IT-4142/EN Supply, Installation, Testing and Commissioning of the HVAC System for the New Building 107 Technical Specification M. Battistin, M. Nonis / EN-CV

The Technical Specification Structure The work is broken down in 11 work lots and the technical specification is composed of: The technical specification featuring all general technical and organisational clauses related to the contract; The requirements documents containing all specific clauses related to a given system, installation or equipment to be installed in the related work lots; The technical prescriptions containing all technical clauses related to a specific installation or equipment and applicable to all the work lots. In case of discrepancies between the present technical specification and the work lots technical requirements the most stringent requirement prevails. 2

Scope Supply, installation, test and commissioning of the following systems for the whole building: Heating/cooling production and distribution system for conditioning purposes (work lot 1); Cooling production and distribution system for process equipment (work lot 2); Air supply and conditioning systems for process related rooms (work lot 3); Ventilation system for the clean room (work lot 4); Air supply and conditioning systems for non-process related rooms such as offices, meeting rooms, changing rooms, toilets and corridors (work lot 5); Air extraction systems including air cleaning system and heat recovery system (work lot 6); Smoke extraction system (work lot 7); Hot domestic water production system and hot/cold domestic water distribution (work lot 8); HVAC system for the electrical room (work lot 9); Electrical distribution system (work lot 10); Control system (work lot 11). 3

Work Lot 1 Heating/cooling production and distribution Two reversible heat pumps … supply chilled water … and hot water … Both heat pumps are provided with desuperheaters… to be distributed to the post heating coils and to the sanitary hot water production system. In winter, as a backup system … it is foreseen to use one … heat exchanging substation…. an electrical heater … emergency system... Dedicated sets of pumps … separated circulation of hot and chilled water … 4 Work Lot 2 Cooling production and distribution for Process One air cooled chiller … on the roof supplies … chilled water … for the cooling of the process equipment.

Work Lot 3 Air Supply System for Process Related Rooms … five air handling units supply air to … EMD workshop room and EMD preparation/stock area (first floor), Electro-chemical Laboratory (mezzanine floor) and Print/QC room (ground floor) inside SF area… PCB process areas excepting Transfer Room… PCB Transfer Room… SF process areas excepting Solvent Machine Room… SF Solvent Machine Room… …air handling units … are equipped with additional pre-heating coils fed by the heat recovery system on exhausted air… workshops are maintained at under-pressure of 5-10 Pa... 5

Work Lot 4 Air Supply System for the Clean Room The clean room is class … located inside the PCB area…. The clean room is maintained at an over-pressure of 20 Pa with respect to … corridors, offices and meeting rooms… Two laminar airflow hoods shall be installed inside the clean room … locally one class 100 … and one class 1000 … zones. 6 Work Lot 5 Air Supply and Extraction System for Non-Process Related Rooms One air handling unit … supplies … all offices and meeting rooms of … SF, PCB and EMD … Air is extracted from corridors, changing rooms and toilets, flowing from non-polluted environments to more polluted ones...

Work Lot 6 Air Extraction System Four … extraction systems … exhaust the polluted air from process equipment: Cyanides; Solvents; Acids/Alkalis; General extractions and Ozone. … cyanides … two extraction fans … and one wet scrubber... … solvents … two extraction fans … heat recovery system and one activated carbons filtering unit... … acids/alkalis … two extraction fans … the heat recovery system and two wet scrubbers... … general and ozone … two extraction fans … and the heat recovery system. 7

Work Lot 7 Smoke Extraction System … SF process area … mechanical smoke extraction system … two roof smoke extractors … … activated by the control system or manually from the firemen cubicle UICN … The smoke extraction system is fed by secured power… 8 Work Lot 8 Hot/Cold Domestic Water System … produced via solar panels … on the roof… CERN’s superheated water network to integrate… dedicated heat exchanging substation… … electrical heater integrates … not sufficient power production from solar panels and unavailability of the superheated water…

Work Lot 9 HVAC System for the Electrical Room … dedicated system … temperature conditions … between 20 and 25°C … RH not controlled… … air exchange rate of 1080 m 3 /h linked to the presence of UPS batteries… 9 Work Lot 10 Electrical Distribution System Two main power distribution switchboards… … All the equipment, the control and power cubicles … shall be fed from the power distribution switchboards... The smoke extraction system shall be fed from the secured electrical network…

Work Lot 11 Controls System The controls system is composed of five control cubicles: UIAO … HVAC of the PCB area; UIAO … HVAC of the SF area; UIAO … HVAC of the clean room…; UIAO … HVAC of the offices and laboratories; UIAO … hydraulics systems… 10

Deliverables and activities Execution design; Procurement; Packing and, if requested by CERN, shipping; Assembly and installation; Test and commissioning; Quality management; Documentation. The contractor shall be aware that the detailed design documents annexed to this technical specification are provided for bidding purposes. CERN will provide a revised detailed design file with minor changes to be used for the development of the execution design at the contract’s signature. 11

Execution Design Selection of equipment and components and associated engineering activities; Provision of the execution design, manufacturing drawings and of all the documentation concerning the implementation of the detailed design provided by CERN taking into account: The selected equipment and components; The presence of other systems and services inside the building; Existing building; If the selected equipment and components lead to layout modifications, the execution design shall include checks and the re-performing of calculations; 12

Execution Design The selection of equipment and components together with the execution design shall respect weights and loads indicated in the TDCs and in the drawings (whose compatibility with the building has been already checked); The selection of equipment and components shall ensure the respect of indoor and outdoor noise limits indicated in the reference documents (see § and of the technical specification); Execution study shall include the update of the 3D model files and of the 2D drawings provided by CERN. A dedicated procedure shall be followed for the 2D and 3D drawings’ issue, exchange, review, update and approval; 13

Execution Design Concerning the metal structures, profiles and frames to interconnect the ducts/pipes’ supports to the rails system the contractor shall provide the overall design (not only execution); Concerning the HVAC system for the electrical room (WL 9) the contractor shall provide the overall design (not only execution). 14

Other Deliverables Daily cleaning of the premises and final cleaning upon completion of the work; Proper sorting and disposal of any waste……; …… daily removal of waste in separate pre-sorted skips supplied by the contractor; Protect CERN’s structures and any other equipment supplied by third parties during the installation phase……; Protect the lining inside the basins of the SF and PCB areas; Reinforce and protect the plastic gratings during the installation phase inside the basins of the SF and PCB areas (including the covering of holes for equipment); …… 15

Items and Services provided by CERN Supply of two heat pumps (WL 1) and one chiller (WL 2); Supply of two main power distribution switchboards (WL10); Handling of major metal structures, heat pumps, chiller and extraction fans on the roof; NOTE: the CERN mobile crane shall be requested by the contractor three weeks in advance and shall be confirmed at least two weeks before the handling activities. When CERN operates the crane, it is the contractor’s sole responsibility to manage and coordinate on-site activities in order to optimize and minimize CERN work. The cost of downtime of the use of the CERN mobile crane shall be borne by the contractor. The cost associated to the use of the CERN crane is 3000 CHF per day; …… 16

Specific Installation Constraints Access of components, equipment, prefabricated spools, etc. shall be foreseen through the existing doors and openings; The access to the main HVAC technical room from the parking level shall take into account the level difference and the presence of the doors’ thresholds: the level difference between the parking level and the threshold of the doors is circa 0.15 m; the level difference between the technical room level and the threshold of the doors is circa 0.45 m; 17 OUTDOOR INDOOR

Specific Installation Constraints The imposed loads of different levels of the building; The installation of pipes and ducts shall be performed when all the internal room partitions are installed: The installation of ducts, pipes, diffusers, fan-coils and in general all equipment to be integrated inside suspended ceilings shall be performed taking into account the possible presence of other installations (including, but not limited to, electrical distribution, lighting, fire detection, IT distribution, general services and suspension wires for the suspended ceiling); The installation of ducts, pipes, diffusers, fan-coils and in general all equipment to be hung on the slab separating the ground floor and the first level, shall take into account the particular nature of the slab itself (pre-tensioned hollow core slab); 18

Specific Installation Constraints The worksite layout and organization ; The phasing of the installation inside different areas shall be planned and coordinated according to CERN’s needs depending on other activities foreseen inside the building (electrical activities and civil works). Continuity between zones is not ensured; The possible coactivity with other contractors working in the same area or zone; The connection of ducts’ and pipes’ supports to the CERN rails system shall take into account that on each single rail it is admissible to hang a maximum concentrated load of 100 kg every 50 cm; 19 The contractor shall verify the flatness, horizontality and verticality of surfaces prior to installing equipment and any supporting structures: the contractor shall put in place and be in charge of all the measures to make surfaces adapted for the state-of- the-art installation of equipment and supporting structures.

On-site Installation Worksite areas foreseen for HVAC contractor’s (see Annex 1.17): Maximum weigth to access parking level: vehicles limited to 3.5 t q k = 2.50 kN/m 2 Q k = 20.0 kN (A = 0.1 m × 0.1 m) H k = 10.0 kN The lighting (indoor and outdoor) shall be provided by the contractor m 2 at parking level 400 m 2 at ground level

Planning The single dates and milestones of the planning (lines 316 to 379 inclusive, see Annex 1.1) shall be respected: otherwise subsequent interventions could be affected causing a deep impact on the schedule of the whole project; Penalties are applicable. 21 Lining installation Intermediate tests LS2

Intermediate Tests Intermediate acceptance inspections shall be organized in order to allow proper control and test while the plants are still fully accessible and inspectable and in order to put in place corrective measures and modifications progressively; Intermediate and final acceptance inspections will be defined by CERN only after receiving the relevant as-built documents; …… 22 Test at CERN and commissioning The contractor shall carry out …… all the …… tests and inspections …… and take the necessary corrective measures …… within the contract schedule; All the tests and inspections shall be registered on concerned quality control plans ……; The performance test ……. split in two different phases ……. the winter performance test ……. the summer performance test, which shall be performed during the normal operation of the facility; ……

Contract Follow-Up The contractor shall send a written progress report to CERN at least every two weeks until completion of the contract …… including in particular: Actual progress of activities in comparison to scheduled progress (including the update of the Earned Value Management form provided by CERN); Updates of Safety documents. The EVM format provided by CERN (circa 50 rows) shall be improved by the contractor according to the detailed development and organization of the activities. 23

EVM document 24

Update of Tender Documents The following documents are updated and are sent with the minutes of the bidders conference: Detailed Quantitative Estimates: WL 5: addition of ceiling diffusers; WL 6: addition of two fire dampers; WL 10/11: modifications of some cables’ sections, variation of some cable lengths and of typology of cable carriers; I/O lists; P&IDs of extraction systems: addition of two fire dampers; These documents given are added to the existing provisions, amend them or replace them according to the situation. 25

Update of Tender Documents Concerning the control cubicle UIAO the following clarifications shall be taken into account: Dimensions of the cubicle shall be increased because of components to be implemented like, but not limited to, PLC output interface relays, additional PLC I/O cards, additional terminals for spare I/O’s; Hardwired interlock circuits for the emergency stops shall be added; Interface relays for all digital outputs shall be added; 32 digital input signals shall be added; 8 digital output signals shall be added; 4 analog input signals shall be added; Hour counters for the AHU fan motors shall be added; Connection of spare I/O’s shall be connected on terminals. 26

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