Attachment-1_-13864-14-001__C-Plant_Refrigeration_Sys_Spec.pdf

13864-14-001 NOT SENSITIVE

SPEC NO. 13864-14-001

29 May 2014

SPECIFICATION

FOR

C-PLANT RC12.1, RC12.2, & RC22.1 REFRIGERATION SYSTEMS

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

IRA-1244

ATTACHMENT #1

ATTACHMENT #1

Table of Contents-1

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1. Government Documents

2.2. Non-Government Documents

3. REQUIREMENTS

3.1. Manufacturer and Modell

3.2. Product Description

3.3. Chiller Performance

3.4. Physical Characteristics

3.5. Nameplates

3.6. Prevention of Corrosion

3.7. System Control

3.8. Control Package

3.9. Human Machine Interface (HMI) Unit

3.10. Emergency Shutdown Switch

3.11. Liquid Refrigerant

3.12. Cooling Water Available

3.13. Drive Motors Electrical Power

3.14. Auxiliary Motors Electrical Power

3.15. Primary Refrigerant Storage

3.16. Piping and Components

3.17. Block and Bleed Valves

3.18. Refrigerant Monitor System

3.19. Control System

3.20. PLC/Controller

3.21. Naming Standards

3.22. Low Voltage Power Distribution

3.23. Junction Boxes

3.24. Spare Parts

4. VERIFICATION

5. PACKAGING

5.1. Preparation for Delivery

6. NOTES

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1. SCOPE

1.1 This specification establishes the performance, design, manufacture, and verification for up to three (3) refrigeration units. This specification includes a base bid with Option 1 for each refrigeration unit. Option one scope includes a portable refrigeration unit.

1.2 This specification includes chiller package, charge of refrigerant and oil, controls and control connections, chilled brine connections, condenser water connections, auxiliary water connections, starters, electrical power connections, and all other equipment required for a fully functional chiller.

2. APPLICABLE DOCUMENTS

2.1 Government Documents:

2.1.1 AEDC Engineering Standard:

A. AEDC-ENGR-STD-T-2 AEDC Standard Pressure Piping.

2.2 Non-Government Documents:

2.2.1 American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc:

A. ASHRAE 15 & 34-13 Safety Standard for Refrigeration Systems.

2.2.2 ASME International (BPVC):

A. ASME B31.3-12 Process Piping.

B. ASME B31.5-13 Refrigeration Piping and Heat Transfer Components.

C. ASME SEC VIII-1-13 (BPVC) Rules for Construction of Pressure Vessels.

2.2.3 The Institute of Electrical and Electronics Engineers, Inc.:

A. IEEE C37.2-08 Electrical Power System Device Function Numbers, Acronyms, and Contact Designations.

3. REQUIREMENTS

3.1 Manufacturer and Model: The chiller shall be a York (Johnson Controls) Model number YDKDKEK7-DKCS with 22-foot evaporators, motor starter, with Option 1 for a portable refrigeration unit. No substitutions will be accepted.

3.2 Product Description: Water cooled, liquid chillers consisting of centrifugal compressors, compressor motor, condenser (s), evaporator(s), refrigeration

Page-2 accessories, instrument and control panel including gages and indicating lights, auxiliary components and accessories, and motor starters. All components shall be suitable and compatible for the operational conditions and fluids. The primary refrigerant shall be R134A. The secondary brine shall be 20% ethylene glycol / water mix.

3.3 Chiller Performance:

3.3.1 Capacity (each):

A. Refrigeration Capacity: 4250 tons.

B. Chilled Brine Flow: 5000 gpm of 20% ethylene glycol/water mix.

C. Leaving Chilled Brine Temperature: 32 degrees F.

D. Entering Chilled Brine Temperature: 53 degrees F.

E. Pressure Drop through the Evaporator: Not to exceed 10.2 psi.

F. Pressure Drop through the Condenser: Not to exceed 13.9 psi.

G. Refrigerant: R134A.

3.4 Physical Characteristics:

3.4.1 Provide all components within the footprint defined on the contract drawings.

The drawings also define the allowable unit heights and define the size and location of existing floor penetrations (no new floor penetrations will be allowed).

3.4.2 The weight of the refrigeration equipment shall not exceed the floor loading and shall be distributed so as not to exceed 500 pounds per square foot or concentrated load of 36,000 pounds.

3.5 Nameplates: The manufacturer’s name, address, and catalog number shall be permanently displayed on a plate securely attached to each major component for item of equipment.

3.6 Prevention of Corrosion: Fasteners and nameplates shall be of corrosion resistant materials.

3.7 System Control:

3.7.1 The units shall be designed such to minimize the use of hot gas bypass.

3.7.2 Refrigeration units shall be able to operate from 0 to 100% external load. A hot gas bypass system may be used to meet the lower load conditions. The secondary brine pumps may also be operated to add load to meet the 0% load condition.

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3.7.3 Refrigeration units shall be capable of meeting full load performance condition in less than 30 minutes from startup.

3.7.4 Load can increase or decrease in 50% increments in one minute. After the load change has been made, the capacity control shall be capable of adjusting to the load change and be back on condition within 10 minutes for each 50% load change.

3.7.5 The control system shall provide automatic and manual process control with minimal operator interfacing.

3.8 Control Package: Each chiller system control package shall be capable of operating independently from each other.

3.9 Human Machine Interface (HMI) Unit: Each refrigeration unit shall be equipped with an electronic (HMI) unit which performs the following functions:

3.9.1 Display real-time operational data of the unit including the parameters specified below as a minimum.

3.9.2 Provide a means for the equipment operator to, at the unit, at an easily accessible location, START the unit, manipulate system control elements to safely operate the unit in MANUAL MODE, set the controls to AUTOMATIC MODE, return to MANUAL MODE as needed, and STOP the unit.

3.10 Emergency Shutdown Switch: Each unit shall be equipped with a manual Emergency Shutdown Switch that operates independently of the HMI unit. This switch shall be capable of shutting down the unit immediately upon activation by the equipment operator. The real-time status of the Emergency Shutdown Switch shall be displayed on the unit HMI.

3.11 Liquid Refrigerant: The design shall be such as to not allow liquid refrigerant to accumulate in the compressor or provide a means to safely remove the liquid refrigerant from the compressor within 10 minutes.

3.12 Cooling Water Available: The following gives the flow rates available for these lines:

3.12.1 RC12 supply (each) – 10,000 gpm.

3.12.2 RC22 supply – 10,000 gpm.

3.12.3 The temperature range is 35 to 90 degrees F. The design temperature is 80 degrees F. The pressure range is 75 to 150 psig. The design pressure is 100 psig.

3.13 Drive Motors Electrical Power: Electrical power for all refrigeration unit drive motors shall be provided by medium voltage (3-phase, 6900 volt AC). The

Page-4 motor shall be a squirrel cage, induction type, and shall be rated at 90 percent minimum power factor at rated load.

3.13.1 The motors shall be equipped with reduced voltage (soft) start capability. The soft starter shall be equipped with a fully rated bypass contactor for optional across-the-line starting. For across-the-line starting, the motors shall be able to start, be stopped, and restarted an average of 6 times in a 24-hour period without incurring damage from excessive start duty during the design life of the motor.

3.13.2 Refrigeration unit drive motors shall interface with the medium voltage power distribution system (3-phase, 6900 volt AC) by means of existing transformer

3.13.3 Refrigeration unit 3-phase, 6900 volt AC drive motors shall be constructed in “wye” configuration that is adequate for providing current differential protection (87M protective relaying per IEEE C37.2) via a Contractor provided set of flux-balance current transformers.

3.13.4 Surge capacitors shall be provided in the motor terminal box of each motor.

3.14 Auxiliary Motors Electrical Power: Electrical power for all auxiliary motors shall be supplied by 480 volt AC, three phase, 60 hertz.

3.15 Primary Refrigerant Storage:

3.15.1 A refrigerant recovery and storage unit with piping and valve system shall be provided to allow maintenance on all refrigerant components.

3.15.2 The unit shall be equipped with a pump out system complete with a transfer pump, condensing unit, and storage vessel constructed according to ASME SEC VIII-1 and shall bear the National Board stamp.

3.15.3 The unit shall interface with the Low Voltage Power System (3-phase, 480 volt AC) for all required electrical power.

3.15.4 The recovery unit must be able to recover the charge to a minimum of 20 in vacuum Hg in less than 8 hours and shall be EPA and ARI 740 certified.

3.16 Piping and Components:

3.16.1 Design, installation, and testing shall be per ASME 31.5 and ASME 31.3.

Pressure piping per AEDC-ENGR-STD-T-2.

3.16.2 All carbon steel components shall be painted per the manufacturer’s instructions. All carbon steel piping to be insulated shall be painted and leak checked prior to insulating.

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3.16.3 Piping and components that are subjected to sweating shall be insulated as specified by the chiller manufacturer.

3.17 Block and Bleed Valves: Design shall incorporate block and bleed valves for the major system components to allow maintenance on one of the chillers without affecting the operation of other chillers. Major components include compressors, evaporators, condensers, and transfer to storage system. AEDC shall provide isolation valves for the brine and water.

3.18 Refrigerant Monitor System: A refrigerant monitor system shall be provided per ASHRAE 15 and 34.

3.19 Control System: The controls shall be a networked PLC/Controller system consistent with the existing plant controls. Control stations shall be located in the approximate location as the existing control stations for the existing chiller units.

3.20 PLC/Controller:

3.20.1 A completely programmed PLC/Controller for each unit shall be provided:

A. The PLC/Controller installation shall be fully documented and be provided with program logic, including theory for which the program was derived.

B. The PLC/Controller shall be fitted with all hardware, power supplies, input/output cards, enclosures, programming, etc. to make the system fully functional.

C. The PLC/Controller shall also be fitted with all hardware, software, and software drivers to provide a fully operational, high speed, communication link between the vendor-supplied PLC/HMI control system and the Government (AEDC) Supervisory Network Interface.

D. The interface communication media shall be by 10Base-T/100Base-TX Ethernet or approved equal.

E. There shall be no hardware required between the PLC/Controller and the Government (AEDC) Supervisory Network Interface.

F. The PLC/Controller network communication capabilities shall enable remote monitoring of all PLC/Controller functions, including hardware status, operating program status, operational mode (automatic or manual mode) status, system alarm status, and all engineering unit data being processed by the PLC/Controller.

G. Communication shall be bi-directional between the vendor's PLC/Controller and GE FANUC Cimplicity Plant Edition, Version 5.5, Service Pack 1. Communication shall make use of existing GE FANUC Cimplicity Plant Edition, Version 5.5, Service Pack 1 drivers.

Communication protocol shall be TCP/IP.

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H. The control system shall be provided with an Industrial Ethernet Real Time Switch for use with 10Base-T/100Base-TX RJ-45 connector terminated connections and shall also provide the integral function of a fiber media uplink (100Base-FX via ST connectors) to provide an interface to the external Government fiber network. The switch shall be a SixNet EtherTRAK Industrial Ethernet Real Time Switch Model Number ET-GT- 9ES-2ST or approved equal, and shall utilize between 10 volts DC and 30 volts DC as its power source.

3.20.2 The Contractor shall provide and configure the software to be compatible with the existing system and to communicate with the PLC/Controller.

3.20.3 A portable laptop computer shall be furnished with the latest PLC/Controller programming software, program logic and the viewer software installed.

A. The laptop shall be provided with an Ethernet interface card and serial port.

B. The laptop shall be provided with all software and operating licenses required to program and monitor the control program logic.

C. The laptop shall be provided with all the necessary software, hardware, and configuration links so that it could be used in place of the local Viewer in case of a viewer station failure.

D. The PLC/Controller shall be furnished with one serial port.

3.21 Naming Standards: Naming standards for Point Name shall be coordinated with the Government Representative.

3.22 Low Voltage Power Distribution:

3.22.1 The following low voltage power is available at AEDC: 24 V DC, 120 V AC single phase, 208 V AC three phase, and 480 V AC three phase. All AC power is 60 Hz. Power panels used for low voltage power shall be determined by AEDC during the design phase.

3.22.2 Provide separate conduits for low voltage power as outlined below:

A. 24 V DC power

B. 120/208 V AC power

C. 480 V AC power

3.22.3 No network or fiber optic cabling is allowed in the same conduit with any of the low voltage wiring conduits.

3.23 Junction Boxes:

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3.23.1 Each junction box shall have a lamacoid or other similar type plastic laminate nameplate permanently fixed to the exterior surface of the door of the box, with the junction box identification engraved in the nameplate.

3.23.2 Each enclosure shall have padlocking provisions for locking the door(s) in the closed position.

3.24 Spare Parts: Provide one set of the OEM’s recommended on-hand spare parts.

4. VERIFICATION

5. PACKAGING AND DELIVERY

5.1 Preparation for Delivery:

5.1.1 The Contractor shall provide all preservation and packaging to ensure safe delivery of the chiller package.

5.1.2 Comply with manufacturer's installation instructions for rigging, unloading, and transporting units.

5.1.3 Protect units from physical damage. Leave factory covers in place until installation.

6. NOTES: None

END OF SPECIFICATION