(C)_Spec 1376 Chiller.pdf

Bldg. 1376 CC, Child Development Center

B1376 Chiller Replacement, OA Damper Replacements, and Room 121F Air Supply

Naval Station, Newport, RI

1. Points of Contact

Contracting Officer: Refer to Solicitation Construction Manager will be designated after award.

2. General Description

2.1. The Contractor shall provide supervision, labor, material, and equipment required to perform all work for the following project:

B1376 Chiller Replacement, OA Damper Replacements, and Room 121F Air Supply at the, Child Development Center, at Naval Station Newport, RI

Repairs include:

1) Demolition of existing air cooled chiller, provision of an air cooled chiller, connection to the existing direct digital controls (DDC) network, piping, insulation, electrical, glycol, and related work.

2) Removal of two existing Outside Air Dampers and Installation of four new Outside Air Dampers including actuators, connection to the existing DDC system and other required ancillary components.

3) Addition of air supply from the VAV box described later herein including balancing and other required tasks.

EXISTING CHILLER:

Model: Trane model RTAA090 Refrigerant: R-22 Size: Nominal 90 tons See nameplate and original submittal directly below.

NEW CHILLER:

Nominal Size: 90 tons Glycol: Yes, 30% Chilled Water GPM: Approximately 125 - 215 EWT/LWT (typ): 54 deg F / 44 deg F (other setpoints possible) Electrical: 460V/3ph/60Hz Trane’s replacement-in-kind model: Trane 90T CGAM New unit shall be equal or better than the model above. Contractor shall provide the chiller submittal no later than 30 days after contract award. Later in this document will be more detailed specifications.

2.2. All work shall be done in a manner to provide a complete, usable and finished end product.

2.3. All work shall be performed in accordance with, but not limited to, the standards referenced herein, state and federal codes, laws and regulations, and the Unified Facilities Criteria.

2.4. ATTACHMENTS TO THIS STATEMENT OF WORK (SOW):

2.4.1. NAVSTA Instruction 5090.10C for Ozone Depleting Substances.

2.4.2. Original mechanical design drawings will be made available for reference only. The government doesn’t represent this as the actual field conditions and the contractor must perform their own field survey to verify.

2.4.3. Building Hazmat survey, available upon request.

3. Location

3.1. The work shall be performed at Bldg. 1376 CC, Child Development Center, Naval

Station Newport, RI. Any work inside the occupied spaces of the building (including the attic but not the mechanical room) shall be performed with the same schedule restrictions as the other work inside the building under this project, that being nights, weekends and holidays.

4. Time for Completion: Refer to solicitation. This additional work shall be accomplished concurrently within the period of performance of the other work comprising this project.

5. Examination of the Premises

5.1. Site visits are required and will be arranged by contacting the Contracting Officer.

6. Inspection and Approval

6.1. All material and workmanship shall be subject to the inspection and approval of the CM.

7. Special Scheduling Requirements/Work Procedures

7.1. Work shall be performed during standard business hours or at the discretion of the CM. Schedule the chiller replacement outside of the cooling season to avoid the need for a temporary chiller.

7.2. Existing and adjacent spaces to remain in operation during construction shall be protected from damage, dust, and debris at all times. Damage to any existing spaces, finishes, items, furniture and equipment, as a result of the contractor’s operations, shall be replaced in-kind by the Contractor at no expense to the Government.

8. Passes and Badges

8.1. All Contractor employees shall obtain the required employee and vehicle passes.

9. Supervision/Quality Control/Safety

9.1. All work shall be conducted in a safe manner and shall comply with all requirements of the U.S. Army Corps of Engineers Safety and Health Requirements Manual EM-385-1-1.

9.2. The Contractor shall submit the Accident Prevention Plan and Activity Hazard

Analysis plan for approval by the CM. Submit within fifteen (15) days from award, and obtain approval prior to start of any construction activities.

9.3. A full time Site Safety and Health Officer (SSHO) shall be required that meets the qualifications as set forth in EM-385-1-1. For the positions of Superintendent, SSHO, and QC Manager, 1 person may fill these 3 roles. Any person filling multiple roles shall meet all requirements for each roles. If the Contractor is unable to find 1 person with appropriate qualifications, then additional qualified personnel meeting these requirements shall be provided at no additional cost to the Government.

9.4. CRANE: Removal of existing chiller and installation of new chiller may require a crane.

9.4.1. All crane operations shall be in accordance the relevant weight handling sections of the EM-385.1.1. Care shall be taken to avoid damage to the area and grass around the unit during installation as contractor will be responsible to leave the area in its previous condition.

10. Environmental

a. Hazardous Materials:

i. This chiller was install after 2003 so no hazardous materials will be encountered during the execution of this project.

ii. Refer to attached NAVSTA Newport Instruction 5090.10C for Ozone Depleting Substances, compliance with which is mandatory.

Coordinate with contracting Officer and NAVSTA Newport Environmental Office prior to any demolition of refrigeration equipment and any new work involving refrigeration equipment.

11. Hazardous Materials Disclosure Statements

11.1. All hazardous material shall be identified and Material Safety Data shall be included in corresponding data records for all hazardous material in accordance with EM-385-1-1 and readily available for reference at the work site.

12. Submittals

12.1. The Contractor shall submit all documents required for government approval such as, but not limited to, manufacturers’ product data, shop drawings, testing data, manufacturer warranties, work schedule, equipment checklist, and any additional information to suit project needs, prior to the start of any construction activities and as directed by the CM. Submit the following technical submittals:

12.2. Pre- and Post-Construction Submittals:

12.2.1. The following are the pre-construction submittals required:

12.2.1.1. Accident Prevention Plan (APP)

12.2.1.2. Applicable Activity Hazard Analysis Plans (AHA)

12.2.1.3. Basic project schedule – simple bar graph, or list of activities with dates will be sufficient.

12.2.1.4. Applicable material/product submittals

12.2.1.5. QC Plan

12.2.2. The following are the post-construction submittals required:

12.2.2.1. Construction As-builts

12.2.2.2. DDC As-Builts

12.2.2.3. DDC and any other training

12.2.2.4. Equipment and other O/M manuals and related data

13. Competent Person

13.1. The contractor shall submit:

13.1.1. Name, address, and telephone number of the Competent Person (CP) selected to perform responsibilities specified in paragraph COMPETENT

PERSON RESPONSIBILITIES.

13.1.2. Documentation that substantiates the CP construction project-related experience for the specified work. (e.g., confined space entry, scaffolding, fall protection or any other activities as specified by OSHA/this manual) and shall be identified and included in the AHA

13.1.3. Proof of the CP competency/qualifications, which shall include proper documentation that the CP is trained and certified in accordance with federal, State and local laws.

14. Competent Person (CP) Responsibilities

14.1. Verify training meets all federal, State, and local requirements.

14.2. Ensure work is performed in strict accordance with specifications at all times.

14.3. Control work to prevent hazardous exposure to human beings and to the environment at all times.

14.4. Certify the conditions of the work as called for elsewhere in this specification.

14.5. The above responsibilities are required but not limited to the work specified in this document.

14.6. All requirements shall comply with the U.S. Army Corps of Engineers Safety and Health Requirements Manual EM-385-1-1.

15. Contractor Presence

15.1. An employee of the prime contractor who has full authority to make decisions and financially or otherwise obligate the prime contractor shall be physically present at any requested key meetings and site visits.

15.2. Key meetings include, but are not limited to pre-construction meetings, progress meetings, and inspections at the job site. Sending a subcontractor to represent prime contractor at related meetings is not authorized.

15.3. A full time superintendent/SSHO/QC Manager is required to be on site at all times when work is taking place. One person may fill the roles of project superintendent, QC Manager, Site Safety and Health Officer subject to paragraph 9.3 above.

16. Work Requirements

1. 90 Ton Air cooled packaged Water Chiller

a. Provide 90 ton chiller to replace-in-kind the existing chiller. Modify all mechanical, electrical, control (DDC), and any other connections as necessary to ensure the new installation meets the full range of operations to ensure a complete and usable Chiller and HVAC system.

b. Tie in to existing DDC for control. Replace temperature/pressure gauges at the chiller supply and return lines inside the mechanical room. Also replace the existing gages outside on the chiller piping with like products.

c. Repair/replace all insulation and other components as necessary.

d. Condenser coils will have a factory applied coating suitable for the marine environment.

e. When connecting the existing chiller water piping to the new chiller, replace the elbow between the shut-off valve and the chiller with a “T” section with another shut-off valve so that a rental chiller can be connected to the piping in case of emergency. Place a blind flange on the new valve and replace in kind the existing shut-off valve.

f. Replace the electrical disconnect switch at the chiller and the circuit breaker in the electrical room.

2. Existing DDC:

a. Johnson Controls Inc. (JCI) with N2 communications protocol. This project will support the update of the communications to Metasys Extended Architecture BACnet MS/TP for the new chiller by the installation of a new supervisory controller, JCI part number M4- SNE22002-0, Version 12, while maintaining the existing system communications to the supervisory controller as-is. Chiller will have a BACnet card to communicate with the new controller via Metasys.

Download the programming in the current supervisory controller for installation to the new supervisory controller for the current N2 system equipment. The new controller will accept a cable from the chiller which will be communicating via Metasys BACnet. Return the old supervisory controller to the base PW engineering branch DDC technician.

3. DDC scope of work (in addition to that above):

a. DDC subcontractor shall be a Johnson Controls Inc. (JCI) Authorized

Building Control Specialist (ABCS) and be certified to install JCI Metasys Extended Architecture and JCI standard Graphics.

b. Connect the Chiller, as described in 3d. below, as a third party piece of equipment on the controls system with Building control system providing an enable and other signals. The chiller will transmit data back to the DDC system such as, but not limited to, run status, alarms, failure modes and any other data that the chiller can report back to the supervisory controller.

c. Provide one half-day of Performance, Verification and Testing (PVT) to demonstrate to the Government the new programming and graphics and to provide 1-hour training session the same day.

d. Run a continuous cable that is appropriate for transmitting the (BACnet) DDC data from the new Chiller to the new Supervisory Controller (Engine) that will be installed in the main lobby, replacing the old supervisory controller which will be returned to the base PW DDC tech.

PHOTOS OF THE EXISTING CHILLER.

4. For the new chiller, the name plate will be of a non-corroding metal such as but not limited to nickel-copper, 304 stainless steel, or monel. Aluminum is unacceptable.

(This supplements Spec 23 64 10 paragraph 2.2). The new chiller will also have a 120 Volt convenience receptacle. The new chiller will have a single 480 V (nominal) 3-phase power connection with internal components to transform power to other voltages, phase configurations and currents (AC versus DC) as needed.

New chiller will have a mesh enclosure similar to the old chiller. Compressors will be provided with sound mitigation accessories. Test the water/glycol mixture and add glycol as necessary to ensure the mix percent is 70% water and 30% glycol.

The swap out of the old chiller to the new chiller will not be allowed during the cooling season unless a contractor request is approved by the Construction Manager.

17. Option 1 requirements:

1. Refer to the data in the General Description above to provide a rental chiller that will function properly with the power available for the existing chiller. Chiller water piping is 4” but contractor will be responsible for field verification of the piping and all other relevant features before providing the rental chiller.

Replace Chiller, B 1376CDC, CC eProjects#1797951

SECTION 23 64 10 Page 1

SECTION 23 64 10

WATER CHILLERS, VAPOR COMPRESSION TYPE

PART 1 GENERAL

1.1 REFERENCES

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

AIR-CONDITIONING, HEATING AND REFRIGERATION INSTITUTE (AHRI)

AHRI 480 (2007) Refrigerant-Cooled Liquid Coolers, Remote Type

AHRI 550/590 I-P (2015; ERTA 2016) Performance Rating Of Water-Chilling and Heat Pump Water-Heating Packages Using the Vapor Compression Cycle

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 9 (2015) Load Ratings and Fatigue Life for Ball Bearings

ABMA 11 (2014) Load Ratings and Fatigue Life for Roller Bearings

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2013) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 90.1 - IP (2013) Energy Standard for Buildings Except Low-Rise Residential Buildings

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME BPVC SEC VIII D1 (2019) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

AMERICAN WELDING SOCIETY (AWS)

AWS Z49.1 (2012) Safety in Welding and Cutting and Allied Processes

ASTM INTERNATIONAL (ASTM)

ASTM B117 (2019) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM F104 (2011; R 2020) Standard Classification System for Nonmetallic Gasket Materials

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

SECTION 23 64 10 Page 2

NEMA MG 1 (2018) Motors and Generators

NEMA MG 11 (1977; R 2012) Energy Management Guide for

Selection and Use of Single Phase Motors

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 82 Protection of Stratospheric Ozone

1.2 SUBMITTALS

Government approval is required for the following submittals per the direction of the COR:

SD-03 Product Data

Water Chiller

Verification of Dimensions

Factory Tests

System Performance Tests

Demonstrations

Refrigerant

Water Chiller - Field Acceptance Test Plan

Compressor Acoustic Blankets

Low Noise Fans

SD-06 Test Reports

Field Acceptance Testing

Water Chiller - Field Acceptance Test Report

Factory Tests

System Performance Tests

SD-07 Certificates

Refrigeration System

SD-08 Manufacturer's Instructions

Water Chiller - Installation Instructions

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals

SD-11 Closeout Submittals

5-Year Compressor Warranty

1.3 CERTIFICATIONS

SECTION 23 64 10 Page 3

1.3.1 Ozone Depleting Substances

Follow Naval Station Newport Instruction 5090.10C Ozone Depleting Substances (ODS).

1.4 SAFETY REQUIREMENTS

Exposed moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel must be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Safety devices must be installed so that proper operation of equipment is not impaired. Welding and cutting safety requirements must be in accordance with AWS Z49.1.

1.5 DELIVERY, STORAGE, AND HANDLING

Stored items must be protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation will be the Contractor's responsibility. Any materials found to be damaged must be replaced at the Contractor's expense. During installation, piping and similar openings must be capped to keep out dirt and other foreign matter.

1.6 PROJECT REQUIREMENTS

1.6.1 Verification of Dimensions

The Contractor must become familiar with all details of the work, verify all dimensions in the field, and advise the Contracting Officer of any discrepancy before performing any work.

PART 2 PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

Materials and equipment will be standard Commercial cataloged products of a manufacturer regularly engaged in the manufacturing of such products, which are of a similar material, design and workmanship. These products must have a two year record of satisfactory field service prior to bid opening. The two year record of service must include applications of equipment and materials under similar circumstances and of similar size.

Products having less than a two year record of satisfactory field service will be acceptable if a certified record of satisfactory field service for not less than 6000 hours can be shown. The 6000 hour service record must not include any manufacturer's prototype or factory testing. Satisfactory field service must have been completed by a product that has been, and presently is being sold or offered for sale on the commercial market through the following copyrighted means:advertisements, manufacturer's catalogs, or brochures.

2.2 MANUFACTURER'S STANDARD NAMEPLATES

Major equipment including chillers, compressors, compressor drivers, condensers, water coolers, receivers, refrigerant leak detectors, heat exchanges, fans, and motors must have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment. Plates must be durable and legible throughout equipment life. Plates must be fixed in prominent locations with nonferrous screws or bolts. Nameplates are required on major components if the manufacturer needs to provide specific engineering

SECTION 23 64 10 Page 4 and manufacturing information pertaining to the particular component.

Should replacement of this component be required, nameplate information will insure correct operation of the unit after replacement of this component.

2.3 ELECTRICAL WORK

a. Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as would be specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Manual or automatic control and protective or signal devices required for the operation specified and control wiring required for controls and devices specified, but not shown, must be provided. For packaged equipment, the manufacturer must provide controllers including the required monitors and timed restart.

b. For single-phase motors, provide high-efficiency type, fractional-horsepower alternating-current motors, including motors that are part of a system, in accordance with NEMA MG 11.

c. For polyphase motors, provide squirrel-cage medium induction motors, including motors that are part of a system, and that meet the efficiency ratings for premium efficiency motors in accordance with

NEMA MG 1.

d. Provide motors in accordance with NEMA MG 1 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Motors must be rated for continuous duty with the enclosure specified. Motor duty requirements must allow for maximum frequency start-stop operation and minimum encountered interval between start and stop. Motor torque must be capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances. Motor enclosure type may be either TEAO or TEFC.

e. Where two-speed motors are indicated, variable-speed controllers may be provided to accomplish the same function.

f. Provide inverter duty premium efficiency motors for use with variable frequency drives, if applicable.

g. Provide 20A, 120V convenience receptacle mounted at exterior condensing unit.

2.4 WATER CHILLER, VAPOR COMPRESSION TYPE

Total chiller system must be certified for performance per AHRI 550/590 I-P.

If chiller is not in scope of AHRI 550/590 I-P then chiller must be rated in accordance with AHRI 550/590 I-P. Individual chiller components must be constructed and rated in accordance with the applicable AHRI standards.

Chiller system must conform to ANSI/ASHRAE 15 & 34. The chiller must be ASHRAE 90.1 - IP compliant and meet 10 CFR Part 433, 434 and 435 efficiency performance standards for federal construction. The manufacturer must provide certification of compliance. Chiller must be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the job site in strict accordance with manufacturer's recommendations. Unit components delivered separately must be sealed and charged with a nitrogen holding charge. Unit

SECTION 23 64 10 Page 5 assembly must be completed in strict accordance with manufacturer's recommendations. Chiller must operate within capacity range and speed recommended by the manufacturer. Parts weighing 50 pounds or more which must be removed for inspection, cleaning, or repair, must have lifting eyes or lugs. Chiller must include all customary auxiliaries deemed necessary by the manufacturer for safe, controlled, automatic operation of the equipment.

Chiller's water cooler must be provided with marine water boxes with welded connections. Chillers must operate at partial load conditions without increased vibration over normal vibration at full load, and must be capable of continuous operation down to minimum capacity. As a minimum, chiller must include the following components as defined in paragraph CHILLER COMPONENTS.

a. Refrigerant and oil

b. Structural base

c. Chiller refrigerant circuit

d. Controls package with BACnet communication connected to existing

Direct Digital Controls (DDC) for Bldg. 1376.

e. Receiver

2.4.1 Compressor-Chiller Unit

As a minimum, the compressor-chiller unit must include the following components as defined in paragraph CHILLER COMPONENTS.

a. Helical rotary screw compressor

b. Compressor driver, electric motor

c. Compressor driver connection

d. Water cooler (evaporator)

2.4.2 Condensing Unit

As a minimum, the condensing unit must include the following components as defined in paragraph CHILLER COMPONENTS.

a. Helical rotary screw compressor

b. Compressor driver, electric motor

c. Compressor driver connection

d. Air cooled condenser

2.4.3 Remote Water Cooler (Evaporator)

2.4.3.1 Shell and Tube Type

Cooler must be constructed and rated in accordance with AHRI 480. Cooler must be of the shell-and-coil or shell-and-tube type design. Cooler's refrigerant side must be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Cooler's water side must be designed and factory pressure tested for not less than 300 psi.Cooler shell must be constructed of seamless or welded steel. Coil bundles must be totally removable and arranged to drain completely. Tubes must be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced

SECTION 23 64 10 Page 6 bore. Each tube must be individually replaceable. Tubes must be installed into carbon mild steel tube sheets by rolling. Tube baffles must be properly spaced to provide adequate tube support and cross flow. Cooler must be skid-mounted.Refrigerant circuit must be complete with liquid solenoid valve and expansion device capable of modulating to the minimum step of capacity unloading. For the water side of water cooler, performance must be based on a fluid velocity not less than 3 fps and not more than 12 fps and a fouling factor per AHRI 550/590 I-P. Evaporator must be provided with electric freeze protection type.

2.4.4 Remote Air-Cooled Condenser

Condenser must be a factory-fabricated and assembled unit, consisting of coils, fans, and condenser fan motors. Unless the condenser coil is completely protected through inherent design, louvered panel coil guards must be provided by the manufacturer to prevent physical damage to the coil.Manufacturer must certify that the condenser and associated equipment are designed for the submitted condensing temperature.

2.4.4.1 Condenser Casing

Condenser casing must be aluminum not less than 0.080 inch or hot-dip galvanized steel not lighter than 18 gauge 0.0516 inch.

2.4.4.2 Coil

Condenser coil must be of the extended-surface fin-and-tube type and must be constructed of seamless copper or aluminum tubes with compatible copper or aluminum fins. Fins must be soldered or mechanically bonded to the tubes and installed in a metal casing. Coils must be circuited and sized for a minimum of 5 degrees F subcooling and full pumpdown capacity. Coil must be factory leak and pressure tested after assembly in accordance with ANSI/ASHRAE 15 & 34. The condenser coil must be of the microchannel heat exchanger technology (MCHX) type consisting of a series of flat tubes containing a series of multiple, parallel flow microchannels layered between the refrigerant manifolds in a two-pass arrangement. Provide coils constructed of aluminum alloys for fins, tubes, and manifolds. Coil must be factory leak and pressure tested after assembly in accordance with

ANSI/ASHRAE 15 & 34.

Coil must be entirely coated by manufacturer's coating for marine environments and in accordance with the requirements of paragraph COIL CORROSION PROTECTION. Coil coating shall be included in the heat transfer rating of the coil.

2.4.4.3 Fans

Provide centrifugal or propeller type fans as best suited for the application. Fans must be direct driven. Fans must be statically and dynamically balanced.

2.4.4.4 Condenser Sizing

Size condensers for full capacity at 30 degrees F temperature difference between entering outside air and condensing refrigerant. Subcooling must not be considered in determining compressor and condenser capacities. For design conditions, submit a cross-plot of net refrigeration effect of compressor to establish net refrigeration effect and compatibility of equipment furnished.

2.4.4.5 Low Ambient Control

SECTION 23 64 10 Page 7

Provide factory mounted head pressure control for operation during low ambient conditions. Head pressure must be controlled by fan cycling, or fan speed control, or condenser refrigerant flooding.

2.5 CHILLER COMPONENTS

2.5.1 Refrigerant and Oil

Refrigerants must be one of the fluorocarbon gases. Refrigerants must have number designations and safety classifications in accordance with ANSI/ASHRAE 15 & 34. CFC-based refrigerants are prohibited. Refrigerants must have an Ozone Depletion Potential (ODP) no greater than 0.0, with the exception of R-123. Provide SDS sheets for all refrigerants.

2.5.2 Structural Base

Chiller and individual chiller components must be provided with a factory-mounted structural steel base (welded or bolted) or support legs for attachment to the concrete pad. Vibration isolators must have isolation characteristics as recommended by the manufacturer for the unit supplied and the service intended, if applicable.

2.5.3 Chiller Refrigerant Circuit

Chiller refrigerant circuit must be completely piped and factory leak tested in accordance with ANSI/ASHRAE 15 & 34. For multicompressor units, not less than 2 independent refrigerant circuits must be provided. Circuit must include as a minimum a combination filter and drier, combination sight glass and moisture indicator, an electronic or thermostatic expansion valve with external equalizer or float valve, charging ports, compressor service valves for field-serviceable compressors, and superheat adjustment.

2.5.4 Controls Package

Provide chillers with a complete factory-mounted, microprocessor based operating and safety control system. Controls package must contain as a minimum a digital display, an on-auto-off switch, motor starters, variable frequency motor controller, disconnect switches, power wiring, and control wiring. Controls package must provide operating controls, monitoring capabilities, programmable setpoints, safety controls, and BACnet BAS/DDC interfaces as defined below.

2.5.4.1 Operating Controls

Chiller must be provided with the following adjustable operating controls as a minimum.

a. Leaving chilled water temperature control

b. Adjustable timer or automated controls to prevent a compressor from short cycling

c. Automatic lead/lag controls (adjustable) for multi-compressor units

d. Load limiting

e. System capacity control to adjust the unit capacity in accordance with the system load and the programmable setpoints. Controls must automatically re-cycle the chiller on power interruption.

SECTION 23 64 10 Page 8

f. Startup and head pressure controls to allow system operation at all ambient temperatures down to 40 degrees F.

g. Startup and head pressure controls to allow system operation at all ambient temperatures down to 40 degrees F.

h. Fan sequencing for air-cooled condenser

2.5.4.2 Monitoring Capabilities

During normal operations, the control system must be capable of monitoring and displaying the following operating parameters. Access and operation of display must not require opening or removing any panels or doors.

a. Entering and leaving chilled water temperatures

b. Entering and leaving chilled water pressure and Chilled water flow

c. Entering and leaving condenser water pressure and Condenser water flow

d. Self diagnostic

e. Operation status

f. Operating hours

g. Number of starts

h. Compressor status (on or off)

i. Compressor load (percent)

j. Refrigerant discharge and suction pressures

k. Magnetic bearing levitation status (if applicable)

l. Magnetic bearing temperatures (if applicable)

m. Oil pressure

2.5.4.3 Configurable Setpoints

The control system must be capable of being configured directly at the unit's interface panel. The programmable setpoints must include the following as a minimum:

a. Leaving Chilled Water Temperature

b. Leaving Condenser Water Temperature

c. Time Clock/Calendar Date

2.5.4.4 Safety Controls with Manual Reset

Chiller must be provided with the following safety controls which automatically shut down the chiller and which require manual reset.

a. Low chilled water temperature protection

b. High condenser refrigerant discharge pressure protection

SECTION 23 64 10 Page 9

c. Low evaporator pressure protection

d. Chilled water flow detection

e. High motor winding temperature protection

f. Low oil flow protection if applicable

g. Magnetic bearing controller (MBC), Internal fault (if applicable)

h. MBC, High bearing temperature (if applicable)

i. MBC, Communication fault (if applicable)

j. MBC, Power supply fault (if applicable)

k. Motor current overload and phase loss protection

2.5.4.5 Safety Controls with Automatic Reset

Chiller must be provided with the following safety controls which automatically shutdown the chiller and which provide automatic reset.

a. Over/under voltage protection

b. Chilled water flow interlock

c. MBC, Vibration (if applicable)

d. MBC, No levitation (if applicable)

e. Phase reversal protection

2.5.4.6 Remote Alarm

During the initiation of a safety shutdown, a chiller's control system must be capable of activating a remote alarm via the BAS/DDC.

2.5.4.7 Utility Monitoring and Control System Interface

Provide a BACnet interface to B1376's existing DDC/BAS. The interface must provide all system operating conditions, capacity controls, and safety shutdown conditions as network points. In addition, the following points must be overridable via the network interface:

a. Unit Start/Stop

b. Leaving Chilled Water Temperature Setpoint

c. Leaving Condenser Water Temperature Setpoint

2.5.5 Compressor(s)

2.5.5.1 Rotary Screw Compressor(s)

Compressors must operate stably for indefinite time periods to at least 25 percent capacity reduction without gas bypass external to the compressor.

Provision must be made to insure proper lubrication of bearings and shaft seals on shutdown with or without electric power supply. Rotary screw compressors must include:

a. An open or hermetic, positive displacement, oil-injected design

SECTION 23 64 10 Page 10

b. directly driven by the compressor driver. Allow access to internal compressor components for repairs, inspection, and replacement of parts.

c. Rotors must be solid steel, possessing sufficient rigidity for proper operation.

d. A maximum rotor operating speed no greater than 3600 RPM. Provide cast iron rotor housing.

e. Casings of cast iron, precision machined for minimal clearance about periphery of rotors with minimal clearance at rotor tops and rotor ends.

f. A lubrication system of the forced-feed type that provides oil at the proper pressure to all parts requiring lubrication.

g. Bearing housing must be conservatively loaded and rated for an L(10) life of not less than 200,000 hours. Shaft main bearings of the sleeve type with heavy duty bushings or rolling element type in accordance with ABMA 9 or ABMA 11.

h. A differential oil pressure or flow cutout to allow the compressor to operate only when the required oil pressure or flow is provided to the bearings.

i. A temperature- or pressure-initiated, hydraulically actuated, single-slide-valve, capacity-control system to provide minimum automatic capacity modulation from 100 percent to 15 percent. A Variable Frequency Drive (VFD) may be used to modulate capacity modulation from 100 percent to 15 percent.

j. An oil separator and oil return system to remove oil entrained in the refrigerant gas and automatically return the oil to the compressor.

k. Crankcase oil heaters must be provided.

2.5.6 Compressor Driver, Electric Motor

Components such as motors, starters, variable speed drives and wiring must be in accordance with paragraph ELECTRICAL WORK. Motor starter or Variable frequency drive must be unit mounted with starter, variable frequency drive type, wiring, and accessories coordinated with the chiller manufacturer.

2.5.7 Compressor Driver Connections

Each compressor must be driven by a V-belt drive or direct connected through a flexible coupling, except that flexible coupling is not required on hermetic units. V-belt drives must be designed for not less than 150 percent of the driving motor capacity. Flexible couplings must be of the type that does not require lubrication.

2.5.8 Water Cooler (Evaporator)

Cooler must be of the shell-and-coil or shell-and-tube type design.

Cooler shell must be constructed of seamless or welded steel. Coil bundles must be totally removable and arranged to drain completely.

Tubes must be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube must be

SECTION 23 64 10 Page 11 individually replaceable. Tubes must be installed into carbon mild steel tube sheets by rolling. Tube baffles must be properly spaced to provide adequate tube support and cross flow. Performance must be based on a water velocity not less than 3 fps nor more than 12 fps and a fouling factor per

AHRI 550/590 I-P.

Brazed plate heat exchanger must be constructed of 304 or 316 stainless steel, designed to a refrigerant-side working pressure of 430 psig and a waterside working pressure of 150 psig. Evaporator must be factory tested at 1.1 times maximum allowable refrigerant side working pressure and 1.5 times maximum allowable water side working pressure. Provide cooler heaters to protect the evaporator to an ambient of minus 20 degrees F.

Provide cooler with factory-installed flow switches. All water connections must use either flanged or grooved-pipe connections. Factory insulate all cold surfaces.

2.5.9 Air-Cooled Condenser Coil

Condenser coil must be of the extended-surface fin-and-tube type and must be constructed of seamless copper tubes with compatible copper or aluminum fins. Fins must be soldered or mechanically bonded to the tubes and installed in a metal casing. Coils must be circuited and sized for a minimum of 5 degrees F subcooling and full pumpdown capacity. Coil must be factory leak and pressure tested after assembly in accordance with ANSI/ASHRAE 15 & 34. The condenser coil must be of the microchannel heat exchanger technology (MCHX) type consisting of a series of flat tubes containing a series of multiple, parallel flow microchannels layered between the refrigerant manifolds in a two-pass arrangement. Provide coils constructed of aluminum alloys for fins, tubes, and manifolds. Coil must be factory leak and pressure tested after assembly in accordance with ANSI/ASHRAE 15 & 34. Coil must be entirely coated by manufacturer's factory marine coating in accordance with the requirements of paragraph

COIL CORROSION PROTECTION.

2.5.10 Receivers

Receiver must bear a stamp certifying compliance with ASME BPVC SEC VIII D1 and must meet the requirements of ANSI/ASHRAE 15 & 34. Inner surfaces must be thoroughly cleaned by sandblasting or other approved means. Each receiver must have a storage capacity not less than 20 percent in excess of that required for the fully-charged system. Each receiver must be equipped with inlet, outlet drop pipe, drain plug, purging valve, relief valves of capacity and setting required by ANSI/ASHRAE 15 & 34, and two bull's eye liquid-level sight glasses. Sight glasses must be in the same vertical plane, 90 degrees apart, perpendicular to the axis of the receiver, and not over 3 inches horizontally from the drop pipe measured along the axis of the receiver. In lieu of bull's eye sight glass, external gauge glass with metal glass guard and automatic closing stop valves may be provided.

2.5.11 Chiller Purge System

Chillers which operate at pressures below atmospheric pressure must be provided with a purge system. Purge system must automatically remove air, water vapor, and non-condensible gases from the chiller's refrigerant while keeping refrigerant emissions below requirements of ASHRAE Std 147.

Purge units must be certified per AHRI 580. Purge system must condense, separate, and return all refrigerant back to the chiller. An oil separator must be provided with the purge system if required by the manufacturer.

Purge system must not discharge to occupied areas, or create a potential

SECTION 23 64 10 Page 12 hazard to personnel. Purge system must include a purge pressure gauge, number of starts counter, and an elapsed time meter. Purge system must include lights or an alarm which indicate excessive purge or an abnormal air leakage into chiller.

2.6 ACCESSORIES

2.6.1 Refrigerant Relief Valve/Rupture Disc Assembly

The assembly must be a combination pressure relief valve and rupture disc designed for refrigerant usage. The assembly must be in accordance with ASME BPVC SEC VIII D1 and ANSI/ASHRAE 15 & 34. The assembly must be provided with a pressure gauge assembly which will provide local indication if a rupture disc is broken. Rupture disc must be the non-fragmenting type.

2.6.2 Refrigerant Signs

Refrigerant signs must be a medium-weight aluminum type with a baked enamel finish. Signs must be suitable for indoor or outdoor service.

Signs must have a white background with red letters not less than 0.5 inches in height.

2.6.2.1 Installation Identification

Each new refrigerating system must be provided with a refrigerant sign which indicates the following as a minimum:

a. Contractor's name.

b. Refrigerant number and amount of refrigerant.

c. The lubricant identity and amount.

d. Field test pressure applied.

2.6.2.2 Controls and Piping Identification

Refrigerant systems containing more than 110 lb of refrigerant must be provided with refrigerant signs which designate the following as a minimum:

a. Valves or switches for controlling the refrigerant flow , the ventilation system, and the refrigerant compressor(s).

b. Pressure limiting device(s).

2.6.3 Gaskets

Gaskets must conform to ASTM F104 - classification for compressed sheet with nitrile binder and acrylic fibers for maximum 700 degrees F service.

2.7 FABRICATION

2.7.1 Factory Coating

Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, must be factory finished with the manufacturer's standard finish, except that items located outside of buildings must have weather resistant finishes that will withstand 500 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride

SECTION 23 64 10 Page 13 solution. Immediately after completion of the test, the specimen must show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8 inch on either side of the scratch mark.

2.7.2 Factory Applied Insulation

Chiller must be provided with factory installed insulation on surfaces subject to sweating including the water cooler, suction line piping, economizer, and cooling lines. Insulation on heads of coolers may be field applied, however it must be installed to provide easy removal and replacement of heads without damage to the insulation. Where motors are the gas-cooled type, factory installed insulation must be provided on the cold-gas inlet connection to the motor per manufacturer's standard practice. Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors must have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces must have a flame spread index no higher than 25 and a smoke developed index no higher than 50.

2.7.3 Coil Corrosion Protection

Provide coil with a uniformly factory-applied epoxy electrodeposition, phenolic, or vinyl type coating for marine environments to all coil surface areas without material bridging between fins. Submit product data on the type coating selected, the coating thickness, the application process used, the estimated heat transfer loss of the coil, and verification of conformance with the salt spray test requirement. Coating must be applied at either the coil or coating manufacturer's factory.

Coating process must ensure complete coil encapsulation. Coating must be capable of withstanding a minimum 6,000 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution.

2.8 FACTORY TESTS

2.8.1 Chiller Performance Test

The Contractor and proposed chiller manufacturer shall be responsible for performing the chiller factory test to validate the specified full load capacity, full load EER, and IPLV/NPLV in accordance with AHRI 550/590 I-P except as indicated. The Contractor and chiller manufacturer must provide to the Government a certified chiller factory test report in accordance with AHRI 550/590 I-P to confirm that the chiller performs as specified.

Tests must be conducted in an AHRI certified test facility in conformance with AHRI 550/590 I-P procedures and tolerances, except as indicated. At a minimum, chiller capacity must be validated to meet the scheduled requirements indicated on the drawings. Tolerance or deviation must be in strict accordance with AHRI 550/590 I-P. Stable operation at minimum load of 10 percent of total capacity must be demonstrated during the factory test.

2.8.1.1 Temperature Adjustments

Temperature adjustments must adhere to AHRI 550/590 I-P to adjust from the design fouling factor to the clean tube condition. Test temperature adjustments must be verified prior to testing by the manufacturer. There must be no exceptions to conducting the test with clean tubes with the temperature adjustments per AHRI 550/590 I-P.

2.8.1.2 Test Instrumentation

SECTION 23 64 10 Page 14

The factory test instrumentation must be per AHRI 550/590 I-P and the calibration must be traceable to the National Institute of Standards and Technology.

2.8.1.3 Equipment Adjustments

If the equipment fails to perform within allowable tolerances, the manufacturer must be allowed to make necessary revisions to his equipment and retest as required. The manufacturer shall assume all expenses incurred by the Government to witness the retest.

2.9 SUPPLEMENTAL COMPONENTS/SERVICES

2.9.1 Refrigerant Piping

Refrigerant piping for split-system water chillers must be provided and installed in accordance with provision normally found in UFGS Section

23 23 00 REFRIGERANT PIPING.

2.9.2 Temperature Controls

Chiller control packages must be fully coordinated with and integrated into the existing B1376 BAS/DDC system.

2.9.3 Compressor Acoustic Blanket Insulation

Provide manufacturer's compressor blanket option for acoustic treatment.

2.9.4 5-year Compressor Warranty

Provide manufacturer's 5-year compressor warranty.

PART 3 EXECUTION

3.1 INSTALLATION

Installation of water chiller systems including materials, installation, workmanship, fabrication, assembly, erection, examination, inspection, and testing must be in accordance with the manufacturer's written installation instructions, including the following:

(1) Water chiller - installation instructions

3.1.1 Installation Instructions

Provide manufacturer's standard catalog data, at least 5 weeks prior to the purchase or installation of a particular component, highlighted to show features such as materials, dimensions, options, performance and efficiency. Data must include manufacturer's recommended installation instructions and procedures. Data must be adequate to demonstrate compliance with contract requirements.

3.1.2 Vibration Isolation

Vibration isolator literature must be included containing catalog cuts and certification that the isolation characteristics of the isolators provided meet the manufacturer's recommendations.

3.1.3 Verification of Dimensions

Provide a letter including the date the site was visited, conformation of

SECTION 23 64 10 Page 15 existing conditions, and any discrepancies found.

3.1.4 System Performance Test Schedules

Provide a schedule, at least 3 weeks prior to the start of related testing, for the system performance tests. The schedules must identify the proposed date, time, and location for each test.

3.1.5 Certificates

Where the system, components, or equipment are specified to comply with requirements of AGA, NFPA, ARI, ASHRAE, ASME, or UL, proof of such compliance must be provided. The label or listing of the specified agency must be acceptable evidence. In lieu of the label or listing, a written certificate from an approved, nationally recognized testing organization equipped to perform such services, stating that the items have been tested and conform to the requirements and testing methods of the specified agency may be submitted. When performance requirements of this project's drawings and specifications vary from standard ARI rating conditions, computer printouts, catalog, or other application data certified by ARI or a nationally recognized laboratory as described above must be included.

If ARI does not have a current certification program that encompasses such application data, the manufacturer may self-certify that his application data complies with project performance requirements in accordance with the specified test standards.

3.1.6 Operation and Maintenance Manuals

Provide three complete copies of an operation manual in bound 8 1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4 weeks prior to the first training course. The booklets must include the manufacturer's name, model number, serial number, and parts list. The manuals must include the manufacturer's name, model number, serial number, service manual, and a full description of all equipment and their basic operating features. Six complete copies of maintenance manual in bound 8 1/2 by 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals must include piping and equipment layouts and simplified wiring and control diagrams of the system as installed. Provide electronically also.

3.1.7 Connections to Existing Systems

Notify the Contracting Officer in writing at least 15 calendar days prior to the date the connections are required. Obtain approval before interrupting service. Furnish materials required to make connections into existing systems and perform excavating, backfilling, compacting, and other incidental labor as required. Furnish labor and tools for making actual connections to existing systems.

3.1.8 Refrigeration System

3.1.8.1 Equipment

Refrigeration equipment and the installation thereof must conform to ANSI/ASHRAE 15 & 34. Necessary supports must be provided for all equipment, appurtenances, and pipe as required, including frames or supports for compressors, pumps, cooling towers, condensers, water coolers, and similar items. Compressors must be isolated from the building structure. If mechanical vibration isolators are not provided, vibration absorbing foundations must be provided per manufacturer’s recommendations. Each foundation must include isolation units consisting

SECTION 23 64 10 Page 16 of machine and floor or foundation fastenings, together with intermediate isolation material. In lieu of concrete pad foundation, concrete pedestal block with isolators placed between the pedestal block and the floor may be provided.