Chillers - GBSD_ICC_FE_Warren_SpecsVol2_RTA_24Feb23.pdf

GBSD Integrated Command Center CUI Ready to Advertise Submittal F.E. Warren Air Force Base, WY 24 February 2023

SECTION 23 64 10

WATER CHILLERS, VAPOR COMPRESSION TYPE

11/ 16, CHG 2: 08/ 18

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

AHRI 575 (2008) Method of Measuring Machinery Sound Within an Equipment Space

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

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) Geospataial Data and Systems

ASTM INTERNATIONAL (ASTM)

ASTM A307 (2021) Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

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

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM E84 (2020) Standard Test Method for Surface Burning Characteristics of Building Materials

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

Jacobs D3420101 SECTION 23 64 10 Page 1

CUI

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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 submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-03 Product Data

Water Chiller; G, AE

Verification of Dimensions; G, RO

Factory Tests; G, RO

System Performance Tests; G, RO

Demonstrations; G, RO

Refrigerant; G, RO

Water Chiller - Field Acceptance Test Plan; G, RO

SD-06 Test Reports

Field Acceptance Testing; G, AE

Water Chiller - Field Acceptance Test Report; G, RO

System Performance Tests

SD-07 Certificates

Refrigeration System; G, RO

Ozone Depleting Substances Technician Certification; S

SD-08 Manufacturer's Instructions

Water Chiller - Installation Instructions; G, RO

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G, RO

SD-11 Closeout Submittals

Jacobs D3420101 SECTION 23 64 10 Page 2

Indoor Air Quality During Construction; S

1.3 CERTIFICATIONS

1.3.1 Ozone Depleting Substances Technician Certification

All technicians working on equipment that contain ozone depleting refrigerants must be certified as a Section 608 Technician to meet requirements in 40 CFR 82 , Subpart F. Provide copies of technician certifications to the Contracting Officer at least 14 calendar days prior to work on any equipment containing these refrigerants.

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.

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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.

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 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. Use adjustable frequency drives for all variable-speed motor applications. Provide variable frequency drives for motors as specified in Section 26 29 23 ADJUSTABLE SPEED DRIVE (ASD) SYSTEMS

UNDER 600 VOLTS.

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

2.4 SELF-CONTAINED WATER CHILLERS, VAPOR COMPRESSION TYPE

Unless necessary for delivery purposes, units must be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the factory.

In lieu of delivery constraints, a chiller may be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the job site by a factory representative. Unit components delivered separately must be sealed and

Jacobs D3420101 SECTION 23 64 10 Page 4 charged with a nitrogen holding charge. Parts weighing 50 pounds or more which must be removed for inspection, cleaning, or repair, such as motors, gear boxes, cylinder heads, casing tops, condenser, and cooler heads, must have lifting eyes or lugs. Chiller must be provided with a single point wiring connection for incoming power supply. Chiller's condenser and water cooler must be provided with standard water boxes with grooved mechanical connections.

2.4.1 Scroll Type

Chiller must be certified for performance per AHRI 550/590 I-P . If specified performance is outside of the Application Rating Conditions of AHRI 550/590 I-P , Table 2 then the chiller's performance must be rated in accordance with AHRI 550/590 I-P . Chiller must conform to ANSI/ASHRAE 15 & 34 . 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

e. Scroll compressor

f. Compressor driver, electric motor

g. Compressor driver connection

h. Water cooler (evaporator)

i. Water-cooled condenser coil

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. Chiller and individual chiller components must be isolated from the building structure by means of molded neoprene isolation pads.

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, Jacobs D3420101 SECTION 23 64 10 Page 5 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, disconnect switches, power wiring, and control wiring. Controls package must provide operating controls, monitoring capabilities, programmable setpoints, safety controls, and 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.

f. Startup and head pressure controls to allow system operation with entering condenser water temperature down to 20 degrees F.

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. Chilled water flow

c. 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)

Jacobs D3420101 SECTION 23 64 10 Page 6

j. Refrigerant discharge and suction pressures

k. Oil pressure

l. Condenser water entering and leaving temperatures

m. Number of purge cycles over the last 7 days

2.5.4.3 Configurable Setpoints

The control system must be capable of being configured directly at the unit's interface panel. No parameters may be capable of being changed without first entering a security access code. The programmable setpoints must include the following as a minimum:

a. Leaving Chilled Water Temperature

b. Leaving Condenser Water Temperature

2.5.4.4 Safety Controls with Manual Reset

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

a. Low chilled water temperature protection

b. High condenser refrigerant discharge pressure protection

c. Low evaporator pressure protection

d. Chilled and condenser water flow detection

e. High motor winding temperature protection

f. Low oil flow protection if applicable

g. 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 and condenser water flow interlock

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 bell. In coordination with the chiller, the Contractor must provide an alarm circuit (including transformer if applicable) and a minimum 4 inch diameter alarm bell.

Alarm circuit must activate bell in the event of machine shutdown due to the chiller's monitoring of safety controls. The alarm bell must not sound for a chiller that uses low-pressure cutout as an operating control.

Jacobs D3420101 SECTION 23 64 10 Page 7

2.5.4.7 Utility Monitoring and Control System Interface

Provide a Utility Monitoring and Control System (UMCS) interface meeting the requirements of Section 23 09 00 INSTRUMENTATION AND CONTROL FOR HVAC and the requirements of Section 23 09 23.02 BACNET DIRECT DIGITAL CONTROL FOR HVAC AND OTHER BUILDING CONTROL SYSTEMS. 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 Scroll Compressor(s)

Compressors must be of the hermetically sealed design. Compressors must be mounted on vibration isolators to minimize vibration and noise.

Rotating parts must be statically and dynamically balanced at the factory to minimize vibration. Lubrication system must be centrifugal pump type equipped with a means for determining oil level and an oil charging valve. Crankcase oil heater must be provided.

2.5.6 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.

2.5.7 Water Cooler (Evaporator)

Brazed plate evaporator to be UL listed. Refrigerant and water side to have maximum design pressure rating of 653 psig at 400 degrees F.

Evaporators to have one or two refrigerant circuits and one chilled water circuit. Evaporator to be insulated with 0.5 inch thick closed-cell flexible insulation with a K value of 0.26 BTU/(hr-ft-deg F) and to be furnished with core inlet and outlet water temperature sensors.

2.5.8 Water-Cooled Condenser Coil

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

2.6 ACCESSORIES

2.6.1 Refrigerant Leak Detector

Detector must be the continuously-operating, halogen-specific type.

Jacobs D3420101 SECTION 23 64 10 Page 8

Detector must be appropriate for the refrigerant in use. Detector must be specifically designed for area monitoring and must include 3 sampling points installed where indicated. Detector design and construction must be compatible with the temperature, humidity, barometric pressure and voltage fluctuations of the operating area. Detector must have an adjustable sensitivity such that it can detect refrigerant at or above 3 parts per million (ppm). Detector must be supplied factory-calibrated for the appropriate refrigerant(s). Detector must be provided with an alarm relay output which energizes when the detector detects a refrigerant level at or above the TLV-TWA (or toxicity measurement consistent therewith) for the refrigerant(s) in use. The detector's relay must be capable of initiating corresponding alarms and ventilation systems as indicated on the drawings. Detector must be provided with a failure relay output that energizes when the monitor detects a fault in its operation.

2.6.2 Refrigerant Fusible Plug

The assembly must be a fusible plug designed for refrigerant usage. The assembly must be in accordance with ASME BPVC SEC VIII D1 and

ANSI/ASHRAE 15 & 34 .

2.6.3 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.

2.6.3.1 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.

2.6.3.2 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).

2.6.4 Gaskets

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

2.6.5 Bolts and Nuts

Bolts and nuts, except as required for piping applications, must be in

Jacobs D3420101 SECTION 23 64 10 Page 9 accordance with ASTM A307. The bolt head must be marked to identify the manufacturer and the standard with which the bolt complies in accordance with ASTM A307.

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 125 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride 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. Cut edges of galvanized surfaces where hot-dip galvanized sheet steel is used must be coated with a zinc-rich coating conforming to ASTM D520, Type I.

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. Flame spread and smoke developed indexes must be determined by ASTM E84. Insulation must be tested in the same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket must be tested as a composite material. Jackets, facings, and adhesives must have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E84.

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 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

Jacobs D3420101 SECTION 23 64 10 Page 10 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 . The manufacturer must clean the tubes prior to testing to obtain a test fouling factor of 0.0000.

2.8.1.2 Test Instrumentation

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.

2.8.2 Chiller Sound Test

Chillers must be sound tested at the factory prior to shipment to confirm the sound pressure level specified herein. Tests and data must be conducted and measured in strict accordance with AHRI 575 at the full load system operating conditions. The chiller sound pressure level, in decibels (dB), with a reference pressure of 20 micropascals, must not exceed 90 dB, A weighted. Ratings must be in accordance with AHRI 575 .

No reduction of entering condenser water temperature or raising of leaving chilled water temperature will be allowed. A minimum of 75 percent of the sound data points must be taken along the length of the machine, and established as the minimum percentage of total possible points used to determine sound levels. In the event that the chiller does not meet the dBA sound pressure level, the manufacturer shall, at his expense, provide sufficient attenuation to the machine to meet the specified value. This attenuation must be applied in such a manner that it does not hinder the operation or routine maintenance procedures of the chiller. The attenuation material, adhesives, coatings, and other accessories must have surface burning characteristics as determined by ASTM E84.

2.9 SUPPLEMENTAL COMPONENTS/SERVICES

2.9.1 Chilled and Condenser Water Piping and Accessories

Chilled and condenser water piping and accessories must be provided and installed in accordance with Section 23 64 26 CHILLED, CHILLED-HOT, AND

CONDENSER WATER PIPING SYSTEMS.

2.9.2 Temperature Controls

Chiller control packages must be fully coordinated with and integrated into the temperature control system indicated in Section 23 30 00 HVAC AIR DISTRIBUTION and Section 23 09 00 INSTRUMENTATION AND CONTROL FOR HVAC and Section 23 09 23.02 BACNET DIRECT DIGITAL CONTROL FOR HVAC AND OTHER

BUILDING CONTROL SYSTEMS.

Jacobs D3420101 SECTION 23 64 10 Page 11

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

If vibration isolation is specified for a unit, 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 existing conditions, and any discrepancies found.

3.1.4 System Performance Test Schedules

Provide a schedule, at least 2 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 Six complete copies of an operation manual in bound 8 1/2 by 11

Jacobs D3420101 SECTION 23 64 10 Page 12 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, and parts list. The manuals must include the manufacturer's name, model number, service manual, and a brief 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.

3.1.7 Refrigeration System

3.1.7.1 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, 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. Each foundation must include isolation units consisting of machine and floor or foundation fastenings, together with intermediate isolation material. Other floor-mounted equipment must be set on not less than a 6 inch concrete pad doweled in place. Concrete foundations for floor mounted pumps must have a mass equivalent to three times the weight of the components, pump, base plate, and motor to be supported. In lieu of concrete pad foundation, concrete pedestal block with isolators placed between the pedestal block and the floor may be provided. Concrete pedestal block must be of mass not less than three times the combined pump, motor, and base weights. Isolators must be selected and sized based on load-bearing requirements and the lowest frequency of vibration to be isolated. Lines connected to pumps mounted on pedestal blocks must be provided with flexible connectors. Foundation drawings, bolt-setting information, and foundation bolts must be furnished prior to concrete foundation construction for all equipment indicated or required to have concrete foundations. Concrete for foundations must be as specified in Section 03 30 00 CAST-IN-PLACE CONCRETE. Equipment must be properly leveled, aligned, and secured in place in accordance with manufacturer's instructions.

3.1.7.2 Field Refrigerant Charging

a. Initial Charge: Upon completion of all the refrigerant pipe tests, the vacuum on the system must be broken by adding the required charge of dry refrigerant for which the system is designed, in accordance with the manufacturer's recommendations. Contractor must provide the complete charge of refrigerant in accordance with manufacturer's recommendations. Upon satisfactory completion of the system performance tests, any refrigerant that has been lost from the system must be replaced. After the system is fully operational, service valve seal caps and blanks over gauge points must be installed and tightened.

b. Refrigerant Leakage: If a refrigerant leak is discovered after the system has been charged, the leaking portion of the system must immediately be isolated from the remainder of the system and the refrigerant must be pumped into the system receiver or other suitable

Jacobs D3420101 SECTION 23 64 10 Page 13 container. The refrigerant must not be discharged into the atmosphere.

c. Contractor's Responsibility: The Contractor must, at all times during the installation and testing of the refrigeration system, take steps to prevent the release of refrigerants into the atmosphere. The steps must include, but not be limited to, procedures which will minimize the release of refrigerants to the atmosphere and the use of refrigerant recovery devices to remove refrigerant from the system and store the refrigerant for reuse or reclaim. At no time must more than 3 ounces of refrigerant be released to the atmosphere in any one occurrence. Any system leaks within the first year must be repaired in accordance with the specified requirements including material, labor, and refrigerant if the leak is the result of defective equipment, material, or installation.

3.1.7.3 Oil Charging

Except for factory sealed units, two complete charges of lubricating oil for each compressor crankcase must be furnished. One charge must be used during the performance testing period, and upon the satisfactory completion of the tests, the oil must be drained and replaced with the second charge.

3.1.8 Mechanical Room Ventilation

Mechanical ventilation systems must be in accordance with Section 23 30 00

HVAC AIR DISTRIBUTION.

3.1.9 Field Applied Insulation

Field installed insulation must be as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS, except as defined differently herein.

3.1.10 Field Painting

Painting required for surfaces not otherwise specified, and finish painting of items only primed at the factory are specified in Section

09 90 00 PAINTS AND COATINGS.

3.2 CLEANING AND ADJUSTING

Equipment must be wiped clean, with all traces of oil, dust, dirt, or paint spots removed. Provide temporary filters for all fans that are operated during construction. Perform and document that proper Indoor Air Quality During Construction procedures have been followed; this includes providing documentation showing that after construction ends, and prior to occupancy, new filters were provided and installed. System must be maintained in this clean condition until final acceptance. Bearings must be properly lubricated with oil or grease as recommended by the manufacturer. Belts must be tightened to proper tension. Control valves and other miscellaneous equipment requiring adjustment must be adjusted to setting indicated or directed. Fans must be adjusted to the speed indicated by the manufacturer to meet specified conditions. At least one week before the official equipment warranty start date, all condenser coils on air-cooled water chillers and split-system water chillers must be cleaned in accordance with the chiller manufacturer's instructions. This work covers two coil cleanings. The condenser coils must be cleaned with an approved coil cleaner by a service technician, factory trained by the

Jacobs D3420101 SECTION 23 64 10 Page 14 chiller manufacturer. The condenser coil cleaner must not have any detrimental affect on the materials or protective coatings on the condenser coils. Testing, adjusting, and balancing must be as specified in Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC.

3.3 FIELD ACCEPTANCE TESTING

3.3.1 Test Plans

a. Manufacturer's Test Plans: Within 120 calendar days after contract award, submit the following plans:

(1) Water chiller - Field Acceptance Test Plan

Field acceptance test plans must be developed by the chiller manufacturer detailing recommended field test procedures for that particular type and size of equipment. Field acceptance test plans developed by the installing Contractor, or the equipment sales agency furnishing the equipment, will not be acceptable.

The Contracting Officer will review and approve the field acceptance test plan for each of the listed equipment prior to commencement of field testing of the equipment. The approved field acceptance tests of the chiller and subsequent test reporting.

b. Coordinated testing: Indicate in each field acceptance test plan when work required by this section requires coordination with test work required by other specification sections. Furnish test procedures for the simultaneous or integrated testing of tower system controls which interlock and interface with controls for the equipment provided under Section 23 09 00 INSTRUMENTATION AND CONTROL FOR HVAC or Section

23 09 23.02 BACNET DIRECT DIGITAL CONTROL FOR HVAC AND OTHER BUILDING

CONTROL SYSTEMS.

c. Prerequisite testing: Chillers for which performance testing is dependent upon the completion of the work covered by Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC must have that work completed as a prerequisite to testing work under this section.

Indicate in each field acceptance test plan when such prerequisite work is required.

d. Test procedure: Indicate in each field acceptance test plan each equipment manufacturers published installation, start-up, and field acceptance test procedures. Include in each test plan a detailed step-by-step procedure for testing automatic controls provided by the manufacturer.

Each test plan must include the required test reporting forms to be completed by the Contractor's testing representatives.

Procedures must be structured to test the controls through all modes of control to confirm that the controls are performing with the intended sequence of control.

Controller must be verified to be properly calibrated and have the proper set point to provide stable control of their respective equipment.

e. Performance variables: Each test plan must list performance variables

Jacobs D3420101 SECTION 23 64 10 Page 15 that are required to be measured or tested as part of the field test.

Include in the listed variables performance requirements indicated on the equipment schedules on the design drawings. Chiller manufacturer must furnish with each test procedure a description of acceptable results that have been verified.

Chiller manufacturer must identify the acceptable limits or tolerance within which each tested performance variable must acceptably operate.

f. Job specific: Each test plan must be job specific and must address the particular cooling towers and particular conditions which exist in this contract. Generic or general preprinted test procedures are not acceptable.

g. Specialized components: Each test plan must include procedures for field testing and field adjusting specialized components, such as hot gas bypass control valves, or pressure valves.

3.3.2 Testing

a. Each water chiller system must be field acceptance tested in compliance with its approved field acceptance test plan and the resulting following field acceptance test report submitted for approval:

(1) Water chiller - Field Acceptance Test Report

b. Manufacturer's recommended testing: Conduct the manufacturer's recommended field testing in compliance with the approved test plan.

Furnish a factory trained field representative authorized by and to represent the equipment manufacturer at the complete execution of the field acceptance testing.

c. Operational test: Conduct a continuous 24 hour operational test for each item of equipment. Equipment shutdown before the test period is completed shall result in the test period being started again and run for the required duration. For the duration of the test period, compile an operational log of each item of equipment. Log required entries every two hours. Use the test report forms for logging the operational variables.

d. Notice of tests: Conduct the manufacturer's recommended tests and the operational tests; record the required data using the approved reporting forms. Notify the Contracting Officer in writing at least 15 calendar days prior to the testing. Within 30 calendar days after acceptable completion of testing, submit each test report for review and approval.

e. Report forms: Type data entries and writing on the test report forms. Completed test report forms for each item of equipment must be reviewed, approved, and signed by the Contractor's test director. The manufacturer's field test representative must review, approve, and sign the report of the manufacturer's recommended test. Signatures must be accompanied by the person's name typed.

f. Deficiency resolution: The test requirements acceptably met;

deficiencies identified during the tests must be corrected in

Jacobs D3420101 SECTION 23 64 10 Page 16 compliance with the manufacturer's recommendations and corrections retested in order to verify compliance.

3.4 SYSTEM PERFORMANCE TESTS

Six copies of the report must be provided in bound 8 1/2 by 11 inch booklets.

3.4.1 General Requirements

Before each refrigeration system is accepted, tests to demonstrate the general operating characteristics of all equipment must be conducted by the manufacturer's approved start-up representative experienced in system start-up and testing, at such times as directed. Tests must cover a period of not less than 48 hours for each system and must demonstrate that the entire system is functioning in accordance with the drawings and specifications. Corrections and adjustments must be made as necessary and tests must be re-conducted to demonstrate that the entire system is functioning as specified. Prior to acceptance, service valve seal caps and blanks over gauge points must be installed and tightened. Any refrigerant lost during the system startup must be replaced. If tests do not demonstrate satisfactory system performance, deficiencies must be corrected and the system must be retested. Tests must be conducted in the presence of the Contracting Officer. Water and electricity required for the tests will be furnished by the Government. Any material, equipment, instruments, and personnel required for the test must be provided by the Contractor. Field tests must be coordinated with Section 23 05 93

TESTING, ADJUSTING, AND BALANCING FOR HVAC.

3.4.2 Test Report

The report must document compliance with the specified performance criteria upon completion and testing of the system. The report must indicate the number of days covered by the tests and any conclusions as to the adequacy of the system. The report must also include the following information and must be taken at least three different times at outside dry-bulb temperatures that are at least 5 degrees F apart:

a. Date and outside weather conditions.

b. The load on the system based on the following:

(1) The refrigerant used in the system.

(2) Condensing temperature and pressure.

(3) Suction temperature and pressure.

(4) Running current, voltage and proper phase sequence for each phase of all motors.

(5) The actual on-site setting of all operating and safety controls.

(6) Chilled water pressure, flow and temperature in and out of the chiller.

3.5 DEMONSTRATIONS

Contractor must conduct a training course for the operating staff as designated by the Contracting Officer. The training period must consist

Jacobs D3420101 SECTION 23 64 10 Page 17 of a total 4 hours of normal working time and start after the system is functionally completed but prior to final acceptance tests. The training course must cover all of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine maintenance operations.

Provide a schedule, at least 2 weeks prior to the date of the proposed training course, which identifies the date, time, and location for the training.

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