15.__23_64_10_26_Oct_16.pdf

Repair Dorms 340, 342 & 350 PRQE 17-0125 McConnell AFB, Wichita, KS

Section 23 64 10 Page 1

SECTION 23 64 10

WATER CHILLERS, VAPOR COMPRESSION TYPE

08/08

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 (2011; Addendum 1 2012; Addendum 2-3 2013)

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

ANSI/AHRI 460 (2005) Performance Rating of Remote

Mechanical-Draft Air-Cooled Refrigerant Condensers

ANSI/AHRI 495 (2005) Performance Rating of Refrigerant

Liquid Receivers

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 11 (2014) Load Ratings and Fatigue Life for

Roller Bearings

ABMA 9 (1990; ERTA 2012; S 2013) Load Ratings and

Fatigue Life for Ball Bearings

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2013; Addenda A 2014; ERTA 1 2014; ERTA 2

2015) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 90.1 - IP (2010; ERTA 2011-2013) Energy Standard for

Buildings Except Low-Rise Residential Buildings

ASHRAE 90.1 - SI (2013; Errata 1-3 2013; Errata 4-6 2014;

Errata 7 2015) Energy Standard for Buildings Except Low-Rise Residential Buildings

26 Oct 16

Section 23 64 10 Page 2

AMERICAN WELDING SOCIETY (AWS)

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

Allied Processes

ASME INTERNATIONAL (ASME)

ASME BPVC SEC VIII D1 (2010) BPVC Section VIII-Rules for

Construction of Pressure Vessels Division 1

ASTM INTERNATIONAL (ASTM)

ASTM A307 (2014) Standard Specification for Carbon

Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A53/A53M (2012) Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

ASTM B117 (2011) Standard Practice for Operating Salt

Spray (Fog) Apparatus

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM E84 (2014) Standard Test Method for Surface

Burning Characteristics of Building Materials

ASTM F104 (2011) Standard Classification System for

Nonmetallic Gasket Materials

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2014) Motors and Generators

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

Selection and Use of Single Phase Motors

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. Submittals with an "S" are for inclusion in the Sustainability Notebook, in conformance to Section 01 33 29 SUSTAINABILITY REPORTING.

Submit the following in accordance with Section 01 33 00 SUBMITTAL

PROCEDURES:

SD-03 Product Data

Water Chiller;

Section 23 64 10 Page 3

Manufacturer's standard catalog data, at least highlighted to show material, size, options, performance charts and curves including full-load and IPLV efficiences (DOE PL-109-58), etc. in adequate detail to demonstrate compliance with contract requirements. Data shall include manufacturer's recommended installation instructions and procedures. Data shall be adequate to demonstrate compliance with contract requirements as specified within the paragraphs:

a. Water Chiller

b. Chiller Components

c. Accessories

If vibration isolation is specified for a unit, vibration isolator literature shall be included containing catalog cuts and certification that the isolation characteristics of the isolators provided meet the manufacturer's recommendations.

Verification of Dimensions

A letter including the date the site was visited, conformation of existing conditions, and any discrepancies found.

Manufacturer's Multi-Year Compressor Warranty

Manufacturer's multi-year warranty for compressor(s) in air-cooled water chillers as specified.

Factory Tests

Schedules which identify the date, time, and location for each test. Schedules shall be submitted for both the Chiller Performance Test and the Chiller Sound Test.

Demonstrations

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

Water Chiller - field acceptance test plan

SD-06 Test Reports

Field Acceptance Testing

Water Chiller - field acceptance test report

SD-07 Certificates

Refrigeration System; G

Where the system, components, or equipment are specified to comply with requirements of AGA, NFPA, AHRI, ASHRAE, ASME, or UL, 1 copy of proof of such compliance shall be provided. The label or listing of the specified agency shall be acceptable evidence. In

Section 23 64 10 Page 4 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 AHRI rating conditions, computer printouts, catalog, or other application data certified by AHRI or a nationally recognized laboratory as described above shall be included. If AHRI 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.

SD-08 Manufacturer's Instructions

Water Chiller - Installation Instruction;

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals;

complete copies of an operation manual in bound 8 1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4 weeks prior to the first training course. The booklets shall include the manufacturer's name, model number, and parts list. The manuals shall 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 shall include piping and equipment layouts and simplified wiring and control diagrams of the system as installed.

1.3 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 shall be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Safety devices shall be installed so that proper operation of equipment is not impaired. Welding and cutting safety requirements shall be in accordance with AWS Z49.1.

1.4 DELIVERY, STORAGE, AND HANDLING

Stored items shall 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 shall be capped to keep out dirt and other foreign matter.

1.5 PROJECT REQUIREMENTS

Section 23 64 10 Page 5

1.5.1 Verification of Dimensions

The Contractor shall 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.

1.6 WARRANTY

In addition to the warranty requirements specification in Division 00, Contract Requirements, the following major components of the chiller shall be covered by a warranty of a duration period of five years: compressor, .

1.7 MANUFACTURER'S MULTI-YEAR COMPRESSOR WARRANTY

The Contractor shall provide a 10 year parts and labor (includes refrigerant) manufacturer's warranty on the chiller compressor(s). This warranty shall be directly from the chiller manufacturer to the Government and shall be in addition to the standard one-year warranty of construction.

The manufacturer's warranty shall provide for the repair or replacement of the chiller compressor(s) that become inoperative as a result of defects in material or workmanship within 10 years after the date of final acceptance.

When the manufacturer determines that a compressor requires replacement, the manufacturer shall furnish new compressor(s) at no additional cost to the Government. Upon notification that a chiller compressor has failed under the terms of the warranty, the manufacturer shall respond in no more than 24 hours. Response shall mean having a manufacturer-qualified technician onsite to evaluate the extent of the needed repairs. The warranty period shall begin on the same date as final acceptance and shall continue for the full product warranty period.

1.7.1 Indexed Notebook

The Contractor shall furnish to the Contracting Officer a bound and indexed notebook containing a complete listing of all water chillers covered by a manufacturer's multi-year warranty. The chiller list shall state the duration of the warranty thereof, start date of the warranty, ending date of the warranty, location of the warranted equipment, and the point of contact for fulfillment of the warranty. This information shall be provided for each chiller and the recorded chiller serial numbers shall identify each chiller. Point of contact shall include the name of the service representative along with the day, night, weekend, and holiday phone numbers for a service call. The completed bound and indexed notebook shall be delivered to the Contracting Office prior to final acceptance of the facility. The Contractor shall furnish with each manufacturer's multi-year warranty the name, address, and telephone number (day, night, weekend, and holiday) of the service representative nearest to the location where the equipment is installed. Upon a request for service under the multi-year warranty, the service representative shall honor the warranty during the warranty period, and shall provide the services prescribed by the terms of the warranty.

1.7.2 Equipment Warranty Tags

At the time of installation, each item of manufacturer's multi-year warranted equipment shall be tagged with a durable, oil- and water-resistant tag, suitable for interior and exterior locations, resistant to solvents, abrasion, and fading due to sunlight. The tag shall be attached with copper

Section 23 64 10 Page 6 wire or a permanent, pressure-sensitive, adhesive backing. The tag shall be installed in an easily noticed location attached to the warranted equipment.

The tag for this equipment shall be similar to the following in format, and shall contain all of the listed information:

MANUFACTURER'S MULTI-YEAR WARRANTY EQUIPMENT TAG

Equipment/Product Covered: ____________________ Manufacturer:_______Model No.:_____Serial No.:__ Warranty Period: From _________to _____________ Contract No.: _________________________________ Warranty Contact: _____________________________ Name: _________________________________________ Address: ______________________________________ Telephone: ____________________________________

STATION PERSONNEL SHALL PERFORM PREVENTIVE

MAINTENANCE AND OPERATIONAL MAINTENANCE

PART 2 PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

Materials and equipment shall 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 shall have a two year record of satisfactory field service prior to bid opening. the two year record of service shall 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 shall be acceptable if a certified record of satisfactory field service for not less than 6000 hours can be shown. The 6000 hour service record shall not include any manufacturer's prototype or factory testing.

Satisfactory field service shall have been completed by a product that has been, and presently is being sold or offered for sale on the commercial market through the following copyrighted means: advertisements, manufacturer's catalogs, or brochures.

2.2 MANUFACTURER'S STANDARD NAMEPLATES

Nameplates are required on major components if the manufacturer needs to provide specific engineering and manufacturing information pertaining to the particular component. Should replacement of this component be required, nameplate information will insure correct operation of the unit after replacement of this component.

2.3 ELECTRICAL WORK

a. Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Manual or automatic control and protective or signal devices required for controls and devices specified, but not shown, shall be provided. For packaged equipment, Section 23 64 10 Page 7 the manufacturer shall 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 shall be rated for continuous duty with the enclosure specified. Motor duty requirements shall allow for maximum frequency start-stop operation and minimum encountered interval between start and stop. Motor torque shall 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.

e. 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 shall 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 shall be sealed and 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, shall have lifting eyes or lugs. Chiller shall be provided with a single point wiring connection for incoming power supply. Chiller's condenser and water cooler shall be provided with standard water boxes with grooved mechanical flanged welded connections.

2.4.1 Scroll, Reciprocating, or Rotary Screw Type

Chiller shall be rated in accordance with AHRI 550/590 I-P. Chiller shall conform to ANSI/ASHRAE 15 & 34. As a minimum, chiller shall 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, reciprocating, or rotary screw compressor

Section 23 64 10 Page 8

f. Compressor driver, electric motor

g. Compressor driver connection

h. Water cooler (evaporator)

i. Air-cooled condenser coil

2.5 CHILLER COMPONENTS

2.5.1 Refrigerant and Oil

Refrigerants shall be one of the fluorocarbon gases. Refrigerants shall have number designations and safety classifications in accordance with ANSI/ASHRAE 15 & 34. Refrigerants classified by the EPA as Class 2 shall not be allowed with the exception of R-123.

2.5.2 Structural Base

Chiller and individual chiller components shall be provided with a factory-mounted structural steel base (welded or bolted) or support legs. Chiller and individual chiller components shall be isolated from the building structure by means of molded neoprene isolation pads. vibration isolators with published load ratings. Vibration isolators shall have isolation characteristics as recommended by the manufacturer for the unit supplied and the service intended.

2.5.3 Chiller Refrigerant Circuit

Chiller refrigerant circuit shall be completely piped and factory leak tested. For multicompressor units, not less than 2 independent refrigerant circuits shall be provided. Circuit shall include as a minimum a combination filter and drier, combination sight glass and moisture indicator, liquid-line solenoid valve for reciprocating, 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

Chiller shall be provided with a complete factory-mounted , prewired electric or microprocessor based operating and safety control system.

Controls package shall contain as a minimum a digital display or acceptable gauges, an on-auto-off switch, power wiring, and control wiring. Controls package shall provide operating controls, monitoring capabilities, programmable setpoints, safety controls, and EMCS interfaces as defined below.

2.5.4.1 Operating Controls

Chiller shall 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

Section 23 64 10 Page 9

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 shall automatically re-cycle the chiller on power interruption.

f. Startup and head pressure controls to allow system operation at all ambient temperatures down to 32 degrees F g.

2.5.4.2 Monitoring Capabilities

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

a. Entering and leaving chilled water temperatures

b. Self diagnostic

c. Operation status

d. Operating hours

e. Number of starts

f. Compressor status (on or off)

g. Refrigerant discharge and suction pressures

h. Magnetic bearing levitation status (if applicable)

i. Magnetic bearing temperatures (if applicable)

j. Oil pressure

2.5.4.3 Programmable Setpoints

The control system shall be capable of being reprogrammed directly at the unit. No parameters shall be capable of being changed without first entering a security access code. The programmable setpoints shall include the following as a minimum.

a. Leaving Chilled Water Temperature

c. Time Clock/Calendar Date

2.5.4.4 Safety Controls with Manual Reset

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

a. Low chilled water temperature protection

Section 23 64 10 Page 10

b. High condenser refrigerant discharge pressure protection

c. Low evaporator pressure protection

d. Chilled water flow detection

e. High motor winding temperature protection

f. Low oil flow protection if applicable

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

h. MBC, High bearing temperature (if applicable)

i. MBC, Communication fault (if applicable)

j. MBC, Power supply fault (if applicable)

2.5.4.5 Safety Controls with Automatic Reset

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

a. Over/under voltage protection

b. Chilled water flow interlock

c. MBC, Vibration (if applicable)

d. MBC, No levitation (if applicable)

2.5.4.6 Energy Management Control System (EMCS) Interface

The control system shall be capable of communicating all data to a remote integrated DDC processor through a single shielded cable. The data shall include as a minimum all system operating conditions, capacity controls, and safety shutdown conditions. The control system shall also be capable of receiving at a minimum the following operating commands.

a. Remote Unit Start/Stop

b. Remote Chilled Water Reset

2.5.5 Compressor(s)

2.5.5.1 Scroll Compressor(s)

Compressors shall be of the hermetically sealed design. Compressors shall be mounted on vibration isolators to minimize vibration and noise. Rotating parts shall be statically and dynamically balanced at the factory to minimize vibration. Lubrication system shall be centrifugal pump type equipped with a means for determining oil level and an oil charging valve.

Crankcase oil heater shall be provided if standard or if available as an option. If provided, the crankcase oil heater shall be controlled as recommended by the manufacturer.

Section 23 64 10 Page 11

2.5.6 Compressor Driver, Electric Motor

Motors, starters, variable speed drives, wiring, etc. shall be in accordance with paragraph ELECTRICAL WORK. Motor starter shall be unit mounted as indicated with starter type, wiring, and accessories coordinated with the chiller manufacturer.

2.5.7 Compressor Driver Connections

2.5.8 Water Cooler (Evaporator)

Cooler shall be of the shell-and-coil or shell-and-tube type design. Cooler shell shall be constructed of seamless or welded steel. Coil bundles shall be totally removable and arranged to drain completely. Tubes shall be seamless copper, plain, integrally finned with smooth bore or integrally finned with enhanced bore. Each tube shall be individually replaceable.

Tubes shall be installed into carbon mild steel tube sheets by rolling.

Tube baffles shall be properly spaced to provide adequate tube support and cross flow. Performance shall be based on a water velocity not less than 3 fps nor more than 12 fps and a fouling factor of 0.0001 h(ft2)(degrees F)/Btu .

2.5.9 Air-Cooled Condenser Coil

Condenser coil shall be of the extended-surface fin-and-tube type and shall be constructed of seamless copper tubes with compatible copper or aluminum fins. Fins shall be soldered or mechanically bonded to the tubes and installed in a metal casing. Coils shall be circuited and sized for a minimum of 5 degrees F subcooling and full pumpdown capacity. Coil shall be factory leak and pressure tested after assembly in accordance with ANSI/ASHRAE 15 & 34. Coil shall be entirely coated with the manufacturer's standard epoxy or vinyl coating.

2.5.10 Receivers

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

2.5.11 Tools

One complete set of special tools, as recommended by the manufacturer for field maintenance of the system, shall be provided. Tools shall be mounted on a tool board in the equipment room or contained in a toolbox as directed by the Contracting Officer.

2.6 ACCESSORIES

Section 23 64 10 Page 12

2.6.1 Refrigerant Signs

Refrigerant signs shall be a medium-weight aluminum type with a baked enamel finish. Signs shall be suitable for indoor or outdoor service. Signs shall have a white background with red letters not less than 0.5 inches in height.

2.6.1.1 Installation Identification

Each new refrigerating system shall 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.

2.6.1.2 Controls and Piping Identification

Refrigerant systems containing more than 110 lbof refrigerant shall be provided with refrigerant signs which designate the following as a minimum:

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

b. Pressure limiting device(s).

2.6.2 Gaskets

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

2.6.3 Bolts and Nuts

Bolts and nuts, except as required for piping applications, shall be in accordance with ASTM A307. The bolt head shall 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, shall be factory finished with the manufacturer's standard finish, except that items located outside of buildings shall have weather resistant finishes that will withstand 500 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution. Immediately after completion of the test, the specimen shall 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 shall be coated with a zinc-rich coating conforming to ASTM D520, Type I.

Section 23 64 10 Page 13

2.7.2 Factory Applied Insulation

Chiller shall 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 shall 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 shall 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 shall 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 shall have a flame spread index no higher than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes shall be determined by ASTM E84. Insulation shall 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 shall be tested as a composite material. Jackets, facings, and adhesives shall 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 shall 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 shall 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 shall be validated to meet the scheduled requirements indicated on the drawings. Tolerance or deviation shall be in strict accordance with AHRI 550/590 I-P. Stable operation at minimum load of 10 percent of total capacity shall be demonstrated during the factory test.

2.8.1.1 Temperature Adjustments

Temperature adjustments shall adhere to AHRI 550/590 I-P to adjust from the design fouling factor to the clean tube condition. Test temperature adjustments shall be verified prior to testing by the manufacturer. There shall be no exceptions to conducting the test with clean tubes with the temperature adjustments per AHRI 550/590 I-P. The manufacturer shall clean the tubes, if necessary, prior to testing to obtain a test fouling factor of 0.0000.

2.8.1.2 Test Instrumentation

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

Section 23 64 10 Page 14

2.8.1.3 Test Report

A certified test report of all data shall be forwarded to the Government for approval prior to project acceptance. Calibration curves and information sheets for all instrumentation shall be provided.

2.8.1.4 Equipment Adjustments

If the equipment fails to perform within allowable tolerances, the manufacturer shall be allowed to make necessary revisions to his equipment and retest as required.

2.9 SUPPLEMENTAL COMPONENTS/SERVICES

2.9.1 Chilled and Condenser Water Piping and Accessories

Chilled and condenser water piping and accessories shall 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 shall be fully coordinated with and integrated into the existing air-conditioning system.

PART 3 EXECUTION

3.1 INSTALLATION

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

3.1.1 Connections to Existing Systems

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

3.1.2 Refrigeration System

3.1.2.1 Equipment

Refrigeration equipment and the installation thereof shall conform to ANSI/ASHRAE 15 & 34. Necessary supports shall be provided for all equipment, appurtenances, and pipe as required, including frames or supports for compressors, pumps, cooling towers, condensers, water coolers, and similar items. Compressors shall be isolated from the building structure.

If mechanical vibration isolators are not provided, vibration absorbing foundations shall be provided. Each foundation shall include isolation units consisting of machine and floor or foundation fastenings, together with intermediate isolation material. Other floor-mounted equipment shall be set on not less than a 6 inch concrete pad doweled in place. Concrete

Section 23 64 10 Page 15 foundations for floor mounted pumps shall 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 shall be of mass not less than three times the combined pump, motor, and base weights. Isolators shall be selected and sized based on load-bearing requirements and the lowest frequency of vibration to be isolated. Isolators shall limit vibration to 10 percent at lowest equipment rpm. Lines connected to pumps mounted on pedestal blocks shall be provided with flexible connectors. Foundation drawings, bolt-setting information, and foundation bolts shall be furnished prior to concrete foundation construction for all equipment indicated or required to have concrete foundations. Concrete for foundations shall be as specified in Section 03 30 00 CAST-IN-PLACE CONCRETE. Equipment shall be properly leveled, aligned, and secured in place in accordance with manufacturer's instructions.

3.1.2.2 Oil Charging

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

3.1.3 Field Applied Insulation

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

3.1.4 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 MANUFACTURER'S FIELD SERVICE

The services of a factory-trained representative shall be provided for 1 days. The representative shall advise on the following:

a. Hermetic machines:

(1) Testing hermetic water-chilling unit under pressure for refrigerant leaks

(3) Starting the machine.

b.

3.3 CLEANING AND ADJUSTING

Equipment shall be wiped clean, with all traces of oil, dust, dirt, or paint spots removed. Temporary filters shall be provided for all fans that are operated during construction, and new filters shall be installed after all construction dirt has been removed from the building. System shall be maintained in this clean condition until final acceptance. Bearings shall be properly lubricated with oil or grease as recommended by the manufacturer. Belts shall be tightened to proper tension. Control valves

Section 23 64 10 Page 16 and other miscellaneous equipment requiring adjustment shall be adjusted to setting indicated or directed. Fans shall 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 shall be cleaned in accordance with the chiller manufacturer's instructions. This work covers two coil cleanings. The condenser coils shall be cleaned with an approved coil cleaner by a service technician, factory trained by the chiller manufacturer. The condenser coil cleaner shall not have any detrimental affect on the materials or protective coatings on the condenser coils. Testing, adjusting, and balancing shall be as specified in Section

23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC.

3.4 FIELD ACCEPTANCE TESTING

3.4.1 Test Plans

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

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 factory prewired or external controls for the equipment provided under Section 23 09 23.13 20, BACNET DIRECT DIGITAL CONTROL SYSTEMS FOR HVAC.

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 shall include the required test reporting forms to be completed by the Contractor's testing representatives. Procedures shall 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 shall 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 shall list performance variables 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

Section 23 64 10 Page 17 manufacturer shall furnish with each test procedure a description of acceptable results that have been verified.

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

f. Job specific: Each test plan shall be job specific and shall 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 shall include procedures for field testing and field adjusting specialized components, such as hot gas bypass control valves, or pressure valves.

3.4.2 Testing

a. Each water chiller system shall 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 shall be reviewed, approved, and signed by the Contractor's test director. The manufacturer's field test representative shall review, approve, and sign the report of the manufacturer's recommended test. Signatures shall be accompanied by the person's name typed.

f. Deficiency resolution: The test requirements acceptably met;

deficiencies identified during the tests shall be corrected in compliance with the manufacturer's recommendations and corrections retested in order to verify compliance.

Section 23 64 10 Page 18

3.5 SYSTEM PERFORMANCE TESTS

3.5.1 General Requirements

Before each refrigeration system is accepted, tests to demonstrate the general operating characteristics of all equipment shall be conducted by a registered professional engineer or an approved manufacturer's start-up representative experienced in system start-up and testing, at such times as directed. Tests shall cover a period of not less than 48 hours for each system and shall demonstrate that the entire system is functioning in accordance with the drawings and specifications. Corrections and adjustments shall be made as necessary and tests shall 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 shall be installed and tightened. Any refrigerant lost during the system startup shall be replaced. If tests do not demonstrate satisfactory system performance, deficiencies shall be corrected and the system shall be retested. Tests shall 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 shall be provided by the Contractor. Field tests shall be coordinated with Section 23 05 93 TESTING, ADJUSTING, AND BALANCING

FOR HVAC.

3.5.2 Test Report

The report shall document compliance with the specified performance criteria upon completion and testing of the system. The report shall indicate the number of days covered by the tests and any conclusions as to the adequacy of the system. The report shall also include the following information and shall 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.

(7)

3.6 DEMONSTRATIONS

Contractor shall conduct a training course for the operating staff as designated by the Contracting Officer. The training period shall consist of a total 4 hours of normal working time and start after the system is functionally completed but prior to final acceptance tests. The field posted instructions shall cover all of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine maintenance operations.

Section 23 64 10 Page 19

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