C05_Salient_Characteristics_-_Attach_002.pdf

PARKER DAM POWERPLANT HVAC CHILLER

Required Salient Characteristics

Chiller Capacity: 100 Tons

Power: 480 Volt 3Φ 250 amp 60-Hz

Full-Load Efficiency: EER: 10.1.

High Ambient Operation:

Chiller designed for operation to 120deg F.

Evaporator: 1) Type: Brazed plate or shell and tube.

2) Pressure Rating: 150 psig.

3) Fluid Type: 70% Water, 30% Propylene Glycol mixture.

4) Design Fluid Flow Rate: 200 gpm.

5) Entering-Fluid Temperature: 55 deg F.

6) Leaving-Fluid Temperature: 43 deg F.

Hydronic Package:

1) Number of Pumps: One or Two.

2) Pump Control: Variable speed.

3) Pump Design Fluid Flow Rate: 200 gpm.

4) Pump Dynamic Head: 75 feet of head.

5) Pump Speed: 1750 rpm nominal.

Compressor:

1) Scroll Compressors:

a) Description: Positive-displacement direct drive with hermetically sealed casing. Scroll motor-compressor with control panel.

b) Operating Speed: Nominal 3600 rpm for 60-Hz applications

c) Features: Centrifugal oil pump, sump oil heater, oil level sight glass, oil charging valve, two-point lubrication for each motor bearing, flooded lubrication for the journal and thrust bearings, check valve on scroll discharge port. Each compressor provided with suction and discharge service valves, and suction strainer.

i) For multiple compressor assemblies, it is acceptable to isolate each compressor assembly in lieu of each compressor.

d) Oil Lubrication System: Automatic pump with strainer, sight glass, filling connection, filter with magnetic plug or removable magnet in sump, and initial oil charge.

i) Manufacturer's other standard methods of providing positive lubrication are acceptable in lieu of an automatic pump.

140R3023Q0049 Attachment 002

Compressor Continued:

4) Vibration Isolation: Mount individual compressors on vibration isolators.

a) For multiple compressor assemblies, it is acceptable to isolate each compressor assembly in lieu of each compressor.

5) Compressor Motors:

a) Suction gas cooled, hermetically sealed.

b) High-torque, two-pole induction type with inherent thermal-overload protection on each phase.

6) Compressor Motor Controllers:

a) Across the Line: NEMA ICS 2, Class A, full voltage, nonreversing.

b) Refrigeration section:

i) Anti-recycle timer.

ii) Reset relay.

iii) Reset switch.

iv) Low- and high-pressure control.

v) Motor winding temperature protection.

c) Manual reset for compressor overload, high motor temperature, and low and high refrigerant pressure.

7) Capacity Control: On-off compressor cycling.

a) Digital compressor unloading is an acceptable alternative to achieve capacity control.

8) a) i) ii)

Air Cooled Condenser:

1) Coil(s) with integral subcooling on each circuit. Provide sub-cooling circuits with liquid accumulators. Air test under water to 425 psig.

2) Copper Tube with Plate Fin Coils:

a) Construct coils of copper tubes mechanically bonded to aluminum fins.

3) Hail Protection: Provide condenser coils with louvers, baffles, or hoods to protect against hail damage.

4) Fans: Direct-drive propeller type with statically and dynamically balanced fan blades, arranged for vertical air discharge.

5) Fan Motors: TENV or TEAO enclosure, with sealed and permanently lubricated bearings, and having built-in overcurrent- and thermal-overload protection.

a) Overcurrent- and thermal-overload protection not integral to motor is acceptable if provided with chiller electrical power package.

6) Fan Guards: Removable steel safety guards with corrosion-resistant coating.

a)

Evaporator:

1) Brazed-plate or shell-and-tube design, as indicated.

2) Shell and Tube:

a) Description: Direct-expansion, shell-and-tube design with fluid flowing through the shell and refrigerant flowing through the tubes within the shell.

b) Code Compliance: Tested and stamped according to ASME Boiler and

Pressure Vessel Code.

c) Shell Material: Carbon steel.

d) Shell Heads: Removable carbon-steel heads with multipass baffles designed to ensure positive oil return and located at each end of the tube bundle.

e) Shell Nozzles: Fluid nozzles located along the side of the shell and terminated with mechanical-coupling end connections for connection to field piping. Furnish flange adapters to mate to flanged piping.

f) Tube Construction: Individually replaceable copper tubes with enhanced fin design, expanded into tube sheets.

3) Brazed Plate:

a) Direct-expansion, single-pass, brazed-plate design.

b) Type 304 or 316 stainless-steel construction.

c) Code Compliance: Tested according to ASME Boiler and Pressure Vessel

Code.

d) Fluid Nozzles: Terminate with mechanical-coupling end connections for connection to field piping. Furnish flange adapters to mate to flanged piping.

e) Inlet Strainer: Factory-furnished, 20 or 40-mesh strainer for field installation in supply piping to evaporator. Manufacturer has option to factory install strainer.

4) Flow Switch: Factory-furnished and -installed, flow switch wired to chiller operating controls.

5) Provide water drain connection and thermometer wells for temperature controller and low temperature cutout

Chilled water Hydronic Pump

Package:

1) Factory-furnished and -installed hydronic package consisting of the following:

a) Pumps: Single or dual pumps with capacity, as indicated.

i) Vertical in-line type, single-stage design, serviceable without disturbing piping connections.

ii) Cast-iron, ductile-iron, bronze, or stainless-steel body.

iii) Bronze or stainless-steel impeller keyed to shaft and secured with screw.

iv) Premium efficient motor with TEFC motor enclosure.

v) Dual pump packages to provide for servicing and replacement of failed pump with other pump operating.

vi) Variable-speed pumps with variable-frequency controllers integral to pump motor or provided with chiller electrical package.

2) Piping: Carbon-steel pipe.

3) Strainers: Y-type at suction side of each pump.

4) Valves:

a) Ball- or butterfly-style valves for isolation and balancing.

b) Check valve on each pump discharge for dual pump packages.

c) Drain valves to be positioned to drain isolated sections of pipe and equipment.

d) Option to use combination valves.

5) Hydronic Specialties:

a) Air Vents: Automatic or manual air vents located and arranged to vent air from high points and locations capable of trapping air.

b) Test Plugs: Located to measure pressure difference across each pump and strainer.

6) Hydronic package rated for same pressure as evaporator.

7) Pressure and leak tested before apply insulation.

8) Insulation on hydronic package shall match evaporator.

9) Controls:

a) Lead/lag operation for dual pump packages.

b) Controlled to automatically equalize run time.

10) Control of variable-speed pumps.

11) Integral to chiller control package.

Cabinet:

1) Base: Galvanized-steel base extending the perimeter of water chiller. Secure frame, compressors, and evaporator to base to provide a single-piece unit.

2) Frame: Rigid galvanized-steel frame secured to base and designed to support cabinet, condenser, control panel, and other chiller components not directly supported from base.

3) Casing: Galvanized steel.

4) Finish: Weather resistant, baked enamel finish.

5) Mount starters and disconnects in NEMA 3R weatherproof panel provided with full opening access doors. Provide mechanical interlock to disconnect power when door is opened.

Refrigerant Circuit:

1) Refrigerant: R-410A. Classified as Safety Group A1 according to ASHRAE 34.

2) Refrigerant Compatibility: Parts exposed to refrigerants shall be fully compatible with refrigerants, and pressure components shall be rated for refrigerant pressures.

3) Refrigerant Circuit:

i) Provide for each refrigerant circuit:

(1) Liquid line solenoid valve.

(2) Filter dryer (replaceable core type).

(3) Liquid line sight glass and moisture indicator.

(4) Liquid-line shutoff valve

(5) Electronic-expansion valve sized for maximum operating pressure.

(6) Charging valve.

(7) Insulated suction line.

(8) Discharge line check valve.

(9) Compressor discharge service valve.

(10) Condenser pressure relief valve.

(11) Suction line accumulator.

(12) Hot-gas muffler.

4) Refrigerant Isolation: Factory install positive shutoff isolation valves in the compressor discharge line and the refrigerant liquid-line to allow the isolation and storage of the refrigerant charge in the chiller condenser.

a) For multiple compressor assemblies, it is acceptable to isolate each compressor assembly in each circuit in lieu of each compressor.

5) Pressure Relief Device:

a) Comply with requirements in ASHRAE 15, ASHRAE 147, and applicable portions of ASME Boiler and Pressure Vessel Code: Section VIII, Division

1.

b) Select and configure pressure relief devices to protect against corrosion and inadvertent release of refrigerant.

c) ASME-rated, spring-loaded, pressure relief valve; single- or multiple-reseating type. Pressure relief valve(s) shall be provided for each heat exchanger.

d) e) f)

6)

Controls:

1) Factory installed and wired, and functionally tested at factory before shipment.

2) Standalone, microprocessor based, with all memory stored in nonvolatile memory so that reprogramming is not required on loss of electrical power.

3) Enclosure: Share enclosure with electrical power devices or provide a separate enclosure of matching construction.

4) Operator Interface: Keypad or pressure-sensitive touch screen. Multiple-character, digital display. Display the following:

a) Date and time. Operating or alarm status.

b) Operating hours.

c) Temperature and pressure of operating set points.

d) Chilled-water entering and leaving temperatures. Refrigerant pressures in evaporator and condenser.

e) Saturation temperature in evaporator and condenser.

f) No cooling load condition.

g) Elapsed time meter (compressor run status).

h) Pump status. Antirecycling timer status.

i) Percent of maximum motor amperage.

j) Alarm history with retention of operational data before unit shutdown.

k) Superheat.

5) Control Functions:

a) Manual or automatic startup and shutdown time schedule.

b) Capacity control based on evaporator leaving-fluid temperature.

c) Capacity control compensated by rate of change of evaporator entering-fluid temperature.

d) Chilled-water entering and leaving temperatures, control set points, and motor load limit. Chilled-water leaving temperature shall be reset based on space temperature.

e) Current limit and demand limit.

f) Condenser-water temperature.

g) External water chiller emergency stop.

h) Antirecycling timer.

i) Automatic lead-lag switching.

Controls Continued:

6) Manual-Reset Safety Controls: The following conditions shall shut down water chiller and require manual reset:

a) Low evaporator pressure or high condenser pressure.

b) Low chilled-water temperature.

c) Refrigerant high pressure.

d) High or low oil pressure.

e) High oil temperature.

f) Loss of chilled-water flow.

g) Loss of condenser-water flow.

h) Control device failure.

7) For each compressor, provide starter, non-recycling compressor overload, starter relay, and control power transformer or terminal for controls power.

Provide manual reset current overload protection

8) Factory-installed wiring outside of enclosures shall be in NFPA 70-complaint raceway.

9) Control Sequence of Operation:

a) Provide standalone packaged control system capable of achieving the following control sequence. Provide installation and operation manual, as well as complete wiring diagrams showing all controlled elements.

i) Chillers shall be enabled by AHU status indicating a call for cooling and building occupancy schedule.

ii) Chiller shall be staged under factory control.

iii) Chilled water pumping system shall operate in a variable primary mode.

iv) Enable Mode:

(1) The factory pump control shall enable the chilled water pumping system when AHU-1 (the buffalo unit) is proven on and there is a call for cooling by thermostat located within the generator floor

(Adj.).

(2) Verify pumps are running by way of pump status and water flow meter.

(3) Upon verification that pump(s) are on and water is flowing, enable the pump control sequence.

(4) Chilled water pumps shall be staged under factory control.

b) Pump Control:

i) Once enabled the pump speed shall be modulated to maintain the differential pressure setpoint (Adj.).

ii) For hydronic packages featuring multiple pumps:

(1) Software lead/lag function shall allow either of the chilled water pumps to act as the lead pump.

Controls Continued:

(2) Alarm on pump failure detected by current sensing switch. Upon failure of the lead pump, the lag pump shall start automatically.

(3) Pump control system shall rotate lead/lag pump based on pump run time. The pump with the lowest calculated run time shall act as lead pump.

ii) Chilled water pumps shall be staged under factory control.

b) Chiller Control:

i) If the chilled water supply temperature rises 4°F above the chilled water setpoint (Adj.), then the chiller shall be allowed to operate.

ii) Once the flow through the chiller is proven by its flow switch, the chiller shall be energized and shall maintain the chilled water supply temperature at 43°F (Adj.).

iii) The chiller control sequence when the chilled water pump has a status of on. When a chiller enable command is sent, the chiller control valve will be fully opened and the chiller will operate under factory control to maintain the chilled water supply temperature at a setpoint 43°F (Adj.).

The chillers safeties circuit will be monitored and the system will report a general alarm condition if a safety is tripped. A manual reset of the chiller safety will be required before the chiller can be restarted.

Accessories:

1) Factory-furnished spring isolators with seismic restraints for field installation.

a) Spring Deflection: 2 inch.

Insulation:

1) Closed-cell, flexible, elastomeric thermal insulation complying with ASTM

C534/C534M, Type I for tubular materials and Type II for sheet materials.

a) Thickness: 3/4 inch.

2) Adhesive: As recommended by insulation manufacturer.

3) Factory-applied insulation over all cold surfaces of chiller capable of forming condensation. Components shall include, but not be limited to, evaporator, evaporator water boxes including nozzles, refrigerant suction pipe from evaporator to compressor, cold surfaces of compressor, refrigerant-cooled motor, and auxiliary piping.

a) Apply adhesive to 100 percent of insulation contact surface.

b) Before insulating steel surfaces, prepare surfaces for paint, and prime and paint as indicated for other painted components. Do not insulate unpainted steel surfaces.

c) Seal seams and joints to provide a vapor barrier.

d) After adhesive has fully cured, paint exposed surfaces of insulation to match other painted parts.

e) Manufacturer has option to factory or field insulate chiller components to reduce potential for damage during installation.

f) Field-Applied Insulation:

i) Components that are not factory insulated shall be field insulated to comply with requirements indicated.

ii) Manufacturer shall be responsible for chiller insulation whether factory or field installed to ensure that manufacturer is the single point of responsibility for chillers.

iii) Manufacturer's factory-authorized service representative shall instruct and supervise installation of field-applied insulation.

paint insulation to match factory-applied finish

Insulation Continued:

iv) After field-applied insulation is complete, paint insulation to match factory-applied finish

Electrical Characteristics and

Components:

1) Factory installed and wired, and functionally tested at factory before shipment.

2) Factory-installed and -wired switches, motor controllers, transformers, and other electrical devices necessary shall provide a single-point field power connection to water chiller.

3) House in a unit-mounted, NEMA 250, Type 3R enclosure with hinged access door with lock and key or padlock and key.

4) Wiring shall be numbered and color-coded to match wiring diagram.

5) Factory wiring shall be located outside of an enclosure in a metal raceway.

Terminal connections shall be made with not more than a 24-inch length of liquidtight conduit.

6) Field power interface shall be to wire lugs NEMA KS 1, heavy-duty, nonfused disconnect switch. Minimum SCCR according to UL 508 shall be as required by electrical power distribution system, but not less than

65,000A.

7) Each motor shall have branch power circuit and controls with one of the following disconnecting means having SCCR to match main disconnecting means:

a) NEMA KS 1, heavy-duty, fusible switch with rejection-type fuse clips rated for fuses. Select and size fuses to provide Type 2 protection according to IEC 60947-4-1.

b) NEMA KS 1, heavy-duty, nonfusible switch.

c) UL 489, motor-circuit protector (circuit breaker) with field-adjustable, short-circuit trip coordinated with motor locked-rotor amperes.

8) Each motor shall have overcurrent protection.

9) Overload relay sized according to UL 1995, or an integral component of water chiller control microprocessor.

10) Phase-Failure and Undervoltage: Solid-state sensing with adjustable settings.

11) Controls Transformer: Unit-mounted transformer with primary and secondary fuses and sized with enough capacity to operate electrical load plus spare capacity.

12) Control Relays: Auxiliary and adjustable time-delay relays, or an integral to water chiller microprocessor.

Electrical Characteristics and

Components Continued:

13) Service Receptacle:

a) Unit-mounted, 120-V GFI duplex receptacle.

b) Power receptacle from chiller internal electrical power wiring.

14) Indicate the following for water chiller electrical power supply:

a) Current, phase to phase, for all three phases.

b) Voltage, phase to phase and phase to neutral for all three phases.

c) Three-phase real power (kilowatts).

d) Three-phase reactive power (kilovolt amperes reactive).

e) Power factor.

f) Running log of total power versus time (kilowatt hours).

g) Fault log, with time and date of each.

15) Electrical Characteristics

a) Controls Power Connection: Fed through integral transformer.

b) Chiller Electrical Characteristics: 480-V ac, three phase, 60 Hz.

16) Motor: NEMA MG1.

a) Disconnect Switch: Factory mount disconnect switch on equipment.

Source Quality Control:

1) Perform functional test of water chillers before shipping.

2) Factory performance test water chillers, before shipping, according to AHRI

550/590.

a) Test the following conditions:

i) Design conditions indicated.

ii) AHRI 550/590 part-load points.

3) Factory test and inspect evaporator according to ASME Boiler and Pressure

Vessel Code: Section VIII, Division 1. Stamp with ASME label.

Performance Requirements:

1) Seismic Performance: Scroll water chillers shall withstand the effects of earthquake motions. term "withstand" means "the unit will remain in place without separation of any parts when subjected to the seismic forces specified.

a) Site Class: D

b) Risk Category: III

c) Importance Factor (Ip) = 1.0

2) Site Altitude: Chiller shall be suitable for altitude at which installed without affecting performance indicated. Make adjustments to affected chiller components to account for site altitude.

a) Site Altitude: 800’

3) AHRI Rating: Rate water chiller performance according to requirements in

AHRI 550/590.

4) ASHRAE Compliance: ASHRAE 15 for safety code for mechanical refrigeration.

5) ASHRAE/IES 90.1 Compliance: Applicable requirements in ASHRAE/IES

90.1, Section 6 - "Heating, Ventilating, and Air-Conditioning."

6) ASME Compliance: Fabricate and stamp water chiller heat exchangers to comply with ASME Boiler and Pressure Vessel Code.

7) Comply with NFPA 70.

8) Comply with requirements of UL 1995, "Heating and Cooling Equipment," and include label by a qualified testing agency showing compliance.

9) Outdoor Installations:

a) Chiller shall be suitable for outdoor installation indicated. Provide adequate weather protection to ensure reliable service life over a 25-year period with minimal degradation due to exposure to outdoor ambient conditions.

b) Chillers equipped to provide safe and stable operation while achieving performance indicated when operating at extreme outdoor temperatures encountered by the installation. Review historical weather database and provide equipment that can operate at extreme outdoor temperatures.

i) Unit Shall be capable of operation at a maximum outdoor air temperature of 120°F.

Startup Service:

1) Engage a factory-authorized service representative to perform startup service.

2) Inspect field-assembled components, equipment installation, and piping and electrical connections for proper assemblies, installations, and connections.

3) Complete installation and startup checks according to manufacturer's written instructions and perform the following:

a) Verify that refrigerant charge is sufficient and water chiller has been leak tested.

b) Verify that pumps are installed and functional.

c) Verify that thermometers and gages are installed.

d) Operate water chiller for run-in period.

e) Check bearing lubrication and oil levels.

f) Verify proper motor rotation.

g) Verify static deflection of vibration isolators, including deflection during water chiller startup and shutdown.

h) Verify and record performance of chilled-water flow and low-temperature interlocks.

i) Verify and record performance of water chiller protection devices.

j) Test and adjust controls and safeties. Replace damaged or malfunctioning controls and equipment.

4) Visually inspect chiller for damage before starting. Repair or replace damaged components, including insulation. Do not start chiller until damage that is detrimental to operation has been corrected.

5) Prepare a written startup report that records results of tests and inspections

Demonstration:

1) Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain water chillers.

a) Instructor shall be factory trained and certified.

b) Provide not less than four hours of training.

c) Train personnel in operation and maintenance and to obtain maximum efficiency in plant operation.

d) Provide instructional videos showing general operation and maintenance that are coordinated with operation and maintenance manuals.

e) Obtain Owner sign-off that training is complete.

f) Owner training shall be held at Project site.

Regulatory Requirements:

1) Products Requiring Electrical Connection: Listed and classified by

Underwriters' Laboratories, Inc. (or other testing agency acceptable to the authority having jurisdiction) as suitable for the purpose specified and indicated.

Safety:

Compressors to include all required OSHA guarding & pressure safety devices, OSHA compliant drive & belt guarding,.

Warranty:

1) Manufacture shall warrant all equipment and material of its manufacture against defects in workmanship and material for a period of eighteen months from date of shipment or twelve months from date of start-up, whichever occurs first.

Shipping, Storage, and

Protection:

1) Comply with manufacturer's installation instructions for rigging, unloading, and transporting units. Unit shall be stored and handled per manufacturer’s instructions.

2) Protect units from physical damage.

3) Unit shall be delivered to job site fully assembled with all interconnecting refrigerant piping and internal wiring ready for field installation. Ship water chillers from the factory fully charged with refrigerant and filled with oil.

4) Shipped to:

a) Parker Dam

Highway 95 Parker Dam Field Division

Parker Dam, CA 92267.

Other requirements:

NOTE:

Installation shall be by Bureau of Reclamation employees.

Operating Manual:

Two complete sets of service manuals to be provided with the delivery of the bandsaw including: operating instructions, technician manuals, maintenance procedures, and an illustrated parts breakdown shall be furnished.

Provide service manuals, both bound copies, and electronic PDF copies, shall contain complete parts identification lists.