Attachment 2 - MAHG201067 SPEC Rev 1 (Dated 10 Aug 2020).pdf

Rev1, 10 Aug 2020

COOLING TOWER SPECIFICATION

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.

Access platforms, ladders and guardrails (both internal & external) must be provided where noted or shown in reference drawing. Access platforms, ladders, guardrails and self-closing gates shall be in accordance with

OSHA 1910.23.

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 shall be the Contractor's responsibility.

Any materials found to be damaged shall be replaced at the Contractor's expense.

During installation, piping and similar openings must be capped to keep out dirt and other foreign matter.

STANDARD COMMERCIAL PRODUCTS

Materials and equipment must be standard commercial catalogued products of a manufacturer regularly engaged in the manufacturing of such products, which are of a similar material, design and workmanship.

The standard products must have been in satisfactory commercial or industrial use in field service for two years prior to bid opening.

The two year use must include applications of equipment and materials under similar circumstances and of similar size.

Products having less than a two year field service record will be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours exclusive of the manufacturer's factory tests, can be shown. This

6000 hour record must not include any manufacturer's prototype or factory testing. Records of satisfactory field use must be completed by a product that had been, and presently is, sold, or offered for sale on a commercial market through the following copyrighted means: advertisements, manufacturer's catalogs.

Products must be supported by a service organization.

System components must be environmentally suitable for the indicated locations.

MANUFACTURER'S STANDARD NAMEPLATES

Major equipment including cooling towers, cooling tower gear drive assemblies, 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.

ELECTRICAL WORK

Provide electrical equipment, including motors and wiring, as specified in UFC 3-520-01.

Refer to NEMA ICS 7 for design criteria related to the selection of the Variable Frequency Drive (VFD).

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.

Contractor shall provide fan motors as follows:

2-25 HP, 3-phase, 480 volt, 1.15 service factor motors w/ premium efficiency ratings that will allow the motor to operate down to 20% of rated speed & comply with Energy Policy Act of 2005.

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.

Motor bearings must be fitted with grease supply fittings and grease relief to outside of the enclosure.

Contractor shall provide the following VFD fan controllers as follows:

Two Yaskawa Z1000 (or approved equals) w/ contactor bypass, variable frequency drives.

Provide Inductive absorbers similar to Cool-Blue (or approved equals) on the cooling tower VFDs.

All VFD startups and Tuning to be performed by factory trained/authorized representative.

Contractor shall provide start-up report for both VFDs.

COOLING TOWER MATERIALS

Stainless steel sheet metal shall be used to fabricate the cooling tower basins, casing, and internal structure.

Stainless steel sheet shall be Type 304 or 316 alloys to be determined by strength required for application.

Foundation cribbing framing, access platforms, guard-rails shall be of zinc-coated ASTM A36 steel.

Zinc coatings must conform to ASTM A153 and ASTM A123, as applicable, and must have an extra heavy coating of not less than 2.35 ounces per square foot of surface.

Four access ladders sections shall be 18” welded aluminum ladders.

Ladder safety cage required on upper two ladder sections shall be of zinc-coated steel.

Guard-rail shall fabricate & deliver in welded sections to be field installed.

Guard-rail will install at two access door platforms and at full perimeter of fan deck.

Four self-closing gates will be required. One at each access platform. One at top of each deck access ladder.

Ladders, access platforms, guard-rails to be field installed.

All joining hardware (ie Threaded fasteners) must be Type 304 or 316 alloy stainless steel. To be determined by strength required for application. Each bolt must be provided similar material washers under the heads.

All hardware must meet the salt-spray fog test as defined by ASTM B117. No signs of corrosion must be evident after 1,000 hours continuous exposure to a 5 percent salt spray.

Drift eliminators, air-inlet louvers, and fill sheets are to be of UV protected, Polyvinyl chloride (PVC) sheets suitable for inlet temperatures to 130 degrees F.

PVC sheets shall meet CTI STD-136 bio-cide requirements.

PVC shall be per ASTM D1784, Type I, Grade 1 with a flame spread rating < 20 per ASTM E84, Class A.

PVC fill sheet thickness shall be 12mil.

PVC flammability shall be self-extinguishing in less than 5sec. per ASTM D635.

MANUFACTURER’S WARRANTY

The cooling tower, as a whole, (all internal & external components, electrical fans & motors) shall be warranted for a 5 year period from original date of installation.

The cooling tower stainless steel casing, basin & structure must be warranted for a 15 year period from the original date of installation.

COOLING TOWERS; DESCRIPTION & PERFORMANCE

The cooling tower must be a factory-assembled, induced draft, cross-flow type, stainless steel cooling tower with PVC film fill.

The cooling tower cells shall have the approx. capacity of 315-330 TON cooling at 930-945 GPM of water, from 95°F to 85°F, at a design entering air wet-bulb temperature of 80°F.

Drift losses shall not exceed 0.005% of the design circulating flow of 930-945 GPM.

The cooling towers shall be capable of a minimum 40.2 gpm/hp efficiency per ASHRAE Standard 90.1.

The cooling tower must have Cooling Tower Institute (CTI) certification per CTI STD-201.

The cooling tower will perform thermally at the rating published by the manufacturer in his copyrighted literature.

Referenced drawing shows a proposed installation scheme for an SPX/Marley NC8403RAS 2-Cell

Induced Draft, Cross-Flow Cooling Tower. Any similar or approved equal will be considered.

See the reference drawing M3.0 for tower cell proposed foundation fabrication, proposed rigging.

See the reference drawing M2.0 for installation details.

CONSTRUCTION

Tower must be constructed to withstand a wind pressure of not less than 30 psf on any external surface.

Fan deck must be constructed to withstand a live load of not less than 60 psf, in addition to the concentrated or distributed loads of equipment mounted on the fan deck.

The hot water distribution system must be of the pressurized spray header type design.

TOWER FRAME AND LOUVERS

Provide frame constructed from stainless steel type 304 or 316 alloy, as noted above. Intermediate structural members must be provided for rigidity and support of casings, louvers, fill, distribution systems, fan decks, and other equipment.

Inlet air louvers must permit free air passage, but no splash-out, and must be designed to prevent debris and sunlight from entering the cold water basin.

AIR INLET AND DISCHARGE CONNECTIONS

The air inlet and discharge connections must have flanged or lipped projections for connecting to ducts.

FILL

The fill must support expected loads without sag or failure and arranged to effectively break up the water.

The fill must be manufactured and performance tested by the cooling tower manufacturer.

DRIFT ELIMINATORS

Provide drift eliminator sections designed and arranged to effectively trap water droplets entrained in the discharge airstream. Drift losses shall not exceed 0.005% of the design circulating flow.

Sections must be assembled in easily removable sections for these cross-flow induced draft tower cells.

COLD WATER BASIN EQUIPMENT.

Cooling tower cell sumps shall be of stainless steel Type 304 or 316, with stainless steel removable screen and vortex breaker, float valves, and necessary pipe connections & fittings within the tower.

Provide float valves with adjustable arms. Valve sizes larger than 1/2"IPS must be balanced piston type.

Valve seats and disks must be replaceable. No electronic water level control is required. No remote monitoring of CT sump water level is required. No sump water level HI-LO alarm is required.

Cold water basins and casings shall be suitably sealed and flashed at joints, connections to ensure watertight construction.

ELECTRIC BASIN HEATER

NO BASIN WATER HEATER WILL BE REQUIRED.

FANS, BLOWERS, AND DRIVES.

The towers must have an axial propeller-type fan installed at each tower cell.

The axial-propeller-type fans shall have not less than four aluminum alloy blades.

Fans must be designed, constructed to withstand 50 percent over-speed above maximum operating speeds.

Shafting for gear drives must have flexible-type couplings requiring no lubrication.

The gear assemblies must be enclosed in an oil filled housing provided with fill and drain plugs.

See ELECTRICAL WORK section above.

TOWER INTERIOR PIPING

The hot water distribution system must be of the pressurized spray header type design.

Interior cooling tower cell piping must be ASTM D2996, PVC SCH40. Fittings for other piping materials must be of the same material or equal and of the same class and grade as the pipe. Spray nozzles shall contain internal, interchangeable flow devices to provide an optimal spray pattern within the 2 to 10 psig operating pressure range.

VIBRATION CUTOUT SWITCH.

Provide (2) electronic vibration cutout switches, each with auxiliary contacts.

The vibration switches are to be mounted in fan ducts.

The vibration switches must interlocked with the VFD fan controller wiring to STOP fan under excessive fan vibration.

Vibration switches will be field installed.

SOUND POWER LEVEL

Cooling tower sound power levels* must be not greater than the maximum permitted dB levels for the designated octave band as set forth in Table I. The sound power level data for the cooling tower must have been verified in tests conducted in accordance with ASA S1.13.

Table I. Sound Power Level For Induced Mechanical Draft Type

Octave Band (Hz) 63 125 250 500 1000 2000 4000 8000

Sound Power Level

(dB)

112 112 110 108 102 98 93 90

*sound power levels given in decibels (dB) with a reference pressure of 0.0002 microbars

LUBRICATION

The lubricating points must be extended to the outside of the unit for easy accessibility.

The lubrication points shall be prominently labeled, stenciled similar to piping identification specification.

Hydraulic lubrication fittings must be in accordance with SAE J534.

Where use of high pressure lubricating equipment, 1000 psi or higher, will damage grease seals or other parts, a suitable warning must be affixed to the equipment in a conspicuous location.

FACTORY FINISH SYSTEM

Stainless steel sheet metal must have been proven to withstand 125 hours in a salt-spray fog test, except that equipment located outdoors must withstand 3,000 hours in a salt-spray fog test.

Salt-spray fog test must be in accordance with ASTM B117.

Immediately after the salt-spray fog test, the specimen must show no signs of rust creepage beyond 0.125” on either side of the scratch mark.

FABRICATION

Equipment located in a sea coast environment must withstand 3,000 hours in a salt-spray fog test.

Salt-spray fog test must be in accordance with ASTM B117.

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.

PIPING AND ACCESSORIES

CW & CHW steel piping, make-up CFW copper piping, and drain PVC piping must be provided and installed in accordance with Referenced Piping Specification. Associated valves, fittings and instrumentation will also be found in this piping specification.

WATER TREATMENT SYSTEMS

CHW system chemical treatment shall be kept operational during partial plant operating conditions, temporary chiller service operating conditions, and also through cooling tower start-up testing.

CW system chemical treatment will be interrupted during cooling tower replacement work. The chemical treatment system will be placed back in service to support cooling tower start-up testing.

Contractor will have no responsibility for ongoing chemical treatment of either CHW or CW systems.

TESTING

Perform CW system hydrostatic test @ 61psi (1.5x 93ftHD WP), upon completion of CW system piping modification at NEW cooling tower. For additional information of this testing see the

Non-Potable Water Piping Specification. Provide test report.

Manufacturer’s factory test report or certification must be provided with new cooling tower.

Perform manufacturer start-up, analysis, and operation tests to prove proper operation of CHW and

CW systems with new cooling towers. The following cooling tower control and operation functions shall be demonstrated, as a minimum. Manufacturer’s factory authorized representative is required.

EMCS control signal function, sump float switch, immersion heater, vibration switch interlock, and tower fan motor variable speed drive testing shall be demonstrated in the manufacturer’s start up testing.

CFW make-up piping shall be visually inspected for leaks during cooling tower start-up tests, with the operation of cooling tower sump float switches.

Drain piping shall be gravity tested, with cooling tower sumps full of water and CW pumps off.

The PVC drain fittings shall be inspected visually for leaks as cooling tower cells and CWS headers are allowed to drain.

Manufacturer’s representative shall certify new cooling tower manufacturer’s warranty as stated in the referenced cooling tower specification.

Manufacturer shall provide cooling tower test report. Report will be delivered to the Vectrus CM on same date as the test is performed.

Contractor shall monitor the operation of the CHW plant, specifically the cooling towers, for a

24hour period after CHW plant is placed back into normal B1002 operation.

Training shall be provided (by factory authorized personnel) to Vectrus HVAC personnel after a successful cooling tower start up with the unit operating under normal conditions. A least two copies of Manufacturer’s Operation & Maintenance Manuals shall be provided to Vectrus

HVAC personnel and Vectrus CM.

OTHER ITEMS

No strip/trace heaters will be required on CWS piping from each CT cell.

Equalizer lines shall be installed between CT cell sumps, with isolation valve/s necessary to uncouple these equalizer lines, as needed.

No vibration isolation or elastomeric pad damping will be necessary at base of CT cells.

PIPING SPECIFICATIONS

A. MATERIALS:

Chilled water and Condenser water piping shall be ASTM A53, 4”-12”IPS, SCH40, hot-dipped, zinc coated, seamless, black-steel pipe with welded joints.

CFW make-up system copper tubing shall conform to ASTM B88, Type K, L or M.

Drain piping system PVC piping must be per ASTM D2665-14, PVC SCH40.

B. VALVES:

Two NEW 10” chilled water isolation valves are required. The isolation valves shall be 10” stainless steel 150# butterfly valves with lugged flanged ends and locking ratchet hand levers, similar or equal to

CRANE, FLOW-SEAL, soft seat, high performance butterfly valves as noted below.

One chiller isolation valve (010-1LA-27DMTG-LLJ) without dead end service.

One temporary service isolation valve (010-1DA-27DMTG-LLJ) with dead end service.

All existing CW isolation valves are to be cycled to prove proper operation as isolation valves.

(Two 12” CWS isolation valves and four 8” CWR isolation valves)

One existing 12” CWS isolation valve must be fit with a new locking ratchet hand lever.

Four existing 8” CWR isolation valves will be removed, but retained for reinstallation.

Two NEW 8” CWR isolation valves are required to isolate each of two cooling tower cells. The isolation valves shall be 8” stainless steel 150# butterfly valves with lugged flanged ends and locking ratchet hand levers, similar or equal to CRANE, FLOW-SEAL, soft seat, high performance butterfly valves as noted below.

Both 8” CWR isolation valves shall be (008-1LA-27DMTG-LLJ) without dead end service.

CFW make-up piping 2” isolation valves at each cooling tower cell are to be cycled to prove proper operation as isolation valves, and retained for reinstallation. If valves do not properly operate as isolation valves, contractor shall file a condition report with Vectrus CM.

No cooling tower or CWS header drain valves are to be impacted by this PVC drain work.

Two 4” CWS header drain piping isolation valves shall be cycled to prove proper operation as isolation valves, and retained for reinstallation. These valves should be proved to hold CW test pressure during

CWS testing, showing no leak thru flow in PVC drain piping.

C. FITTINGS & JOINTS:

CHW, CW system pipe fittings shall be 4”-12”, 150#, ASTM A234 WPB carbon steel fittings with ASME B16.25 butt welded joints.

Flanged joints in CHW, CW system piping shall use standard 4”-12” IPS, 150# ASTM A105 carbon steel flanges to ANSI B16.5 dimensions, as needed. Gasket material to be asbestos free and suitable for pressure, temperatures, and fluid of piping system. Gaskets shall be non-metallic gaskets per

ANSI/ASME B16.21 and ASTM F104. Gasketing shall be fully-faced gaskets per ASTM D1330 Gr2

(SBR red rubber, 70 durometer, 1/8” thick, rated at temperatures from -20 to 180 degF)

CFW make-up piping shall use bronze fittings which will be brazed or threaded.

Brazed joints shall be made in conformance with AWS B2.2, ASME B16.50, and CDA A4015 with flux and are acceptable for all pipe sizes. Brazing material shall conform to AWS A5.8, BCuP-5.

Brazing flux shall be in paste or liquid form appropriate for use with brazing material. Flux must be as follows: lead-free; have a 100 percent flushable residue; contain slightly acidic reagents; contain potassium borides; and contain fluorides.

Threaded joints shall have American Standard taper pipe threads conforming to ASME B1.20.1. Only male pipe threads shall be coated with graphite or with an approved graphite compound, or with an inert filler and oil, or shall have a PTFE tape applied.

DRAIN piping shall use ASTM D2466-17, F1866-18 PVC SCH40 threaded and socket fittings.

PVC piping & socket fittings shall be joined with a two-step primer & solvent cement joint per ASTM D2855 using ASTM F656 primers & ASTM D2564 solvents. The safe handling and use of these primers, cements shall be followed per ASTM F402.

D. INSTALLATION:

Pipe and tubing shall be cut accurately to measurements established at the building by The Contractor and shall be worked into place without springing or forcing. Care shall be taken not to weaken the structural portions of the building. Installation of pipe and fittings shall be made in accordance with this specification and applicable manufacturer's recommendations. Mitering of joints for elbows and notching of straight runs of pipe for tees will not be permitted.

New CHW, CW, CFW, and drain piping shall install and route parallel / perpendicular to the lines of the building unless otherwise shown or noted in reference drawing MAHG 20-1067 Replace Cooling

Towers B1002 noted in SOW. Reducers, Elbows (90deg & 45deg), Tees, flanges, blind flanges, welded/threaded outlets are shown in reference drawing MAHG 20-1067 Replace Cooling Towers B1002 also.

E. HANGERS AND SUPPORTS:

Design and fabrication of pipe hangers, supports, and welding attachments shall conform to MSS SP-58 and ASME B31.9. Hanger types and supports for bare and covered pipe shall conform to

MSS SP-69 for the temperature range.

F. TESTS:

Upon completion of the chilled water system piping modification at chiller #2, prior to install of the temporary service chiller, shall be tested at a hydrostatic pressure of 38psig (1.5x 58ftHD WP), and proved tight at that pressure.

Upon completion of the condenser water system piping modifications, prior to start-up testing of the

NEW cooling tower, shall be tested at a hydrostatic pressure of 61psig (1.5x 93ftHD WP), and proved tight at that pressure.

Note that this testing can be split-up into two CWS cell tests and a single CWR tower test.

CWS piping hydrostatic tests can occur from each cooling tower sump flange to the associated

CWS isolation valves. CWS testing shall confirm that existing CWS header drain valves hold pressure with no leak thru flow to PVC drain piping.

CWR piping hydrostatic test must have isolation of CWR piping in B1002 Mech Rm to properly test all CWR fitting joints in 12”CWR line, then to cooling tower inlet valves. Proper isolation shall be approved by Vectrus CM, PM when arranging test coordination.

CFW make-up piping shall be visually inspected for leaks during cooling tower start-up tests, with the operation of cooling tower sump float switches.

Drain piping shall be gravity tested, with cooling tower sumps full of water and CW pumps off. The PVC drain fittings shall be inspected visually for leaks as cooling tower cells and CWS headers are allowed to drain.

Where a portion of the water piping system is to be concealed before completion, this portion shall be tested separately in the same manner as specified for the entire system.

Contractor shall provide a chilled water test report, prior to connecting temporary chiller at chiller #2.

Contractor shall provide a condenser water test report, prior to start-up testing of NEW cooling tower.

Contractor shall provide CFW make-up piping and drain piping test reports as part of cooling tower start-up testing report.

Manufacturer’s start up test must be accomplished to prove the manufacturer’s warranty acceptable.

EMCS control signal function, sump float switch, immersion heater, and tower fan motor variable speed drive testing shall be demonstrated in the manufacturer’s start up testing.

Manufacturer shall provide start-up, operational test report.

G. PIPE INSULATION

CHW and CFW make-up piping will require insulation.

All pipe, joints, fittings, and valves shall be insulated with factory pre-molded, precut or field-fabricated insulation. The type and thickness of insulation required shall be as listed herein.

CFW make-up piping shall use black flexible EPDM elastomeric-based unicellular insulation with aluminum jacket per ASTM C534, Type I, Tubular Gr 1; see Armacell, AP Armaflex Tube or equal.

Seal all insulation joints and secure jacket with adhesive, per ArmaFlex 520 adhesive or equal.

1” CFW make-up piping shall use 1-1/2” thick

2” CFW make-up piping shall use 2” thick.

CHW piping 4”-12” shall use 2” thick cellular glass insulation with aluminum jacket per

ASTM C552, Gr 6; see Owens-Corning, FOAMGLAS One or equal. Seal all insulation joints with asphalt-based protective, vapor barrier coating, similar to Owens Corning PITTCOTE 300 or equal.

Secure jacket with an MS polymer sealant, similar to Owens Corning PITTSEAL CW sealant or equal.

Aluminum roll jacket shall be per ASTM B209, AL3105 or AL3003, H14 sheet metal at 0.016” thick;

with 3mil thick poly-film moisture barrier laminated to jacket interior surface; per GLT products or equal.

Insulation shall be continuous through hangers. Extend all surface finishes to protect all surfaces, ends, and raw edges of insulation. Bevel and seal the edges of exposed insulation. Where pipes penetrate fire walls, provide mineral-fiber insulation inserts and sheet-metal sleeves. Insulate flanges, unions, valves and fittings in accordance with manufacturer’s published instructions. Cover circumferential joints with butt strips, not less than 3-inches wide, of material identical to the jacket material. Overlap longitudinal laps of jacket material not less than 1-1/2 inches. Use a vapor barrier coating on the ends of section of insulation that butt against flanges, unions, valves and fittings and joints. Apply this vapor barrier coating at all longitudinal and circumferential laps. At penetrations by pressure gauges and thermometers, fill the voids with the vapor barrier coating. Seal with a brush coat of the same coating.

H. PIPE IDENTIFICATION:

Label pipe with direction of flow and system clarification, as noted.

CHWS Chilled Water Supply CHWR Chilled Water Return

CFW Make-Up Water @ Cooling Tower

CWS Condenser Water Supply CWR Condenser Water Return

DRN Drain @ Cooling Tower & CWS Header

Exterior CWS, CWR, CFW, and drain piping at cooling tower shall be labeled using stencil. Stencils shall use semi-gloss enamel paint, and shall be marked with clean cut symbols and letters. Contractor shall also label all lubrication points on cooling tower using stencil.

Interior B1002 Mech. Rm CHW piping must use plastic tape pipe markers. Plastic tape pipe markers shall be of flexible, vinyl film tape with adhesive backing and printed markings as manufactured by W.H.

Brady Company. For insulated & non-insulated indoor pipe use Brady B350.

Pipe identification is to be installed at ten foot intervals, as a maximum.