PROJECT # 25-0438

MECHANICAL MACC

TITLE: FY26 Wallace Creek BEQ Chiller Repairs

General Description:

Replace Chillers and Pumps at the following building

1. WC105 is a 90 nominal ton chiller.

2. WC110 is a 90 nominal ton chiller.

3. WC115 is a 90 nominal ton chiller.

4. WC120 is a 90 nominal ton chiller.

5. WC130 is a 120 nominal ton chiller.

6. WC135 is a 120 nominal ton chiller.

*Chiller and disconnect sizes should be verified by the contractor.

*** Chiller, Pumps, and Disconnect Sizes and Types Shall Be Verified by the Contractor *** It is the responsibility of the contractor to replace pump/pumps on site of each new chiller installation and assure the pump/pumps will operate the new chiller with the proper GMP. If the existing pump does not meet the new chiller requirements it is the responsibility of the contractor to resize the pump/pumps with the proper style and GPM for the chiller. Verifying pump voltages is the responsibility of the contractor.

SCOPE OF WORK:

The contractor shall provide all material, labor, equipment, and supervision required to accomplish the following:

Detailed Requirements and Specifications: The contractor shall make site visits coordinated with PWD, Scotty Sholar-910-389-4418

Chiller Specifications and Basis of Design.

1. All chilled water piping and strainers shall be cleaned prior to installation of new chiller. See attachment for hydronic pipe cleaning and flushing procedures.

2. Replace chilled water pumps and drives on all chiller installs. Pump must meet the manufacturer specifications for each chiller.

3. All chiller manufactures must provide a 10-year parts, labor, and refrigerant warranty for entire

.chiller. A factory installed water strainer shall also be included for each chiller.

4. Chiller shall be equipped with a 20amp GFCI convenience outlet for maintenance to be performed. Chiller disconnects shall be replaced along with the conduit and connectors between disconnect and the chiller( unless otherwise noted). New disconnect shall meet the manufacturers’ recommendations. Heat Trace shall protect the evaporator and all piping that is subject to freezing. All field installed heat tracers must be tested prior to installing pipe insulation. The 20amp heat trace circuit shall be on a separate circuit. It is the responsibility of the contractor to verify circuit is active. If not, a new circuit shall be run.

5. Chiller shall include single point power connection to a non-fused disconnect switch with through-the-door handle and compressor circuit breakers.

6. Chiller condenser fan motors shall include VFD’s to optimize chiller efficiency and maintain proper head pressure. The condenser fan motors shall be TEFC PSC style motors.

7. Condenser coils shall have a flexible cationic epoxy polymer e-coat uniformly applied to all metallic surfaces with no material bridging between fins. The electro-coat shall ensure complete HX encapsulation of all conductive surfaces with uniform dry film thickness from 0.6-1.2 mils (15-30um). E-coating shall meet 5B rating for cross- hatch adhesion per ASTM B3359. Corrosion durability will be confirmed through testing no less than10000 hours salt spray resistance per ASTM B117 using scribed aluminum test coupons.

After e-coat cure, HX shall receive a spray applied, 2K polyurethane black topcoat to prevent UV degradations of epoxy e-coat film. Topcoat shall have a 60-degree gloss (<90%) and dry film thickness of 50-60um.

8. All condenser coils shall be Microchannel coils constructed of aluminum alloy 9150 (Long Life Alloy), to help prevent inter-granular corrosion and increase mechanical strength before and after brazing. Aluminum alloy 3102 coils will not be accepted due to mechanical failure rates. Copper tube and aluminum fin condenser coils will be accepted as an alternate if they can include the factory coating with published 10000-hour salt spray rating listed above.

9. Condenser coils shall be protected by louvered coil guards and compressor housing shall have equivalent protection.

10. Chiller shall sit on Seismic Feet and rubber pads installed on bottom of rails to elevate side rails to allow wash down of debris from under chiller.

11. Chiller must include thermal dispersion type flow switches. Paddle type will not be accepted. The flow switch shall be factory installed at the evaporator outlet.

12. Chillers must include phase loss with under/over voltage protection with LED indication of the type of fault to guard against compressor motor burn out.

13. Emergency Chiller Connections: a set of emergency tees shall be installed before entering the chiller on supply and return lines. The tees shall match the diameter of the pipe. Lug type butterfly valve and a bolted cover plate shall be installed. No wafer type butterfly valve shall be installed.

14. Control panels shall have access to microprocessor (controller) for viewing and set up, without interrupting machine operation. Chiller shall include a centrally located weatherproof control panel including DDC microprocessor controller. Control boxes shall be designed in accordance with NEMA 3R rating. Controllers and screens must be located within the panel and not exposed to sunlight. All wiring within control panels shall be ran through slotted wiring duct with covers. Loose wires with zip ties will not be accepted.

15. Units 75 nominal tons and up shall include reduction mode to allow for reduced sound operation. VFD’s are to limit the condenser fan speeds to reduce sound. Users shall be able to specify times chiller will operate in sound reduction mode. Chiller shall be set to override the reduced sound mode when the additional capacity is needed. This will make sure the chiller is optimized between required capacity and the lowest sound level possible.

16. Each condenser circuit shall have isolation valves, service valves and replaceable core filter driers.

17. Chillers must meet the sound data listed in the below at specified frequencies.

Nominal Tonnage

Octave Band at Center Frequency, 30 ft. from unit. Overall A-Weighted 63 125 250 500 1000 2000 4000 8000 100%

Load 75% Load

50% Load

25% Load

30 65 64 61 60 56 51 46 41 61 60 58 57 35 65 64 62 60 56 51 46 41 61 60 58 57 40 65 64 63 61 57 52 47 42 62 61 59 58 45 66 65 64 62 58 52 47 42 63 62 60 59 50 66 66 64 62 58 52 47 42 63 62 60 59 55 66 66 66 62 59 54 49 44 64 63 61 60 60 67 66 67 62 59 54 49 44 64 63 61 60 65 68 67 67 62 60 54 49 44 65 64 62 61 70 68 68 67 62 60 54 49 44 65 64 63 62 75 68 68 68 62 60 54 49 44 65 64 62 61 80 66 63 63 63 62 56 53 53 66 65 63 62 90 67 67 67 64 62 56 54 54 67 66 64 63

100 66 65 65 65 62 56 57 55 67 66 64 63 110 66 67 67 65 61 55 55 55 67 66 64 63 120 68 67 67 65 61 59 60 57 68 67 65 64 130 67 68 68 64 61 60 60 55 68 67 65 64 140 68 69 69 65 61 60 61 56 69 68 66 66 150 69 70 70 65 62 62 62 56 70 69 67 66 160 69 70 70 65 62 63 62 56 70 69 67 66 170 69 71 69 67 64 61 60 58 70 69 67 66 180 69 71 69 67 64 61 61 58 70 69 67 66 190 69 71 69 67 64 61 61 58 70 69 67 66

Sound data must be published to meet or be lower than the above numbers for respective tonnage. Any chiller that does not conform to these published sound targets must provide attenuation to meet at the installing contractor’s expense. Sound attenuation should not affect or degrade the chillers performance. The chiller manufacturers catalog data should support all listed sound data.

18. Factory supplied strainer shall be field installed on the evaporator inlet side. The strainers shall be “Y” type with blow down nipples., valves, and caps. There are to be no welds downstream of the strainer prior to the heat exchanger.

Chiller manufacturer must provide “Y” type strainer with the following CV values listed below.

Pipe Size CV 2” 120

2.5” 165 3: 227 4” 457 5” 641 6” 976 8” 1,607 10” 2,574 12” 3,576

19. The contractor is responsible for recording Pre-Installation water flow readings and Post-Installation water-Flow readings. The water flow readings must be submitted with the Maximo information. The water flow must meet the manufacturer’s operating requirements

20. Sight glasses shall be installed.

21. Controls shall be BACnet/MSTP, the controller shall be in English, and must monitor phase loss, over and under voltage, line, and load monitoring. Chiller shall be enabled on 45 Degree F and above.

Any control interface presently installed and operable on the chiller shall be reinstalled and made to operate. This includes hardwire start-stop, alarm, trouble, or integration to a BACnet/MSTP communication bus.

22. Chiller manufacture must have a service organization with at least one service technician within 35 miles from Camp Lejeune, NC.

23. New Chiller must comply with the buy America Act/Free Trade Agreement with the United States of America.

24. Piping diagrams shall be developed by the contractor based on chiller selection.

1.1 All piping shall be approved by PWD/OPS. Prior to installation submit shop drawings for chiller piping station, supports, electrical, control layout and fabrication etc. (1) Proposed fabrication & assembly (2) Installation – fit & attachment details of materials and equipment) (3) Include drawings, diagrams, layouts, schematics, descriptive literature, illustrations, and similar materials furnished by the contractor to explain specific portions of the work required by contract.

1.2 All piping 4” and below is to be copper and piping 5” and greater shall be a minimum of schedule 40 welded steel. All welds shall be primed and painted with a minimum of two (2) coats of alkyd enamel.

All external piping shall have heat trace( minimum 5watts per foot) to prevent freezing. All pipes shall be insulated with minimum of 2” of polyisocyanurate insulation. All insulation shall be covered with aluminum UV cover. All piping shall be supported with pipe stands and or welded supports. Pipe stands or supports bases must be a minimum of 12’x12” or 12” round by 8” thick, if not supported by the equipment pad. Floating blocks are not permitted.

1.3 By-pass piping and valves must be installed and depicted on the shop drawings for testing and flushing, to eliminate testing through the chiller.

25. Electrical feed

1.1 All electrical feeds and controls shall conform to the “NEC”. Contractor shall replace electrical disconnects and liquid tight conduit and connectors. Existing wiring can be reused if it meets manufacturers’ recommendations.

1.2 All electrical wiring sizes, voltage and amp draws of equipment are the responsibility of the contractor.

1.3 All information provided in this scope of work is for reference only.

1.4 Site visits shall be required by all bidding contractors.

26. Perform hydrostatic test on installed piping. Hydrostatic testing and flushing through the chiller barrel are not permitted. The hydrostatic test shall be tested at no less than 150 psig The piping must maintain 150 psig for 2 hours with no leakage or reduction in gage pressure prior to insulation being installed.

27. Chiller start-ups must be performed by manufacturer authorized/ qualified personnel. Start-up reports must be submitted prior to BOD.

28. Chillers must be installed in accordance with the manufacturers’ recommendations for clearances for proper operation and maintenance.

DETAILED REQUIREMENTS AND SPECIFICATIONS

1. Provide spec sheets for material and equipment being used prior to start of work for government approval.

Provide a copy of Maximo Equipment Inventory Sheet for each piece of equipment removed and installed.

SPECIAL SCHEDULING AND ACCESS:

1. Scheduled outages are to be scheduled thru PWD. Outages shall be scheduled fourteen (14) days prior to equipment shut down. Contact Scotty Sholar @910-389-4418.

SPECIAL CONDITIONS: Contract shall be completed with in 300 days after award.

Contractor shall ensure all employees and subcontractors have access and fully vetted.

The contractor shall give Public Works the right to all HVAC equipment, including but not limited to chillers, AHUs, DOAS units, and any DDC controllers that are involved with the sequence of operation for the buildings HVAC system.

The contractor shall give Public Works the right to reclaim all refrigerant from any HVAC system before any equipment is to leave the work area. Any controls that are on existing chiller that need to be installed on new chiller can be removed and installed by the contractor. After Public Works remove any parts as listed above, the chiller will be the property of the contractor to dispose of offsite.

Submittals:

All equipment shall /must be approved. Summit all proposals to the ROICC and PWD for consideration. The contractor shall be required to submit work schedules to POC for approval. The contractor shall submit to the Contracting Officer, the manufacturer’s product specifications, complete with technical product data. The product specifications shall, as a minimum, provide technical details on the following items:

a. Manufacturer’s name and product line.

b. Manufacturer’s Warranty

HAZARDOUS MATERIALS: None

ENVIRONMENTAL: None