Supply, Installation, Testing And Commissioning Of Single Stage Reciprocating Compressor-Supply, Installation, Testing and Commissioning of Single stage reciprocating Compressor (1 nos. working) to be provided for catering to the refrigeration load of around 316 KW for Existing Cold Rooms. The system offered should be energy efficient with flexibility in operations to allow for multiple storage of products and partial loads in cold rooms incorporating latest technology (Air Cooled Type). This compressor is proposed as replacement of existing compressor and allied equipment and should be incorporated with existing refrigeration system. This includes all miscellaneous spears parts and ancillaries required to complete the work.a) Compressor system to be provided of following specifications:1. Compressor shall be 1 No 2. Evaporating SST – 5Deg C3. Condensing SDT +40 Deg C4. Refrigerant - Ammonia5. Refrigeration System – Pump feed, single stage reciprocating compressors6. Type of Compressor -Single stage Reciprocating with belt driven drive through 7. Compressors should be provided complete with all accessories including suction and discharge manifolds with isolating valves; safety relief valve; High/Low oil pressure gauge along with panel board; oil separator; High, low and differential pressure cuts out of Danfoss/ equivalent make; Oil gauge glass with valves, high pressure gauge and cut outs; other standard accessories including drive set, flywheel, belt guard, driven V-belts, base frame, toolkit, set of spare gasket, oil paper and wire filters.8. LPR system to be provided9. Capacity control in terms of multiple compressors and individual compressor steps10. 4 pole TEFC squirrel cage induction motor of 1440 RPM of suitable HP. (Make: ABB/CGL/Kirloskar)11. Complete Selection to be submitted for approval before execution of work at site.12. Make: Bitzer /Kirloskar - KCX 6/ Frick /Mycom b) Low Pressure Liquid Receiver (1 no.)of suitable geometric volume to be provided of following specifications:1. Horizontal Low pressure accumulator 2. Minimum Design pressure for the vessel shall be 18 kg/sqm3. LP vessel to be manufactured as ASME SEC VIII Div-I4. Material of construction MS Plate made of SA 516 Grade 70 material along with all interconnection of piping suitable for supply liquid ammonia at desired temperatures5. Wet return lines and interconnecting flanges to be provided6. Safety valve connection, liquid pump outlet connection, liquid overfeed return line connection all are to be provided as suitable for system7. Stand for the receiver with necessary thermal break for receiver and structure8. Vapor vent line with all necessary interconnecting pipes up to receiver9. Un-insulated pipe for indication of the liquid level in receiver tank10. Standpipe for mounting all the control and level switches11. Valves and controls to be of Danfoss or equivalent make12. LP vessel to be designed considering defrosting air cooling unit at a time13. Liquid Ammonia Pump (1 working& 1 standby) of 51cum flow rate with bearing work hour indicator complete with all standard accessories and control valves and fittings. The pump should be capable of circulating the liquid ammonia at required ratios and minimum flow/head should be 7.5 HP/40m head. (Pump Make – Hydrodyne/Flowdyne/Preseion/Witt make)14. GA drawing of vessel to be submitted for approval.c) High Pressure Liquid Receiver (1 no.) of suitable geometric volume to be provided of following specifications:1. Horizontal Straight through type liquid receiver2. Material of construction MS Plate of SA 516 Grade 70, shell thickness 14mm and dish end thickness 16mm complete with radiography, along with 300 PSIG hydro pressure testing .3.Receiver is provided with suitable valves/nozzles to connect liquid inlet/ outlet connection, pressure gauge connection, safety relief valve connection, liquid level glass connection, base support and other accessories.4. Operating temperature : 40 deg C5. Max. allowed pressured : 21 bar (G)6. The receiver should include stop/service valves; level gauge glass, pressure gauge, safety relief valve, oil drain valves. It should be finished with paint after having been tested at high pressure. d)Refrigeration Piping, Fittings, Valves & Controls (1 lot)The interconnecting ammonia piping between the various parts of the plant shall be scheduled seamless pipes upto 25mm NB and ERW C-class Heavy Duty Pipes thereafter (Makes – Jindal/ Tata/ equivalent). The piping scope shall include supply of pipe lengths,necessary liquid feed assemblies comprising of solenoid valve, liquid strainer, stop valves, accessories like elbows. Tees, reducers, thermal break, clamps, threaded ends and fastener material etc. wherever required. Also included are primary and secondary steel structure and additional constructions for mounting the pipes and coolers and connecting the complete equipment. Valves for controlling the interlinked equipment like compressor, condenser, cooling water pumps, liquid ammonia receiver, chiller etc.and controls shall be viz. electronic float valve, ammonia solenoid valves, temp. humidity and pressure indicators, flow switches etc. (Make: Danfoss/ Manik/ equivalent). Digital temperature indicator cum controller of range -50 to +50 deg C (Make: AKO/Dixel/Equivalent) to control the auto run & defrost cycles with help of inbuilt timers & controls. Ammonia Gas leak detection system with alarms to be provided.e) Refrigeration line insulation & drain pipes(1 lot)RPUF sections of suitable thickness with cladding of 26 gauge aluminum sheet is used for insulating the Ammonia pipes cold surface including intercooler, LPR etc. Drain Piping with GI ‘B’ class pipe from units to outside the chiller shall be provided. Type of insulation for the drain pipe shall be Armoflex/ Vedoflex insulation along with heaters. f) VFD cum MCC Electrical Starter Panel (1 lot)The MCC Panel shall be fabricated by MS Powder coated cubicle type Panel board, dust and vermin proof having isolating switch, fuse, contractors, circuit breaker, hour meter with bus bar suitable for 400/440 volts giving output and PLC touch operated auto/manual system suitable for VFD of all compressor motor each, DOL/Star Delta Starters for cooling tower motor, condenser pumps. Electrical cables for supply items. All the main ACB/MCB/ Relays shall be of Siemens/ABB/Schneider/ L&T make and only standard components will be used for fabricating the panel. The bus bar and the mains component capacity shall be strictly based as per the power requirement sheet. Distribution panels shall be provided wherever found necessary.Automation Panel – Programmable Logic Controller complete with display for automatic operation and control of refrigeration equipment as per standards. Basic control will consist of :1) Automatic capacity control of compressors2) Sequence control liquid pumps3) Temperature Control and indication4) Warnings and failures indication5) Possibility for automatic or manual operation6) Leakage detectiong) Electrical Control Cabling and Wiring/Cable Tray (1 lot)Electrical cabling and wiring between the main switch panel and the refrigeration equipment shall include:-1) Power supply cable2) Control and communication cable with cable trays between the panel and field instruments and PLC and various controls3) Cable ducts etc.4) All cables, trays etc. shall be of approved makes.h) Structure & Support Material (1 lot)M.S. Structure, supports, angles, channel for the equipment etc. for erection of complete refrigeration equipment, pipeline support and others.i) Painting for the equipment and all the pipelines after installation (1 lot)j) First Charge of Ammonia Gas and Oil (1 lot)The system will be charged with ammonia and oil charge for the whole system being commissioned. 2 Supply, Installation, Testing and Commissioning of Evaporative type condenser (1 Lot) induced draft type with pump, ancillary equipment and all accessories of 300 TR Minimum capacity to be provided of following specifications:1. Heat Rejection Capacity – 300 TR minimum2. Condensing Temp. –45 Deg C3. Coil Data – SS 3044. MOC – Casework (AZ150), Water Tank (AZ150)5. Supply, Installation and Commissioning of Condenser with receiver and compressor discharge header on turnkey basis with all spares & accessories 6. M.S. Structure, supports, angles, channel for the equipment etc. for erection of complete condenser installation work, pipeline support and others.7. Supply, Installation and Commissioning of Water softener with capacity of 5000 ltr.including 5000 ltr. Water storage tank.8. Make – Star Cooler/ WAPCO/ BCE/THERMAX9. This includes all miscellaneous spears parts and ancillaries required to complete the work.
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