36C25618B0167-002.docx

BUILDING 170 CHILLER #2 SOW

PART 1: GENERAL

1.01 SUMMARY

A. Section includes design, performance criteria, refrigerants, controls, and installation requirements for water-cooled centrifugal chillers.

B. This is performance contract with the chiller installation being a turn-key project. It is the Contractor’s responsibility to raise concerns or questions during the RFP process.

1.02 REFERENCES

A. Comply with the following codes and standards: AHRI 550/590, AHRI 575, NEC, ANSI/ASHRAE 15, OSHA as adopted by the State, ETL, ASME Section VIII

1.03 SUBMITTALS

A. Submittals shall include the following:

1. Dimensioned plan and elevation view, including required clearances, and location of all field piping and electrical connections.

2. Summaries of all auxiliary utility requirements such as: electricity, water, air, etc. Summary shall indicate quality and quantity of each required utility.

3. Diagram of control system indicating points for field interface and field connection. Diagram shall fully depict field and factory wiring.

4. Manufacturer’s certified performance data at full load plus IPLV or NPLV.

5. Installation and Operation manuals.

7. All warranties on components and sub components.

1.04 QUALITY ASSURANCE

A. Regulatory Requirements: Comply with the codes and standards in Section 1.02.

B. Chiller manufacturer plant shall be ISO 9001 and14001 Certified.

C. The chiller shall be factory tested at the manufacturer’s plant prior to shipment and shall include Eddy current test results.

1.05 DELIVERY AND HANDLING

A. Chillers shall be delivered to the job site completely assembled and charged with refrigerant R134a and be shipped on skids with a weather resistant cover before any demo work begins on existing chiller #2.

B. Chiller and supplies shall be delivered no later than 90 days past the notice to proceed being issued.

C. Comply with the manufacturer's instructions for rigging and handling equipment. Leave protective covers in place until installation.

1.06 WARRANTY

A. The chiller manufacturer’s standard warranty shall cover parts and labor costs for the repair or replacement of defects in material or workmanship for the entire unit, for a period of one year from equipment startup or 18 months from shipment, whichever occurs first. Refrigerant warranty for one year.

1.07 MAINTENANCE

A. A 10-year maintenance agreement that provides parts, labor, and all preventative maintenance required by the manufacturer’s operating and maintenance instructions B. The manufacturer shall also include at no charge for a period of 10 years an annual refrigerant analysis report to identify chiller contamination due to water leaks. If the analysis identifies water, or other contaminant levels higher than specified by the manufacturer, the refrigerant must be replaced or returned to the manufacturer’s original specification at no cost to the owner. The manufacturer shall provide an eddy current test as a base line and the contractor shall provide eddy current tests each three years during the 10 year maintenance agreement.

PART 2: PRODUCTS

2.01 UNIT DESCRIPTION

A. Provide and install a factory assembled, charged, and tested water-cooled centrifugal chiller. Chiller shall have at least (3) compressors oil-free, magnetic bearing, centrifugal compressors (no exceptions) to provide for redundancy and capacity turndown flexibility. Each compressor shall have an integrated variable-frequency drive operating in concert with inlet guide vanes for optimized full and part load efficiency. The evaporator and condenser refrigerant sides and the expansion valve shall be common and the chiller shall be capable of running on one compressor with the other compressors or any of its auxiliaries inoperable or removed.

2.02 Design Requirements

A. General: Provide a complete water-cooled, oil-free centrifugal compressor water chiller as specified herein. The unit shall be provided according to standards indicated in Section 1.02. In general, unit shall consist of multiple oil-free magnetic bearing, completely oil-free centrifugal compressors, refrigerant, condenser and evaporator, and control systems including integrated variable frequency drive, operating controls and equipment protection controls. Chillers shall be charged with refrigerant HFC-134a. Manufacturer shall provide, in writing, documentation signed by an officer of the company assuring refrigerant availability and price schedule for a 20-year period.

B. The entire chiller system, including all pressure vessels, shall remain above atmospheric pressure during all operating conditions and during shut down to ensure that non-condensables and moisture do not contaminate the refrigerant and chiller system.

C. Performance: Refer to chiller performance rating

1. Chiller shall have 900 ton capacity

2. Chiller KW/TON .525 +-3%

3. Integrated Part Load Value 0.316 +-3%

4. Evap. GPM 2,160

5. Cond. GPM 2,700

6. Voltage 460/3/6

D. Compressors:

1. The unit shall utilize magnetic bearing, oil-free, semi- hermetic centrifugal compressors. The compressor drive train shall be capable of coming to a controlled, safe stop in the event of a power failure.

2. The electronic and electro mechanical parts of the chiller shall be liquid refrigerant cooled.

3. The chiller shall be equipped with a refrigerant cooled and integrated Variable Frequency Drive (VFD) to automatically regulate compressor speed in response to cooling load and the compressor pressure lift requirement. Movable inlet guide vanes and variable compressor speed shall provide unloading. The chiller controls shall coordinate compressor speed and guide vane position to optimize chiller efficiency.

4. Each compressor circuit shall be equipped with a 5% line reactor to help protect against incoming power surges and help reduce harmonic distortion.

E. Evaporator and Condenser:

1. Provide sufficient isolation valves and condenser volume to hold the full unit refrigerant charge in the condenser during servicing or provide a separate pump out system and storage tank sufficient to hold the charge of the largest unit being furnished.

2. The evaporator and condenser shall be separate vessels of the shell-and-tube type, designed, constructed, tested and stamped according to the requirements of the ASME Code, Section VIII. The tubes shall be individually replaceable and secured to the intermediate supports without rolling. Provide a refrigerant economizer to allow lower chilled water supply temperature and improved efficiency down to 75% unloaded.

3. The evaporator shall be flooded type with copper tubes rolled into carbon steel tube sheets. The evaporator shall have right-hand connections when looking at the unit control panel. The evaporator shall have Marine Water box with hinges on both ends and valved drain and vent connections.. Water connections shall be grooved suitable for Victaulic couplings. The heads shall be carbon steel and the tube sheets shall be carbon steel. The waterside shall be designed for a minimum of 150psig. The wall copper tubes shall be 0.025 in.

4. The condenser shall have rolled tube sheets. The condenser shall have left-hand connections when looking at the unit control panel. The condenser shall have Marine Water box with hinges on both ends and valved drain and vent connections. Water connections shall be grooved suitable for Victaulic couplings. The heads shall be carbon steel and the tube sheets shall be carbon steel. The wall copper tubes shall be 0.025 in. The waterside shall be designed for a minimum of 150psig.

5. An electronic expansion valve shall control refrigerant flow to the evaporator. Fixed orifice devices or float controls with hot gas bypass are not acceptable because of inefficient control at low load conditions. The liquid line shall have moisture indicating sight glass.

6. Re-seating type spring loaded pressure relief valves according to ASHRAE-15 safety code shall be furnished. The evaporator shall be provided with single or multiple valves. The condenser shall be provided with dual relief valves equipped with a transfer valve so one relief valve can be removed for testing or replacement without loss of refrigerant or removal of refrigerant from the condenser. Rupture disks are not acceptable.

7. The evaporator vessel, including suction line and any other component or part of a component subject to condensing moisture (excluding the waterbox), shall be insulated with UL recognized 3/4 inch closed cell insulation. All joints and seams shall be carefully sealed to form a vapor barrier.

8. The evaporator waterbox shall be insulated with UL recognized ¾ inch closed cell insulation. All joints and seams shall be carefully sealed to form a vapor barrier.

9. Provide factory-mounted and wired, differential pressure flow switches on each vessel to prevent unit operation with no or low water flow.

F. Provide neoprene waffle-type vibration isolators for each corner of the unit.

G. Power connection shall be single -point to the chiller.

H. Chiller Control:

1. The unit shall have a microprocessor-based control system consisting of a 15-inch VGA touch-screen operator interface and a unit controller.

2. The touch-screen shall display the unit operating parameters, accept set point changes (multi-level password protected) and be capable of resetting faults and alarms. The following parameters shall be displayed on the home screen and also as trend curves on the trend screen:

a. a. Entering and leaving chilled and condenser water temperatures

b. b. Evaporator and condenser saturated refrigerant pressures

c. c. Percent of 100% speed (per compressor)

d. d. % of rated load amps for entire unit

3. In addition to the trended items above, all other important real-time operating parameters shall also be shown on the touch-screen. These items shall be displayed on a chiller graphic showing each component. At a minimum, the following critical areas must be monitored:

a. a. Compressor actual speed, maximum speed, percent speed, Evaporator water in and out temperatures, refrigerant pressure and temperature

b. Condenser water in and out temperatures, refrigerant pressure and temperature

c. Liquid line temperature

d. Chilled water set point

e. Compressor and unit state and input and output digital and analog values

4. A fault history shall be displayed using an easy to decipher, color coded set of messages that are date and time stamped. The alarm history shall be downloadable from the unit’s USB port. An operating and maintenance manual specific for the unit shall be viewable on the screen and downloadable.

5. All set points shall be viewable and changeable (multi- level password protected) on the touch screen and include set point description and range of set values.

6. Automatic corrective action to reduce unnecessary cycling shall be accomplished through preemptive control of low evaporator or high discharge pressure conditions to keep the unit operating through abnormal transient conditions.

7. The chiller shall be sequenced on and water temperature reset through the existing Siemens Building Automation system

8. The factory mounted controller(s) shall support operation on a BACnet® network via BACnet MS/TP or Ethernet as specified by the existing Siemens Building Automation System.

9. The chiller shall be able to maintain operation during a momentary power loss event lasting up to 5 seconds when operated at standard AHRI load and lift conditions. The chiller shall be able to ride through this momentary power loss event without shutting down.

2.03 ITEMS – Testing, commissioning and certification shall be included

0. The following items shall be furnished: Three New Chilled water pumps to replace existing Chilled Water pumps P5,P6,P7 sized for GPM of new unit. Provide new suction strainers for each pump. Pump motors shall be NEMA rated premium efficient.

0. New Variable Frequency Drives sized for new P5,P6,P7 Chilled water pumps networked to the BAS.

0. New electrical service to feed from the MCC which currently serve the existing pumps to the installed new Frequency Drives for each new pump. Contractor is responsible for revising the over current protection as necessary NFPA 70.

A.

1. Refrigerant monitor with local strobe light capable of communicating with the BAS

2. Unit Testing: To ensure quick and trouble free start up and commissioning, each chiller shall pass a full battery of factory tests with a complete test report submitted. These tests will include the verification of operating and compressor controls to ensure full unit functionality and manufacturing integrity. Any deviation from stringent factory quality standards shall be remedied prior to shipment. No additional testing points.

3. Certifications

4. Training of VA personnel on proper operation (any certification requirements)

PART 3: EXECUTION

3.01 INSTALLATION - Installing contractor to:

A. Install per manufacturer’s requirements, shop drawings, and contract documents.

B. Chiller installation for this project is to be done per approved submittals.

C. Adjust chiller alignment on foundations, or subbases as called for on drawings.

D. Arrange piping to allow for dismantling to permit head removal and tube cleaning.

E. All piping is to be painted and inspected by the COR prior to insulation.

F. Coordinate electrical installation with electrical contractor.

G. Coordinate controls with control contractor.

H. Provide all material required for a fully operational and functional chiller.

I. Work to be performed during winter months, Nov-Feb timeframe.

J. POP Not to exceed 150 days, Including equipment and supplies arrival.

3.02 Start-Up

Factory Start-Up Services: Provide for as long a time as is necessary to ensure proper operation of the unit, but in no case for less than two full working days. During the period of start-up, the start-up technician shall instruct the owner’s representative in proper care and operation of the unit.

SPECIAL CONSIDERATIONS BY THE CONTRACTOR:

1. All disposal costs and fees for debris removal will be the contractor’s responsibility.

1. The contractor will be responsible for cleanliness of the building area both interior and exterior.

SAFETY CONSIDERATIONS:

1. Contractor’s workmen shall provide and utilize all safety requirements in accordance with OSHA regulations during all phases of the work.

Site shall be kept clean and free from debris at all times and contractor shall remove debris daily from the health care system property. Contractor will not be allowed to use Government tools, materials, and/or labor for this project.

FIRE PROTECTION DURING CONSTRUCTION:

1. Coordinate with the facility prior to and throughout the construction period.

1. Fire protection during construction shall comply with VA Master Construction Specification (VAMCS) 01 00 00, General Requirements. (Note: VAMCS 01 00 00, General Requirements, addresses NFPA 241, Joint Commission Interim Life Safety Measures, Hot Work Permits. This specification section was formerly section 01010.)

1. Separate all occupied areas from demolition, renovation, or construction activities by temporary smoke-tight construction partitions of gypsum board or other approved non-combustible or limited-combustible material. Partitions shall be full height, extending through suspended/hard ceilings to the floor slab or roof deck above and shall be one-hour fire rated, unless sprinklers are installed and are operational on both sides of the temporary partition whereupon the partition may be permitted to terminate at the ceiling in accordance with NFPA 241. Where the ceiling on one side of the temporary construction barrier has been removed, the temporary wall would need to go to the deck above.

1. Note: This requirement is due to the inherently greater potential for fire or hazardous materials incidents associated with the combustibles and operations of demolition/construction. This risk is made worse by the likelihood of compromised fire protection systems and fire/smoke resistant construction. This does not obviate the need to provide other protective measures to contain dust and debris as specified by VAMCS 01 00 00 section 1.8(D)(2). Sprinklers are considered to be operational when they are installed in accordance with NFPA 13 (spacing, protection, distance from the ceiling, etc.) and there is a sufficient automatic water supply. If the ceiling was removed and the sprinklers remain at the original ceiling level, they would likely not be considered operational.

1. Phase construction as necessary to ensure that obstruction of exits is minimized or avoided. If exits are obstructed during construction, provide alternate exit routes during each phase of construction and identify the alternate routes on the construction drawings.

1. Minimize or avoid disruptions to fire alarm and sprinkler systems. Delineate phasing of construction to ensure that installations of new systems are expedited, and where possible, maintain existing systems in service until the replacement system is operational. If fire protection systems are to be disrupted, ensure procedures are incorporated to maintain equivalent levels of fire protection and provide formal notification to the facility while systems are down.

Most work is to be performed during the hours of 7:00 AM and 4:30 PM, Monday through Friday, exclusive of Federal holidays. However, some areas may require work to be performed outside of normal working hours. Any work performed outside of normal working hours shall be coordinated with the project manager.

Site shall be kept clean and free from debris at all times and contractor shall remove debris daily from the health care system property. Contractor will not be allowed to use Government tools, materials, and/or labor for this project.