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Group Code: ST-CV Original: EnglishEDMS No.: LHC Project document No.:
IT-3013/ST
Technical Specification for Supply and Installation of an Air Conditioning Plant,
air handling units and chilled water plant, for the Silicon Facility Area in Hall 186
AbstractThis Technical Specification concerns the design, manufacturing, transport to CERN, installation and commissioning of the air conditioning units and the chilled water production plant for the Silicon Facility Area, a clean area to be built in Hall 186, in the CERN Swiss site of Meyrin.
This delivery is foreseen to be completed in March 2002.
July 2001
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Table of Contents
1. INTRODUCTION............................................................................................................................................4
1.1 INTRODUCTION TO CERN...........................................................................................................................41.2 INTRODUCTION TO THE LHC PROJECT.......................................................................................................41.3 INTRODUCTION TO THE LHC EXPERIMENTS..............................................................................................4
2. SCOPE OF THE TENDER.............................................................................................................................4
2.1 SITE LOCATIONS.........................................................................................................................................52.2 SERVICES PROVIDED BY CERN..................................................................................................................5
3. GENERAL CONDITIONS FOR TENDERING AND CONTRACTING..................................................6
3.1 TENDER PROCEDURE..................................................................................................................................63.1.1 Pre-tender Discussions......................................................................................................................63.1.2 Preliminary Program.........................................................................................................................63.1.3 Subcontractors...................................................................................................................................63.1.4 Documents to Submit with the Tender................................................................................................63.1.5 Country of Origin...............................................................................................................................7
3.2 CONTRACT EXECUTION..............................................................................................................................73.2.1 Responsibility for Design, Components and Performance................................................................73.2.2 Contract Follow-up............................................................................................................................7
3.2.2.1 Design Approval and Production....................................................................................................................73.2.2.2 Contract Engineer............................................................................................................................................73.2.2.3 Progress Report...............................................................................................................................................7
3.2.3 Deviations from this Technical Specification.....................................................................................73.3 FACTORY ACCESS.......................................................................................................................................8
4. TECHNICAL REQUIREMENTS..................................................................................................................8
4.1 GENERAL DESCRIPTION..............................................................................................................................84.2 VENTILATION DESIGN CRITERIA................................................................................................................8
4.2.1 Cleanliness and atmospheric conditions............................................................................................84.2.2 Heat Loads.........................................................................................................................................9
4.2.2.1 Latent Heat Load.............................................................................................................................................94.2.2.2 Sensible Heat Loads........................................................................................................................................9
4.2.3 Noise Level.......................................................................................................................................104.3 VENTILATION MATERIALS........................................................................................................................10
4.3.1 Air Handling Units...........................................................................................................................104.3.1.1 The Location of the AHUs............................................................................................................................104.3.1.2 Flow Rates.....................................................................................................................................................104.3.1.3 AHUs Dimensions.........................................................................................................................................114.3.1.4 AHUs Components........................................................................................................................................11
4.3.2 Air Ducts..........................................................................................................................................134.3.2.1 Ventilation Ducts...........................................................................................................................................134.3.2.2 Supply Grilles................................................................................................................................................14
4.3.3 AHUs Electric cubicles....................................................................................................................144.4 COOLING DESIGN CRITERIA.....................................................................................................................14
4.4.1 Hydraulic Principles........................................................................................................................144.4.2 Design Codes and Principles for the Cooling Plant........................................................................144.4.3 Chilled Water (+5 °C) Production...................................................................................................15
4.4.3.1 Installed Cooling Power................................................................................................................................154.4.4 Cooling Plant...................................................................................................................................154.4.5 Piping...............................................................................................................................................154.4.6 Lagging.............................................................................................................................................154.4.7 Welding.............................................................................................................................................16
4.4.7.1 Welders' Qualifications.................................................................................................................................16
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4.4.7.2 Inspection of Welds.......................................................................................................................................164.4.8 List of Special Requirements for Piping and Welding.....................................................................164.4.9 Pumps...............................................................................................................................................16
4.4.9.1 Pump Specifications......................................................................................................................................174.4.9.2 Motor.............................................................................................................................................................17
4.4.10 Other Equipment..............................................................................................................................174.4.10.1 Screen Strainers Filters.............................................................................................................................174.4.10.2 Drain Valve and Bleeds Cocks.................................................................................................................184.4.10.3 Pressure Vessel.........................................................................................................................................18
4.5 COOLING SYSTEM MATERIALS.................................................................................................................184.5.1 Special Design Requirements...........................................................................................................18
4.6 CONTROL AND REGULATION SYSTEM......................................................................................................184.6.1 Equipment.........................................................................................................................................18
4.6.1.1 PLC................................................................................................................................................................184.6.1.2 Development software...................................................................................................................................194.6.1.3 Application software.....................................................................................................................................194.6.1.4 Operation panel.............................................................................................................................................194.6.1.5 Instrumentation, general characteristics........................................................................................................19
4.6.1.5.1 Flow rate and differential pressure transmitters......................................................................................194.6.1.5.2 Temperature transmitters.........................................................................................................................19
4.6.2 Functional and dysfunctional analysis.............................................................................................204.6.2.1 General description of the process operation................................................................................................204.6.2.2 Functional analysis........................................................................................................................................204.6.2.3 Dysfunctional analysis..................................................................................................................................214.6.2.4 Recommendation...........................................................................................................................................21
4.6.3 Measurements and regulation loops................................................................................................214.6.3.1 General..........................................................................................................................................................214.6.3.2 Validation of measurements..........................................................................................................................214.6.3.3 Regulation loops............................................................................................................................................22
4.6.4 Training............................................................................................................................................224.6.4.1 General..........................................................................................................................................................234.6.4.2 Control and regulation: the PLC...................................................................................................................234.6.4.3 Local supervision: the OP.............................................................................................................................23
4.7 SCHEMATICS AND DRAWINGS..................................................................................................................234.8 PLANNING AND SCHEDULE.......................................................................................................................234.9 WORK REGULATIONS...............................................................................................................................23
4.9.1 General Rules for opening a worksite at CERN ST/CV...................................................................234.9.2 Work Areas.......................................................................................................................................244.9.3 Site Supervision................................................................................................................................244.9.4 Manpower, Tooling and Assembly...................................................................................................24
4.9.4.1 Contractor’s Staff..........................................................................................................................................244.9.4.2 Replacement of Staff.....................................................................................................................................244.9.4.3 Special Tooling and Equipment....................................................................................................................244.9.4.4 Assembly.......................................................................................................................................................24
4.9.5 Contractor’s Installations at CERN.................................................................................................244.9.6 Waste Disposal.................................................................................................................................254.9.7 Fire Permit.......................................................................................................................................254.9.8 Electricity Distribution.....................................................................................................................25
4.10 SAFETY.....................................................................................................................................................25
5. APPLICABLE DOCUMENTS.....................................................................................................................26
5.1 STANDARDS..............................................................................................................................................265.1.1 CERN Regulations............................................................................................................................26
5.2 SUPPLY OF DOCUMENTS...........................................................................................................................275.2.1 Documents in Computer Readable Form.........................................................................................275.2.2 Documents to be Delivered..............................................................................................................28
6. QUALITY.......................................................................................................................................................29
6.1 QUALITY CONTROL..................................................................................................................................29
7. TESTS.............................................................................................................................................................29
7.1 TESTS TO BE CARRIED OUT AT THE CONTRACTOR'S PREMISES................................................................297.2 TESTS TO BE CARRIED OUT AT CERN......................................................................................................29
7.2.1 Control and Regulation System........................................................................................................30
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7.2.1.1 Static Tests Stage...........................................................................................................................................307.2.1.2 Dynamic Tests Stage.....................................................................................................................................30
7.2.2 Electricity and Air Handling Systems..............................................................................................307.3 NON-COMPLIANCE....................................................................................................................................31
8. DELIVERY AND COMMISSIONING.......................................................................................................31
8.1 PROVISIONAL DELIVERY SCHEDULE........................................................................................................318.2 PACKING AND TRANSPORT TO CERN......................................................................................................318.3 HANDLING AT CERN...............................................................................................................................328.4 WORKING HOURS AT CERN.....................................................................................................................328.5 COMMISSIONING.......................................................................................................................................328.6 TRAINING..................................................................................................................................................328.7 CLEANING.................................................................................................................................................328.8 MAINTENANCE..........................................................................................................................................338.9 ACCEPTANCE AND GUARANTEE...............................................................................................................33
8.9.1 Provisional Acceptance....................................................................................................................338.9.2 Guarantee.........................................................................................................................................338.9.3 Final Acceptance..............................................................................................................................33
9. Persons technically responsible at CERN....................................................................................................33
ANNEX 1: Technical Requirements
ANNEX 2: List of drawings and schematics
ANNEX 3: Tests – Checks – Inspections
ANNEX 4: Particular Specifications for Electrical Schematic Diagrams
ANNEX 5: DQE
ANNEX 7: CERN Drawings Storage ????????????
List of Tables
TABLE 1 – ROOMS DIMENSIONS.................................................................................................................................8TABLE 2 – DESIGN PARAMETERS................................................................................................................................8TABLE 3 – LATENT INTERNAL LOADS........................................................................................................................9TABLE 4 – SENSIBLE INTERNAL LOADS......................................................................................................................9TABLE 5 – NOISE LEVEL...........................................................................................................................................10Table 6 - AHUs flow rates.......................................................................................................................................10
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Terms and Definitions
Term DefinitionCDD CERN Drawing Directory
EDMS Engineering Data Management SystemQAP Quality Assurance Plan
Chilled Water Cooling water delivered by chillers at a temperature of 5 °C with a t of 6 k
1. INTRODUCTION
1.1 Introduction to CERNThe European Organization for Nuclear Research (CERN) is an intergovernmental
organization with 20 Member States*. It has its seat in Geneva but straddles the Swiss-French border. Its objective is to provide for collaboration among European States in the field of high-energy particle physics research and to this end it designs, constructs and runs the necessary particle accelerators and the associated experimental areas.
At present more than 5000 physicists from research institutes world-wide use the CERN installations for their experiments.
1.2 Introduction to the LHC ProjectThe Large Hadron Collider (LHC) is the next accelerator being constructed on the
CERN site. The LHC machine will mainly accelerate and collide 7 TeV proton beams but also heavier ions up to lead. It will be installed in the existing 27 km circumference tunnel, about 100 m underground, that previously housed the Large Electron Positron Collider (LEP). The LHC design is based on superconducting twin-aperture magnets which operate in a superfluid helium bath at 1.9 K.
1.3 Introduction to the LHC ExperimentsFour experiments will be built to study the collisions produced by the LHC: ATLAS CMS ALICE LHCBEach experiment is divided into subdetectors whose assembly has to be done in
particular conditions. For this purpose, a clean area will be constructed in Hall 186 at CERN Meyrin site.
2. SCOPE OF THE TENDER
CERN intends to put out a contract for the provision of the following:
* CERN Member States are: Austria, Belgium, Bulgaria, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Italy, The Netherlands, Norway, Poland, Portugal, Slovak Republic, Spain, Sweden, Switzerland and the United Kingdom.
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Design of the air conditioning systems described in the next sections of this document.
Design of the cooling systems described in the next sections of this document. Electrical design for the air conditioning and cooling plants. Selection of the programmable controllers and design of the control systems. Supply of the working drawings, theoretical diagrams and functional analyses. Supply of execution drawings. Supply of the designed systems. Transport and delivery to building 186 worksite. Lifting equipment for all the needs during the life of the contract. Assembly and installation of all the supplied equipment. The wiring of the instrumentation for each AHU and other equipments. Manufacture and factory-testing. Hydraulic and electrical connections to existing equipment. Testing at CERN. Commissioning of the installation. Training of CERN staff in the maintenance and operation of the installation. Cleaning the site daily and at completion of works. Supply of technical documents.The Contractor shall be solely responsible for doing the work detailed in this
Technical Specification. CERN’s responsibility will be restricted to defining the scope of the supply and supervising the acceptance tests.
The appended drawings show the surface area and layout chosen for the construction of the three Air Handling Units and the Cooling plant.
2.1 Site LocationsThe work referred to in this call for tenders is to be done at Hall 186 in CERN Meyrin
site, Switzerland.
2.2 Services provided by CERNCERN will supply the Contractor with: Civil engineering works. Lighting of the rooms. Connections for the Contractor’s power supply cubicle to the mains. Temporary electrical supply for the works (no electrical cupboard is supplied).
3. GENERAL CONDITIONS FOR TENDERING AND CONTRACTING
3.1 Tender Procedure
3.1.1 Pre-tender DiscussionsA bidder’s conference will be organised Monday 3rd September at 14.00 at CERN,
with all potential contractors, before the submission of the bids. Attendance to this bidder’s conference is mandatory. Failing to do so will entail the disqualification of the bid.
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3.1.2 Preliminary ProgramThe Bidder shall propose a preliminary design and manufacturing schedule with the
tender, based on the specified CERN provisional delivery schedule.
3.1.3 SubcontractorsThe Bidder shall declare in the tender documents any subcontractors whose services
he intends to use in the event of a Contract. Refer to the commercial bidding documents for more details. If awarded the Contract, the Bidder shall restrict himself both to the subcontractors and the amount mentioned in the tender document. If, for some reason, he wants to change any subcontractor, or the scope of subcontracted work, or the amount subcontracted, he must obtain CERN’s prior agreement in writing.
3.1.4 Documents to Submit with the TenderThe Bidder is requested to supply with his tender all the documents and descriptions
needed to supplement it and to provide as clear as possible an understanding of the installation which he proposes to build. The tender and all the accompanying documents must be in French or English and submitted in duplicate.
In order that his tender may be considered, the Bidder shall send to CERN together with a cover letter and the company’s name, a packet, bearing the reference number of the call for tenders and his own name and address, containing the following:
Detailed description with prices of main components (see DQE), copies of the technical information (technical data sheet) for all the proposed equipment, clearly showing the results of the selection in accordance with CERN specifications and requirements,
a brief description concerning the safety as asked in § 3.3 Safety below, schematics indicating the overall dimensions and the weights in kg of the
equipment proposed, schematic and general assembly drawings (DWG format) indicating the layout
proposed for the stations, dimensions of the different items and necessary, the tender form, completed in full, in duplicate.The costs associated with drawing up the tender shall be met entirely by the Bidder.
CERN will not contribute in any way to the expenses incurred by bidders in connection with the tendering procedure.
The Bidder shall submit with his tender any observations or suggestions he may consider useful concerning the requirements or the drawings. No exceptions to the terms and conditions of the call for tender documents may be made without a written order signed by CERN. Incomplete tenders (missing documents or documents not completed in full) and tenders which do not fully meet the specified requirements will not be taken into consideration by CERN.
3.1.5 Country of OriginPlease refer to the commercial bidding documents for specific conditions concerning
the country of origin of the equipment or services to be supplied.
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3.2 Contract Execution
3.2.1 Responsibility for Design, Components and PerformanceThe Contractor shall be responsible for the correct performance of all items supplied,
irrespective of whether they have been chosen by the Contractor or suggested by CERN. CERN's approval of the design and component choice does not release the Contractor from his responsibilities in this respect.
CERN assumes responsibility for the performance of items and sub-systems supplied by CERN.
CERN reserves the right to make minor modifications to this Technical Specification before placing the Contract. Parameters and/or dimensions, which may change slightly, are clearly indicated in the tables and in the attached drawings by the letters T.B.C. (To Be Confirmed) just beside their actual nominal value. Unless clearly stated by the Bidder in the tender document together with a justification, these minor changes shall not affect the contractual price that shall remain fixed.
3.2.2 Contract Follow-up
3.2.2.1 Design Approval and ProductionThe Contractor shall supply, within 10 days of notification of the Contract, a written
programme detailing the manufacturing and testing schedules.The detailed design shall be submitted to CERN for approval. CERN will give its
approval or refusal, in writing, within one week. Component ordering and equipment manufacture shall not start without CERN’s written prior agreement.
3.2.2.2 Contract EngineerThe Contractor shall assign an engineer to be responsible for the technical execution
of the Contract and its follow-up throughout the duration of the Contract.
3.2.2.3 Progress ReportThe Contractor shall send a written progress report to CERN every 3 weeks until
completion of the Contract.
3.2.3 Deviations from this Technical SpecificationIf, after the Contract is placed, the Contractor discovers that he has misinterpreted this
Technical Specification, this will not be accepted as an excuse for deviation from it and the Contractor shall deliver equipment in conformity with this Technical Specification at no extra cost.
During execution of the Contract, all deviations from this Technical Specification, the tender, or any other subsequent contractual agreement, proposed by the Contractor, shall be submitted to CERN in writing for the latter's approval.
CERN reserves the right to modify this Technical Specification during execution of the Contract. The consequences of such modifications shall be mutually agreed between CERN and the Contractor.
3.3 Factory AccessCERN and its representatives shall have free access during normal working hours to
the manufacturing or assembly sites, including any subcontractor’s premises, during the
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Contract period. The place of manufacture may only be changed after written approval by CERN.
4. TECHNICAL REQUIREMENTS
4.1 General DescriptionOn the ground floor of 186 building there is a hall of about 850 m2 in which three
rooms (whose dimensions are given below) will be erected using leak tight brick walls. The rooms will be dedicated to the handling and the installing of some components of the four detectors of LHC project. For these reasons all the tree rooms needed a fixed level of cleanliness in order to preserve the quality of the electronic devices installed on the machines.
Table 1 – Rooms dimensions
room A room B room C
Surface [m2] 152 370 334
Volume [m3] 456 1110 1269
The access of the personnel to the room A and B will be regulated through 2 SAS (see drawing XXXX). Another SAS will be erected to allow the passage of the material between C and B rooms. The ventilation of the SASs will be the same ventilation systems of the correspondent rooms.
The systems shall have cooling and dehumidification coils and a humidification section (steam injection system) to allow an efficient control of the relative humidity all year round. As the existing CERN chilled water network is not close to this building a dedicated chilled water plant has to be installed too. Air distribution shall be made via simple and double skinned leak tight ducts.
Electric and control cubicles, including cables and cables trays, instrumentation and connection shall be also part of the supply. A regulation system shall be included to control temperatures, humidity and operation modes.
The present Technical Description concerns the air conditioning plant, complete of chilled water system, necessary for the future use of the clean rooms only.
4.2 Ventilation Design CriteriaThe future configuration of the three clean rooms will have similar cleanliness
classes, temperature and humidity conditions. As the activities in the three rooms are different a different level of cleanliness and atmospheric control has to be kept: room A is the most strict and room C the less one. To avoid external contamination a constant pressure difference has to be kept between each rooms and with outside too (all these parameters are listed on table 2).
4.2.1 Cleanliness and atmospheric conditions
Table 2 – Design parameters
Room
A
Room
B
Room
C
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Cleanness class <100.000 100.000 >100.000
Temperature [C] 21 1 21 1 21 2
Relative Humidity [%] 45 5 45 5 45 15
Over-pressure [Pa] 10 over room B
10 over room C
10 over outside
The external weather conditions in the Geneva region (temperature and humidity) are the following:
Winter: -10°C 90% Summer: 32°C 40%
4.2.2 Heat Loads
4.2.2.1 Latent Heat LoadThe activities inside the three rooms are different. In room A and B there will be the
assembly electronic devices on the particle detector component. This is an activity that required great attention. people are supposed to remain seated for the most part of the time. In room C there will be the handling of the material coming from outside before going on to the two main clean rooms. That is the reason why the cleanliness control is less tight and the workload activity is more heavy for the people.
The latent heat load to be considered is related to the number of persons working inside the rooms.
Table 3 – Latent internal loads
Room
A
Room
B
Room
C
Persons working [n] 12 15 15
No other latent heat load but the people working have to be taken into consideration for the design of the air conditioning plant.
4.2.2.2 Sensible Heat LoadsThe following sensible heat load can be assumed for the rooms:
Table 4 – Sensible internal loads
Room
A
Room
B
Room
C
Lighting Level on working tables [lux] 500-600 500-600 500-600
Equipment heat load [kW] 16 10 13
Winter external heat load [kW] -1.5 -6 -8
Summer external heat load [kW] 2 3 4
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4.2.3 Noise LevelFor the room A and B the noise level must be lower than 50 dB(A) in any point of the
room at height 1.2 m . In room C According to the CERN’s Safety Code A8 the noise level must be lower than 55 dB(A) in any point of the room at height 1.2 m. In conformity with this document, environmental protection requirements (i.e. permissible average noise levels), must be met. The noise level at 1m from the AHU shall be lower than 60 dB(A).
Table 5 – Noise level
Room
A
Room
B
Room
C
Max Noise level(*) [dB(A)] 50 50 55
4.3 Ventilation Materials
4.3.1 Air Handling UnitsThe three AHUs will be adapted for horizontal mounting. They shall be designed for
an inside installation. They shall be fabricated from heavy gauge pre-galvanised sheet steel, folded to form sturdy side, top and bottom panels. Panels and frame shall have all cut edges within the unit and be secured using internally bolted fixings. The case shall be of double wall type with thermal insulation of minimum 40mm thick and characterised by a high resistance to corrosion. Access to all components requiring servicing and maintenance shall be on one side of the unit. The unit shall be delivered with its own basement.
4.3.1.1 The Location of the AHUsThe location of the three air handling units is foreseen inside the building 186 (see
drawing XXXX) in a technical room close to the room C.
4.3.1.2 Flow RatesFor the foreseen configuration CERN ask for three AHUs with the following flow
rates:Table 6 - AHUs flow rates
Room
A
Room
B
Room
C
Minimum new air flow rate [m3/h] 500 500 500
Maximum new air flow rate [m3/h] 2.000 2.000 2.000
Total flow rate (new + recirculating) [m3/h] 7.000 17.000 20.000
The AHU for room A shall allow a future extension of performance in terms of cleanliness class. The total flow rate will reach 14.000 m3/h. A number of fun-filter units will replace the false ceiling grilles (that will increase the internal sensible heat load too).
The Bidder shall leave spaces to add hot and cold coils, steam system motor and fan. The Bidder shall design the air ducts for the future flow rate.
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4.3.1.3 AHUs DimensionsThe doors of the AHUs shall be sized in a way that make it possible to open them
completely according to the position of the AHU in the technical room. The AHUs dimensions have to be as small as possible to preserve as maximum as
possible the working surface of the room C.
4.3.1.4 AHUs ComponentsThe air handling unit systems shall be realised with a first-step handling unit, whose
aim is to handle the external fresh air flow rate (central AHU), and a dedicated AHU for each clean room.
The central AHU will consist of the following parts:1. Fresh air filter section (class EU7)2. Electric heater section 3. Chilled water coil section4. Supply fan section
The only aim of this unit is to obtain a fresh air flow rate at 21C before entering in the room dedicated air handling units.
The room dedicated AHUs will consist of the following parts (see schematic 2):1. Mixing box with damper 2. Chilled water coil section3. Electric heater section4. Supply fan section 5. Divergent duct 6. Humidification section7. HEPA filter section
The characteristics of the different section are:Air filter section (class EU7)According to the CERN regulations this filter panel shall be fireproof using synthetic
media. The filter cells shall be mounted in a galvanised steel frame and held tightly in their place by spring wire clips.
The filter medium shall be fireproof (class M0), disposable, synthetic fibre, class EU7.
The filter shall be located adjacent to the mixing air box. An inclined gauge manometer shall indicate when the filter needs replacement (Pmax = 200Pa). At least 17 weeks of continual operation are required without the filters needing replacement. The corrugated medium cells shall be mounted on easily removable rails (replacement has to be performed without using any tools).
The filter section shall be placed at an adequate distance from the following heating section to preserve them from the possibility of fire.
Electric heater sectionThis element shall supply the heat necessary to worm-up the temperature of the fresh
air needed for the three AHUs.
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Electric heater elements shall be rack mounted and fixed to a frame of galvanised steel housed in slide rails for lateral withdrawal. Elements shall be wired to a terminal strip and provided with two overheat thermostats (+70°C) per heater and overheat safety cut-out. Controlling of heating power will be done by a thyristor based on the full-wave principle.
There shall be interlock provided by differential pressure sensor preventing the powering of the heaters when there is not enough airflow.
When the heating system is shut down, the cooling of the unit shall be ensured by a delay in the stopping of the fan.
The heaters should be efficient enough to allow the supply of air at min.+22°C with the total airflow during the worst outdoor winter conditions and maintain ambient temperature of +21ºC in the dehumidification mode during the worst outdoor summer conditions.
Chilled water coil sectionThe units shall be operating using chilled water as refrigerant. Water at 5/11ºC will be
available in the proximity of the air handling units from a dedicated chilled water plant. The cooling coil tubes shall be of copper with aluminium fins. Each cooling coil power shall be 10% higher than the calculated (design) power.
The Contractor shall dimension the units to permit a future installation of coils of a power 2 times higher than the calculated design power.
The Contractor shall size the coil needed for cooling and dehumidification taking into account the maximum available pressure difference between supply and return water lines of 1.5 bar. The Contractor shall foresee a drop separator wherever it’s necessary, in any case the frontal air velocity shall not exceed the 2m/s.
Supply fan sectionSupply fan shall be of the double-inlet type and be arranged for horizontal air
discharge. The fan and motor package shall be mounted on a common base frame and insulated from the unit casing by means of rubber/spring anti-vibration mounts and a flexible fan discharge sleeve. A beam shall be installed over the motor package to help the handling operations.
The available head has to be sufficient to deliver the required flow rate of air when the filters reach the Pmax (200Pa) value, taking into consideration also the pressure drop of the rest of components of the unit.
The fan motors shall be: Type: asynchronous, 3 phases Standardisation: to IEC Construction: Standard Rated power: Calculated for maximum permissible flow-rate + 10% Rated voltage: 400 V Internal protection: by thermal switch Ingress protection: IP55 Starting: Direct Max. rotation speed: 1500 rpm. Frequency: 50 Hz Insulation class: F Service type: to IEC 34.1 S1. Greasing: automatic.Electromagnetic pollution levels shall conform to the prescriptions of IEC 61000 and
60439 and EN 55011.
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The motors shall be adequate for a future use of VFD (Variation Frequency Device).Mixing box with damperThe mixing air box shall have opposed blade dampers with geared linkages and self-
lubricating bearings. The dampers shall be situated inside the box and have a possibility of controlling the airflow from the outside. The dampers’ blades shall be of airfoil section with seals at interlocking, leading and trailing edges. The fresh air inlet section shall be complete of a filter section too.
Divergent sectionThis is a part of the unit that helps the air stream to diverge after the fun section and
before to reach the HEPA filter to avoid stratification effects that could compromise the filter efficiency.
Humidification sectionThe Contractor shall supply and install a steam injection system. The systems shall be
installed after the AHU on the first part of the ducts that is inside the building.The system shall be of the type DEFENSOR MK5 from AXAIR or equivalent,
comprising all fittings. The Contractor shall install all the necessary equipment to that purpose.HEPA Filters sectionThis filter panel shall be placed at the outlet of each AHU. The filter cells shall be
mounted in a galvanised steel frame and held tightly in their place by spring wire clips.A pressure gauge shall indicate when the filter needs replacement. At least 26 weeks
of continual operation is required (Pmax = 200Pa). The corrugated medium cells shall be mounted on easily removable rails (replacement has to be performed without using any tools).
4.3.2 Air DuctsThe air-handling units described above will be connected to the various assembly
rooms via the network of ventilation ducts. In the rooms A and B there will be a false ceiling where the ducts will take place. No false ceiling will be installed in room C. A large part of the room C close to the main entrance door will be left free up the maximum ceiling high of 3.8 meters to let some large detector element to enter. Supply and extraction of air to and from each zone will be done through grilles located as shown in drawing number XXXX.
4.3.2.1 Ventilation DuctsVentilation ducts shall have circular or rectangular section; in any case they have to
be installed inside the false ceiling that is 80 cm high under the concrete ceiling.The ducts conveying pre-cooled air shall be double-skinned with a galvanised sheet
inside, a galvanised sheet outside and internal mineral wool insulation, density 70 kg/m3, of 35 mm thick, as per requirements. No insulation will be installed on the extraction ducts.
The part of the ducts that runs outside the building shall be insulated with the same kind of insulation detailed on the above paragraph, but with a thickness of 100 mm.
The section of the duct just after each air handling unit is calculated in order to maintain the inside air velocity at 8 m/s maximum. The design velocity for the rest of the ducts is 6 m/s in order to maintain the noise level requested. The schematic XXXX shows the preliminary ducts distribution in the three rooms.
The extraction ducts will run inside the false ceiling and will reach the extraction grilles placed at the ground level.
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The ducts shall be supported on galvanised sections secured to the wall or to the roof, depending on their positions. The seals or strips used shall be waterproof and non-combustible; the fixing means shall be of cadmium-plated or galvanised steel.
Every duct branch has to be tight. Tightness will be proved through dedicated tests.The Contractor shall perfectly seal all the cutting works done for the passage of the
distribution ducts to maintain the tightness of the rooms.
4.3.2.2 Supply GrillesThe supply grilles will be installed on the false ceiling. Their position and number is
showed on drawing number XXXX. The size must be determined to meet the terminal velocity requirements of 0.2 m/s at the height of 2 m from the floor and a maximum velocity through the grilles of 5 m/s. The dimension of the ducts and of the grilles in room A has to fit with the dimension of fan-filter units that could be installed in a second time.
The grilles shall be equipped with the flow controlling dampers and have the horizontal and vertical blades.
4.3.3 AHUs Electric cubiclesThree electrical cubicles will be installed closed to each AHU to provide control and
the power. Their characteristics are described in the annexe 1 (“Technical Requirements”).
4.4 Cooling Design Criteria
4.4.1 Hydraulic PrinciplesDrawings and schematics in Annexes show the design cooling layout specified for the
chilled water production plant.The pressure needed for the operation of the pumps in the circuit shall be provided by
one expansion vessel.Each pump shall be fitted: with isolating valves On the discharge: with a check valve.The circuit shall be connected to the raw water system for make-up. The connections
shall be fitted with anti-pollution devices. An automatic top-up valve shall regulate the pressure in the circuit.
The final layout of the station shall allow normal maintenance activities to be performed in safe and comfortable conditions.
4.4.2 Design Codes and Principles for the Cooling PlantMechanical components subject to fluid pressure shall comply with the requirements
of the CERN Pressure Equipment Code D2, which refers to the European Directive 97/23/EC.
4.4.3 Chilled Water (+5 °C) ProductionThe chilled water is to be produced in the plant for the cooling and dehumidification
coils in the three AHUs of the clean rooms area. The chilled water, to be produced at a temperature of 5 °C by chiller, shall be distributed to the various air handling units through a closed circuit.
The chiller will be air cooled. It will be placed beside the building186, next to the air handling units. The whole cooling installation has to be designed to stand the winter outdoor conditions in Geneva. The minimum temperature to be considered for the design of the
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equipment is -10°C. The chilled water shall consist of a mixture of water and 10% ethylene glycol. The pipes will be properly insulated to avoid condensation and they shall be equipped with heating wires.
Each user is to be connected in parallel to the central chilled water production system, with a common distribution pump ensuring the necessary flow rate. The supply of chilled water to the units shall be obtained through a single pipe DN100.
4.4.3.1 Installed Cooling PowerThe cumulative power at the various air handling units is 120 kW.The chilled water temperature in the supply and the return lines is + 5 °C / + 11 °C
4.4.4 Cooling PlantAll the technical requirement for the cooling plant will be defined in the Annexe 1
“Technical Requirements”
4.4.5 Piping
All the equipment supplied shall correspond to the special technical specifications set out in this Technical Specification.
In general: All distribution circuit pipes shall be made of carbon steel for chilled water. The
nominal pressure will be PN16. Common parts such as drain top-up and bleed valves etc. shall be made of
galvanised steel. Supports are part of the supply. Pipes shall be painted and marked with labels and flow indication arrows. Insulation has to follow the technical specification in annexe 1.
4.4.6 LaggingThe pipes have to be surrounded completely by a layer of Foamglas® Coriglas® or
similar, with a minimum thickness of 40 mm. This lagging has to be protected on the outside by a layer of sheet aluminium. The Foamglas® has to be replaced by 40 mm high density polyurethane (RG80 or similar) where the pipe supports are placed, in order to guarantee stability.
4.4.7 Welding
4.4.7.1 Welders' QualificationsWelders of pressure vessels shall posses a certificate recognised by the approved
inspection authority. Pipe welders working at CERN will have to pass a test by the CERN Technical Inspection and Safety Commission (TIS); please refer to TIS document TIS/GS/GR/IR/94-01. The cost of which is to be borne by the contractor.
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4.4.7.2 Inspection of WeldsThe degree of X-ray of welded joints shall be as laid down in the design code, please
refer to TIS document TIS/GS/CM/IR/95-003. Other non-destructive tests may be required by CERN in case of doubt. As a minimum requirement three joints in pressure vessels shall be X-rayed 100%, circumferential welds and longitudinal welds in pipework shall be X-rayed at not less than 10%. If faults are discovered, CERN or the inspector may require additional X-rays, up to 100%, if necessary. The cost of which is to be made by the contractor.
These radiographs will be evaluated in accordance to ISO standard 5817,requirement B.
4.4.8 List of Special Requirements for Piping and WeldingIn addition to the requirements of the codes of practice and operating conditions
specified above, the Bidder shall conform to the following special requirements: The extremities of the pipes are mostly inside the buildings, not down in the
galleries or ducts. The pipes are supposed to end in flanges. The flanges and blank flanges on the ends of a pipe shall be of the same material
as the pipe itself. All pipework shall be made from straight pipe segments or prefabricated T-pieces
and bends. In no case CERN will accept that short pieces are welded together in order to replace standard pipes of 6 m of length.
The inside of the pipework has to be clean, degreased and free from contamination, dirt, welding scale and oil.
Metric dimensions shall be used for bolting. All pipework shall be welded. At a change of direction, the bends specified in Annex 2 shall be used. Only if
there is a small change in direction and the distance between the two welds is less than 13 mm, measured on the inner part of the bend, then the bend may be replaced by a bevelled cut on the pipes.
When a weld joins two pipes, care should be taken that the two longitudinal welds do not fall in line. They should be at least 13 mm apart, measured along the circumference.
4.4.9 PumpsThe distribution circuit shall be equipped with two identical pumps: one main pump
and one on stand-by. The make of the pumps has to be the same for the circuit object of this Call for Tender. The impeller shall not be the biggest one, and have to be chosen at efficiency higher than 60%.
The contractor shall define the capacity of the pump, the pressure, the flow rate and the needed power for the electrical cubicles to supply the pumps, according to the characteristics of the circuit. The supplied equipment shall allow a margin of 10% for future upgrades.
The pumps will be placed inside a heated hut, placed between the chiller and the air handling units (see schematic XXXX). The hut will be provided by CERN.
4.4.9.1 Pump SpecificationsHorizontal volute-type process centrifugal pump shall be used for distribution
circuits. Standardised to EN 22858.
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Entirely removable internal components, consisting of standardised sub-components.
Materials:Casing: Spheroidal graphite cast ironImpeller: BronzeShaft: Stainless steel, jacketedBearing: Cast ironBase: Steel or cast iron Curves (flow/pressure): to ISO2548 and ISO 9906 Class 2 Plummer block bearings: C3 class aircraft-type Bearing lubrication: Oil sump Moving parts: Static and dynamic balancing, bench tested Mechanical seal: Stuffing box (“tresses”) Coupling: Escodisc type Max. rotation speed: 1500 rpm.
4.4.9.2 Motor Type: asynchronous, 3 phases Standardisation: to IEC Construction: Standard Rated power: Calculated for maximum permissible flow-rate + 10% Voltage: 400 V Internal protection: by thermal switch Ingress Protection: IP55 Starting: Direct Frequency: 50 Hz Insulation class: F Service type: to IEC 34.1 S1.
4.4.10 Other Equipment
4.4.10.1 Screen Strainers FiltersThe circuit shall be fitted with a stainless steel basket-type filter. Each filter shall be
replaceable and include a system for disposing of accumulated waste, and the mesh size shall be 0.5 mm. To detect the fouling of the filter a differential pressure switch shall be installed.
4.4.10.2 Drain Valve and Bleeds Cocks
A drain valve shall be fitted at every low point of each circuit and automatic bleed with isolated valves at every high point.
4.4.10.3 Pressure Vessel
An expansion vessel has to be foreseen for each circuit at the aspiration of the distribution pumps, to avoid hammers and to compensate the variations of water level in the circuit.
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4.5 Cooling System MaterialsAll materials and components used in the construction shall be new and suitable for
the use for which they are intended. The specifications for the materials will be subject to approval by CERN.
The choice of any non-metallic material shall be in accordance with the CERN Safety Instruction 41.
The material for the pipes shall be certified by batch and the cast numbers are to be transferred to the material used before cutting from the stock in the presence of an independent inspection authority. Longitudinal welds are allowed exclusively for stainless steel pipes and require inspection certificate.
All the pipes of the chilled water circuit shall be insulated see Annex XXX.
4.5.1 Special Design RequirementsThe design equipment and the choice of components and material shall be adapted to
the operating conditions of the pipes, the pressure ratings and the design pressures of the fluids inside the components. Temperature variations shall not give rise to uncontrolled stresses.
4.6 Control and Regulation System
4.6.1 Equipment
4.6.1.1 PLCThe programmable controller shall consist of Siemens S7 or Schneider Premium
TSX technology modulesThe minimum configuration below shall be provided: 220 V power supply module, Siemens S7 413-2 DP CPU module (DP coupler, FlashEprom, stand-by
battery included) or, Schneider Premium TSX 57-253 CPU module (FlashEprom, stand-by battery included),
Siemens CP 443-1 TCP communication board or,Schneider Ethway TSX ETY110 TCP/IP communication module,
main rack, Siemens S7 development and communications software (STEP 7+NCM S7) -
latest versions- or,Schneider PL7-Pro software -latest version-,
I/O modulesThe Contractor shall estimate and propose the I/O composition, as well as foresee and
extension rack should it be required. The Contractor's proposal, which shall be based on the input/output lists estimated by CERN, will be submitted to CERN's approval.
The PLC will be identified by a reference subsequently given by CERN, which shall be engraved on a label secured in a clearly visible manner close to the controller.
4.6.1.2 Development softwareThe Siemens S7 development software or the Schneider PL7-Pro software, in
their latest versions, shall be included in the tender. The software used, on PC platform, shall be delivered to CERN on the date of provisional acceptance and contain all the
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communication modules (drivers) needed to develop the application programs. This software shall be supplied on CD-ROM with the users' licence(s).
4.6.1.3 Application softwareThe application software shall be developed in accordance with the standard IEC
1131.3. It shall be provided on CD-ROM in triplicate. All the variables, the sequential lines, the function blocks, the operating grafcets and the system function calls shall be clearly commented.
4.6.1.4 Operation panelThe local supervision operation panel shall be integrated in the control cubicle.
Access for the monitor screen shall be provided on the door of the control cubicle.The minimum configuration below shall be provided: Siemens SIMATIC OP 17
4.6.1.5 Instrumentation, general characteristicsThe manufacturer for all the instrumentation is at the Contractor's discretion, but must
belong to a European country which is a CERN Member State. The equipment proposed by the Contractor shall meet CERN's required general characteristics in all respects. The manufacturers' documents shall be attached to the technical tender.
The wiring between the various components shall meet CEM standards (immunity to interference and interference transmission -low voltage EN50178, IEC 1000-4-2 / EN 61000-4-2…4-5, IEC 1800-3 / EN 61800-3, EN 55022 class B-)4.6.1.5.1Flow rate and differential pressure transmitters
4-20 mA output, configuration parameters available, supplied with an integrated and switchable square extractor.The Contractor shall integrate a 3-way valve manifold for the flow rate transmitters.
4.6.1.5.2Temperature transmitters
PT100 temperature sensor, fitted on sliding union, average insertion length 100 mm, response time < 2 s, precision 0.1% of full scale, integrated transmitter fitted in the sensor head with adjustable output range, fed
by the circuit. The output current shall be 4-20 mA.The Contractor shall supply soldered unions with seals for fitting the temperature
sensors.
4.6.2 Functional and dysfunctional analysis
4.6.2.1 General description of the process operationThe Contractor shall clearly set out in the document "General description of the
operation of the process" the operating principle of the process(es), give the details of the purposes of the sub-assemblies, describe the physical principles which regulate and govern the process(es) and state the constraints inherent in each item of equipment which he is to install
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with the monitoring system. This document shall constitute a basic document for entering the functional and dysfunctional analysis stage.
4.6.2.2 Functional analysis The Contractor shall set out in the document "Functional and dysfunctional Analysis"
the functional analysis of the various processes including all the applications. This functional and dysfunctional analysis shall be given in detail and perfectly identify every task. The Contractor shall provide in the "Functional and dysfunctional analysis" document the software requirements in terms of:
Functional requirementsThe functional requirements are derived from the logical model, which is in turn
derived from the user's requirements.
Interface requirementsThese specify hardware, software or database elements with which the system, or
system component, must interact or communicate. Interface requirements should be classified into software, hardware and communication interfaces. Software interface could include operating system and software environments, file formats and other software environments.
Hardware interface requirements may specify the hardware configuration. Communication interface requirements constrain the nature of the interface to other hardware and software. This may demand the use of a particular network protocol.
Operational requirements These specify how the system will run and how it will communicate with the human
operators. Operational requirements include all user interface, human-computer interaction requirements.
Resource requirements They specify upper limits on physical resources such as PLCs processing and
communicating module power, main memory CPU module, etc.
Verification and validation tests requirementsThese specify the constraints on how the software is to be verified. They might
include requirements for simulation, emulation, live tests with simulated input output signals.
Documentation requirementsThey specify project-specific requirement for documentation.
Security requirementsThey specify the requirements for securing the system against threats to its integrity
and availability.
The Contractor may draw up, during the functional analysis stage, certain detailed parts of logic sequences in an oriented Grafcet form or in others like phase diagram, operating organisational chart or description by functional blocks.
The functional analysis shall contains the items below for the PLCs monitoring software:
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the starting and stopping sequences, the various operating modes (Remote-Local-Maintenance), the various operating options, the main automatic systems, the shared and/or dedicated sub-routines, the PID loops.
4.6.2.3 Dysfunctional analysisIn the same way as for the functional analysis, the dysfunctional analysis must be
precise and fully identify the behaviour of the process after a restart caused by power failures or breakdowns in the various components. It shall contain:
initialisation and general control phases, transient task identification, transient task sequencing.
4.6.2.4 RecommendationST division and the CV group attach particular importance to the care taken in
drawing up the "Functional and dysfunctional Analysis" document. The Contractor shall draw up a methodical analysis of the project in order to perfectly identify all possible requirements. The Contractor shall minutely identify the resources needed to perform the work and complete the on-site tests.
4.6.3 Measurements and regulation loops
4.6.3.1 GeneralThe regulators shall be of the self-adjusting PID type. The Contractor shall clearly
define the methods used for analysing the design of the high-performance regulators. Following the commissioning stage and during the operating period, the Contractor
shall demonstrate the behaviour of the regulators in closed circuit to optimise the adjustments and behaviour around the operating point.
4.6.3.2 Validation of measurementsThe measurement precision will be assessed only if it is possible to make a sequence
of measurements without any variation in the value measured during the sampling period. The number of samples shall be large enough for the mean value to be as close as possible to the value measured. The uncertainty in the measurement shall be expressed by the degree of dispersion.
The measurements shall be characterised by the degree of dispersion in the measured values (dispersion, variance). This factor is important for the assessment of a corresponding mean value.
Since the coefficient of variation (relative variance), representing a ratio between the variance and the mean value is much more significant, it may also be used to express the measurement uncertainty.
4.6.3.3 Regulation loopsThe contractor shall have characterised each one of the regulating loops according to
the items below:
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stability, assurance that the process will be controlled in any circumstances, precision with which the set value is reached and maintained, regulation rate, the time needed for the system to react to variations. A
distinction is made between the establishment characteristics applying on start-up and the continuous characteristics applying to variations from an established balance,
time delay, the time elapsing between the variation in stage and the measurement of 50% of the final one,
rise time, the time needed for measurement on a stage rises from 10 to 90% of the final value,
response time, that elapsing from the start to the time when the difference is a maximum of +5%,
peak time, that elapsing from the start of the variation of the measurement to the time when the first overshoot reaches its maximum,
overshoot, the maximum difference occurring after the set value has been reached on the application of a step,
damping, the ratio between the amplitude of successive oscillations resulting in a change of stage (change in the parameterisation).
4.6.4 TrainingThe CERN staff responsible for the use and operation shall be trained after work has
been completed and CERN takes the installation over. Training will be required for about 8 people.
The training shall enable the maintenance and operation technicians to take effective action on the installations in the event of a breakdown or any other occurrence resulting in an unscheduled stoppage of the installation.
Following this training, the CERN staff shall: be capable of very quickly diagnosing a fault on the PLC based control system, have a good knowledge of the PLC application software and the OP, be perfectly familiar with the control system structure, be able of perform all the operations concerning the use of the local supervision
(OP), be capable of loading a program in the PLC and OP.CERN and the Contractor will agree on the date on which the training is to be given.The training shall at least consist of:
4.6.4.1 General Details of the components of the hardware architecture Details and mechanisms of the software architecture Communication relationships involved
4.6.4.2 Control and regulation: the PLC Composition of the rack(s) Details of the application program Communication capabilities Loading a program in the CPU Access to the program data
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4.6.4.3 Local supervision: the OP Operation functions: process data display and organisation, default and alarms
messages management (display, acknowledgement, priority levels), function keys, alphanumeric input of set points, users' access control (passwords)
A user manual shall be prepared by the Contractor and used as training material
4.7 Schematics and DrawingsTwo schematic diagrams of all circuits subject to this Technical Specification, can be
found in drawings listed in Annex XXXX.A general implementation plan can be found in Annex XXX to which it is also
attached. This drawing is indicative for use on tendering only. It may in no circumstances be used as working or assembly drawing.
4.8 Planning and ScheduleThe schedule for the works is given in §8.1. CERN reserves the right to slightly
modify the schedule; in any case the deadlines for the completion of the works will be postponed.
4.9 Work Regulations
4.9.1 General Rules for opening a worksite at CERN ST/CV
Two weeks before starting the work a kick-off meeting shall be held between the Contractor, CERN Project Leader and Work Supervisor. The procedures for opening a worksite shall be gone through. See the following website with the attached documents:
http://cern.web.cern.ch/CERN/Divisions/ST/CV/Baseline/works/procedures/opening_worksite.html
This meeting shall be followed by a site visit to control the security aspects concerning the work. Depending on the size of the work (man hours), it may be required from the Contractor to make a risk prevention plan for CERN Technical Inspection and Safety Division (TIS). A template for that can be obtained from CERN.
Contractor is responsible for obtaining all the necessary permits for his personnel, equipment and tools. CERN will take care of the internal permits for opening a worksite (Avis Ouverture de Chantier, Permis de Feu)
4.9.2 Work AreasThe working areas attributed to the Contractor for carrying out the installation work
on the CERN sites shall not be extended without agreement of CERN; no storage of material or equipment is permitted elsewhere. The Contractor shall provide the necessary containers, fences and signs. For any movement of cars or engines, the official speed limitations valid for the different CERN areas shall be respected.
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4.9.3 Site SupervisionDuring the work, the Contractor shall provide access to the work site to all persons
appointed by CERN to supervise the work. He shall appoint a manager to represent him on the work site to supervise the personnel, equipment and the proper performance of the work. This representative shall be in a position to provide CERN with all the information it needs to monitor the work.
4.9.4 Manpower, Tooling and Assembly
4.9.4.1 Contractor’s StaffThe Contractor shall provide a list of all his staff working on the CERN sites and
their qualifications prior to the start of the work and shall ensure that it is kept up-to-date at all times. He shall be responsible for the specific training his personnel requires to work in the structures and to use the overhead travelling cranes. The certificates corresponding to this training shall be submitted to CERN. At least one member of Contractor’s staff present on site must speak French or English.
4.9.4.2 Replacement of StaffCERN reserves the right to demand at any time the immediate replacement of any of
the Contractor’s staff whose actions or behaviour or whose legal position with respect to the authorities of their home country and the competent authorities are such that they could interfere with the proper running of the worksite.
4.9.4.3 Special Tooling and EquipmentThe Contractor shall equip his assembly crew with all the necessary individual
tooling and any special equipment such as: scaffolding, ladders and special hoisting gear which they may require during assembly, as well as the instruments needed for the tests. All such equipment shall comply with EU regulations and shall be approved by an official body.
4.9.4.4 AssemblyThe assembly operations shall be performed with the greatest of care and diligence in
accordance with the contract requirements and normal trade practice. Both parties shall immediately record any interruption in the work.
4.9.5 Contractor’s Installations at CERNSpecial attention has to be paid when working inside Hall 186. All cutting and other
work that produce dust or otherwise cause impurities or excessive noise, are to be done outside in the vicinity of the hall in a place appointed by CERN. In addition, the Contractor may not store such materials as flammable packaging inside CERN buildings.
The Contractor shall foresee the beaconing of the area under the work zone and shall put all the means to avoid any material fall.
In case of work by hot points, the Contractor shall have a fire permit and must foresee the collection and treatment of the emanations from the welding spot.
If the Contractor fails to comply with the above requirements, he will be held fully liable for any resulting losses or expenses (including for example extra cleaning costs).
4.9.6 Waste DisposalThe Contractor will be in charge of the waste disposal; the Contractor shall bring all
the necessary recycle bins to sort the waste materials.
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4.9.7 Fire PermitIn order to keep risks of fire or explosion to a minimum, CERN requires application
of a special procedure (fire permit) for any work with 'hot points', that is welding, cutting, grinding etc. The local person responsible of the Contractor shall take the necessary actions to obtain the fire permit in each case. The rules are laid down in the CERN Safety Code E (Fire protection), which can be obtained on request.
4.9.8 Electricity DistributionAll electrical installations, even though they might be only temporary, have to
conform to CERN Safety Code C1 (Electrical Safety).
4.10 SafetyThe work covered by this invitation to tender shall be performed in accordance with
all the CERN safety rules in force in accordance with the provisions of the attached documents, namely Safety Regulations Applicable to the Work of Contractors at CERN [Reference CERN/TIS-GS/98-10 of May 1998], "Special Health and Safety Committee" [TIS/ES/MD/rb/89-423] and "Relations between CERN, the competent authorities in the host countries and contractors", concerning occupational health and safety on the Organization’s site" [DA-OF/RH/1850, May 1988].
In this context, they shall, in particular: Take account of all the safety rules and apply them to prevent occupational
accidents and illnesses. Take steps to ensure environmental protection. Take part with the safety co-ordinator in the prior inspection of the working
areas. Draw up and provide the safety co-ordinator with a Special Safety and Health
Protection Plan (PPSPS).All safety precautions and measures must be taken, considering: Organisational measures described in the present technical specification. The environmental conditions of the existing structures and their particular
hazards. The work to be done by the Contractor in order to protect people from injuries or
illnesses, installations and equipment from damages and environment from pollution and to avoid interference with possible other work in the vicinity.
Concerning the personnel, the Contractor will guarantee the presence of at least one rescuer-first-aid worker for every ten workers on the work site.
Contractors shall take all the necessary precautions for pipework and laying, especially:
All the necessary signs shall be set up. The premises for the staff and the work site electric switchboards shall be fitted with 30 mA differential protection
The hoisting and handling methods and gear shall be clearly defined All the protective measures required for the performance of work at height shall
be implemented.
Ten days at the latest before the start of work, the Contractor shall provide the official in charge of the contract with his PPSPS. This document shall be supplemented by a brief but adequately clear and complete description of the working methods and the protective measures
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to be implemented. The equipment and staff used shall be specified. A timetable for the performance of the various stages in the work shall also be attached.
CERN expects its Contractors to attach great importance to the observation of the (safety) rules to which they are subject and that they will take all the necessary steps to prevent their staff from suffering occupational accidents and illnesses and avoid damage to equipment, without restriction.
Any further information on the safety rules applicable at CERN may be obtained from the CERN ST-CV group and CERN TIS-GS Safety Group.
5. APPLICABLE DOCUMENTS
Please refer to the Covering Letter for the complete list of documents attached to this Invitation to Tender.
The contents of all the documents referred to below shall be applicable throughout the execution of the contract. This list is not exhaustive and serves only as a reminder of the main documents that are applicable.
The Bidder shall be deemed to be familiar with all the statutory instruments referred to in all the documents of this call for tenders and the act of submitting a tender shall imply that he agrees to comply with them in all respects.
The international (ISO) or European (EN and Eurovent) standards will be generally applied, where these do not exist, the most recent standards in force in the country where the installation is to be located will be used.
5.1 StandardsThe following standards, in order of priority, are applicable for the execution of the
Contract in addition to those specified in § 4.7.
5.1.1 CERN RegulationsThe following CERN regulations, which are applicable to the performance of the
contract, may be obtained from CERN on request. “General requirements””- ST/IE-PGI, December 1994, for electrical installations, “The Use of Plastic and other Non-Metallic Materials at CERN with respect to
Fire Safety and Radiation Resistance”- TIS/IS/41, March 1995 edition, Safety code E - fire protection, "Contractors and Their Staff – Access to and Activities on the CERN Site"
[DSU-DO/RH/1845], Safety code A3 Rev. relating to safety colours and safety signs,1992 Safety code A8 relating to protection against noise,1993 Electrical Safety Code C1., 1990 edition, Welder’s qualification [TIS/GS/GR/IR/94-01]. Inspection of welds [TIS/GS/CM/IR/95-003]. Numbering of CERN-ST drawings format of CAD/Cam files
[ST/TFM/jg(241198)]. Safety Code D1 Rev., 1997edition, relating to Lifting equipment Safety code D2 (Rev.21998) relating to pressure equipment Safety instruction IS5 relating to emergency stops,1985
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Safety instruction IS23 Rev.2 concerning Criteria and standard test for the selection of electrical cables, wires and insulated parts with respect to fire safety and radiation resistance,1993.
Safety instruction IS24 concerning regulations applicable to electrical installations (1990),
Safety instruction IS37 Rev.2 concerning regulations applicable to alarms and alarm systems (1998),
General requirements for electrical installations ref. ST/IE-PGI (December 1994),
Contractors and their staff: Access and activities on the CERN Site-DSU-DO/RH/1845,January 1995.
All the documents applicable for the execution of the contract are attached or, if not, can be obtained from CERN on request.
5.2 Supply of DocumentsAll documents shall be submitted in three copies, of which one shall be in a form
suitable for reproduction. They may be either in English or in French.All documentation has to be prepared in accordance with the relevant European or
international standards and codes. Within two weeks after receipt of a document for approval by CERN, one copy shall
be returned to the Contractor marked “approved”, or showing the modifications which may be required. If no return copy is received within 2 weeks, tacit approval can be assumed. Approval given by CERN does not release the Contractor from the responsibility of fulfilling the requirements stipulated in this Technical Specification. In the final documentation the quality and safety documents shall be separated from the other technical documents.
5.2.1 Documents in Computer Readable FormAll documentation supplied to CERN shall also be made available in computer-
readable form. The Contractor is responsible for the transfer of his documents to the mentioned formats.
All mechanical drawings shall be supplied in AutoCAD® 1 version 14.0 or later.All electrical drawings shall be supplied in SEE3000® 2
For all other documents the following software shall be used: Microsoft Word® 3 version 97 for text documents. Microsoft Excel® 4 version 97 for lists. Microsoft Project® 5 version 97 for planning.All drawings shall be introduced by the Contractor on the CERN CDD System.
5.2.2 Documents to be DeliveredThe timetable for the delivery of all documents shall be determined jointly after the
signature of the contract. The supply of the complete documentation shall be a condition for the provisional acceptance certificate.1 AutoCAD® is a registered Trade Mark of Auto Desk2 SEE3000® is a registered Trade Mark3 Microsoft Word® is a registered Trade Mark of Microsoft4 Microsoft Excel® is a registered Trade Mark of Microsoft5 Microsoft Project® is a registered Trade Mark of Microsoft
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a) Documents to be submitted for approval regularly during the period between signature of the contract and provisional acceptance of the pipework.
Every two weeks a progress report shall review the situation; this report may be replaced by minutes of a joint CERN / contractor progress meeting to be organised by the Contractor.
Major manufacturing problems or any difficulty likely to affect the agreed time schedule shall be reported immediately to CERN.
Reports on all tests carried out in the factory and at CERN, inspection reports and material certificates. Results of tests shall be reported to CERN not later than one week after the test has been successfully or unsuccessfully carried out.
b) Documents to be submitted for approval prior to any fabrication. Detailed drawings showing all components, air ducts dimensions and location. Detailed drawings showing all components, connections and valves and
indicating the sizes of pipes and valves. A detailed calculation for the mechanical resistance and thermal contraction of
the pipes. The main characteristics of all components. The calculation note of the circuits and of the equipment. Detailed drawings for electrical part and functional analysis. The delivery and tests schedule.
c) Documents to be submitted for approval prior to any test of equipment and at least two weeks prior to the first delivery to CERN.
Assembly drawings of all components with parts lists indicating the materials used with important details, main dimensions and weights.
Detailed specification and data sheets for components, in particular those supplied by subcontractors.
All relevant information on subcontracted equipment, such as copies of order, manuals, drawings, etc.
The final test programme.d) Documents to be submitted at least three weeks before provisional acceptance (on three
copies and on electronic file) The final revision of the total documentation "as built", included:
The test recordsThe materials certificatesThe operating and maintenance instructions and a list of spare parts to keep in
stock for first intervention.All drawings and technical documents according to the existing regulations.
6. QUALITY
6.1 Quality ControlThe bidder must be able to demonstrate that he has ISO9001 certification, or an
equivalent quality control certification, which is appropriate to the subject of the specification: Design and manufacture of ventilation equipment Design, fabrication, installation of duct work Design and manufacture of refrigeration equipment
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Design, fabrication, installation of pipe work Design, fabrication, installation of electrical. electromechanical and electronic
equipment.The bidder shall supply the name of the inspection agency body which awarded this
and the date of award.
7. TESTS
7.1 Tests to be carried out at the Contractor's Premises CERN reserves the right to be present or to be represented by an organisation of its
choice, to witness any tests carried out at the Contractor or his subcontractors’ premises. The Contractor shall give at least 10 working days notice of the proposed date of any such tests.
7.2 Tests to be carried out at CERN The Contractor shall produce a test protocol document to be submitted to CERN for
approbation before the starting of the works.As soon as the equipment is installed on the CERN site, the following aspects shall be
checked with a CERN responsible: The compliance of every element in the system with the approved working
drawing, the specifications and design memoranda, the compliance of the assembly work on the systems, their compliance with legal requirements and technical standards, the availability of all the documentation on the system, the identification labels for every component in every section of the ventilation
and the cooling systems (fan, filter, chillers, coils, pumps, etc.), the identification labels on air ducts and the air flow indication arrows, the identification labels on water pipes and the water flow indication arrows, graduated segments and labels for viewing the settings of dampers, labelling for electrical components and control devices, any defects in equipment liable to have been damaged in transit or assembly
(metalwork, painting, etc.). For specific hydraulic tests, see Annex 3For the electrical part, an inspection, with a CERN responsible, shall be made to
ensure that all the equipment operates properly and that the various adjustments have been correctly made. Various inspections shall be made, e.g:
Measurement of the insulation of the systems between phases, neutral and with respect to earth,
measurement of the insulation of the systems between phases and neutral, inspection of the control, protection, safety and signalling devices, phase balance check, checking and inspection of the equipotential links, check on the general operation of the installation.Before commissioning, all the cables without exception shall be inspected with
special regard to the measurement of the insulation and their marking.
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The Contractor shall provide the equipment needed for the tests. The equipment shall be calibrated in the presence of the various parties.
7.2.1 Control and Regulation System
7.2.1.1 Static Tests StageThe static tests procedure shall be implemented without the electrical supply of the
components. The control system tests procedure shall be: Check on the continuity of the programmable controller inputs and outputs. Full testing of the process measurements. Check on the automatic sequences. Safety system tests. Full testing of the supervisory application. Test on the controls. Check on the process alarms. Equipment_Controller tests.
7.2.1.2 Dynamic Tests StageOnce all the operating defects discovered during the static testing stage have been
eliminated, the Contractor shall submit to CERN’s approval, in accordance with the schedule for the other operations on the CERN work site, the date of the dynamic tests stage.
The dynamic tests stage consists of the installation tests with the electrical power for all components. The principal criteria for the dynamic tests is whether the considered installation is ready for an operational run. A period of a dynamic operation for the installation is required to show that all software and hardware meets all the requirements of Function and Malfunction draft in accordance with the specifications (see Annex 4).
7.2.2 Electricity and Air Handling SystemsThe Contractor shall provide all the necessary (officially calibrated) measurement
devices and other equipment needed for the testing.The tests will aim to check: the air flow rates to be provided and power absorbed by the ventilation system
(the corresponding effective rotation speeds will also be measured and reported); the working points for the different settings will be shown on the characteristic curves and annexed to the test protocols. The current and power consumption measured will be compared with the ratings given on the motor data plates;
the different operating modes at winter and summer settings; allowance will be made for air temperatures and humidity at the time of testing to correct power consumption.
sound attenuation measurements — Noise limits : the measurements shall be done in accordance to the requirements given in section 3.1.1 of the technical specification;
cleanliness class requested inside each rooms. the good working of the electrical power supply system for the part of contractor
responsibility.
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7.3 Non-ComplianceThe Contractor shall, at his own expense, replace any item of equipment or part of the
installation that fails to meet the specifications and documents approved by CERN or which does not reach the specified cooling capacity or their guaranteed efficiencies (COPs).
8. DELIVERY AND COMMISSIONING
8.1 Provisional Delivery Schedule Sending out IT 23rd July 2001 Bidders’ Conference 3rd September 2001 Return of tenders 1st October 2001 Award of contract end of November 2001 Start of works 7th January 2002 Component installation do be defined with Contractor Commissioning 15th March 2002 Provisional acceptance 30th March 2002
8.2 Packing and Transport to CERN The Contractor shall be responsible for the packing of the material. The Contractor
may quote the transport in his bid, but CERN reserves the right to contract the transport services itself.
If the transport to CERN is done by the Contractor, he shall ensure that the equipment is delivered to CERN without damage and any possible deterioration in performance due to transport conditions. In this case, if any damage is produced during transportation, they will be fully responsible and shall replace the damaged equipment.
8.3 Handling at CERNThe Contractor shall be responsible for all handling operations other than that
mentioned in § 2.3.All handling of material at the charge of the Contractor shall be done with equipment
conforming to TIS Safety Code D1 “Lifting Equipment”.
8.4 Working hours at CERNThe Contractor shall consider a maximum working time of 8 hours/day for 5
days/week and that there is no possibility to work at CERN on Saturdays or Sundays or during the CERN official holidays.
8.5 CommissioningAs soon as the Contractor considers that the assembly work has been completed and
the equipment is ready for operation, he shall inform CERN thereof in writing.The commissioning shall cover the following aspects: checking and operational testing of all safety devices, commissioning of electrical and control systems,
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commissioning of air-handling system, commissioning of regulated settings, checking air flow-rates, checking air-tightness of duct systems, checking the chiller cooling power, checking the chiller flow rate, checking the system performance in terms of cleanliness and atmospheric control
during a running period of one week.Instruments used for the tests shall meet manufacturing standards and shall be
perfectly calibrated.Once the acceptance tests have been satisfactorily concluded and all the terms of the
contract have been met (including the supply of technical documents, instructions for use, etc.), CERN’s duly authorised representative will grant provisional acceptance of the installation. From that date on CERN will operate and maintain the installation.
8.6 TrainingAs soon as CERN takes over the installations and at a date mutually agreed, the
Contractor shall delegate a qualified representative for a duration matching the size and complexity of the installation to instruct the operating staff in every detail of its operation and maintenance.
8.7 CleaningThe Contractor shall be responsible for daily cleaning of his work site.The Contractor shall supervise or carry out this cleaning work himself with the
greatest care, and shall be totally responsible for the work involved. In addition, he may not store such materials as flammable packaging inside CERN buildings.
The Contractor will be in charge to sort the waste material for recycling reasons (wood, plastic, iron, aluminium, copper, etc.); the Contractor shall bring all the necessary recycle bins to contain different waste materials.
8.8 MaintenanceThe Contractor shall provide a maintenance plan for the whole installation.
8.9 Acceptance and Guarantee
8.9.1 Provisional AcceptanceThe Contractor shall remain fully responsible for the installation until provisional
acceptance.Before provisional acceptance the performance tests will be done at CERN to establish
that the equipment fully meets the Technical Specification. Before acceptance the work-site and all equipment shall be carefully cleaned.
The Contractor shall, at his own expense, replace any item of equipment or part of the installation that fails to meet the specification and documents approved by CERN.
The Contractor shall ask to CERN for the provisional acceptance; provisional acceptance will be given by CERN, convoked by the CERN Project Leader only after all items have been delivered in accordance with the conditions of the contract including documentation
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referred to in this Technical Specification, all tests specified have been successfully completed and all test/other certificates and technical documentation, have been supplied to CERN.
During the provisional acceptance remarks shall be noted, and the Project Leader shall draft the hand-over certificate of the installation. If there are remarks during the provisional acceptance, modifications must be carried out within the next 15 days by the Contractor.
The guarantee period starts from the successful provisional acceptance and the length of it is defined in the commercial documents.
8.9.2 GuaranteeThe guarantee period shall be two years and be in conformity with the provisions stated
in Article 16 of the General Conditions of CERN Contracts (CERN/FC/18-14-II). The guarantee period shall commence on the date of the provisional acceptance.
The guarantee shall include the cost of parts, labour and travel.
8.9.3 Final AcceptanceFinal acceptance will take place at the end of the guarantee period, during which
time, the equipment must fully meet the CERN specification. In the event of doubt, CERN reserves the right to repeat the provisional acceptance tests.
Any deviations from the specification shall be corrected immediately at CERN at the Contractor’s cost.
9. PERSONS TECHNICALLY RESPONSIBLE AT CERN
Name Tel-Fax Email
Emma VIGO CASTELLVI
Michele BATTISTIN
Fax: +41 22 767 8767
Fax: +41 22 767 8767
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