DBR for HVAC

Sheet 1 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru

Client Location Consultant

: Hindustan Coca-Cola Beverages Pvt. Ltd. : Bidadi, Bengaluru : ANA Design Studio Pvt. Ltd.

FINAL HVAC DESIGN BASIS REPORT

CONTENTS Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Section 11 Section 12 Section 13 Section 14

1.0

: General : Specific Design Notes : Building Description : Scope of Work : Standard & Codes : Geographical Details : Input Data - Basis of Design : Cooling Loads : Design Considerations : HVAC System Design : Controls : Energy Conservation : Items to be provided by other agency : Water Requirement

General:

Document No. HVAC/DBR-0

Revision No. R2

ANA DESIGN TEAM Prepared By Checked By Approved By Subhas Satish Amin

Date 22.09.2012

Sheet 2 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru This report outlines the system design, basis of design, and cooling load summary of the HVAC system. The report has been prepared based on the information furnished and the standard data available. While the basic system design is not likely to change, the rating and specification of the main equipment may change after firming up the detailed engineering. 2.0

Specific Design Notes: Chilled Water Plant:

Ammonia based chillers are proposed as Ammonia being most environmental friendly gas having Zero ODP and GWP rating. 2 Nos. of 350 TR capacity Ammonia Screw type chillers (both working) with minimum two compressors shall be housed in the space provided in the utility block. Ammonia chillers shall be water cooled type and separate cooling tower shall be installed near to the chillers for condenser cooling. Chilled water pumping system shall be proposed to be variable secondary pumping system for the energy saving purpose. Chilled & Condenser water pumps shall be centrifugal horizontal split casing back-pull out type for the ease of maintenance purpose. Cooling tower shall be forced draught type. Condenser & evaporator will be PHE type. Chiller plant shall have hot well and cold well capacity to provide back-up for min-10-15 minutes. Filler and sugar syrup process water requirement shall be fed from individual VFD based secondary pumping system based on the output parameters as below required by client. Cooling Load required for Process Area (Input provided by client): a) Filler - Flow - 55 KL/ hr., Inlet Temp. : 32 Deg.C b) Sugar Syrup - Flow - 15 KL/ hr., Inlet Temp. : 55 Deg.C

Outlet Temp. : 10 Deg C Outlet Temp.: 25 Deg C

Process Area (double height):

Separate double skinned 2 stage evaporator cooler (in mechanical spaces) with minimum filtration of 20 micros shall be provided for sugar area like CIP, Sugar dissolving, and Ready Syrup with food grade PIR ducting / rectangular ducting. 20 ACPH needed for Ready Syrup & Sugar Dissolving & 25 ACPH for CIP room needs to be maintained.2 stage evaporator cooling shall be provided for spot cooling too for the cooling purpose. ACPH shall be cross checked against the heat load calculations and whichever is higher shall be taken for maximum air flow. 2 stage evaporator exhaust will be provided through the Cabinet type DIDW backward curved fan with SS rectangular ducting inside process area. . A mechanical exhaust system will be provided for Chemical Store area to extract any fumes with 15 ACPH. Process line Panel room: This room shall be provided air-conditioning by means of Hi-wall DX type units as per client requirement. Kitchen:

DIDW inline centrifugal Exhaust fan will be provided for kitchen area. Kitchens shall be kept at negative pressure. Since there is no cooking in kitchen area, air scrubber is not considered. No fresh air will be provided for kitchen as fresh air shall be from open area only.

Processing Area:

Document No. HVAC/DBR-0

Revision No. R2

ANA DESIGN TEAM Prepared By Checked By Approved By Subhas Satish Amin

Date 22.09.2012

Sheet 3 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru By looking at favorable natural weather condition at the location, we are proposing Natural Ventilation system for process area at 12 ACPH. As per weather data available average wind speed through the year is 2.8 m/s and wind flow direction is mostly from south and west face of the building. Fresh air entry shall be provided at 1 Mtrs. from FFL at west and south side walls by means of Al. extruded fixed type gravity louvers with bird screen at the face. Exhaust opening will be provided at the opposite side of the fresh air entry and at the top level of building wall. This will create buoyance and stack effect of natural phenomenon of natural ventilation. In addition to this Turbo ventilator fans shall be provided at the roof level for natural exhaust purpose. The external face of the louvers for Natural Ventilation will be covered with wire mesh of not more than 6 mm to prevent entry of Birds/ Insects into premises. Additionally turbo-ventilator fans of 2164 CFM x 92 nos shall be provided at roof sheet for natural exhaust @ 4 ACPH. Natural ventilation area provided will meet the requirement of natural smoke ventilation as per clause mentioned in NBC-2005.( ACPH at 12 to be maintained as per the clause). (Pls refer separate attached calculation sheet for detailed calculations). Note: Actual CFD (Computational fluid Dynamics) analysis to be carried out for natural ventilation scheme to know the exact Air flow pattern &behavior.

A mechanical ventilation system shall not be provided as per client requirement. The external face of the louvers for Natural Ventilation will be covered with wire mesh of not more than 6 mm to prevent entry of Birds/ Insects into premises. 2 stage evaporator cooler spot cooling (at the location suggested by client) with round ducting and SS made jet nozzles with 26/28 Gauge SS Cladding on insulation will be provided for the human spot cooling purpose. Ducted exhaust shall be connected from outlet of Class 10,000 Enclosure of blow moulding section of the combil line to the outside of building. 1) Direct exhaust from exhaust hood as per the location suggested by client with SS ducting without external exhuast fans as confirmed by client(Enclosure shall be supplied along with exhaust fan only) Process Storage Area:

Natural ventilation cum smoke ventilation scheme adopted for processing area shall be maintained in the storage area. Mechanical ventilation shall not be there as a substitute as its non- critical zone used for storage. Server Room

Separate DX HI wall type Units (1 working + 1 standby) will be provided. This room shall be designed at temperature of is 22 +/-2 Deg. C.

Quality & Micro Lab

Document No. HVAC/DBR-0

Revision No. R2

ANA DESIGN TEAM Prepared By Checked By Approved By Subhas Satish Amin

Date 22.09.2012

Sheet 4 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru The Quality Lab Area & Micro Lab will be 24 hrs. working. The air conditioning will be through separate wall mounted DX-split units. A mechanical exhaust system will be provided for the Micro Lab as per the standards provided by client. Whole lab AC and ventilation shall be as per the standard inputs provided by client. All lab shall be designed at temperature of is 22 +/-2 Deg. C. Concentrate Room

The concentrate room shall be as per Cold room application. Cold room shall be broadly designed based on the following inputs provided by client: 1) type of product required inside the room-Dry and wet 2) Product Entry temperature - 30 +/-2 Deg. C . 3) Product Final temperature required 4 Deg. C 4) Product Final temperature required for dry part - 22 Deg. C 5) Pull down / Cool down time required - 24 hrs 6) Daily turnover of Product (Fresh load) / Day - 2 MT ( both dry and wet parts) 7) No. of door opening / Day - 8-10 times 8) Occupant load –03 Nos 9) Size of room – As per Architectural scheme. 10) Design ambient temp- 40 Deg. C 11) Consumption /day – 2MT Offices, Reception, Training Room, Meeting Rooms & Supervisor Office

The air-conditioning in Main Reception, Admin Office, Shipping Office, Training Room, and meeting rooms & Supervisor Office will be through individual Hi-wall type DX Units. All this area shall be designed at temperature of is 24 +/-1 Deg. C Shelf Life

The Shelf Life area will be used for the sample storage; hence air conditioning will not be required, though the natural ventilation will be provided by means of louvered opening with bird screen. Loading /Unloading Area:

High velocity air curtains shall be provided at the entrance level to prevent birds /insects entry inside the premises. Utility block : This block shall be provided with Tube axial fans for mechanical exhaust with GI ducting. No fresh air fan shall be provided for this as fresh air shall be drawn through open area or through mesh shutter. Fresh Air provision:

Fresh air shall be provided as per ASHRAE standard /NBC -2005 codes to the area.

3.0

Building Description:

Document No. HVAC/DBR-0

Revision No. R2

ANA DESIGN TEAM Prepared By Checked By Approved By Subhas Satish Amin

Date 22.09.2012

Sheet 5 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru The Bottling Plant is proposed to be built for Coca – Cola at Bangalore. The building details are as follows :

2 stage evaporator

cooling area

AC AREA

FLOOR

Naturally Ventilated area

Mechanical Exhaust

Reception Meeting Rooms

Utility Block

Quality Area Shelf Life Micro Lab Lobby (double Height

Concentrate Store (cold room)

Lobby Ground Floor

Chemical Room

CIP Room

Process line panel room

Ready Syrup Sugar Dissolving

Factory Process Area

Labeling area, Shrink packer/Palletiser (spot cooling)

Cafeteria sitting arrangement area

Cafeteria kitchen area

Admin Office Training Room

Engineering Store

Server Room First Floor

Supervisor Office Packing Material Store Lobby (First Floor) Sugar Store Toilets

4.0

Scope of Work:

Document No. HVAC/DBR-0

Revision No. R2

ANA DESIGN TEAM Prepared By Checked By Approved By Subhas Satish Amin

Date 22.09.2012

Sheet 6 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru To design a “round the year” air conditioning system to maintain comfortable conditions inside the building. The scope of work for HVAC work would include the following: a. b. c. d. e. f. g. h.

Water Cooled Screw type Ammonia water Chilling Units with Hot and cold vessel.(High side) Chilled Water Pumps with variable pumping secondary circuit. (High side) Condenser cooling tower with condenser water pumps (High side) 2 S t a g e e v a p o r a t i v e cooler Units (Double Skinned) Centrifugal/Axial Flow Fans/double skin cabinet type DIDW centrifugal fan Chilled Water & condenser water Piping including valves & fittings Air distribution system including duct work, grilles, diffuses, fire dampers etc. O–Class Anti-bacterial, Food grade Nitrile rubber Insulation work for piping and ducting including Acoustic work j. Automatic Controls. k. Electrical panels & cabling work etc. for A.C system from one single point provided by client. l. Natural ventilation work. m. VFD drives with VFD bypass starter panels for all equipments like pumps , 2 stage evaporator coolers , fans etc.

5.0

Standard & Codes: The applicable standards / codes are:a. American Society of Heating, Refrigeration and Air-Conditioning Engineer (ASHRAE STANDARD – 90.1–2010, 62.1–2010) b. National Building Codes – Building Services-NBC- 2005 c. Indian Society of Heating, Refrigeration and Air-Conditioning Engineer (ISHRAE). d. British Standard

6.0

Geographical Details: Location: Bangalore lies in the southeast of the South Indian state of Karnataka. It is in the heart of the Mysore Plateau (a region of the larger Precambrian Deccan Plateau) at an average elevation of 900 m (2,953 ft). It is located at 12°58′N 77°34′E 12.97°N 77.56°E and covers an area of 741 km² (286 mi²).The majority of the city of Bangalore lies in the Bangalore Urban district of Karnataka and the surrounding rural areas are a part of the Bangalore Rural district. The Government of Karnataka has carved out the new district of Ramanagara from the old Bangalore Rural district. The topology of Bangalore is flat except for a central ridge running NNE-SSW. The highest point is Vidyaranyapura Doddabettahalli, which is 962 m (3,156 ft) and lies on this ridge. No major rivers run through the city, though the Arkavathi and South Pennar cross paths at the Nandi Hills, 60 km (37 mi.) to the north. River Vrishabhavathi, a minor tributary of the Arkavathi, arises within the city at Basavanagudi and flows through the city. The rivers Arkavathi and Vrishabhavathi together carry much of Bangalore's sewage. A sewerage system, constructed in 1922, covers 215 km² (133 mi²) of the city and connects with five sewage treatment centres located in the periphery of Bangalore. In the 16th century, Kempe Gowda I constructed many lakes to meet the town's water requirements. The Kempambudhi Kere, since overrun by modern development, was prominent among those lakes. In the earlier half of 20th century, the Nandi Hills waterworks was commissioned by Sir Mirza Ismail (Diwan of Mysore,

Document No. HVAC/DBR-0

Revision No. R2

ANA DESIGN TEAM Prepared By Checked By Approved By Subhas Satish Amin

Date 22.09.2012

Sheet 7 of 15

FINAL HVAC DESIGN BASIC REPORT

Client: Hindustan Coca-Cola Beverages Pvt. Ltd , Bidadi, Bengaluru 1926–41 CE) to provide a water supply to the city. Currently, the river Kaveri provides around 80% of the total water supply to the city with the remaining 20% being obtained from the Thippagondanahalli and Hesaraghatta reservoirs of the Arkavathi river. Bangalore receives 800 million litres (211 million US gallons) of water a day, more than any other Indian city. However, Bangalore sometimes does face water shortages, especially during the summer season- more so in the years of low rainfall. A random sampling study of the Air Quality Index (AQI) of twenty stations within the city indicated scores that ranged from 76 to 314, suggesting heavy to severe air pollution around areas of traffic concentration. Bangalore has a handful of freshwater lakes and water tanks, the largest of which are Madivala tank, Hebbal lake, Ulsoor lake and Sankey Tank. Groundwater occurs in silty to sandy layers of the alluvial sediments. The Peninsular Gneissic Complex (PGC) is the most dominant rock unit in the area and includes granites, gneisses and migmatites, while the soils of Bangalore consist of red laterite and red, fine loamy to clayey soils. Vegetation in the city is primarily in the form of large deciduous canopy and minority coconut trees. Though Bangalore has been classified as a part of the seismic zone II (a stable zone), it has experienced quakes of magnitude as high as 4.5. Climate Bangalore experiences a tropical savanna climate (Köppen climate classification Aw) with distinct wet and dry seasons. Due to its high elevation, Bangalore usually enjoys a more moderate climate throughout the year, although occasional heat waves can make things very uncomfortable in the summer. The coolest month is December with an average low temperature of 15.4 °C and the hottest month is April with an average high temperature of 32.8 °C. The highest temperature ever recorded in Bangalore is 38.9 °C(recorded in March 1931) and the lowest ever is 7.8 °C (recorded in January 1884). Winter temperatures rarely drop below 12 °C (54 °F), and summer temperatures seldom exceed 34–35 °C (