER’s piping system is full of clean water and is clear fromunwanteddebrisandparticles.

After MARAFEQ approves the water quality analysis, the building system may bestartedandcommissioned.

2.7 PressureTests,InspectionsandQualityControl

TheCUSTOMERshallpriortoMARAFEQtakingoveroperationalresponsibilityfortheETSand theprimary sidepiping getMARAFEQ’sapproval for theworksdoneby theCUSTOMER.

This includes all the CUSTOMERS activities regarding cleaning and commissioning asmentioned in 2.6, but also necessary inspections, x‐ray, quality control and pressuretests. This approval must be obtained before MARAFEQ will connect to the DistrictCoolingNetworkandstartcommissioning/testrunfollowedbycommercialoperation.

2.8 ProceduresforConnectiontoDistrictCooling

ToconnecttotheMARAFEQdistrictcoolingsysteminvolvesaconnectionapprovalprocedure.TheconnectionprocedurestartswiththeCUSTOMERcontactsMARAFEQforanintroductionmeeting.ACoolingSupplyAgreement(CSA)shallbenegotiatedandsigned.PrecedingthesigningoftheCSAaMoUnormallywillbeagreedupon.ThiswillinitiateMARAFEQplanningoftheconnectiontothedistrictcoolingsystem.

TheCUSTOMERshallpresentestimationsofthecoolingdemands.MARAFEQwillreviewtheestimatedcalculatedcoolingdemandandassisttheCUSTOMERifrequired.

FortheinstallationsoftheDCconnectionandbuildingcoolingsystemstherequirementsinthe“MARAFEQTechnicalRequirementsforconnectiontotheDistrictCoolingsystem”mustbefollowed.

MARAFEQshallapprovethelocationoftheETSroom.TheactuallocationofconnectionpointfromtheprimarydistrictcoolingpipesystemwillalsobedecidedbyMARAFEQ.

TheapprovalproceduresfortheinstallationinvolvesthattheCUSTOMERshallpresent;(LayoutsoftheETSRoomforDistrictCooling),(Pre‐designofthebuildingcoolingsystems)and(Templatewithinformationfortheapplicationof“DesignConformanceCertificate”.)SeeAppendix1.

Whenthe“DesignConformanceCertificate”fortheETSplusinstallationofDCconnectionisapprovedan“OrderofDCsupply”shouldbesubmittedbytheCustomer.Theinstallationworkmaythenstart.

WhentheETSinstallationisreadyafinalinspectionshallbeperformed.MARAFEQshallbeinvitedtothefinalinspection,performedbyMARAFEQ.Whenthefinalinspectionisapproved,MARAFEQwillissuea“ETSConformanceCertificate”.Applicationfor“ETSConformanceCertificate”seeAppendix2.Start‐upforcoolingoperationswillbeinitiatedwhenMARAFEQconnectsthebuildingtotheDCnetwork.TheCUSTOMERstartspre‐commissioningofcoolingoperation,trialoperations,testrunsareperformed.AfterthisthecommercialDCoperationscanstart.


3 TECHNICALREQUIREMENTSANDRECOMMENDATIONS

MARAFEQ reserves the right to review and approve the design of the ETS andsecondary side of the cooling system tomake sure itwillwork andoperate togetherwiththeDistrictCoolingNetwork.

The schematics of an ETS installation and the components is shown in the followingfigure.(CanalsobefoundinAppendix3wherealsothesymbolsareeasiertoread.)

Figure2:Districtcoolingsystem–schematicsPI&D

MARAFEQrecommendations:• ForhighqualityandshortinstallationtimeonsiteMARAFEQrecommendtheuseof

pre‐fabricatedstandardizedETS.• Theinstallationcandependingonneededcoolingdemandbedividedupwith1,2or

3 standardPHE.This applies for standardETS installations for subscribedcoolingdemandsbetween70and2900TR.

• Cooling demand over 2900TRwill need special attention, since standard conceptnormallynotcanbeused.

• Whenhighavailabilityofcooling isof special importanceat least two50%PHE isrecommendedinsteadofonlyone100%PHE.HigheravailabilitymightberequestedforCommercialusethanforResidentialbuildings.

• Agoodredundancycanalsobeachievedwithtwo60%PHE.IncaseofafailureononePHE,itisstillpossibletosupply60%ofthedemand.

• EachPHEshouldhavea20%extraspace forcapacityexpansionpossibilityontheframe.

• RedundancyPHEisnormallynotrequired.

3.1 DesignCriteria

Table3.1:DesignCriteria

Designpressure,primaryside Bar(g) 16Testpressure,primaryside Bar(g) 23MaximumpressuredifferenceoverETS(ΔP) kPa Tobeprovided


Designambienttemperature forinstallation,primaryside ºC 50Maximumallowedpressuredropatnominalflowandsubscribedloadbetweenincomingisolationvalvesatthewallpenetration.NOTE1)

kPa 150

MaximumHEXpressuredrop atdesignflow kPa 65CoolingCapacity: TR TobespecifiedAvailabledifferentialpressure.NOTE2) kPa TobedecidedSupplychilledwatertemperature,DCSide(tDCS): ºC +5.0Returnchilledwatertemperature,DCSide(tDCR): ºC +14Supplycoolingwatertemperature,CUSTOMER Side(tCCS): ºC +6.5Returncoolingwatertemperature,CUSTOMER Side(tCCR): ºC +15.5Maximumchilledwaterflowpertoncoolingload(design): l/s 0.095NOTE1):ActualavailabledifferentialpressuredependsontheETSlocationintheDistrictCoolingNetworkandcanbemuchhigher.Themaximumpressuredropshallbeusedwhendesigningconnectingpipesandcomponentsassumingthecontrolvalvestobefullyopen.NOTE2):TheactualavailabledifferentialpressurefortheETSdependsonthelocationintheDistrictCoolingNetworkandmayalsochangeovertimeastheDistrictCoolingNetworkdevelops.TobeprovidedbyMARAFEQ.Notes:‐ Itiscriticalthatallairhandlingunits,fancoilsunitsetcaredesignedforthestatedCustomerSide

temperaturesinthetableabovetoprovideatleasta+14°Cprimaryreturntemperature.Thismeansthatthemaximumflowrequiredfor1tonofcoolingloadis0.095l/s(1.5USGPM).Ifthebuildingcannotmeetthisrequirement,MARAFEQcannotguaranteeasupplychilledwatertemperatureof+6.5°ContheCustomerSideatpeakloadconditions.

‐ Pipepressuredropcalculationsandpumpsflow‐headdiagramsanddifferentialpressuresetatcircuitendoftheCustomer’schilledwatercircuit(secondaryside)aretobecoordinatedwithMARAFEQduringdesignstage.

3.2 NormsandStandards

Thesestandardsmustbeusedfortheprimaryside,butarerecommendedforthesecondarysideaswell.• EN253:2009 Districtheatingpipes–Pipes(applicableparts)• EN448:2009 Districtheatingpipes–Fittings(applicableparts)• EN489:2009 Districtheatingpipes–Jointing(applicableparts)• EN13480:2011 Metallicindustrialpiping• EN13941:2009 Designandinstallationofpre‐insulatedpipes• 97/23/EG PressureEquipmentDirective(PED)• Directive2006/42/EConmachinery• Kahramaa RegulationsfortheInstallationofElectricalWiring,

ElectricalEquipmentandAirConditioningEquipment(applicableparts)

3.3 ETSPlantRoomforDistrictCooling,ParticularRequirements

Whetherthe“ETSPlantRoomforDistrictCooling”isinaseparatebuildingorpartofanexistingornewstructurethereareseveralrequirementstoconsider.MARAFEQRequirements:• TheETSPlantRoomforDistrictCoolingshallbe locatednothigher than5meters

abovegroundlevelandhavesufficientceilingheight(min4m).• ThetransportwaystotheETSplantroom,includingalldoorsshallallowaccessfor

theheatexchanger(s)withoutanyneedfordisassembling.• Ventilation air into the room shall be filtered and cooled as required tomeet the

operating requirements/limits for all ETS equipment or to amax temperature of28±2oCand50‐60%RH.


• ETSroomlightingshallconsistofoverheadwhitefluorescenttypelighting(notlessthan150Lux).

• Firedetectionandalarmsystemshallbeprovided.• Lockable,insulatedsecuritydoorsshouldbeprovided.• Thespaceshouldbeprovidedwithallnecessaryoverheadandunder‐floorplumbing

includingservicewaterpipingandfloordrains.

MARAFEQRecommendations:• Theroomshouldbeacousticallytreatedsothenoise levelmeetstheCUSTOMER's

expectations.• The room should have finished painted walls and oil resistant non‐slip finished

floor.

3.4 ETSInstallationandComponentRequirements

MARAFEQRequirements:• Primarysystempiping,valvesandequipmentmustbeallwelded.Allshallbeof

industrialstandard.Noflangesareallowedexceptforthestrainer,controlvalve(s)andflowmeter.

• PrimarysystempipingandvalvesmustbepreinsulatedorthermallyinsulatedwithclosedcellelastomericmaterialtypeArmaflexorequalwithaprotectivejacket.

• Isolationvalvesmustbeprovidedinthesupplyandreturnpipearoundtheheatexchanger(s)toallowformaintenanceandcleaning.

• Safetyreliefvalvelocatedbetweentheisolationvalvesateachheatexchangerinordertopreventoverpressureduringshutdowns.

• Aballvalve(DN50)withhoseconnectionandcapformanualairventonthetopconnectionsideoftheheatexchangerasshownontheschematic.Alsoaballvalve(DN50)withhoseconnectionandcapfordrainageatthebottomconnectionoftheheatexchanger.Endplugscanberemovedfromeachendtoallowconnectiontocleanwatersotheheatexchangercanbeflushedandcleanedwhiletheisolationvalvesareclosed.

• Installationoftwothermowellsonboththeprimarysideandthesecondaryside,tobeusedfortemperaturetransmitters(TT).

• MARAFEQrequirestheusageofpressureindependentcontrolvalvesforhighestpossibleΔT,minimumenergyuseandreducedlabourcost.ForhighestpossibleavailabilityonecontrolvalveforeachPHEisrecommended,andthennaturallyseparatetermowellsforeachcontrolvalve.

• Astrainerisrequiredattheinletoftheheatexchanger(s)withapressuregaugearrangedsothatitispossibletomeasurethepressureupstream/downstreamthestrainerandinthesupplypipeasperattachedPI&Dschematic,seeAppendix3.

3.5 SecondarySideChilledWaterSystem,PumpsandOperation

MARAFEQRequirements: OnesetofvariablespeedpumpsforinternalchilledwaterdistributionforeachETS,

withanexpansiontankcompletewithasafetyreliefvalveforeachclosedloop.

Variablespeedpumpsshallbecontrolledbyutilizingat least two industrialgradepressuredifferential transmitters (PDT)across the twomosthydraulically remoteterminal units in each building as shown in Appendix 3. Exact location shall becoordinatedwithMARAFEQ.

Variablespeedpumpsshallbeequippedwithatleastonepressureswitchinthesupplylinethatwillstopthepumpsatmaxdesignpressureincaseofavalveclosureand/orafailurewiththeVFD:s(VariableFrequencyDrive).Thepressure


switchshouldbehardwiredtothepumpsandnotthroughtheordinarycontrolsystem.

MARAFEQrecommendations: AsindicatedonPI&DAppendix3itisrecommendedforlowflowcontrolforFVD

pumpstoadda2‐waycontrolbypassvalvearoundthepump.The2‐waycontrolbypassvalveshallcorrespondtoamaximumsecondarysidechilledwaterflowof5%ofthefulldesignflow.

3.6 SecondarySideAirHandling‐,FanCoil‐andTerminalUnits

MARAFEQRequirements:• Useonlytwowaycontrolvalvesforallairhandlingunitsandfancoilunits.The

valvemustbecapableofcontrollingflowthroughfullrangeofexpectedturn‐downandthroughfullrangeofexpectedΔPacrossthevalve.

• Test,adjustandbalancethehydraulicsystemtomakesurethatthechilledwaterrequirementofeachfancoilunitandairhandlingunitismet,preferablytheTesting,AdjustingandBalancing(TAB)shallbecarriedoutbyaspecializedthirdpartycommissioningfirm.

MARAFEQrecommendations:• MARAFEQstronglyrecommendstheusageofpressureindependentcontrolvalves

forhighestpossibleΔT,minimumenergyuseandreducedlabourcost.• Ifpressureindependentcontrolvalvesarebeingused,nomanualbalancingvalves

arerequired.Otherwiseallairhandlingunits,fancoilsunitsandmainbranchesshallhavemanualbalancingvalveswithself‐sealingtestpointusedforchilledwaterflowmeasurementasrequiredduringbalancingandcommissioning.

3.7 Electricalpowersupply

TheCUSTOMERshallprovideadedicatedDistributionBoardforPowersupplytotheEnergyMeter.Electricalpowerrequirementissinglephase240V,50Hz,10AmpsperETS.


4 SPACEANDEQUIPMENT

4.1 Locationandsizes

Considerationshouldbegiventotransportationsandaccesssothatrepair,replacement,etc.easilyandrapidlycanbemade.Ifthebuildingownerdoesnotallowfreepassagetothebuildingaseparateaccessdoorfromoutsidemustbearranged.Spacerequirementsshouldbedeterminedbytheservicepossibilities.

TheETSroomshallbeavailableforMARAFEQforcontrolandmanualreadingofmeteringequipment.AtypicalinstallationofastandardizedETSequippedwithonePHEisshowninfigure2.

Figure2:Districtcoolingsystem–generalplaneandviews

4.2 ETSequipmentrequirements

Scopeofequipmentisexplainedinthefollowingtable.

C=ProvidedbyCUSTOMER(orhisappointedDesignerorContractor)M=ProvidedbyMARAFEQ

Table4.2:ETSscopeofequipment

SpaceforETS ShouldbeincludedCUSTOMERsscope

ProvidedfromMARAFEQ

Lighting C Electricalsupply C Meterplace C Floordrain C Flushingpossibility C


ETSprimaryside ConnectionValves C Strainer(s) C Pressuregauges C Temperatureindicators C Heatexchanger(s) C Controlvalve(s)DC C Differentialpressureregulator(ifnecessary,connectionshallbeincluded)

M

Dummypipe/flowsensors C Meteringequipment M(Note1)Ventingvalves C Drainvalves C CIPconnections C ETSsecondaryside Circulationpumps C Expansionvessel C Temperaturetransmitters C Pressureindicatorsandtransmitters C Safetyvalve C Fillingvalve C Strainer(s) C Drainvalves C CIPconnections C

Note1:Seealsotable5.1

4.3 ETSEnvironmentandConditions

4.3.1 ETSROOMCONDITIONS

TheCUSTOMERshallmaintainthefollowingambientconditionsintheETSroom:

Temperature: 28°C±2oC

Relativehumidity: HR50‐60%

4.3.2 ROOMVENTILATION

MechanicalventilationoftheETSroomshallprovidecontinuousrefreshmentoftheair,topreventcondensationthatwilleventuallycausecorrosiononequipment.

Ventilationairintotheroomshallbefilteredandcooledasrequiredtomeettheoperatingrequirements/limitsforallETSequipment.Seeconditions4.3.1.Minimumfreshairventilationration0.5volumesperhourandkeepingapositivepressurelevelintheETSroom.

4.3.3 PRIMARYINTERCONNECTINGPIPESPROTECTION

Thenetworkshallbeprotectedfromtheweather,watersplashes,shocksandingeneralanyriskofdegradationalongthepathoftheprimarynetworkinroomsthroughwhichitpasses.

Pipeprotectorsshouldbeaddedtoanypipingwithingarbagerooms,parkingrampsorotherhighlytraffickedareaswherepipingcouldgetdamaged.


4.3.4 MAKE‐UPWATERANDCHEMICALWATERTREATMENTONTHESECONDARYSYSTEMS

TheCUSTOMERwillberesponsibleforfillingtheinternalchilledwatersystemalongwithprovidingbreaktanksofsuitablecapacitiesandwithpressurizationunitswhichshallbeincorporatedtopreventbackflowandpositivesupplyintothesystem.

ADN20potablewatersupplyshallbeprovidedwithaballvalveandAwaterlineshouldbestubbedtothespacewithahosebibconnectionforcleaningofthePHEwhendisassembled.

Thechilledwaterisconsideredanon‐potablewatersource.Consequently,thelocalwaterauthoritywillrequireabackflowpreventertobeinstalledonallcitywaterlinesconnectedtothebuildingchilledwatersystem.

Watertreatmentsystemincludingmanualfeedchemicalsdosingpotwithnecessaryrustinhibitorsandbiocidesquantitynecessaryfortesting,commissioningandoperation.Aspecializedprofessionalcompanyshallhandlethewatertreatmentsystem.TheCUSTOMERshallprovideananalysisofthephysicochemicalcharacteristicsofthewaterinhissecondarycircuit,beforetheCommercialOperationofhisETS.

TheMARAFEQOperationservicereservestherighttodrawoffwatersamplesfromthesecondarycircuitandanalysesitatanytime.

TheCUSTOMERshallpayformaintenanceandwatersamplingcostsifhiswatertreatmentisnotconformingtothespecificationsmentionedabove.Thesecharacteristicsmaybemaintainedbyconditioningthesecondarynetwork.

4.3.5 WATERQUALITYONTHESECONDARYSYSTEMS

Fortheoperationofthedistrictcoolingitisimportanttomaintainahighwaterquality.Theoperation’sisdependentontheheattransferbetweentheprimaryandthesecondary.AcleanPHEmustbesecured.ImportantisthattheCUSTOMERsecureaminimumwaterqualityinthesecondarysidesystemsinordertoreduceimpactoffoulingandalsothereducecorrosion.AfouledPHEsurfacewillleadtoreducedcapacity.Thefollowingcharacteristicsshouldthenbefollowed:

• TH<10°f(=100ppmCaCO3)

• pH:8to10

• Suspendedparticles:Sizegrading<0.4mm

• Contentofdrymaterials<0.2%(bymass)

• Conductivitybetween50µs/cmand500µs/cm

• Resistivitybetween1kand10k

4.3.6 PLUMBING/EVACUATIONS

Afloordrainorasump(withliftingpump)shallbeprovidedtoevacuatedrainwater,washingwaterandvariousdrips.Openguttersarepreferred.

Itshallbeprovidednecessaryventsinhighpointsanddrainsinlowpointswithoutletconduitslocatedalongthepathoftheprimarypipesasfarasthespecialconnectiontotheseweratthepenetrationpointintothebuilding.

Itmustbepossibletodischargewatereffluentstonearbydrains,afterspecificmaintenanceoperations.Thepositionsofeachshouldbespecifiedonconstructiondrawingsandondetaildrawings.

Ventinganddrainpointsshouldremainaccessiblefornetworkmaintenance.


4.3.7 POWEROUTLET/LIGHTING

TheCUSTOMERshallprovideanadditionalandseparatedfromtheETS240Vsinglephase+earthpoweroutletprotectedbya16Acircuitbreaker(Dcurve),necessaryformaintenanceoperations.

Theroommustbesufficientlywellilluminatedwithoverheadwhiteflorescenttypelighting,sothatmaintenanceoperationscanbecarriedoutundergoodsafetyconditions.

4.3.8 FIBREOPTIC

Tobedecided.


5 ENERGYMETERS

5.1 General

MARAFEQwillfreeissuethefieldinstrumentandtransmittersfortheenergymetersystem,thatwillbeusedforbilling.ThisequipmentshallbeinstalledmechanicallybytheCUSTOMER.ElectricalworksandinstallationofthethermosensorswillbedonebyMARAFEQ.TheelectricalconnectionandcommissioningwillbedonebyMARAFEQ.

MARAFEQwillgivedetailedinstructionsandsupervisetheinstallationofthisequipment.TheCUSTOMERshallprovideadummy(spoolpiece)fortheflowmeterandinstallwhenappropriate.

Table5.1:ETScontrolandinstrument

ETSControlandInstrument

Item Description SupplyBy

InstalledBy

CableTraysandladders

ConnectionBy

1 ThreadoletsforInstruments

C C N/A N/A

2 Thermowellsfortemperaturetransmitters

M C N/A N/A

3 Instruments(PT/PDT/TT/PS)

M C C(Note1)

M

4 FlowMeter(FM) M C C M

5 EnergyMeter M M C M

6 ControlValve C C C C

7 PLC‐Panel C C C C

8 Wiringforcontrols C C N/A C

Note1.Instrumentandsensorswillbefreeissuedincludingcables.

M=MARAFEQC=CUSTOMERorhisappointedDesignerorContractor

5.2 PLCRequirements

Nodata from the CUSTOMERBuildingAutomation System (BAS) is required for PLCmonitoring.MARAFEQcanhoweverexportdatapointsusedtocalculatebillingfromthedistrict cooling PLC to the BAS.Wiring between the BAS panel and the PLC and anynecessaryadditionstothePLCprogrammeshallbebytheCUSTOMERandaccordingtoMARAFEQrequirements.MARAFEQRequirements:The CUSTOMER shall provide, at no cost to MARAFEQ, all control wiring linkingbetweentheCUSTOMERsbuildingautomationsystem(BAS)toPLCintheETS.Thedatapointsusedtocalculatebillingare:


‐DistrictCoolingSupplyTemperature‐DistrictCoolingReturnTemperature‐DistrictCoolingFlow

Figure3:Datapointsformeteringandbillingpurposes

Outputswill bepoweredby thePLC and shall be24VDC sinking at theCUSTOMERsBAS.


6 DISTRICTCOOLINGSYSTEMCOMPONENTSANDMATERIALSDESCRIPTIONS

Componentsandfittingsshallbeofsamematerialsandhaveatleastthepressureclassrequiredintheactualsystem.Suitablematerialsaresteelandstainlesssteel.ConnectionsincludinganygasketsshallmeetrequirementsoftheapplicableANSI/ASME/ENstandardsandshallberatedforthesystempressureandtemperatures.Thecomponentsmustbeinstalledinamannersotomaintenanceandreplacementcanbeeasilydone.Connectiontothemainsshallbewelded/brazed.ComponentsoftheETSshouldbeofthesamematerialtoavoidgalvaniccorrosion.

6.1 Pipesandfittings

ETSthatareconnectedshouldbeexecutedsothatthedistrictcoolingsidepipingwithassociatedpartsmusthaverobustness.Thismeansthatthejointingmethod,couplings,sealingmaterialsandfittingsmustmeettherequirementoftightnessandmechanicalstress.Incouplingsgasketsshallhaveacentersupportsothatthewholesealingsurfacewillbecoveredbythegasket.

6.1.1 COMPONENTS

Componentsfortheprimarydistrictcoolingsideshouldbeofthefollowingmaterialswithatleastthequalitydefinedforeachmaterialtypein:

‐ Pressurevesselsteel P295GHorcorresponding

‐ Stainlesssteel AISI316orcorresponding

6.1.2 PIPES

Pipescanbemadeofstainlesssteelorblacksteelandshouldrespecttherequirementsofexistingmaterialsmeetpipestandards,furtherinformationcanbefoundinEuroheat&PowerTechnicalRecommendationsforDistrictCoolingPipesatwww.euroheat.org.

Usuallythepipesareofordinarycarbonsteel.Thedisadvantageofthecarbonsteelcoolingpipesistheriskofcorrosionattacks,especiallyfromtheoutside.Atlowtemperaturesbelow+5°Ccanbrittlefracturealsooccurinweldsforthelowgradematerials.Thereforemustso‐called“killedsteel”beusedinordertopreventbrittlefracture.Inordertoavoidcorrosionattackhasitbecomecommonwithalloystainlesssteelmaterialincoolingsystems.Stainlesssteelrequiresspecialskillsofwelders.

6.2 Valves

6.2.1 ISOLATIONVALVES

Mainisolaitionvalvesshallbelocateddirectlyinsidethebuildingascloseaspossibletothewalls.Connectiontothedistrictcoolingnetworkshouldbebywelding.

Isolationvalvesmustbeprovidedinthesupplyandreturnpipearoundtheheatexchanger(s)toallowformaintenanceandcleaning.


Allisolatingvalvesshallbeoftypeweldedballvalves.Cautionisneededsothatthesealsinthevalvesnotwillbedamagedduringtheweldingprocess.

Allvalvesshallbeeasilyaccessibleandtagged.

6.2.2 MANUALBALLVALVESFORDRAINANDVENTOFTHEHEATEXCHANGER(S)

Twoballvalves(DN50)formanualairventanddrainshallbeprovidedforeachheatexchangerasshownintheP&IDschematic,Appendix3.Theseconnectionswillalsobeusedforfuturechemicalinjectionandperiodicflushingofeachheatexchangerwhiletheisolationvalvesareclosed. Providehoseconnectionandcapforeachvalve.

Body,discandseatratedforazeroleakageshutoffatnotlesspressureclassthantheheatexchanger(s)designpressure.

Provideleverhandlewithmetallicextendedstemforinsulation.

6.2.3 SAFETYRELIEFVALVES

Asafetyreliefvalveshallbelocatedbetweentheisolationvalvesateachheatexchangerinordertopreventoverpressureduringshutdowns.Thevalveshallbesizedforthermalexpansionatdesignloadconditionsandthesetpressureshouldbeconsistentwiththepressureclassoftheheatexchanger.ThecustomershallsubmitcalculationsandsizinginformationtoMARAFEQforapproval.

Directspringloadedtype(proportionalflow).

Leveroperated,withnonadjustablefactorysetdischargepressure.

6.3 Strainers

Astrainerisrequiredattheinletoftheheatexchanger(s)toprotectitfromanysuspendedparticlesanddebris.Thestrainerelementshallbepossibletodischargewithoutthestrainerneedstobedismantled.Theconnectionsshallbeflangedorwelded.

StrainershallbeY‐patternwithblowoffdrainvalve.

Screenshallbemadeofstainlesssteelwithmaxperforationmeshsize0.6‐1.0mm.

Screenshallbeaccessedbywayofthreadedorboltedcover.

6.4 Indicators

6.4.1 PRESSUREINDICATORS

PressureGaugeformanualreadingoftheprimarysidepressureshouldbeincluded.Thescaleshouldbefrom0‐25bar.

Industrialgradepressuregaugeshallbeprovidedandarrangedsothatitispossibletomeasurethepressureupstream/downstreamofthestrainerplusinthesupplypipe.

Thepressuregaugeshallbebourdontubetype,phenolicorstainlesssteelcasewithplasticlens,blacklettersonwhitesurface,solidfrontandblowoutbackstyle.

Stainlesssteelmovementandwettedparts

Gaugesdialshouldbe100mmdiameter


6.4.2 TEMPERATUREINDICATORS

IncaseofmorethanoneheatexchangerrequiredforasingleETS,industrialgradethermometersmustbeprovidedinthesupplyandreturnlineofeachheatexchanger

ThermometersshallbeBi‐metaltypethermometerswith125mmdiameterstainlesssteeldialandshatterproofglass,blacklettersonwhitesurface,externalpointeradjustmentandrearangleadjustablewithconnectiontothermowell.

Thermowellsshallbe316stainlesssteelbarstockconstruction,steptype.

Thethermowellshallprotrude1/3–1/2pipediameterinsidethepipeandlaggingextensionsuitablefortheinsulatedpipe.

6.5 TemperatureTransmitters

Temperature transmitetrs can be done directly with thermometers or transmittersconnectedtosurveillanceequipment.Theyshouldhavearangethatcoversatleastthemaximumtemperaturevariation.Pocketsforthetemperaturetransmittersmustnotbeisolatedover. It should atO&Mbepossible to see if the transmitters aremounted inpockets.Thetemperaturerangeshouldbeadaptedforcoolingpurposesandpositionedsothatitiseasytoread.For each control valve two temperature transmitters with thermowells for theCUSTOMERcoolingwatersystemshallbeinstalledbytheCUSTOMER’scontractor. Thermowellsshallbe316stainlesssteelbarstockconstruction,steptypewith3/4”

NPTprocessconnection.

Thermowells shall protrude 1/3 – 1/2 pipe diameter inside the pipe and laggingextensionsuitablefortheinsulatedpipe.

6.6 HeatExchanger

ThematerialoftheHeatExchangers(PHE)mustwithstandbothsystemsliquidmedia.Nameplateshouldbevisibleandreadable.Forchemicalcleaning,themanufacturershallbeconsulted.PHEshallbelocatedonadriptray.

PHEshallbedesigned,builtandmarkedinfullcompliancetoAHRI‐400Liquid‐to‐LiquidPlateHeatExchangerswithZEROtolerances.

ManufacturersofheatexchangersshouldbeabletoshowthatheatexchangersmeetsthetestprogramdescribedinthestandardEN1148orequal.Thecontrolalsoincludesthemanufacturer'sdatadesignprogramsareconsistentwithproductperformance.Alwaysusethelatestversionofthedesignprogram.

6.7 CIPConnection

InordertomakeCIP(CleaningInPlace)ofPHEplatespossibletheETSshallhaveconnectionsinstalled.CIPisdonewithoutdismountingthePHE.

InordertosaveCIPchemicalsthewatervolumeshallbereducedtoaminimum.ForthistheisolatingvalvesshouldbelocatedcloselytothePHE.

6.8 PLCSystem

Thesystemconsistofcontrolvalvesandactuators,sensorsandPLCcabinet.Abilitytomanualadjustmentofcontrolvalveshallbepossible.ThePLCcabinetisduringcommissioningsetsothatstablecontrolisobtained.ThevaluesarerecordedanddocumentedinthePLCcabinet.


Controlvalvesshalloperatewithoutdisturbingnoiseatadifferentialpressureofupto0.6MPa(6bar)atapressureofatleast0.1MPa(1bar)afterthevalve.Theremustbereadablesignonthevalveshowingtype,DN,pressureclassandkvs‐value.

6.9 DistrictCoolingMetering

Inrespecttothatthecoolingmetering’stemperaturesensormeasuresthetemperaturedifferencesfrom2°Cto25°Candthatthereisarequirementofabsolutetemperaturemeasurements,temperaturesensorandintegratormustbeadaptedforthispurpose.

6.10 MeteringPlace

Themeteringplacehasinthesupplypipetemperaturesensorandthereturnpipeflowsensorandtemperaturesensor.Inaddition,placeforintegratorandpowersupplyshouldbearrangedfor.

TheinstallationmustbedoneaccordingtoMARAFEQinstructions.Flowsensor;temperaturesensorandintegratorshouldbeinstalledsotheyareeasytoreadandreplace.Incaseswheretemperaturesensorsaremountedwithoutpocketsitshouldclearlybelabeledonthesensors.Temperaturesensorsshouldforbestperformancebeconnectedtointegratorwith4‐wireconnection.(NotpossibleonsmallpipeDN.)

TheenergymeterisMARAFEQpropertyandwillbeprovidedfortheinstallation.

MARAFEQshouldhavethepossibilitytoconnectthemeteringdevicestoaPLCsystemformeteringvaluestransmission.

ConnectedmeteringdevicesmustnotbedisconnectedbyanyoneotherthanMARAFEQstaff.

6.11 VentingValvesandDrainValves

VentingvalveDN15withbleedsshouldbeinstalledonthehighestpointinthedirectionofflowoftheDCpipesformanualextractionofairinthesystem.Thebleedsshouldbefittedwithvalveendcap400mmabovefloor.

DrainvalveDN15withbleedsshouldbeinstalledatthelowestpointofthepipes.Thebleedsshouldbefittedwithendcap.

7 INSTALLATION

7.1 Jointing

Worksontheprimarydistrictcoolingside(andalsoonthesecondarycoolingsystemifdirectconnectionisused)shouldbecarriedoutbythecompanywithweldinglicenseandcertifiedwelderswhocarriedouttheapprovedwelderqualificationtestinaccordancewithEN287‐1orpassedbrazingtestsaccordingtoQualificationonCopperpipesaswithBS1724orequal.

Installationofvalvesinprimarydistrictcoolingsystemmustweldingmethodbeusedwhichnotcausedamagetothevalveseal.Thereforeitrequireselectricfusionweldingiftheweldislocatedatshorterdistancesthan0.5mawayfromthevalvehouse.Inadditionthevalvesupplier’srecommendationsshallbefollowed.


7.2 Insulation

Inordertoavoidcondensationofmoistintheaironthepipes,valvesandothercomponentsshallhaveinsulation.Inordernottogetcondensationwatertodripthefacilityshouldbeequippedwithdriptraysandisolationwithvaporbarrier.

Pipesshouldpreferablybepre‐insulatedaccordingtoEN253pipesorEN244fittings.

Isolationcanalsobeofcellularrubberwhichisgluedtogether,edgetoedge.Themontagemustbeairtight.Insulationthicknessshallbebasedonnocondensationwithanambientairtemperatureof28Cand75%relativehumidity.

PolyurethanefoamwiththetoplayerofAluminumisusedforhighrequirementsonvaporbarrierandresistanceagainstmechanicalimpact.

InsulationforheatexchangersarerecommendedtobeprovidedfromthePHEmanufacturer.

Generallyinsulationworkshallbecarriedoutbyanapprovedspecialistthermalinsulationcontractor.

7.3 Tagging

Pipes,valvesandequipmentshallbetaggedaccordingBS1710orequal.

Eachitemofequipmentshallbeidentifiedbyusingwhitenon‐corrodingshatterprooflaminatedplasticlabelsengravedwithblackletters,6mmhigh,thefunctionandnumberofeachpieceofequipment,i.e.primarychilledwaterpump,pumpnumbers,etc.Alllabelsshallbefixedwithscrewed,rivetedorgluedtoequipmentcover.Whereapieceofequipmentisinsulatedtheidentificationlabelshallbefixedtotheexternalsurfaceoftheinsulation.

Valvesshallbetaggedwithidentificationdiscsattachedwithwithasplitring,S‐hookorbrasschain,whicheveristhemostappropriate.

Allprimaryandsecondarychilledwaterpipeworkshallhaveself‐coloured,self‐adhesivePVCtapebandscolourcodedinaccordancewithBS1710sofarasthisisapplicableandatsuitableintervals.


8 CHANGESTOTHESYSTEM

Oncethedesignhasbeenapproved,theCUSTOMERshouldnotchangeorreplaceanyequipmentduringtheinstallationwithoutinformingMARAFEQ.Anyfuturechangestothebuilding'scoolingwatersystemthatwillimpacttheDCsystemmustbereportedtoand,whenappropriate,reviewedbyMARAFEQ.

TheCUSTOMERisresponsibleformaintaininghissystemsothatitcontinuestoperformasintended.

Ifwarrantedbychangesintemperaturesandflowconditions,theCUSTOMERshouldverifythathissideoftheETSisproperlybalanced.

Appendix 1

Application for “Design Conformance Certificate”

(Design information that shall be included on the ETS plant PID)

Address……………………………………………………………………………………………………………………………………

Plot ID……………………………………………………………………………………………………………………………………..

Gross Floor Area (GFA) ……………………………………………….. m2

Net Floor Area (NFA) – Cooled Area …………………………… m2

AHU (Air handling Units)…………………………………………….. TR …………………………………………(kW)

FCU (Fan Coil Units)…………………….…………………………….. TR …………………………………………(kW)

Process cooling ………………………………………………………….. TR …………………………………………(kW)

Others ……………………………………………………………………….. TR …………………………………………(kW)

ERU (Energy Recovery Units).…………………………………….. TR …………………………………………(kW)

District cooling system (Primary)

PHE supplier

Type / number of plates

Design flow m3/h

Pressure loss kPa

Design temperature oC

Building cooling water system (Secondary)

Design flow m3/h

Pressure loss kPa

Design temperature oC

Control valves / actuators supplier (Primary side)

Type of control unit / program version

Type of control valve

Flow m3/h

Pressure loss kPa

Calculation of valve DN/kv‐value

Chosen valve DN/kvs‐value

Regulating range

Actuator time “o to c”, ”c to o”

Appendix 2

ETS Examination summary ETS ID:

Date: Executed by:

Customer/Company: Type of control:

DISTRICT COOLING SYSTEM BUILDING COOLING SYSTEMMeter readings Temperature District Cooling Secondary side

1 Energy TRh 6 Temperature supply oC 8 Temperature supply

oC

2 Volume m3 7 Temperature return

oC 9 Temperature return

oC

Pressure

3 Supply, before strainer MPa/kPa Other

4 Supply, after strainer MPa/kPa 10 Outside temperature oC

5 Return MPa/kPa

Pos System / component Pos Fault description / remarkStatus: 1=Acute 2=Action needed 3=Info 4=Executed by observer

Status 1‐4

Proposedaction

District cooling system

Isolating valves

Strainer

Pressure sensors

Temperature sensors

Flow transmitter

Calculation unit

Temperature transmitter

Others

PHE

Control unit

Control valve

Buildings cooling system

Strainer

Pressure sensors

Temperature sensors

Pumps

Expansion tank / safety valve

Valves

Others

Other equipment

district cooling lusail -...

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