60 TON CHILLER SPECIFICATIONS DOCUMENT.pdf

SPECIFICATION FOR

STACKABLE 60 TON CHILLED WATER UNITS

Page 1 of 26 31 May 2024

1 GENERAL PRODUCT DESCRIPTION/PERFORMANCE:

1.1 This specification is for a portable/stackable skid-mounted, air cooled, nominal 60 ton capacity, R-454B, chilled water unit for waterfront use in a Government shipyard in Bremerton, WA (Technical Point of Contact: Code 270.4 Chris Stewart or Shaun Federighi 360-476-7060). The shipyard is a high-abuse, marine, industrial environment. Unit shall be new, constructed with all new components. Throughout this specification, the completed system, including all components, is referred to as the “chilled water unit”.

1.1.1 Throughout this specification, the portions of the “chilled water unit” which include the evaporator, condenser, associated refrigeration piping and controls is referred to as the “refrigeration unit”.

1.2 In addition to the delivery of the chilled water unit described below, drawings, documentation, notifications and test certifications which warrant separate deliverables are described in paragraph 2 of this document.

1.3 The chilled water unit shall be designed per the schematic in Figure 1 and the requirements of this specification. Some components required by this specification are not shown on Figure 1.

1.4 The chilled water unit will be used as a portable source of chilled water, connected to a closed loop, temporary industrial cooling system in an industrial environment. The cooling water pump, a (minimum) 500 gallon volume tank, and a chilled water filter shall be installed on the skid along with the refrigeration unit, so that the package can supply chilled water without the need for additional equipment.

1.5 Typically, the chilled water unit will be operated as an independent, stand-alone unit and shall be designed for continuous operation with a nominal load of 60 Tons (rated 58 Ton minimum) with rapid changes in the load. The peak load capability of the chilled water unit may be higher than the rated capacity. The chilled water unit shall automatically accommodate loads below 8 tons while continuously circulating water. The chilled water unit may also be installed in parallel with a second, identical chilled water unit to serve a combined load of 120 Tons with frequent load variations as low as 8 Tons.

1.6 The chilled water unit shall be designed for continuous operation. The chilled water unit shall have automatic controls so that it can operate unattended with a load varying over the full rated load range and ambient temperatures varying over the full specified range. When flow to the process loop is restricted, a pressure bypass valve (back-pressure regulator) shall ensure continuous flow through the chilled water unit and limit the peak pressure at the chilled water unit outlet connection as required.

1.7 Chilled water leaving temperature shall be 42F to 45F. The rated capacity shall be achieved with 45F leaving water temperature. The return temperature will vary unpredictably and quickly from 45 to 55F. Sometimes, the return temperature will be as high as 105F for a prolonged period, but at a lower flow rate. The load applied to the chilled water unit will sometimes exceed the cooling capacity of the refrigeration unit. The chilled water is fresh water from a municipal potable water main with low hardness and no user-added chemicals.

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1.8 During operation the unit shall not produce an overall A-weighted sound power level greater than 84 dB(A) when tested IAW AHRI 370. Sound level test shall be performed on unit with 100% of pump discharge flow directed through pressure bypass valve.

1.9 Ambient conditions: 0 to 125ºF high humidity, and exposure to rain, sleet, snow, sun, heavy fog, infrequent salt spray, and moderate dust.

1.10 Overall Dimensions:: The chilled water unit shall have a footprint no larger than 120 in. by 240

in. and shall be no taller than 108 in. high. A smaller size is preferred.

1.11 The chilled water unit shall be complete in all respects, devoid of any defects, requiring only connection to a source of make-up water and a single service of electrical power , except a separate electrical service is required for the heat trace.

1.12 The chilled water unit shall operate with 460 V, 60 Hz, 3 phase power, excluding electrical service required for the heat trace. Other voltages required by installed components shall be supplied by transformers supplied integrally with the chilled water unit.

1.13 Water recirculated by the chilled water unit is non-potable fresh water. Water for initial fill enters the chilled water unit from a municipal potable water system via 1½” Volume Tank drain.

Water for makeup enters the chilled water unit via 1” connection at the pump suction (Figure 1).

1.14 The chilled water unit shall be designed for at least a 15-year service life.

1.15 The chilled water unit will be moved every six to twelve months in the shipyard by truck, crane, and forklift. When installed, the chilled water unit will rest upon uneven soil or pavement. The contractor shall ensure that the chilled water unit is designed to operate properly and reliably under these conditions.

1.16 Chilled water units are only to be stacked during storage. Chilled water units will not be stacked during operation.

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FIGURE 1

Chilled Water Unit Schematic – 60 Ton

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2 SUMMARY OF SUPPORTING DELIVERABLES:

This paragraph contains drawings, documentation, notifications and test certification which warrant separate deliverables in addition to the delivery of the equipment described in the Scope of this document. Code 244 shall notify C/270.4 once deliverables are received. Some or all tests listed in Testing Section of specification do not appear on this list. C/270.4 has determined that asking for test data sheets to be submitted as part of the Post –deliverable Manual is adequate for these items. Additional testing requirements and standards (e.g. ASTM B117 Salt Spray Test) are referenced in this specification to identify selection criteria for individual parts; however, certification is only required as listed below:

2.1 Pre-Deliverables:

2.1.1 Drawing: Pre-construction component sketch or drawing

Item: Chilled water unit skid assembly

Performance: Prior to Construction: A system sketch or drawing, in “.pdf” format, shall be delivered to the contracting officer for technical acceptability based on the specification requirements. Submitted data shall include major components, pipe details, and approximate dimensions. The drawing may be developed using methods selected by the vendor (e.g. hand drawn or Computer Aided Drafting Software) and shall be delivered no more than 10 days after award.

Acceptance: The initial review of the drawings by C/270.4 shall take no more than 3 business days once received by the Government.

2.1.2 Calculations: Lifting Structure Design Calculations

Items: Chilled water unit skid structure

Performance: Prior to Delivery: Lifting Structure Design Calculations in accordance with the Skid and Lifting Structure Calculations section of this specification, and stamped by a Licensed Professional Structural Engineer shall be delivered to the contracting officer for technical acceptability based on the specification requirements.

Acceptance: The initial review of the calculations by C/270.4 shall take no more than 10 business days once received by the Government.

2.2 Post-Deliverables:

2.2.1 Manual: Engineering Data Manual

Item: Chilled water unit skid assembly

Performance: Three hard copies of the data listed in the Engineering Documents section of this specification shall be delivered within 30 days of the initial chilled water skid delivery. If more than one chilled water skid is ordered, only three total sets of data are required. Each set shall include both a paper copy and a copy of the data on CD. Electronic copies shall include electronic drawing files created for unit design (if CAD, AutoCad or Solid Edge 3D format preferred but not required).

Acceptance: The initial review of the manuals by C/270.4 shall take no more than 10 business days once received by the Government.

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3. COMPONENT SPECIFICS

3.1. Refrigeration Unit

3.1.1. General

3.1.1.1. Refrigeration unit rated capacity: At least 58 Tons, at standard rating conditions as defined in AHRI STANDARD 550/590 (I-P)-2023. It is understood the capacity will be reduced at elevated ambient temperatures. The refrigeration unit shall bear the AHRI Certified mark.

3.1.1.2. Seismically isolated from the skid (Paragraph 3.7).

3.1.1.3. Chilled water leaving temperature shall be 42F to 45F. The rated capacity shall be achieved with 45F leaving water temperature. The return temperature will vary unpredictably and quickly from 45 to 55F. Sometimes, the return temperature will be as high as 105F for a prolonged period, but at a lower flow rate. The load applied to the refrigeration unit will sometimes exceed the cooling capacity of the refrigeration unit.

3.1.1.4. The unit shall meet the efficiency standards of the latest ASHRAE Standard 90.1.

3.1.2. Refrigerant Circuits

3.1.2.1. Refrigerant shall be R-454B.

3.1.2.2. The unit shall include two independent refrigerant circuits.

3.1.2.3. The number of mechanical joints shall be kept to a minimum. Brazed connections shall be used.

3.1.2.4. The refrigeration unit shall be designed to permit continued operation while one of the refrigerant circuits is being serviced.

3.1.2.5. Each refrigerant circuit shall include a compressor suction and discharge service valve and a filter/dryer with a removable core and isolation valves.

3.1.2.6. The refrigerant circuit shall include a sight-flow indicator with moisture indicator.

3.1.2.7. Refrigerant return pipes shall be insulated.

3.1.3. Compressors

3.1.3.1. Four hermetic scroll compressors (two per refrigerant circuit).

3.1.3.2. During low load conditions, the refrigeration unit shall automatically increase and decrease the number of compressors operating to match the load.

3.1.3.3. Hot gas bypass and compressor staging shall be utilized to accommodate changes in load.

3.1.3.4. The compressors shall be surrounded by access panels with acoustic insulation on the interior side.

3.1.3.5. Each compressor shall have a crankcase heater.

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3.1.4. Condenser

3.1.4.1. The condenser shall be protected from corrosion by a dip-applied epoxy coating.

The coating shall not be spray applied. Coating shall have previously passed a 3,000 hour, or longer, ASTM B117 Salt Spray Test. Bridging of the coating between fins is not acceptable.

3.1.4.2. A heavy metal grill or louvered panel shall protect the condenser from damage.

Where gauges or manually-operated chilled water valves are located behind the grill or louvered panel, a hinged, expanded metal cover shall be installed. This cover shall permit the valves and gauges to be seen without opening the cover.

Also, the cover shall be large enough to allow operation of the valves when open.

Opening the hinged, expanded metal cover shall not require the removal of threaded fasteners.

3.1.4.3. The condenser cooling fans shall automatically cycle and/or vary speed to accommodate low ambient temperature.

3.1.4.4. Condenser may be either aluminum microchannel or copper tube and copper plate fin construction.

3.1.4.5. The condenser fins and tubes shall be protected from corrosion by a catalyzed coating designed for use on condenser coils in industrial environments. The coating shall be applied in accordance with the coating manufacturer’s instructions.

3.1.4.6. Condenser fans shall have plastic or composite blades. The hub shall be metal.

3.1.5. Evaporator

3.1.5.1. Plate-type. Tube and shell is not a permitted alternative.

3.1.5.2. Insulated.

3.1.5.3. Evaporator shall be protected from freezing by heat trace (see paragraph 3.3).

3.1.5.4. Valves and fittings shall be provided to permit the evaporator to be drained and vented without disassembly.

3.1.5.5. Designed, tested, and stamped in accordance with ASME for the refrigerant side working pressure. Standard manufacturer UL label is an acceptable alternative.

The evaporator shall be designed for a water side working pressure of at least 215 psi.

3.1.5.6. A strainer with blow-down shall be installed upstream of the evaporator.

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3.2. Other Components

3.2.1. General

3.2.1.1. Figure 1 shows piping arrangement with pump, filter, flow sensor, flowmeters and volume tank which all shall be mounted on the skid. The volume tank, pump, and filter shall be installed upstream of the evaporator. All return water shall flow through the volume tank in order to provide a thermal lag when sudden changes in load occur.

3.2.1.2. System components shall be selected to minimize pressure loss and turbulence through the system. The system connection to the pump inlet shall be a straight pipe section at least five pipe diameters long.

3.2.1.3. Design working pressure at least 150 psig at 120°F.

3.2.1.4. Wetted components such as pipe, valves, gauges, sensor connections, vacuum breaker and fittings shall be constructed of copper, copper-nickel, brass, stainless steel, or bronze except as noted. This requirement is also applicable for portions of wetted components which are not in contact with process flow. Process piping shall be stainless steel.

3.2.1.5. All piping system low points shall include drain valves. Low point drain valves not shown in Figure 1 shall be 1 in. NPT, or larger, ball valves. Water filled sensor tubing low point drains and high point vents can be sized identical to tubing size (Swagelok type ball valves).

3.2.1.6. Pipe, valves, and components in the primary process water flow path shall be 2½

in. nominal pipe size (NPS), except the pump, make-up water, and pressure bypass valve shall be sized to match the application. Skid supply and return connections centerline shall not be more than 3 feet above grade.

3.2.1.7. Cam and groove (C&G) fittings shall be installed in the locations shown on Figure 1.

3.2.1.8. C&G fittings shall be per Commercial Item Description A-A-59326 and these additional requirements, which take precedence in case of conflict: pressure rating 300 psig (minimum); stainless steel cam arms with passive locking feature, and stainless steel or ASTM B61 C92200 bronze body. PT Coupling “heavy duty” fittings, p/n 1400125H and p/n 1400125HD are examples of items meeting these specifications.

3.2.1.8.1. Each C&G connection shall include a metal C&G dust cap or plug, tethered near the connection via braided stainless cable. Caps and plugs shall have 1/8” holes to allow for piping cavity draining and to avoid pressure build-up should the isolation ball valve leak by. No portion of the cap or plug, when installed, shall extend beyond the four vertical planes formed by the outside edges of the skid.

3.2.1.8.2. Fitting gender shall carry fluid flow out of male C&G fittings into female C&G fittings.

3.2.1.9. Manual valves shall be accessible while standing at grade.

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3.2.2. Ball Valves

3.2.2.1. Size 2½ in. ball valves: Shall be full port, three-piece body, bronze construction with stainless steel trim and vented ball. Nibco T-595-Y-66-SS or equal.

3.2.2.2. Ball valves shall have an extended handle to prevent interference with lagging.

3.2.2.3. No valve components shall be carbon steel.

3.2.2.4. Ball valves shall be installed with ball vent port on downstream side of system flow direction when valve is in closed position.

3.2.3. Relief Valves

3.2.3.1. Relief valves shall include a manual lift device.

3.2.3.2. Relief valves shall not have any components made of carbon steel (including the spring).

3.2.3.3. Relief valve on make-up water connection line shall bear the ASME seal.

Setpoint shall be 25 psi.

3.2.3.4. Relief valve on volume tank shall bear the ASME seal. Setpoint shall be 150 psi.

3.2.3.5. Relief valve discharges shall be piped down to the skid.

3.2.3.6. Relief valves shall be sized for full flow through make-up water line.

3.2.4. Flow Switch

3.2.4.1. Chilled water unit shall include a flow switch(s) to sense low chilled water flow and shut down the refrigeration circuit and chilled water pump when the chilled water flow is reduced to about 55 GPM. Note: It may be required to install a timer/delay to allow the chilled water pump to initiate flow from zero. The flow switch shall be a NEMA 4X electronic flow switch (such as the Ameritrol, Inc.

FX series, or equal). The use of a paddle type flow switch is not permitted.

3.2.5. Pressure Bypass Valve, Manual Bypass Valve and Associated Piping.

3.2.5.1. Pressure bypass control valve shall be a flanged or union connection and shall have a customer adjustable setpoint.

3.2.5.2. Epoxy coated ductile iron is an acceptable material for valve body in the pressure bypass valve, in addition to the materials listed in the General Piping Section of this document. Spence, Model C34Q or equal.

3.2.5.3. The pressure bypass valve (PBV) shall automatically bypass flow to keep the skid supply pressure from exceeding 85 psig (at initial setpoint).

3.2.5.3.1. The pressure bypass valve shall be sized so that when the only flow path on skid is through the pressure bypass valve at least 135 gpm but no more than 200 gpm of water will flow.

3.2.5.4. Manual bypass valve (V-11):

3.2.5.4.1. Shall be a globe valve.

3.2.5.4.2. The manual bypass valve shall be sized so that when the only flow path on skid is through the manual bypass valve, at least 135 gpm but no more than 200 gpm of water will flow through the fully open manual bypass valve.

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3.2.6. Make-up Water Pressure Reducing Valve (PRV) and Associated Piping:

3.2.6.1. Water shall enter the unit through a 1 in. NPS pressure regulator. The pressure shall be continuously applied during system operation, at the regulator set point of 15psig.

3.2.6.2. Fresh Water Fill piping and components shall meet the requirements in the “General Piping” section of this document.

3.2.6.3. PRV shall have union or flanged ends to facilitate removal.

3.2.7. Expansion Tank

3.2.7.1. Bladder-type with a 10 to 12 psi precharge.

3.2.8. Pump

3.2.8.1. The pump design point shall be 140 gpm at 82 psi minimum, with 70°F fresh water.

3.2.8.2. Close coupled, multi-stage, vertical centrifugal with mechanical seal and flanged connections.

3.2.8.3. Stainless steel casing and impeller.

3.2.8.4. Shut-off head of the pump shall not exceed 150 psig. The pump shall operate without malfunction during prolonged low flow conditions (80 gpm).

3.2.8.5. Pump shall be selected so that the chilled water pressure and flow specified are within 5% of the best efficiency point of the pump.

3.2.8.6. The motor shall be constructed in accordance with IEEE 841-2021, IEEE Standard for Petroleum and Chemical Industry—Premium-Efficiency, Severe- Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induction Motors— Up to and Including 370 kW (500 hp).

3.2.8.6.1. Bearings shall not be sealed – instead, grease fittings and spring loaded relief plugs shall be provided to allow lubrication. Lubrication extension tubes shall be installed as necessary to ensure accessibility.

3.2.9. Filter Housing

3.2.9.1. The filter housing shall and meet the following specifications:

3.2.9.1.1. Accommodate the Government’s standard filter cartridges which are 40 in.

long 50 micron or 60 micron nominal, cellulose or acrylic fiber, phenolic resin 3M Micro-Klean RT, P/N RT40L16G20NN or equal

3.2.9.1.2. Capacity: seven or more 40 in. long cartridges.

3.2.9.1.3. Inlet and outlet: 2½ or 3 in. flanged connections.

3.2.9.1.4. Swing bolt cover closure with EPDM O-Ring.

3.2.9.1.5. Swing bolts and nuts: Stainless steel or a copper alloy. Nut/bolt combinations shall not both be of stainless steel so as to prevent stainless thread galling. Eye nuts shall be used vice hex nuts to secure filter housing cover.

3.2.9.1.6. Filter body and cover: Stainless steel 304L or 316L.

3.2.9.1.7. Internal components: Stainless steel.

3.2.9.1.8. Differential pressure gauge connections.

3.2.9.1.9. Four mounting legs welded to the filter housing.

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3.2.9.1.10. Mounting legs shall be bolted to frame with fasteners in accordance with paragraph 3.2.13.

3.2.9.1.11. Filter housing drains with 90 degree brass elbows and ball valves.

3.2.9.1.12. ASME code stamped pressure vessel not required.

3.2.9.2. The filter housing shall have a full set of filter cartridges installed. It is not permissible to substitute four 10 in. long cartridges for the 40 in. long cartridges.

3.2.10. Gauges:

3.2.10.1. Pressure gauges shall be installed as required by Figure 1 with an isolation valve or valves (differential pressure gages).

3.2.10.2. Differential pressure, (for filter): In-line 0/20 psid, 2-1/2” face, Stainless steel body, BUNA soft goods, ¼” NPT/F, adjustable maximum pointer, safety glass.

DP gage shall be installed with SS pipe unions (or similar) on, valved gage sensing lines for ease in removal/reinstallation for calibration purposes.

METCAL requirement not needed for this item. Ashcroft Model 1130 or equal.

3.2.10.3. Pressure: Industrial, SS or brass case, 3.5 inch or 4 inch face, ¼ in. NPT lower mount, 0-160 psig, ± 1% of full scale, glycerine filled, has a 24 month calibration period in the Navy METCAL program. Ashcroft 35-1009-SL-02L-XLL-160 or WIKA 213.40, or equal.

3.2.10.4. Temperature: ºF; bimetallic, range 0 to 100ºF, 3 inch face. diameter dial with reset screw, stainless steel, hermetically sealed, divisions 1ºF and has a 24 month calibration period in the Navy METCAL program. Ashcroft 30-EI-60-X-0/100F or equal.

3.2.11. Flowmeters:

3.2.11.1. Continuously indicate flow in gpm when chilled water unit is energized.

3.2.11.2. If powered, the flowmeters shall be powered from the electric control panel.

Battery powered flowmeters shall not be used.

3.2.11.3. Flowmeters shall have flanged or union connections or shall mount in a flanged spool piece.

3.2.12. Volume Tank

3.2.12.1. Tank shall be made of steel and be constructed, tested and labeled in accordance with UL-142, Steel Above Ground Tanks for Flammable and Combustible Liquids.

3.2.12.2. Tank shall have a rated nominal capacity of at least 500 gallons and a rated design pressure of 150 psi.

3.2.12.3. Tank shall have no baffles.

3.2.12.4. Return water shall enter near the top of the tank and exit near the bottom of the tank through 2½ in flanged connections. Fitting arrangement shall encourage mixing in the tank and no short circuiting.

3.2.12.5. Drain and vent piping shall be 1½ in. NPS. User connection on drain shall be a 1½ in. male C&G fitting.

3.2.12.6. The tank shall have tank level indicator such as a magnetic float and flipper type.

Tank level indicator shall be of rugged construction or shall be adequately protected from damage. Valves shall be installed at the top and bottom of the

Page 11 of 26 31 May 2024 indicator to permit isolation during replacement/damage control. The valves shall each include a drain/vent petcock. The indicator shall not extend outside the vertical envelope of the skid.

3.2.12.7. Vent and drain components shall meet the requirements in the “General Piping” section of this document.

3.2.12.8. Tank shall have a manhole. The manhole cover shall not collect or hold water.

3.2.12.9. Tank interior and exterior surfaces shall be cleaned and blasted prior to coating, to SSPC-SP10. Tank exterior surface shall be coated with zinc primer, an epoxy intermediate coat, and a catalyzed urethane top coat. Each coating shall be applied in accordance with the coating manufacturers’ instructions. Tank interior coating shall be a two part polyurethane, two coats, 15 mils minimum dry film thickness.

3.2.12.9.1. Note for coating selection: the water in the tank is non-potable.

3.2.12.10. The tank shall be insulated per the Insulation section of this specification.

3.2.12.11. Tank Bolts, nuts, and washers shall be stainless steel or meet ASME B18.2.1, grade 8 with 1,000 hours of salt spray resistance per ASTM B117. An example of a grade 8 fastener which meets this specification is McMaster Carr p/n 91286A407.

3.2.12.11.1. In order to prevent galling problems experienced by the customer, stainless steel nuts shall not be used with stainless steel bolts or studs.

3.2.13. Fasteners

3.2.13.1. Unless otherwise noted, bolts, nuts, and washers shall meet ASME B18.2.1, grade 8 with 1,000 hours of salt spray resistance per ASTM B117. An example of a grade 8 fastener which meets this specification is McMaster Carr p/n 91286A407.

3.2.13.1.1. Exception: Tank fasteners may be stainless steel.

3.2.13.1.2. Exception: Equipment foundation fasteners or inaccessible fasteners shall have self-locking nuts. These nuts may be stainless steel.

3.2.13.2. In order to prevent galling problems experienced by the customer, stainless steel nuts shall not be used with stainless steel bolts or studs.

3.2.14. Electrical Requirements

3.2.14.1. Electrical connections exposed to condenser airflow inside the refrigeration unit and/or exposed to outdoor conditions shall be watertight and rated for outdoor use. For example, electrical connections to the refrigerant solenoid valves, heat trace, and chilled water flow switch shall be watertight. All wires in the weather or exposed to condenser airflow inside the refrigeration unit shall be contained within liquid-tight conduit.

3.2.14.2. The equipment shall be designed for operation and storage outdoors.

3.2.14.3. The chilled water unit shall be designed and constructed in accordance with the requirements of the National Electrical Code.

3.2.14.4. The chilled water unit shall be listed by Underwriter’s Laboratory or certified by an independent third party certification process as complying with NEC requirements for installation in the weather.

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3.2.14.5. Electrical enclosures, all enclosure penetrations and all components outside the electrical enclosures shall be constructed in accordance with NEMA 4X.

3.2.14.5.1. Other voltages required by installed components shall be supplied by transformers supplied integrally with the chilled water unit.

3.2.14.5.2. A unit-mounted disconnect switch with lockable external operator handle to isolate the chilled water unit from main power for servicing shall be provided in compliance with Article 440.14 of the 2014 National Electric Code and OSHA regulation 29 CFR 1910.147 “The control of hazardous energy (lockout/tagout).”

3.2.14.5.3. Electrical power lead shall be wired through the bottom of the electrical enclosure, sealed with a NEMA 4X cable penetration and with a strain relief device to protect the conductor exiting the enclosure. Conductor shall extend fifty (50) feet outside of enclosure and meet the following specification.

3.2.14.5.3.1. 4 AWG, 4 Conductor, Stranded, 600/2000 V, 90 Degree C, Type W, UL Listed, 100A min. capacity, 3-Ph plus ground, VU-Tron Jacket, Copper, Round Style, Black Color, Flexible Cord, plain end for Government to connect to power supply.

3.2.14.5.4. Electrical enclosure component corrosion protection. Prior to shipping unit(s) from manufacturer, a Vapor Corrosion Inhibitor (A-A-59411, Type 1, 2-year protection) shall be installed interior to each electrical enclosure for circuitry corrosion protection. Four (4) each unopened (original individual wrapped) VCI units, for each enclosure, shall be shipped with each unit.

3.2.14.5.5. Circuit Breaker with High Fault Rated Control Panel: The chill water unit shall have a MOPD (Maximum Overcurrent Protection Device) rating of 200 Amps, or below.

3.2.14.5.6. Short Circuit Rating: The chill water unit shall have a rating of at least 65,000 amp SCCR (short circuit current rating).

3.2.15. Controls

3.2.15.1. Refrigeration unit control shall be microprocessor-based and designed per UL 1995.

3.2.15.2. The controls shall be the standard controls of the OEM refrigeration unit manufacturer and shall include optional control components as needed to meet the requirements of this specification.

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3.2.15.3. The refrigeration unit control PLC (a.k.a. microprocessor control) shall include a control panel with an LCD touch-screen or digital display with keypad and padlockable cover. The display shall be legible in direct sun.

3.2.15.3.1. The control system shall automatically detect and protect the refrigeration unit from likely fault conditions, for example:

3.2.15.3.1.1. Low evaporator refrigerant temperature and pressure.

3.2.15.3.1.2. High condenser refrigerant pressure.

3.2.15.3.1.3. Critical sensor or detection circuit faults.

3.2.15.3.1.4. High compressor discharge temperature.

3.2.15.3.1.5. Phase loss or phase reversal.

3.2.15.3.1.6. Loss of evaporator water flow.

3.2.15.3.1.7. High returning water temperature.

3.2.15.4. The control system shall also include features to minimize the occurrence of nuisance trips.

3.2.15.5. Sufficient information shall be displayed to permit troubleshooting and system monitoring. Information shall include refrigerant high side and low side pressures, chilled water entering and leaving temperatures, set points, and compressor voltage and amperage.

3.2.15.6. The control panel shall be covered with a normally closed, hinged access panel.

Access to the control panel shall not expose any live circuits.

3.2.15.7. Refrigeration unit control set points shall be accessible from the control panel.

The Government shall have access to change the set points. This access shall be password protected.

3.2.15.8. The controls for the refrigeration unit shall automatically operate the components of the refrigeration unit without the need for operator input or monitoring.

3.2.15.9. The refrigeration unit control system shall be designed to prevent nuisance trips.

3.2.15.10. Separate LED indicators shall be installed on the exterior of the refrigeration unit:

3.2.15.10.1. POWER: Power is supplied to the chilled water unit.

3.2.15.10.2. CRANKCASE HEATERS: Crankcase heaters are energized.

3.2.15.10.3. RUN: The refrigeration unit is operating normally.

3.2.15.10.4. REFRIGERATION UNIT FAULT, RESET REQUIRED: Chiller was shut down by the controls due to an alarm or fault.

3.2.15.10.5. CHILLED WATER UNIT ALARM: An alarm exists.

3.2.15.10.6. PHASE/VOLTAGE FAULT: The phase relay is preventing refrigeration unit start.

3.2.15.10.7. Indicator lights shall include a push to test feature.

3.2.15.11. Controls shall include a phase sequence, phase loss, & low voltage relay.

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3.2.15.12. The hinged cover for accessing the fuses, PLC (microprocessor control), breakers, and other control and power components shall include an angled rain lip above the cover.

3.2.15.13. Chilled water unit shall include a NEMA 4X flow switch, set to the minimum safe flow rate for the refrigeration unit. See 3.2.4 for flow switch specifics.

3.2.15.14. Mechanical elapsed hour meter for each compressor. The use of digital hour meters in the control system is not an acceptable alternative. The mechanical meters allow the elapsed time to be viewed while the unit is not energized.

3.2.15.15. The controls shall permit operating the chilled water pump independent of the refrigerant circuit components. The pump shall continue to operate when the refrigeration units stop as part of automatic cycling.

3.2.15.16. Each wire inside the enclosure shall include a permanent, unique label at each end.

3.2.15.17. Switch and indicator light label plates shall be manufactured and installed per Section 3.5.

3.3. Freeze Protection / Heat Trace

3.3.1. The chilled water unit shall not be damaged by exposure to freezing temperatures at the specified ambient temperatures during use or while stored, either drained or undrained.

3.3.2. Thermostat controlled heat trace. All components containing water (including the evaporator, not including the load tank) shall be protected against freeze damage by heat trace (i.e., piping to include all low point drains, instrumentation and regulating valve tubing, pump, sensors, etc.). Tracing shall be installed per tracing supplier and component manufacturer instructions.

3.3.2.1. Controls for the heat trace shall be located in a separate electrical enclosure which only serves the heat trace controls, protective devices, and connections.

This arrangement shall allow the chilled water unit main power cabinet to be fully de-energized while the heat trace is energized.

3.3.2.2. Power/electrical enclosure to the heat trace controls shall be a male 120VAC, 3 prong inlet receptacle (NEMA 5-15P) recessed in a NEMA 4X enclosure separate from the main electrical/controls panel.

3.3.2.3. A light adjacent to the plug shall illuminate when power is supplied to the thermostat(s). A second light shall illuminate when the heat trace is energized.

The lights shall be recessed in the freeze protection electrical enclosure.

3.3.2.4. Heat trace shall be controlled by two thermostats wired in series, each set at 40°F. The two thermostats shall energize the heat trace when both the pipe surface temperature (directly upstream of load tank drain isolation valve at a distance of no less than 24 in. axial pipe length from tank connection) and the ambient temperature are both lower than the setpoint.

3.3.2.4.1. The adjustment shall be mechanical (i.e. dial-type; adjustable while de-energized). The two thermostat adjustment dials shall be located inside the electrical enclosure(s) to prevent unauthorized setpoint adjustment. United Electric Controls model B100 and E100 or equal.

3.3.2.5. A 30 mA Ground Fault Equipment Protector (GFEP) circuit breaker shall be provided in a dead-front NEMA 4X enclosure to protect against heat trace faults, per the National Electrical Code and heat trace manufacturer’s instructions.

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3.4. Coatings and corrosion control - The following requirements apply to all system components except as stated in other sections of this specification:

3.4.1. The exterior and interior of all enclosures and components shall have a protective coating unless they are fabricated of stainless steel, fiberglass, plastic, Alloy 5XXX or 6XXX aluminum, Silicon Bronze, or hot-dip galvanized steel. Hot-dip galvanized surfaces do not require any additional coating. The coatings and sealants shall be designed for use in a marine environment.

3.4.2. Where a material is required to be galvanized or coated to resist the specified marine environment, galvanizing or coating shall either be prior to assembly or the equipment shall be disassembled, the surfaces prepared, and additional coatings added prior to reassembly. Future equipment disassembly shall not degrade the coating.

3.4.3. Carbon steel components exposed to the weather shall be protected by hot dip galvanizing except as noted.

3.4.3.1. Galvanizing shall be per ASTM A123-13, Standard Specification for Zinc (Hot- Dip Galvanized) Coatings on Iron and Steel Products. Damaged galvanized coating shall be repaired per ASTM A780, Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings.

3.4.4. Weld spatter, burrs, and surface contaminants shall be removed prior to galvanizing or the application of protective coatings.

3.4.5. Lead base and chromium base paints are prohibited.

3.4.6. Where a protective coating is required, the surface shall be:

3.4.6.1. Cleaned to SSPC-SP1.

3.4.6.2. Abrasive blasted to SSPC-SP10 for liquid or powder coatings.

3.4.6.3. Primed with liquid or powder epoxy. Where the epoxy is applied to carbon steel, it shall be zinc-rich, such as Sherwin Williams Zinc Clad II Plus Primer liquid epoxy. Application thickness shall be as recommended in the product literature.

3.4.6.4. Topcoated with either polyester powder coating, polyamide epoxy liquid coating, or aliphatic urethane liquid coating. Total topcoat thickness 4-6 mils DFT for powder coating and 6-8 mils for liquid coating. Coating manufacturer literature shall state that the topcoat is compatible with the primer.

3.4.7. Electrical enclosure component corrosion protection. Prior to shipping unit(s) from manufacturer a Vapor Corrosion Inhibitor (A-A-59411, Type 1, 2-year protection) shall be installed interior to each electrical enclosure for circuitry corrosion protection. Four

(4) unopened (original individual wrapped) VCI units, for each enclosure, shall be shipped with each unit.

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3.5. Labels

3.5.1. Labels on the exterior of the unit shall include the following information:

3.5.1.1. This label shall not be combined with any other. Text size 0.5 in. high or larger.

SIMPLIFIED OPERATING INSTRUCTIONS:

1. Start-up delay warning: Number of hours to energize crankcase heaters before starting unit with reference to crankcase heater indication light.

2. Warning to not leave recirc pump running for extended periods when refrigeration unit is not operational to avoid heating water to dangerous levels.

3. Proper button to push to start the chilled water unit. Mention where it is.

4. Proper button to push to shut down the chilled water unit. Mention where it is.

5. Direction to refer to detailed operating instructions for additional requirements not provided on this label plate.

3.5.1.2. Component Identification: Each system valve, gage, meter and switch shown in Figure 2 shall be labeled with numbering and plain English description of the component function as shown in Figure 2. Label plates shall be 4” x 1-1/4” with 1/2” text for component designator and 1/4” text for plain English description.

3.5.1.2.1. A unique label plate similar in style and format to those shown in Figure 2 shall be provided for each system component which is not represented in Figure 2 and each external connection. If additional valves or components are required to meet these specifications contact Government POC for numbering and description.

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FIGURE 2

Chilled Water Unit – Component Label plates

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3.5.1.3. Controls/Indicators shall have labels consistent with description in Section 3.5.

3.5.1.4. Pump Curve.

3.5.1.5. Consumables including the correct filters.

3.5.1.6. Freeze Protection: State the steps needed to protect the unit from freeze damage during use and when preparing for storage.

3.5.1.7. System diagram, similar to Figure 1.

3.5.1.8. Serial Number – each completed skid shall have a unique serial number.

3.5.1.9. Refrigerant, system rating, electrical circuit required, allowed ambient conditions, limits on water temperature and flow, and serial number.

3.5.2. Material. Label plates installed outside the electrical enclosure shall be made of the following material:

3.5.2.1. Engraved stainless steel or brass with a minimum thickness of 1 mm. Engraving shall be to a minimum depth of 0.2 mm, filled with black paint.

3.5.2.2. Metal labels shall be attached to the equipment using stainless steel fasteners or adhered using a permanent RTV adhesive. Attachment with wire is NOT allowed. An example of an adhesive appropriate for this application is Dow Corning 832.

3.5.2.3. A waterproof and fade-proof copy of the electrical and refrigeration schematics shall be secured to the interior of the motor control enclosure. The schematics are not required to be metal labels; however, the schematics shall not be paper or laminated paper. The material shall be waterproof and fade-proof. Label plates may be combined, except where noted.

3.5.3. Lifting Label Plates:

3.5.3.1. Rigging Label Plate: A label shall state and illustrate the skid weight, sling arrangement, minimum sling (pendant) length, equipment dimensions, and center of gravity and that chilled water must be drained before lifting.

3.5.3.2. Each lifting attachment shall be labeled with the working load limit (WLL) and the test date.

3.5.3.3. Lifting label plates shall be mechanically fastened to rigid structure using stainless steel threaded fasteners.

3.6. Insulation

3.6.1. After installation of heat trace, system components containing water shall be insulated with flexible, elastomeric, closed-cell insulation.

3.6.2. Design shall allow removal and reinstallation of the flow meters, low flow switch and adjustment of the pressure bypass valve without damaging the insulation or lagging.

3.6.3. Closed-cell insulation shall be installed with adhesive and sealed seams in accordance with the manufacturer’s instructions. Seams shall be taped using the tape or adhesive recommended by the insulation manufacturer. Duct tape and electrical tape shall not be used.

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3.6.4. Closed cell insulation shall be protected from damage by either fiberglass cloth lagging or mastic with embedded fiberglass mesh.

3.6.4.1. Fiberglass cloth lagging.

3.6.4.1.1. Applied with adhesive on one side only (the side facing the insulation), and protected by an exterior layer of mastic. Materials shall be designed for use in the weather and shall be installed in accordance with manufacturer’s instructions.

3.6.4.1.2. Fiberglass lagging fabric: 17.8 ounces per square yard. Alpha Maritex 2025/9383 or equal.

3.6.4.1.3. Lagging adhesive: Designed for use in the weather; appropriate for bonding fiberglass cloth to elastomeric foam insulation.

3.6.4.1.4. Vapor barrier: Designed for use in the weather; solvent based, white, applied to the exterior of the fiberglass cloth.

3.6.4.2. Mastic with imbedded fiberglass mesh.

3.6.4.2.1. Mastic: Vapor barrier, solvent based, non-asphaltic, white; designed for high abuse environments and use in the weather. Applied in at least two layers. Foster 6090/6095 or equal.

3.6.4.2.2. Fiberglass mesh: 3.9 oz/yd minimum weight, open weave, resin treated, fiberglass, with from 5 x 5 to 10 x 10 threads per square inch. Childers Chil-Glas#5 or equal.

3.6.4.2.3. Before applying mastic coating, apply a heavy fillet of caulking mastic to inside corners of insulation and junctions of insulation and metal.

3.6.4.2.4. Apply double layer of reinforcing cloth in mastic to outside corners of insulation. Round outside corners of insulation.

3.7. Skid

3.7.1. All components of the chilled water unit shall be mounted upon a single welded skid.

3.7.1.1. All welding shall be performed in accordance with AWS D1.1-2010. Welders shall be qualified for the welds used per AWS D1.1-2010. Both inspection and verification shall be performed by the contractor.

3.7.2. Chilled water unit skids shall be stackable to a maximum height of 2 units without plastic deformation of the skid. Chilled water units will be drained prior to stacking.

3.7.2.1. Chilled water units are only to be stacked during storage. Chilled water units will not be stacked during operation.

3.7.3. No portion of the skid structure, including refrigeration unit enclosure, shall collect water.

3.7.4. No skid component (to include valve handles whether in open or shut position) or electrical component(s) shall extend past the four vertical planes or top horizontal plane formed by the skid outside edges.

3.7.5. The skid shall be designed to permit access to the different components of the chilled water unit for operation, maintenance, repair and replacement.

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3.7.6. The skid base and major structural elements shall be painted or constructed of hot dip galvanized steel in accordance with the coatings and corrosion control section of this specification.

3.7.7. The skid shall be rugged, designed to be moved frequently and placed upon uneven surfaces without damage or deformation. The skid shall include cross-bracing and gussets for rigidity.

3.7.8. The enclosure containing the refrigeration unit (condenser, evaporator, and compressor) shall be resiliently mounted upon the skid. The resilient mount system shall comply with seismic application per the most recent version of the International Building Code (IBC). Metal at least 3/8” thick shall be installed between the enclosure and the resilient mounts to prevent distortion of the enclosure base. This metal shall be the length of the enclosure and shall be galvanized or painted to prevent corrosion as described above for major structural elements. The metal shall be bent 90° or shall be a standard structural shape (C-channel, I-beam, 90° angle, etc.) so that it will resist bending.

4. Lifting & Handling – The chilled water unit will be moved by crane and/or forklift several times each year. This section details the requirements that shall be followed in designing the unit for lifting and handling during the lifetime of the equipment.

4.1.1. General Lifting and Handling Requirements:

a. The mounting base shall include design features that permit moving the complete chilled water unit assembly by forklift, without removing any components from the assembly.

b. Mounting base shall be designed to minimize the possibility of deflection (wobble) during times the unit is being transported by forklift over rough, bumpy roads or surfaces.

c. The equipment shall be readily and safely liftable by crane via lift points meeting the requirements of this specification. Lift points shall be located, designed, certified, and marked per this section.

d. All lifting attachment points shall meet the lifting design requirements of Section 4.1.6.

e. Welding shall comply with applicable American Welding Society (AWS) Standards.

f. The following label plates shall be provided and permanently attached to the equipment.

Refer to Section 3.5 for additional details.

i. Rigging diagram label plate. Attached in a conspicuous location on the equipment.

See Para. 3.5.3.1.

ii. Lifting attachment label plates. Attached adjacent to each lift point. See Para. 3.5.3.

g. The vendor shall supply a letter of certification stating that the lifting attachment points and lifting structure meet the specified design criteria. At a minimum the certification document will include equipment nomenclature, serial number, test loads applied, duration of each test load and name and signature of the qualified person conducting the load test.

4.1.2. Forklift Slots:

4.1.2.1. The base shall include fully enclosed 6”x10” Hollow Structural Section (6x10 HSS) forklift slots for handling with a forklift truck from either of three sides.

a. Forklift slots shall be spaced 45” (± 1”) apart (on center) and shall extend far enough to prevent the forklift from contacting non-structural chilled water unit components.

b. Both sets of forklift slots shall have the same spacing between forklift tube centerlines.

4.1.2.2. The center of gravity of the chilled water unit assembly shall be centered between each pair of forklift tubes.

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4.1.3. Lifting Attachment Points:

4.1.3.1. Custom Designed Lift Points: Custom design lifting points are lifting attachment points installed on equipment of unique design (i.e., not mass produced). Custom design lifting attachment points shall comply with section 1926.251(a)(4) of 29CFR, Chapter XVII, Part 1926, Subpart H, Materials Handling, Storage, Use and Disposal.

4.1.3.2. Original Equipment Manufacturer (OEM) Lift Points: OEM lifting attachment points are commercially available, mass produced lift points, such as lugs and integral pad-eyes (i.e., not bolt-on), designed specifically to be integral to, or part of, the load, to facilitate attaching rigging gear to a load. OEM lift attachment points are authorized for use at PSNS &IMF provided the attachment points accommodate common rigging gear (e.g., shackles, wire rope pendants/grommets, etc.) and comply with all applicable ASME visual inspection standards (RUD, Model ABA or equal).

a. Requirements of 1926.251(a)(4) do not apply to mass produced, commercially-available equipment with lifting accessories specifically designed for lifting that OEM mass produced equipment.

4.1.4. Lifting Attachment Point Requirements:

a. Integral (i.e., not bolt-on) lifting point items such as lugs, thru-holes, and pad-eyes are authorized for use at PSNS & IMF. OEM integral pad-eyes are preferable.

b. Removable lift points such as swivel hoist rings, eye bolts, or other bolt-on type lift points, are not authorized.

c. Lift point(s) shall accommodate ASME B30.26-15 (Rigging Hardware, Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings) common rigging gear (e.g., shackles, wire rope pendants/grommets, etc.).

d. Lift points shall be located so that the routing of rigging gear (e.g., slings) does not come into contact with any part of the equipment while maintaining the units’ smallest footprint as possible. This is to avoid damaging equipment, chaffing, etc. Maximum sling length is 40 feet.

e. Lift point(s) shall be located symmetrically around the Center of Gravity (CG) and shall be in a common, horizontal plane, above the center of gravity. Equipment shall lift level within 3°, assuming all sling legs are equal length.

4.1.5. Pad-eyes shall be aligned so their primary plane is toward the CG so that the slings do not pull out of plane by more than 5°. Exceptions may be acceptable if they are designed to account for the resultant out-of-plane loading (such as OEM pad-eyes); however, as a minimum, padeyes shall be designed for an out-of-plane pull of ±5°.

4.1.6. Lifting Design Requirements:

4.1.6.1. Design requirements for the fabrication, selection, and installation of lifting attachment points and lifting accessories, if supplied, shall comply with industry standards such as:

a. ASME BTH-1, Design of Below the Hook Lifting Devices,

b. AWS D14.1, American Welding Society Specification for Welding of Industrial and

Mill Cranes and Other Material Handling Equipment

c. AWS D1.1, Structural Welding Code – Steel

d. Steel Construction Manual – American Institute of Steel Construction (AISC)

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4.1.6.2. The structure supporting the lifting attachments shall be designed to sustain the various lateral loads imparted by the arrangement of the lifting attachments and the induced sling loads. The design shall be calculated as though the actual weight were borne on no more than two pads.

a. The lifting structure shall be designed to a minimum safety factor of three (3) based on material yield strength, or, a minimum safety factor of five (5) based on ultimate strength, whichever is the most conservative.

4.1.6.3. Lifting attachments shall be designed and manufactured in accordance with ASME B30.20 and…