23 64 00 - Packaged Water Chillers.ASI001.pdf

DWIGHT D. EISENHOWER VA MEDICAL CENTER

ERHM Infrastructure Upgrades - Leavenworth VAMC

Project #: 589A6-21-700

Packaged Water Chillers

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SECTION 23 64 00

PACKAGED WATER CHILLERS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Centrifugal water-cooled chillers, complete with accessories.

1.2 RELATED WORK

A. Section 01 00 00, GENERAL REQUIREMENTS.

B. Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, and SAMPLES.

C. Section 13 05 41, SEISMIC RESTRAINT REQUIREMENTS FOR NON-STRUCTURAL

COMPONENTS.

D. Section 23 05 11, COMMON WORK RESULTS FOR HVAC and STEAM GENERATION.

E. Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC and STEAM GENERATION

EQUIPMENT.

F. 23 21 23Section 23 05 41, NOISE and VIBRATION CONTROL FOR HVAC PIPING and

EQUIPMENT.

G. Section 23 09 23, DIRECT-DIGITAL CONTROL SYSTEM FOR HVAC.

H. Section 23 21 13, HYDRONIC PIPING.

I. Section 23 21 23, HYDRONIC PUMPS.

J. Section 23 23 00, REFRIGERANT PIPING.

K. Section 23 31 00, HVAC DUCTS and CASINGS L. Section 23 65 00, COOLING TOWERS.

M. Section 25 10 10, ADVANCED UTILITY METERING SYSTEM.

N. Section 26 29 11, MOTOR CONTROLLERS.

O. Section 01 91 00, GENERAL COMMISSIONING REQUIREMENTS P. Section 23 08 00, COMMISSIONING OF HVAC SYSTEMS: Requirements for commissioning, systems readiness checklists, and training.

1.3 DEFINITIONS

A. Engineering Control Center (ECC): The centralized control point for the intelligent control network.

The ECC comprises of personal computer and connected devices to form a single workstation.

B. BACNET: Building Automation Control Network Protocol, ASHRAE Standard 135.

C. Ethernet: A trademark for a system for exchanging messages between computers on a local area network using coaxial, fiber optic, or twisted-pair cables.

D. FTT-10: Echelon Transmitter-Free Topology Transceiver.

1.4 QUALITY ASSURANCE

A. Refer to Paragraph, QUALITY ASSURANCE, in Section 23 05 11, COMMON WORK RESULTS FOR HVAC and STEAM GENERATION, and comply with the following.

B. Refer to PART 3 herein after and Section 01 00 00, GENERAL REQUIREMENTS for test performance.

C. Comply with AHRI requirements for testing and certification of the chillers.

D. Provide a 5-year motor and compressor warranty to include materials, parts and labor.

E. Refer to OSHA 29 CFR 1910.95(a) and (b) for Occupational Noise Exposure Standard F. Refer to ASHRAE Standard 15, Safety Standard for Refrigeration System, for refrigerant vapor detectors and monitor.

1.5 APPLICABLE PUBLICATIONS

A. The publications listed below form a part of this specification to the extent referenced. The publications are referenced in the text by the basic designation only.

B. Air Conditioning, Heating and Refrigeration Institute (AHRI):

370-01 Sound Rating of Large Outdoor Refrigerating and Air-Conditioning Equipment

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495-1999 (R2002) Refrigerant Liquid Receivers 550/590-03 Standard for Water Chilling Packages Using the Vapor Compression Cycle 560-00 Absorption Water Chilling and Water Heating Packages 575-94 Methods for Measuring Machinery Sound within Equipment Space

C. American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE):

ANSI/ASHRASE-15-2007 Safety Standard for Mechanical Refrigeration Systems GDL 3-1996 Guidelines for Reducing Emission of Halogenated Refrigerants in Refrigeration and Air-Conditioning Equipment and Systems

D. American Society of Mechanical Engineers (ASME):

2007 ASME Boiler and Pressure Vessel Code, Section VIII, "Pressure Vessels - Division 1"

E. American Society of Testing Materials (ASTM):

C 534/ C 534M-2008 Preformed, Flexible Elastomeric Cellular Thermal Insulation in Sheet and Tubular Form C 612-04 Mineral-fiber Block and Board Thermal Insulation

F. National Electrical Manufacturing Association (NEMA):

250-2008 Enclosures for Electrical Equipment (1000 Volts Maximum)

G. National Fire Protection Association (NFPA):

70-2008 National Electrical Code

H. Underwriters Laboratories, Inc. (UL):

1995-2005 Heating and Cooling Equipment

1.6 SUBMITTALS

A. Submit in accordance with Specification Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, and SAMPLES.

B. Manufacturer's Literature and Data.

1. Centrifugal water chillers, including motor controllers, control panels, and vibration isolators, and remote condenser data shall include the following:

a. Rated capacity.

b. Pressure drop.

c. Efficiency at full load and part load without applying any tolerance indicated in the

AHRI 550/590/Standard.

d. Refrigerant

e. Accessories.

f. Installation instructions.

g. Startup procedures.

h. Wiring diagrams, including factory-installed and field-installed wiring.

i. Sound/Noise data report. Manufacturer shall provide sound ratings. Noise warning labels shall be posted on equipment.

j. Refrigerant vapor detectors and monitors.

C. Maintenance and operating manuals for each piece of equipment in accordance with Section 01 00

00, GENERAL REQUIREMENTS.

D. Run test report for all chillers.

E. Product Certificate: Signed by chiller manufacturer certifying that chillers furnished comply with AHRI requirements. The test report shall include calibrated curves, calibration records, and data sheets for the instrumentation used in factory tests.

F. Provide seismic restraints for refrigeration equipment to withstand seismic forces.

PART 2 - PRODUCTS

2.1 CENTRIFUGAL WATER-COOLED WATER CHILLERS

A. General: Chiller shall be factor-assembled and-tested, complete with evaporator, condenser, unit mounted Variable Speed Drive (VSD), marine water boxes for condenser and evaporator, compressor, motor, starter, oil heater and cooler, economizer or intercooler, purge system, refrigerant piping, instrumentation and control piping, operating and safety controls mounted on the chiller, and other auxiliaries necessary for safe and proper operation of the unit. Chiller operation shall be fully automatic. Make provision for space and design piping layout to suit the marine water boxes.

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B. Performance: Provide the capacity as shown on the drawings. Part load and full load efficiency ratings of the chiller shall not exceed those shown on the drawings. If chillers are required to operate at less than 25 percent of full unit rated capacity, specify provision for hot gas by-pass, to operate the unit stable at any stage of capacity reduction.

C. The initial charge of refrigerant shall be supplied, factory charged in the chiller or shipped in containers and cylinders for field installation.

D. Capacity of a single water-cooled chiller shall not exceed 1,250 Tons (Standard AHRI Conditions).

E. Applicable Standard: Chillers shall be rated and certified in accordance with AHRI Standard 550/590.

Chillers shall be AHRI stamped. Chiller efficiency shall comply with FEMP (Federal Energy Management Progress) requirements.

F. Acoustics: Sound pressure levels shall not exceed the following specified levels. The manufacturer shall provide sound treatment if required to comply with the specified maximum levels. Testing shall be in accordance with AHRI 575.

OCTAVE BAND Overall 63 125 250 500 1000 2000 4000 8000 dB(A) 41 57 66 71 72 71 81 89

G. Hermetic or open: Chillers shall be open or hermetically sealed, using one of the following refrigerants: HFC-134a.

H. Compressor (Centrifugal Type): Single stage, powered by a high speed, direct-drive electric motor.

A cast aluminum, fully shrouded impeller shall be mounted directly to the motor shaft. The impeller shall be designed for balanced thrust, dynamically balanced and overspeed tested for smooth, vibration free operation. Compressor castings shall be designed for 235 psig (16 barg) working pressure and hydrostatically pressure tested at 355 psig (24.4 barg) for R-134a units. Capacity control shall be achieved by the combined use of variable speed control and mechanical flow regulation to provide fully modulating control from maximum to minimum load. The unit shall be capable of operating with lower temperature cooling tower water during part load operation in accordance with AHRI Standard 550/590. All capacity control devices shall be automatically controlled to maintain a constant leaving chilled water temperature.

I. Evaporator: Evaporator shall be a shell and tube, hybrid falling-film type designed for 235 psig (16 barg) working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plate with fusion welded seams; have carbon steel tube sheets, drilled and reamed to accommodate the tubes; and intermediate tube supports spaced no more than four feet apart. The refrigerant side shall be designed, tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII-Division 1.Tubes shall be high-efficiency, internally and externally enhanced type having plain copper lands at all intermediate tube supports to provide maximum tube wall thickness at the support area. Each tube shall be roller expanded into the tube sheets providing a leak proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 fps. A liquid level sight glass will be located on the side of the shell to aid in determining proper refrigerant charge. A suction baffle eliminator will be located above the tube bundle to prevent liquid refrigerant carryover to the compressor. The evaporator shall have a refrigerant relief device sized to meet the requirements of ASHRAE 15 Safety Code for Mechanical Refrigeration. Water boxes shall be removable to permit tube cleaning and replacement. Stub-out water nozzle connections having ANSI/AWWA C-606 grooves shall be provided. Waterboxes shall be designed for 150 psi (10.3 bar) design working pressure and tested at 225 psig (15.5 bar). Vent and drain connections with plugs shall be provided on each waterbox, except for marine waterboxes with vertical nozzles where there are drain connections only. Low flow protection shall be provided by a thermal-type flow sensor, factory mounted in the water nozzle connection and wired to the chiller Control Center. Performance shall be based on a water velocity not less than 1 m/s (3 fps) nor more then 4 m/s (12 fps), and fouling factor of 0.0000176 m2 degrees C (0.0001 hr. sq. ft. degrees F/Btu). Removable marine water box shall be constructed of steel. Design working pressure shall be 1035 kPa (150 psig pressure tested at 130 percent of working pressure. Water nozzle connections shall be flanged.

J. Condenser: Condenser shall be of the shell and tube type, designed for 235 psig (16 barg) working pressure on the refrigerant side. Shell shall be fabricated from rolled carbon steel plate with fusion welded seams; have carbon steel tube sheets, drilled and reamed to accommodate the tubes; and intermediate tube supports spaced no more than four feet apart. The refrigerant side shall be

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23 64 00 - 4 designed, tested and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII-Division 1. Tubes shall be high-efficiency, internally and externally enhanced type having plain copper lands at all intermediate tube supports to provide maximum tube wall thickness at the support area. Each tube shall be roller expanded into the tube sheets providing a leak proof seal, and be individually replaceable. Water velocity through the tubes shall not exceed 12 fps. Waterboxes shall be removable to permit tube cleaning and replacement. Stub-out water connections having ANSI/AWWA C-606 grooves will be provided. Waterboxes shall be designedfor 150 psi (10.3 bar) design working pressure and tested at 225 psig (15.5 bar). Vent and drain connections with plugs shall be provided on each waterbox, except for marine waterboxes with vertical nozzles where there are drain connections only. Performance of condenser shall be based on a water velocity not less than 1 m/s (3 fps) nor more than 4 m/s (12 fps), and a fouling factor of 0.000044 m2 degrees C (0.00025 hr. sq. ft.) degrees F/Btu. Removable marine water box shall be constructed of steel. Design working pressure shall be 1035 kPa (150 psig); pressure tested at 130 percent of working pressure.

Water nozzle connections shall be flanged.

K. Insulation: Evaporator, suction piping, compressor, and all other parts subject to condensation shall be insulated with 40 mm (1.5 inch) minimum thickness of flexible-elastomeric thermal insulation, complying with ASTM C534.

L. Motor Load Limiter: Provide a sensing and control system, which will limit maximum load current of compressor motor to a manually selectable percentage of 40 percent to 100 percent of full load current. System shall sense compressor motor current and limit it by modulating inlet guide vanes at the compressor, overriding other controls in their ability to increase loading, but not overriding their ability to reduce loading.

M. Purge System: Chillers using refrigerants with vapor pressure less than 100 kPa (14.7 psig) shall be supplied with Purge System. Purge unit shall be factory-mounted, complete with necessary, piping, operating and safety controls and refrigerant service valves to isolate the unit from the chilling unit.

Purge unit shall be air, water, or refrigerant cooled. When in operation, purge system shall function automatically to remove, water vapor, and condensable gases from refrigeration system and to condense, separate, and return to system any refrigerant present therein. Purge system shall be manually or automatically started and stopped, and shall be assembled as a compact unit. As an option, a fully automatic purge system that operates continuously while main unit is operating may be furnished. Such purge system shall provide a means to signal operator of occurrence of excessive purging indicating abnormal air leakage into unit. The purge system shall be of high efficiency in recapturing the refrigerant at all load and head conditions and with capability to operate when the chiller is off. The purge unit shall be UL listed.

N. Spring Isolators: Per Specification Section 23 05 41, NOISE and VIBRATION CONTROL FOR HVAC PIPING and EQUIPMENT.

O. Chillers using refrigerants HFC-134a shall be supplied with single or multiple reseating type, spring-loaded relief valve.

P. Service valves shall be provided to facilitate refrigerant reclaim/removal required during maintenance.

Q. Controls: Chiller shall be furnished with unit mounted, stand-alone, microprocessor-based controls in

NEMA 12 enclosure, hinged and lockable, factory wired with a single point power connection and separate control circuit. The control panel provide chiller operation, including monitoring of sensors and actuators, and shall be furnished with light emitting diodes or liquid-crystal display keypad.

1. Following functions shall display as a minimum:

a. Date and Time.

b. Outdoor air temperature.

c. Operating set point temperature and pressure.

d. Operating hours.

e. Operating or alarm status.

f. Chilled water temperature-entering and leaving.

g. Condenser water temperature-entering and leaving.

h. Refrigerant pressure-condenser and evaporator.

i. Low oil pump pressure.

j. High oil supply pressure.

k. Chiller diagnostic codes.

l. Current limit set point.

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m. Number of compressor starts.

n. Purge suction temperature.

o. Purge elapsed time.

2. Control Functions:

a. Manual or automatic startup and shutdown time schedule.

b. Control set points for entering and leaving chilled temperatures.

c. Condenser water temperature.

d. Current/demand limit.

e. Motor load limit.

3. Safety Controls: Following conditions shall shut down the chiller and require manual reset to start:

a. High condenser pressure.

b. High oil temperature.

c. High or low oil pressure.

d. Loss of flow-condenser or chilled water.

e. Low chilled water temperature.

f. Low evaporator refrigerant temperature.

g. Sensor malfunctions.

h. Power fault.

i. Extended compressor surge.

j. Communication loss between the chiller and its control panel. A signal must be transmitted to Energy Control Center, if provided, for this communication loss and for any abnormal.

4. The chiller control panel shall provide a relay output to initiate system changeover to free cooling. This relay shall be energized upon initiation of free cooling at the chiller control panel.

5. Leaving chilled water temperature reset, where specified in the control sequence, shall be based on return water temperature 4-20 MA or 0-10 VDC signal from a building automation system.

6. Chillers shall be pre-wired to terminal strips for interlocked to other equipment.

7. Provide contacts for remote start/stop, alarm for abnormal operation or shut down, and for

Engineering Control Center (ECC) interface .

8. Chiller control panel shall reside on the "BACnet network", and provide data using open protocol network variable types and configuration properties, BACnet interworking using ARCNET or MS/TP physical data link layer protocol for communication with building automation control system .

9. Auxiliary hydronic system and the chiller(s) shall be electronically interlocked to provide time delay and starting sequence as indicated on control drawings.

10. The chiller control panel shall utilize the following components to automatically take action to prevent unit shutdown due to abnormal operating conditions which will perform as follows.

a. High pressure switch that is set to 20 psig (adjustable setting) lower than factory pressure switch that will automatically unload the compressor to help prevent a high pressure condenser control trip. One switch is required for each compressor and indicating light shall also be provided.

b. Motor surge pressure that is set at 95% of compressor RLA that will automatically unload the compressor to prevent an over current trip. One protector is required for each compressor and indicating light shall also be provided.

c. Low pressure switch that is set at 5 PSIG above the factory low pressure switch that will automatically unload the compressor to help prevent a low evaporator temperature trip. One switch is required for each compressor and indicating light shall also be provided.

d. In all the above cases, the chiller will continue to run, in an unloaded state and will continue to produce some chilled water in an attempt to meet the cooling load.

However, if the chiller reaches the trip-out limits, the chiller controls will take the chiller off line for protection, and a manual reset is required. Once the "near trip"

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23 64 00 - 6 condition is corrected, the chiller will return to normal operation and can then produce full load cooling.

11. With variation of +/-10% of design flow per minute, chiller shall be able to maintain +/-0.5 degrees F leaving water temperature control. The chiller must be able to withstand a +/- 30% change in flow rate per minute without unit trip. Variations in the primary flow allow for optimal system efficiency, but the chiller must be able to maintain temperature control to help ensure occupant comfort.

12. The chiller control panel shall provide +/-0.5 degrees F leaving water temperature control during normal operation. The chiller shall provide multiple steps leaving chilled water temperature controller to minimize part load energy use and optimize leaving chilled water temperature control. If manufacturer is unable to provide at least several steps of unloading, hot gas bypass shall be required to minimize loss of leaving water temperature control.

13. The chiller control panel shall provide a 2-minute stop-to-start and 5 minute start-to-start solid state timer. If the anti-recycle timers are longer than 5 minutes, then hot-gas bypass shall be provided to limit loss of leaving chilled water temperature control in low-load conditions.

R. Motor: Refer to Section 23 05 11, COMMON WORK RESULTS FOR HVAC and STEAM GENERATION. Compressor motor furnished with the chiller shall be in accordance with the chiller manufacturer and the electrical specification Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC and STEAM GENERATION EQUIPMENT. Starting torque of the motor shall be suitable for the driven chiller machine.

S. Motor Starter/Controller: Refer to Section 23 05 11, COMMON WORK RESULTS FOR HVAC AND STEAM GENERATION. Provide a starter for each centrifugal chiller in NEMA I enclosure, designed for floor or unit mounting. For floor mounted starter provide wiring from starter to chiller. Starter shall be a variable frequency drive type. Provide starter with the following features in addition to the ones specified in Electrical Specification Section 26 29 11, MOTOR CONTROLLERS.

1. Starter shall include incoming line provision for the number and size cables shown on the drawings. Incoming line lugs shall be copper mechanical type.

2. Terminals connection pads shall be provided to which customers supply lugs can be attached.

3. Starters shall be coordinated with chiller packages(s) making certain all terminals are properly marked according to the chiller manufacturer’s wiring diagram.

4. Contactors shall be sized per NEMA requirements to the chillers for full load currents.

5. Ammeter(s) shall be provided, capable of displaying current to all three phases. Ammeter shall be calibrated so that inrush current can be indicated.

6. Chiller starter shall include an advanced motor protection system incorporating electronic three phase overloads and current transformers. This electronic motor protection system shall monitor and protect against the following conditions:

a. Three phase loss with under and over voltage protection.

b. Phase imbalance.

c. Phase reversal.

d. Motor overload.

e. Motor overload protection incorrectly set.

f. Momentary power loss protection with auto restart consisting of three phase current sensing device that monitor the status of the current.

g. Starter contactor fault protection.

h. Starter transition failure.

i. Distribution fault protection.

7. When a motor driven oil pump is furnished, provide a 120- volt control circuit, mounted within starter enclosure. When an oil pump starter is provided at the refrigeration machine, provide fused disconnect in star delta starter for oil pump.

8. The starter shall be equipped with pilot relays to initiate the start sequence of compressor.

These relays shall be a self-monitoring safety circuit, which shall indicate improper operation (slow operation, welding of contacts, etc) and shall cause the chiller unit to be shut down and a fault trip indicator be displayed. The "starter circuit fault" indicator shall be located in the door of the enclosure and shall require manual reset.

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9. A lockout transition safety circuit shall be provided to prevent damage from prolonged energization due to malfunction of the transistor contactor. Malfunction shall cause the chiller unit to shut down and the "starter circuit fault" indicator be displayed.

10. A permanent nameplate shall be provided and mounted on the starter panel. It shall identify the manufacturer, serial or model number identifying the date of manufacturing and component replacement parts, and all current and voltage rating, and as built wiring schematic showing all items provided.

11. Non-fused main power disconnect switch.

T. Variable- Speed Drive (VSD)

1. A VSD shall be factory installed on the chiller. It will vary the compressor motor speed by controlling the frequency and voltage of the electrical power to the motor. The capacity control logic shall automatically adjust motor speed for maximum part load efficiency by analyzing information fed to it by sensors located throughout the chiller.

2. Drive shall be PWM type utilizing IGBTs with a displacement power factor of 0.97 or better at all loads and speeds.

3. The VSD shall be unit mounted in a NEMA -1 enclosure with all power and control wiring between the drive and chiller factory installed. Field power wiring shall be a single point connection and electrical lugs for incoming power wiring will be provided. The entire chiller package shall be UL listed.

4. The VSD shall be cooled using condenser water and all cooling connections shall be factory installed.

5. Provide the following features:

a. Door interlocked rotary disconnect switch or circuit breaker capable of being padlocked.

b. Ground fault protection.

c. Over-voltage and under-voltage protection.

d. 3-phase sensing motor over current protection.

e. 3-phase sensing input over current protection.

f. Single phase protection.

g. Insensitive to phase rotation.

h. Over temperature protection.

i. VSD to produce low levels of harmonic distortion while helping the building comply with the requirements of the IEEE Std. 519, IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems.

j. Digital readout at the chiller unit control panel of output frequency, output voltage, 3-phase input current, 3-phase output current, input kVA, Kilowatts and Kilowatt-hours, input voltage THD, input current TDD, self-diagnostic service parameters. Separate meters for this information will not be acceptable.

k. KW Meter - The unit’s input power consumption will be measured and displayed digitally via the unit’s control panel. The KW meter accuracy is typically +/- 3% of reading. KW meter scaleis 0 - 788 KW.

l. KWh Meter – The unit’s cumulative input power consumption is measured and displayed digitally via the unit’s control panel. KWh meter scale is 0 – 999,999 kWh.

m. Ammeter – Simultaneous three-phase true RMS digital readout via the unit control panel. Six current transformers provide isolated sensing. Ammeter scale is 0 - 545 A

RMS.

n. Voltmeter – Simultaneous three-phase true RMS digital readout of input voltage and motor voltage via the unit control panel. Voltmeter scale is 0 – 670 VAC.

o. Elapsed Time Meter – Digital readout of the unit’s elapsed running time (0 – 876,600 hours, resettable) is displayed via the unit control panel.

U. Refrigerant Isolation Valves

1. Provide Factory-installed isolation valves in the compressor discharge line and refrigerant liquid line shall be provided. These valves shall allow isolation and storage of the refrigerant charge in the chiller condenser during servicing, eliminating time-consuming transfers to remote storage vessels. Both valves shall be positive shutoff, assuring integrity of the storage system.

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V. Refrigerant Flow Control

1. Provide Refrigerant flow to the evaporator shall be controlled by a variable orifice. The variable orifice control shall automatically adjust to maintain proper refrigerant level in the condenser and evaporator. This shall be controlled by monitoring refrigerant liquid level in the condenser, assuring optimal subcooler performance.

2.2 REFRIGERANT MONITORING AND SAFETY EQUIPMENT

A. General: Provide refrigerant monitoring sensor/alarm system and safety equipment as specified here.

Refrigerant sensor and alarm system shall comply with ASHRAE Standard 15. The refrigerant monitoring system will be provided by the chiller manufacturer and shall be interfaced with the DDC control system.

B. Refrigerant monitor shall continuously display the specific gas (refrigerant used) concentration; shall be capable of indicating, alarming and shutting down equipment; and automatically activating ventilation system. On leak detection by refrigerant sensor(s), the following shall occur:

1. Activate machinery (chiller) room ventilation.

2. Activate visual and audio alarm inside and outside of machinery room, with beacon light(s) and horn sounds equipment room and outside equipment room door(s). Shut down combustion process where combustion equipment is employed in the machinery room.

3. Notify Engineering Control Center (ECC) of the alarm condition.

C. Refrigerant monitor shall be capable of detecting concentration of 1 part per million (ppm) for low-level detection and for insuring the safety of operators. It shall be supplied factory-calibrated for the apparent refrigerant.

D. Monitor design and construction shall be compatible with temperature, humidity, barometric pressure, and voltage fluctuations of the machinery room operating environment.

PART 3 – EXECUTION

3.1 EXAMINATION

A. Examine roughing-in for concrete equipment bases, anchor-bolt sizes and locations, piping and electrical to verify actual locations and sizes before chiller installation and other conditions that might affect chiller performance, maintenance, and operation. Equipment locations shown on drawings are approximate. Determine exact locations before proceeding with installation.

3.2 EQUIPMENT INSTALLATION

A. Install chiller on concrete base with vibration isolators.

1. Concrete base is specified in Section 03 30 00, CAST-IN-PLACE CONCRETE

2. Vibration isolator types and installation requirements are specified in Section 23 05 41, NOISE and VIBRATION CONTROL FOR HVAC PIPING and EQUIPMENT

3. Anchor chiller to concrete base according to manufacturer’s written instructions and for seismic restraint on vibration isolators.

4. Charge the chiller with refrigerant, if not factory charged.

5. Install accessories and any other equipment furnished loose by the manufacturer, including remote starter, remote control panel, and remote flow switches, according to the manufacturer written instructions and electrical requirements.

6. Chillers shall be installed in a manner as to provide easy access for tube pull and removal of compressor and motors etc.

B. Install refrigerant monitoring and safety equipment in accordance with ASHRAE Standard 15.

C. Install refrigerant piping as specified in Section 23 23 00, REFRIGERANT PIPING and ASHRAE

Standard 15.

D. Install thermometers and gages as recommended by the manufacturer and/or as shown on drawings.

E. Piping Connections:

1. Make piping connections to the chiller for chilled water, condenser water, and automatic tube brush cleaning system and other connections as necessary for proper operation and maintenance of the equipment.

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2. Make equipment connections with flanges and couplings for easy removal and replacement of equipment from the equipment room.

3. Extend vent piping from the relief valve, rupture disk and purge system to the outside.

3.3 STARTUP AND TESTING

A. Engage manufacturer's factory-trained representative to perform startup and testing service.

B. The services of a factory trained, field service representative will be provided to supervise the final leak testing, charging and the initial startup and conduct concurrent operator instruction.

C. Inspect, equipment installation, including field-assembled components, and piping and electrical connections.

D. After complete installation startup checks, according to the manufacturers written instructions, do the following to demonstrate to the VA that the equipment operate and perform as intended.

1. Check refrigerant charge is sufficient and chiller has been tested for refrigerant leak.

2. Check bearing lubrication and oil levels.

3. Verify proper motor rotation.

4. Verify pumps associated with chillers are installed and operational.

5. Verify thermometers and gages are installed.

6. Verify purge system, if installed, is functional and relief piping is routed outdoor.

7. Operate chiller for run-in-period in accordance with the manufacturer’s instruction and observe its performance.

8. Check and record refrigerant pressure, water flow, water temperature, and power consumption of the chiller.

9. Test and adjust all controls and safeties. Replace or correct all malfunctioning controls, safeties and equipment as soon as possible to avoid any delay in the use of the equipment.

10. Prepare a written report outlining the results of tests and inspections, and submit it to the VA.

E. Engage manufacturer’s certified factory trained representative to provide training for 40 hours for the VA maintenance and operational personnel to adjust, operate and maintain equipment, including self-contained breathing apparatus.

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