25-0454 CHILLER REPLACEMENT - SOW.pdf

Project #: 25M107CN

MACC # 25-0454

TITLE: Chiller Replacement Bldgs. 1005, 1, PP100, and PP200

ATTACHMENTS:

Chiller SpecificaƟons and Basis of Design

LocaƟon Maps

Loop Clean Procedures

Site Photos

GENERAL DESCRIPTION:

Replace Chillers at the following buildings:

Building 1 – 101 nominal tons. Tag Data A ached. The exisƟng Chiller is currently in operaƟon. Verify operaƟon of exisƟng equipment controls. The Chiller is to be turned over to the Government. The contractor must include logisƟcs, to the Government lay-down yard on Railroad Rd (by car wash) for the demo-ed chiller. It is the responsibility of the contractor to verify that the equipment pad and the piping configuraƟon is compaƟble for the new equipment. The contractor can uƟlize exisƟng valves and piping, if compaƟble. The contractor will be required to install a balancing valve at the chiller. The contractor must confirm that the exisƟng electrical service is sized appropriate for the new equipment. If compaƟble, the equipment disconnect and load-side can be re-used. The exisƟng heat tracer controller and wiring can be retained for use with new piping (funcƟonal test will be performed prior to installaƟon of pipe insulaƟon)

Buildings PP100 & 200 – (Buildings are idenƟcal except exterior electrical disconnect) 1- 70 ton chiller at each building

70 - nominal tons. TAG Data A ached. The exisƟng Chiller is currently in operaƟon. Verify operaƟon of exisƟng equipment controls. The contractor is to noƟfy PWD prior to removing the chillers from the jobsite to allow recovery of any usable parts. Replace all piping above ground piping. Provide tees and buƩerfly valves for Emergency ConnecƟons. It is the responsibility of the contractor to verify that the equipment pad is large enough for the new equipment. Pad enlargement and addiƟonal piping is responsibility of the contractor. The equipment disconnects and load-side wiring are to be replaced. Provide freeze protecƟon on all exterior piping (funcƟonal test will be performed prior to installaƟon of pipe insulaƟon). Replace Chilled

Water Pumps, Disconnects and VFD’s. Photos and schedules are aƩached. It is the Contractor’s responsibility to provide equipment compaƟble with the building’s control system.

Building 1005 – 100 nominal tons. Tag Data AƩached. The exisƟng Chiller is currently in operaƟon. Verify operaƟon of exisƟng equipment controls. The contractor is to noƟfy PWD prior to removing the chillers from the jobsite to allow recovery of any usable parts. Replace all piping above ground piping. Provide tees and buƩerfly valves, with bolt-on flanges) for Emergency ConnecƟons. It is the responsibility of the contractor to verify that the equipment pad is large enough for the new equipment. Pad enlargement and addiƟonal piping is responsibility of the contractor. Provide new exterior buffer tank (data plate photo provided).

Provide line size by-pass around buffer tank. Replace Chilled Water Pump and Disconnect. There is currently no VFD for the Chilled Water but it is the intent of this contact to install a VFD for the new Chilled Water

Pump. Provide tracer for all exterior piping to include the Buffer Tank(funcƟonal test will be performed prior to installaƟon of pipe insulaƟon). Th power to the chiller is supplied by a 225A breaker located in Panel CH.

The intent of this contract is to replace the breaker in Panel CH and the load-side wiring, if the service wire is compaƟble with the new equipment.

SCOPE OF WORK:

The contractor shall provide all material, labor, equipment, and supervision required to accomplish the following:

Detailed Requirements and Specifica ons:

The contractor shall make site visits coordinated with PWD, ScoƩy Sholar at scoƩy.sholar.civ@usmc.mil or call 910-389-4418.

Chiller Specifica ons and Basis of Design:

1. All chilled water piping and strainers shall be cleaned prior to installaƟon of new chiller. See aƩachment for hydronic pipe cleaning and flushing procedures.

2. Replace chilled water pumps and VFD on all chiller installs. Pumps must meet the manufacture specificaƟons for each chiller. (EXCEPT BUILDING-1)

3. Chiller may have brazed plate heat exchangers if the manufacture can provide a 10-year parts, labor, and refrigerant warranty for the enƟre chiller. Chiller may also have shell and tube evaporator. Tubes shall be mechanical cleanable with removable heads. Water shall through the shell of the evaporator. Refrigerant shall run through the tubes of the evaporator. In addiƟon to adding a bypass line that allows the chiller to be isolated from the rest of the chilled water piping loop for post-installaƟons/pre-start up system flushing. A factory or field installed water strainer shall also be included for each chiller.

4. Chiller shall have a 1 (one) year parts and labor warranty from date of startup.

5. Chiller shall be equipped with a 20amp GFCI convenience outlet for maintenance to be performed.

Chiller disconnects shall be replaced along with the flexible liquid Ɵght conduit and connectors between disconnect and the chiller (Except Building 1). New disconnect shall meet the manufacturers recommendaƟons. Heat trace shall be protecƟng the evaporator and all piping that is subject to freezing. The 20amp heat trace circuit shall be on a separate circuit. It is the responsibility of the contractor to verify circuit is in place and operable. If not, a new circuit shall be run.

6. Chiller shall include a single point power connecƟon to a non-fused disconnect switch with thru the door handle and compressor circuit breakers.

7. Chiller condenser fan motors shall include VFD’s to opƟmize chiller efficiency and maintain proper head pressure. The condenser fan motors shall be TEFC PSC style motors.

8. Condenser coils shall have a flexible caƟonic epoxy polymer e-coat uniformly applied to all metallic surfaces with no material bridging between fins. The electro-coat shall ensure complete HX encapsulaƟon of all conducƟve surfaces with uniform dry film thickness from 0.6-1.2 mils (15-30um).

E-coaƟng shall meet 5B raƟng for cross- hatch adhesion per ASTM B3359. Corrosion durability will be confirmed through tesƟng no less than10000 hours salt spray resistance per ASTM B117 using scribed aluminum test coupons. AŌer e-coat cure, HX shall receive a spray applied, 2K polyurethane black topcoat to prevent UV degradaƟons of epoxy e-coat film. Topcoat shall have a 60-degree gloss

(<90%) and dry film thickness of 50-60um. All condenser coils shall be Microchannel coils constructed of aluminum alloy 9150 (Long Life Alloy), to help prevent inter-granular corrosion and increase mechanical strength before and aŌer brazing. Aluminum alloy 3102 coils will not be accepted due to mechanical failure rates. Copper tube and aluminum fin condenser coils will be accepted as an alternate if they can include the factory coaƟng with published 10000-hour salt spray raƟng listed above.

9. Chiller shall sit on Seismic Feet. And rubber pads installed on bottom of rails to elevate side rails to allow wash down of debris from under chiller

10. Condenser coils shall be protected by louvered coil guard and compressor housing shall have equivalent protecƟon.

11. Chiller shall sit on seismic feet. And rubber pads installed on boƩom of rails to elevate side rails to allow wash down of debris from under chiller.

12. Chiller must include thermal dispersion type flow switches. Paddle type will not be accepted.

The flow shall be factory installed at the evaporator outlet.

13. Chiller must include phase loss with under/over voltage protecƟon with LED indicaƟon of type of fault to guard against compressor motor burn out.

14. Emergency chiller connecƟons: a set of emergency tees shall be installed before entering the chiller on supply and return lines. The tees shall meet the diameter of the pipe. A buƩerfly valve and a bolted cover plate shall be installed.

15. Control panel shall have access to microprocessor (controller) for viewing and set up, without interrupƟng machine operaƟon. Chiller shall include a centrally located weatherproof control panel including DDC microprocessor controller. Control box shall be designed in accordance with

NEMA 3R raƟng. Controllers and screens must be located within the panel and not exposed to sunlight. All wiring within the control panel shall be ran through sloƩed wiring duct with covers.

Loose wires with zip Ɵes will not be accepted.

16. Each chiller must include a minimum of two scroll compressor. MulƟple scroll compressors shall be uƟlized to prevent large capacity loss due to compressor failures. Compressor modules must have isolaƟon valves and controls to lock out individual compressor stages. If low load levels are required, then the chiller is to include hot gas bypass to allow unit operaƟon to 10% of full load to prevent compressors from staging on and off.

17. Controls shall be BACnet/MSTP, the controller shall be in English, and must monitor phase loss, over and under voltage, line, and load monitoring. Manual latch on criƟcal faults and delayed restart on non-latched errors. Chiller shall enable on 45-degree F and above. Any control interface presently installed and operable on chiller shall be reinstalled and made to operate. This includes hardware wire start-stop, alarm, trouble, or integraƟon to a BACnet/MSTP communicaƟon buss.

18. Chiller manufacture must have a service organizaƟon with at least one service technician within

35 miles of Camp Lejeune, NC.

19. Chiller must comply with Buy America Act/Free Trade Agreement with the United States of

America.

20. Piping diagrams shall be developed by the contractor based on the chiller selecƟon.

1.1 All piping shall be approved by PWD/OPS prior to installaƟon.

1.2 All piping 4” and below is to be copper and piping 5” and greater shall be a minimum of schedule 40 welded steel. All steel piping shall be primed and painted with a minimum of two (2) coats of alkyd enamel. All external piping shall have heat trace to prevent freezing.

All pipes shall be insulated with a minimum of 2” of polyisocyanurate insulaƟon. All insulaƟon shall be covered with aluminum UV cover. All piping shall be supported with pipe stands and or welded supports.

21. Chillers must meet the sound data listed in the below at specified frequencies.

Nominal Tonnage

Octave Band at Center Frequency, 30 ft. from unit. Overall A-Weighted

63 125 250 500 1000 2000 4000 8000 100% Load

75% Load

50% Load

25% Load

30 65 64 61 60 56 51 46 41 61 60 58 57

35 65 64 62 60 56 51 46 41 61 60 58 57

40 65 64 63 61 57 52 47 42 62 61 59 58

45 66 65 64 62 58 52 47 42 63 62 60 59

50 66 66 64 62 58 52 47 42 63 62 60 59

55 66 66 66 62 59 54 49 44 64 63 61 60

60 67 66 67 62 59 54 49 44 64 63 61 60

65 68 67 67 62 60 54 49 44 65 64 62 61

70 68 68 67 62 60 54 49 44 65 64 63 62

75 68 68 68 62 60 54 49 44 65 64 62 61

80 66 63 63 63 62 56 53 53 66 65 63 62

90 67 67 67 64 62 56 54 54 67 66 64 63

100 66 65 65 65 62 56 57 55 67 66 64 63

110 66 67 67 65 61 55 55 55 67 66 64 63

120 68 67 67 65 61 59 60 57 68 67 65 64

130 67 68 68 64 61 60 60 55 68 67 65 64

140 68 69 69 65 61 60 61 56 69 68 66 66

150 69 70 70 65 62 62 62 56 70 69 67 66

160 69 70 70 65 62 63 62 56 70 69 67 66

170 69 71 69 67 64 61 60 58 70 69 67 66

180 69 71 69 67 64 61 61 58 70 69 67 66

190 69 71 69 67 64 61 61 58 70 69 67 66

Sound data must be published to meet or be lower than the above numbers for respective tonnage.

Any chiller that does not conform to these published sound targets must provide attenuation to meet at the installing contractor’s expense. Sound attenuation should not affect or degrade the chillers performance. The chiller manufacturers catalog data should support all listed sound data.

22. Electrical Feed

1.1 All electrical feeds and controls shall conform to the “NEC”. Contractor shall replace disconnects and liquid Ɵght conduit and connectors. ExisƟng wiring can be reused if it meets manufactures recommendaƟons.

1.2 All electrical wiring sizes, voltage and amp draws of equipment is the responsibility of the contractor.

1.3 All informaƟon provided in this scope of work is for reference only.

1.4 Site visits shall be required for all bidding contractors.

DETAIL REQUIRMENTS AND SPECIFICATION:

1. Provide spec sheet for material and equipment used prior to start of work for government approval. Provide a copy of Maximo Equipment Inventory Sheet for each piece of equipment removed and installed.

SPECIAL SCHEDULING AND ACCESS:

1. Scheduled outages are to be scheduled thru PWD. Outages shall be scheduled fourteen (14) days prior to equipment shut down. contact ScoƩy Sholar 910-389-4418.

2. Work shall not be performed between the months of June-August.

3. Chiller Replacement priority:

A. 1005

B. 1

C. PP100

D. PP200

SPECIAL CONDITIONS:

Contract shall be completed 540 days aŌer award. Contractor shall ensure all employees and subcontractors have access and are fully veƩed.

The contractor shall give Public Works the right to all HVAC equipment, including but not limited to chillers, AHU’s, DOAS units, and any DDC controllers that are involved with the sequence of operaƟon for the buildings HVAC System.

The contractor shall give Public Works the right to reclaim all refrigerant from any HVAC system before any equipment is to leave the work area. Any controls that are on exisƟng chiller that need to be installed on new chiller can be removed and installed by the contractor. AŌer Public Works remove any parts as listed above, the chiller will be the property of the contractor to dispose of offsite.

SUBMITTALS:

All equipment shall/must be approved. Submit all proposals to the ROICC and PWD for consideraƟon.

The contractor shall be required to submit work schedules to POC for approval. The contractor shall submit to the ContracƟng Officer, the manufactures product specificaƟons, complete with technical product data. The product specificaƟons shall, as a minimum, provide technical details on the following items:

1. Manufacturer’s name and product line.

2. Manufacturer’s warranty.

HAZARDOUS MATERIAL:

NONE

ENVIROMENTAL:

NONE

T46

P286

S1680

SPP200G

SPP200F SPP200E

SPP200D

SPP200C

SPP200B

SPP200A E

SPP100B SPP100G

SPP100F SPP100E

698A SPP100D

SPP100A SPP100C

699A

S1032

08 06 02 00

30 26 24 22 20 18 16

31 29

41 39 37 35 33 10

65 61

53 51

59 57 55

49 47 43

34 32

36 63

54 52

44 42 50 48

62 60 58 56

S1032

835B