DO-29161/EN Provision of Engineering Services in Heating, Ventilation and Air Conditioning for Building 107 Project R. Bozzi, M. Nonis / EN-CV

DO-29161/ENProvision of Engineering Services in Heating, Ventilation and Air Conditioning for Building 107 Project

R. Bozzi, M. Nonis / EN-CV

http://cern.ch/

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Overview

• Introduction to the Project• Technical Specification

The B107 ProjectRoberto A. Bozzi / EN-CV-PJ

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The B107 Project• CERN runs in-house facilities

dedicated to the:

• Surface finishing (SF) treatments, like cleaning of components, electrochemical deposition and electrochemical polishing of accelerator and detector components.

• Electronic module design (EMD) dealing with the assembly of the design and assembly electronic modules and components.

• Printed circuit board (PCB) manufacturing.

• These installations are now located in building 102: they are becoming obsolete and it is more and more difficult to maintain the existing facility while complying with present safety and environmental standards.

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The B107 Project

All these activities deal with surface finishing of components and have similar requirements and infrastructure in terms of air extraction and wastewater treatment.

CERN has therefore decided to group both activities into a single new building (Building 107), which is currently being built on the Swiss CERN site, near the recently commissioned wastewater treatment plant (building 676).

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The B107 Project

3D view of the new Building 107 from the south

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The B107 Project

Layout of the B107

SFPCBE

MD

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The B107 Project

• SURFACE FINISHING AREA: This area is approximately 1480 m2 with process tanks and pits and rinsing basins of various depths between 1 and 4 m, chemical storage rooms, workshops and toilets, etc. The process tanks and pits are serviced via five overhead gantry cranes. There is also a 270 m2 mezzanine floor (level +4.320) with offices, a lab and technical service rooms.

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The B107 Project

• SURFACE FINISHING AREA: This area is approximately 1480 m2 with process tanks and pits and rinsing basins of various depths between 1 and 4 m, chemical storage rooms, workshops and toilets, etc. The process tanks and pits are serviced via five overhead gantry cranes. There is also a 270 m2 mezzanine floor (level +4.320) with offices, a lab and technical service rooms.

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The B107 Project

• PRINTED CIRCUIT BOARD AREA: This middle part of the building has a surface area of approximately 1450 m2, with three process areas with retention basins of around 1 m depth, workshops, one clean room, test areas, toilets and conference rooms, etc.

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The B107 Project

• ELECTRONIC MODULE DESIGN AREA: the ground floor (level +2.700) is an administrative area of approximately 400 m2 including a design office. The first floor (level +7.560) is around 350 m2 and will house an assembly workshop and a storage. room.

FIRST FLOOR

GROUND FLOOR

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The B107 Project

• THE CV TECHNICAL ROOM: the remaining part of the first floor (level +7.355) consists of a parking deck and various technical service rooms for electrical and HVAC equipment.

630 m2 circa

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The B107 Project

• THE ROOF: it is foreseen to install the solar panels (west side) and some HVAC equipment as chiller and heat pumps (east side).

The Technical SpecificationM. Nonis / EN-CV

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Scope

• Design studies related to the following systems for the whole building:• Heating production and distribution;

• Cooling production and distribution for process (15 users for unit power from 2 to 10 kW) and ventilation purposes (chilled water);

• Domestic and process cold/hot water production and distribution;

• Process ventilation (fresh air supply, extraction, air recycling);

• Ventilation of all premises;

• Air treatment and filtration before reject;

• Heat recovery;

• Smoke extraction.

• N.B: “system” includes – for each of the above mentioned items – the related Electrical plants and Instrumentation & Control plants.

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Phases

Phase 1: Preliminary design.

Phase 2: Detailed design and provision of tender documents.

Phase 3: Assistance during invitations to tender and comparison of bids.

Option: Phase 4: Assistance during construction.

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Phase 1: Preliminary design

1. Analysis of all existing documents and work

2. Take into account the following constraints:• The main structure of the building is already done;

• Existing parts: external metallic support framework, the building basement, and the ground floor roof slab that is the floor of the raised car parking and of the Technical Room; the holes in this slab for the passage of ducts, pipes and cableways are already done;

• Compatibility with process equipment and infrastructures in workshops;

• All the agreements delivered by the Swiss authorities to CERN, as defined in the documents presented to obtain the Building Permit Authorization.

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Preliminary design (cont)

• The preliminary design shall include:

• The definition of general criteria applicable for the selection and sizing of systems equipment and distribution circuits:

• Noise limits

• Air exhaust quality

• …..

• Availability requirements: equipment redundancy and/or electric supplies

• Modes of operation (i.e.: on/off or proportional), ranges of regulation

• Fire Safety requirements

• The definition of the ATEX zones

• The definition of HVAC zoning and thermal / air balances, air treatments (temperature and / or humidity control, particulate and / or gas removal) in conformity with CERN Safety rules (for fire compartmentation, ATEX etc.)

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• The selection and sizing of the main equipment and components for each system (i.e. AHU, chillers, wet scrubbers, ...), including dimensions and weights;

• The definition of control and monitoring requirements: preliminary version of functional description …

• The preliminary P&ID for each system;

• The preliminary block diagram of the Control System and of the Electrical System;

• A report with a preliminary assessment of the safety file of the systems:

• Abnormal conditions and scenarios of the ventilation system

• Fail safe and reliable detection of abnormal conditions

• Strategies and measures to prevent and minimize dangerous abnormal conditions and scenarios

• The definition of interfaces with power supply distribution

• The definition of interfaces with fluid systems

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• Preliminary drawings (2D/3D models, layouts, sections and sketches) aiming to the:

• Definition of a first equipment layout

• Definition of power and control cubicles layout

• Definition of main ducts, piping and cables passages

• Highlighting accessibility requirements for erection, operation and maintenance

• Estimate of the construction costs within a ±20% margin

• A general schedule for the construction, deadlines and execution (respecting CERN’s main schedule of the project)

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Phase 2: Detailed design

The preliminary design shall be used to validate the proposed solutions.

• Detailed design for each system and in particular the following documents:• A technical report with the detailed description of the systems

(scope, operating parameters, equipment, components, materials, etc.) …the HAZOP analysis and the final definition and assessment of abnormal conditions and scenarios, their detection and the strategies/measures to prevent and minimize dangerous abnormal conditions and scenarios;

• The balance diagram of all systems (with main operating parameters such as flow rates, pollution, temperatures, heating/cooling powers);

• Calculation notes with the sizing of each component and equipment (standard material available on the market);

• Piping and instruments diagram.

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Detailed design

• Detailed functional descriptions, functional and safety interlocks, HMI, comprehensive lists of interfaces of field elements and electric supplies with control and monitoring system;

• The list – for each power distribution cubicle – of the electrical equipment and users and the evaluation of the overall electrical power absorption;

• Complete instrument lists, complete I/O list for control PLCs;

• Wiring diagrams of power and control cubicles;

• Data sheets of equipment, components and instruments (where requested by CERN for maintenance reasons, the contractor will already indicate the selected manufacturer, model and part number);

• …

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Detailed design

• Structural calculations of main brackets, supports and carpentries

• Acoustic impact assessment ….outside the building and ….. inside the working spaces and technical rooms

• Detailed working drawings (2D/3D models, layouts of all equipment, cubicles and air/fluid distribution networks, definition of interfaces with process devices …..) and all construction details (including detail of brackets, supports, carpentries, connections to equipment, etc.)

NOTE: the detailed drawings shall also foresee the study of the routing and dimensions of electrical cable trays.

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Detailed design

• The list of deliverables to be produced by the suppliers of the different systems;

• The Factory Test Plan, identifying which equipment (AHUs, scrubbers, cubicles, etc.) shall be tested, in which phase and the tests to be performed;

• The Overall Acceptance Test Plan, identifying the tests foreseen on site with the relevant procedure and the test equipment;

• A detailed quotation ( ±10%);

• A detailed Description and Quantity Estimate (DQE) for each system.

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Phase 3: Assistance during IT

• The tendering phase will be directly managed by CERN;

• Assistance to CERN in answering the requests for clarification and modifications of technical solution adopted, if needed.

• Upon reception of the tenders:• A comparison of the bids as well as analysing the

variants proposed by the firms (if any);

• Validation of the technical compliance of two bids to CERN tendering documents and of the technical solutions proposed.

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Phase 4: Assistance during constructionOPTIONAL

Subject to CERN’s prior written confirmation, the contractor shall perform the following services:• Verification that third parties’ manufacturing and as-built

drawings are compliant with the engineer’s drawings;

• Checking the use and implementation of materials and equipment as prescribed;

• Monitoring of the work execution (quality, respect of schedule and design etc.);

• Safety inspections and supervision of the worksite;

• Validating the firms’ work progress and invoicing, assisting CERN in settlement of claims;

• ……….

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Assistance during construction

• Management of changes suggested by the construction contractor in charge of the work or by CERN and related documentation, including:• The variants for execution and the corresponding

construction procedure, including the technical control and evaluation of the firm’s proposals for execution and details;

• Verification of the necessity of changes to the design as the execution progresses;

• A guarantee that the project documents are kept up-to-date.

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Summary table CERN CONTRACTOR Phase 1 - Preliminary design Analysis of existing dossiers and documents X Definition of general design criteria X Definition of ATEX zones X Definition of HVAC zoning, thermal/air balances and air treatments X Calculations and sizing of the systems X Definition of control and monitoring requirements X Provision of piping and instrument diagrams for all systems including block diagrams of Control System and Electrical part. X Assessment of the safety file of the systems X Definition of interfaces of the systems (both on electrical side and on fluids/gases side) X Provision of drawings (layouts, sections, sketches) X Costs estimate X Provision of general schedule X Design validation X

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Summary table CERN CONTRACTOR Phase 2 - Detailed design Provision of Technical reports X Provision of balance diagram of the systems and Piping and instrument diagrams X Provision of calculations and sizing of the systems X Provision of functional description of. the systems X Provision of list of electrical and control equipment (instruments and I/Os) X Provision of wiring diagrams of power and control cubicles X Provision of data sheets of equipment, components and instruments X Provision of structural calculations of brackets, supports, carpentries and networks X Provision of acoustic impact assessment X Compliance matrix X Provision of drawings (layouts, sections, sketches) and construction details X Definition of list of deliverables for the installation phase X Provision of tests procedures and plans (Factory Test Plan, Overall Acceptance Test Plan) X Costs estimate X Detailed Quantity Estimate X Design validation X Bid's documents preparation X X

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Summary table

CERN CONTRACTOR Phase 3 - Tendering Invitations and bidders conference X Answers to bidders' questions X X Technical analysis/comparison of bids X X Validation of the technical compliance of bids X Adjudication of the contract X

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Summary table

CERN CONTRACTOR Phase 4 - Construction phase (as an option) Contract management X Verification of manufacturing drawings X Management of changes suggested by the construction contractor or by CERN X Verification that project documents are kept up-to-date X Verification of works execution (quality, respect of schedule and design, use and implementation of materials and equipment as prescribed, etc.) X Safety inspections and supervision X X Validation of works progress and invoices X Assisting CERN in settlement of claims X Assistance/validation during tests and commissioning X X Verification of as-built dossiers X Final acceptance X

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Drawings, 3D models

• Drawings and 3D models provided by CERN:• CERN will provide to the contractor 3D models in

CATIA format, 2D models in dwg format; alternatively CERN can make available to the contractor 3D models in IGS format.

• Drawings and 3D models provided by the contractor:• All drawings shall be issued by the contractor with

AutoCad (Release 2010 as minimum) or CATIA.

• In case the contractor will use AutoCad, the exchange file format of the 3D drawings with CERN shall be the IGS format.

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Meetings at CERN

The contractor shall attend various inspections and meetings on the CERN site: Phase 1:

• coordination meetings with CERN (every week);

• checking of the basic data, geometry and constraints imposed, and assessment of the areas in which the work is being integrated and performed

Phase 2:

• coordination meetings with CERN (every week);

Phase 3:

• n. 4 meetings with CERN and bidders;

Phase 4 (optional services):

• weekly worksite meetings (coordination and/or with construction contractor);

• day-to-day monitoring of the execution of the work.

• Contract meetings

• Ad hoc meetings

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Schedule Compulsory technical visit

(as defined in section 1.2.2 of the tender form): 2nd March 2015

Deadline for submission of bids: 31st March 2015

Estimated date of contract adjudication: 6th April 2015

Phase 1

o Estimated duration: 2 months

o Estimated date for the end of phase 1 8th June 2015

Phase 2


o Estimated date for the end of phase 2 29th September 2015

Phase 3


o Estimate date for the end of phase 3 30th January 2016

Phase 4


o Estimated start date of the HVAC work: 1st August 2016

o Estimated end date of the HVAC work: 1st August 2017 Estimated end date of commissioning of HVAC: 1th October 2017

Please note that phase 1 and phase 2 could be not consecutive.

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Safety coordination

• The execution of the contract shall be subject to safety coordination for the provision of services (Category 2 work).

• A risk prevention plan must be drawn up jointly by CERN and the contractor at CERN’s initiative (see Section 3.1 of the document “Working on the CERN site”).

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Training

• The contractor must train his personnel in Safety matters.

• Members of the contractor’s personnel working on the CERN site must complete CERN’s online safety awareness courses according to their activity and the areas that they will have to access.

• Bidders may consult Chapter 2 of the document “Working on the CERN site” for more information.

• The Contractor must also ensure that his employees have completed the safety training required by the Host States.

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Project team

• The contractor shall ensure that the project team possesses the appropriate qualifications and professional skills required for its proper execution.

• In particular, the project manager for the mandate must possess the following qualifications as a minimum:• be an experienced university graduate in mechanical

engineering with at least 5 years of experience in design of HVAC for industrial plants with chemical products;

• good knowledge or capability to acquire it of standards and Swiss applicable laws on ventilation and environment;

• proven experience in design studies and project management of similar size and complexity.

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Project team

• The other minimum qualifications for the other members of the team are: Electrical Engineer

be an experienced university graduate in electrical engineering with at least 5 years of experience in design of electrical plants for ventilation systems;

Draftsman

be a technician with at least 5 years of experience in design of HVAC systems for industrial plants;

• The contractor shall be able to provide additional people to the project team, if so requested by CERN for a limited duration in time; the minimum requirement is to have an experience of at least 2 years in the specific role he is covering in the frame of the services.

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Documents Refer to annex B

Before the adjudication of the contract the documents will be updated

AUTORISATION DE CONSTRUIRE - AUTHORITY ACCEPTANCE

Document title Document ref. Rev Date

Autorisation de Construire DD 104704-2 \ 12-Jul-12

Preavis DG EAU \ \ 20-Feb-12

Preavis energetique (ScanE) \ \ 24-Jan-12

Preavis SEN \ \ 04-Jun-12

Courrier OCEN MF/14.51.2.58a/mf \ 19-Jun-13

EQUIPMENT INFORMATION


BLD 107_Equipment Plan View ---.CE-1.0107.0016A \ 03-Feb-15

Extraction data \ \ 27-Jan-15

Room Design Conditions \ \ 01-Jun-12

CERN Building 107 Smoke extract SF-area 9W3961-W61/R0

0116/JHO/adr/Nijm \ 14-Mar-2014

EN/CV TECHNICAL PRESCRIPTIONS


Annex 1 - Technical Prescriptions for HVAC \ (*) \ Annex 2 - Technical Prescriptions for Pipework and Accessories EDMS n. 1271865 v.6 11-Feb-2015 Annex 3 - Technical Prescriptions for Control and Regulation \ (*) \

Annex 4 - Technical Prescriptions for Instrumentation \ (*) \

Annex 5 - Technical Prescriptions for Electricity \ (*) \

Annex 6 - Technical Prescriptions for Identification \ (*) \

Annex 7 – CERN electrical parameters \ (*) \

Questions and answers