Equipment Procurement Specifications for

Replace Chiller #3 at Central Chilled Water Facility

Building 600

August 2026

ESH&Q Risk Level: QA-3 Specification 14721

Manager: C. Ogeka GPP

Engineer: S. Adhya P/A 71226 / 71228

Brookhaven National Laboratory

Brookhaven Science Associates

Facilities & Operations Directorate

Modernization Project Office

Upton, NY 11973

SECTION 23 64 16.16

WATER COOLED CENTRIFUGAL CHILLERS

PART 1 - GENERAL

1.01 SECTION INCLUDES

A. Factory assembled and tested, packaged, Semi-hermetic, electric-motor-driven, water-cooled, direct-drive centrifugal chillers that shall use R-514A including accessories as required for a complete, properly function chiller with remote start-up capability.

1.02 QUALITY ASSURANCE

A. Standards

1. The equipment shall comply with the applicable portions of the current editions of the following standards:

a. Conform to AHRI Standard 550/590 code for rating and testing of centrifugal water chillers and shall bear and AHRI certification label.

b. Conform to UL 1995 for Safety Testing for Heating and Cooling

Equipment.

c. Conform to ANSI/ASME SECTION VIII Boiler and Pressure Vessel Code for construction and testing of centrifugal chillers as applicable.

d. Conform to latest revision of ANSI/ASHRAE STANDARD 15, Safety Code for Mechanical Refrigeration.

e. Evaporator and Condenser shall include an ASME “U” stamp and nameplate certifying compliance with ASME VIII, Division 1 Code for

Unfired Pressure Vessels.

f. ASHRAE Standard 34, Number Designation and Safety Classification of

Refrigerants.

g. ARI / AHRI 575, Method of Measuring Machinery Sound and Vibration within Equipment Rooms.

h. ARI 740, Refrigerant Recovery / Recycling Equipment

i. Chiller shall be UL listed and labeled.

j. Chiller manufacturer shall provide LEED-NC EA Credit Calculation for each chiller utilizing the following factors as specified by the U.S. Green

Building Council based upon equipment life of 25 years:

i. Next Generation Refrigerants

Brookhaven National Lab - Building 600 CCWF

Chiller No. 3 Replacement

R-514A Chillers

ODP 1

GWP 1.75

Annual Leakage Rate 2.0%

End of Life Ref. Loss 10%

ii. Chiller must ship with low-GWP, next generation refrigerant R-

514A.

B. Requirements of Regulatory Agencies

1. Provide materials and equipment and execute work, including tests and inspections, per applicable provisions of Federal, State and local laws and ordinances (including referenced codes and standards). They shall constitute the minimum project requirements.

C. Brookhaven National Labs (BNL) Site Requirements

1. All contractors, sub-contractors and vendor’s authorized technicians must have an up-to-date completion of the following minimum training and procedures to perform work on site:

a. Contractor Vendor Orientation (CVO) must be current for each employee.

b. Health and Safety Plan (HASP) must be completed.

c. Job Hazard Analysis (JHA) must be completed.

d. Electrical Safety / Qualified Electrical Worker

e. Lock Out / Tag Out Training (LOTO) & associated Job Practical Measure

f. Current CPR qualifications – not required to be obtained through BNL

g. Use of portable ladder – not required to be obtained through BNL

h. Confined Space – not required to be obtained through BNL

D. Quality Assurance & Factory Testing

1. Perform standard factory shop test for each component to ensure compliance with intent of these specifications.

2. Factory Performance Testing Requirements:

a. Full-Load Performance Test: Conduct factory full-load ARI test at design full-load condition.

b. Performance Tolerances: Chiller shall meet the minimum capacity (1250 tons) at 85°F condensing water temperature with 42°F leaving evaporator water temperature. Flow rates shall be as specified in Section 4.01

SCHEDULE of this specification. Zero (0) tolerance on tonnage at design full load; standard tolerance on efficiency at design full load.

c. Factory Restart Test: Conduct factory restart test integrated with

Uninterruptible Power Supply (UPS).

d. Test Matrix & Load Points: Complete a total of 12 test points comprising

100%, 75%, 50%, and 25% load points at entering condenser water temperatures (ECWT) of 90.9°F, 85°F, and 65°F.

e. Full-Load Design Point: 100% load at 85°F entering condenser water temperature.

f. Special Operating Condition Test: Minimum capacity of 1,170 tons at maximum power input of 0.630 kW/ton under 100% load / 90.9°F ECWT, subject to standard tolerances.

g. The chiller shall be capable of operating continuously with condenser water temperatures as low as 65°F and as high as 90.9°F at all range of load conditions. Safety trips, surging or other machine failures or non-conformances at this condition shall be considered as a failure of the factory test.

h. Chiller must meet or exceed the current ASHRAE 90.1 efficiency standards at 85°F entering condenser water temperature.

i. Witnessing: Provide virtual witnessing capabilities for Owner and/or designated Owner's representatives.

i. BNL personnel shall witness the chiller tests outlined above through live video link with the vendor’s test facility. The chiller nameplate shall be permanently affixed at the time of the test and shall be “witnessed” as in place prior to commencing.

ii. Perform factory restart demonstration while connected to AHRI loop as part of “witnessed” factory testing. Submit record of restart demonstration with chiller documentation.

j. Non-Destructive Testing: Factory baseline eddy current testing shall be included and performed on all evaporator and condenser tubes prior to shipment.

k. Acoustic Testing: Full-load factory sound testing conducted concurrently with full-load performance testing.

l. Vibration Testing: Conduct standard factory vibration testing; results shall be reported within the Instruction, Operation, and Maintenance (IOM) manual.

3. Should the chiller fail to meet any of the capacity or efficiency requirements outlined above BNL shall refuse shipment of the chiller.

E. Noise Control Design

1. Equipment noise shall not exceed 90 dB(A) measured five (5) feet from the chiller per all applicable standards. A record of the acoustical test shall be included as a in the Operations and Maintenance Manual.

2. Manufacturer must provide a record of a sound test to confirm the design noise level of the specific model and configuration of the machine being provided at full load with 85°F entering condenser water temperature. Utilizing “typical” sound test shall not be accepted.

1.03 WARRANTY AND SERVICE

A. As an explicit part of the warranty the chiller shall be guaranteed by the manufacturer to meet the operating conditions, capacity and performance conditions for the various time periods as specified and to remain serviceable for a minimum of 25 years. BNL reserves the right to request a performance test throughout the specified first year warranty period.

If the unit fails the performance test then warranty shall be extended for a period of 1 year.

B. Warranty Coverage:

1. Year 1 Whole-Unit Labor Warranty: Complete unit coverage including labor, contingent upon installation with Trane-supplied starter.

2. Year 1 Refrigerant Warranty: Full refrigerant quality warranty.

3. Years 2 through 5 Extended Warranty: Parts-only warranty covering the compressor and drive motor assembly.

4. Delayed Startup Warranty: Coverage extends 12 months from actual unit startup, not to exceed 24 months from original shipment date.

5. Startup Requirement: Equipment startup MUST be performed strictly by authorized

Trane Service personnel for all warranties to remain valid.

C. Delivery, Field Maintenance & Holding Inspection:

1. Unit shall ship with a factory nitrogen holding charge.

2. Factory service shall provide up to 18 monthly field inspection visits to monitor and verify the factory nitrogen holding charge prior to final commissioning.

3. Replacement nitrogen supply (if depleted) is excluded from manufacturer scope.

4. Comply with manufacturer's installation instructions for rigging, chiller loading, local transportation requirements, unloading, storage, and final setting.

5. Protect chiller and controls from physical damage. Leave factory shipping covers in place until installation. The entire unit must be shrink wrapped with an environmentally recyclable material standard. The material shall include an imbedded desiccant to minimize/eliminate internal moisture.

6. The chiller shall ship with a full charge of oil.

D. Leak Tight Warranty: Provide as part of the chiller scope a refrigerant loss warranty for the lesser of 60 months from initial start-up or 66 months from date of shipment. During this period, manufacturer shall furnish replacement refrigerant which is lost due to a leak in the machine. Once a leak is determined, action must be taken (acceptable to the manufacturer) to eliminate the source of the leak. Replacement parts and labor are not covered under this warranty.

E. Maintenance / Installation Services

1. Provide the following services for installation of chillers during the installation period through start-up and acceptance:

a. All pre-startup inspections and required service of units shall be accomplished by factory trained and authorized service technicians.

b. All labor for pre-inspection and leak checking the chiller according to the manufacturer's IOM and documentation must be included.

c. Proper evacuation and disposition of Nitrogen charge within chiller as well as refrigerant charging / chiller purging prior to start-up. Service technicians shall monitor the refrigerant charge throughout the start-up period to ensure chiller has sufficient refrigerant for proper operation and/or leaks are not present after initial charging was performed.

d. Provide certified technicians for field installation of remote starter components and wiring as outlined in other sections of this specification

(including modification of the controls connection box) and confirm integration with CCWF Chief Engineer allowing for proper operation.

e. Provide start-up support and service for chiller during initial construction energizing and testing and all commissioning acceptance tests.

f. Provide all necessary training for CCWF staff including review of current

IOM materials.

1.04 SUBMITTALS

A. Furnish Submittal for all items identified within this specification. Refer to Division 01 for all of the administrative requirements governing submittal procedure.

B. Submittals shall all bear the current contract identifying name and number.

C. Shop Drawings:

1. Submit all required data for verification of compliance of unit performance requirements including but not limited to:

a. ARI/AHRI certified performance data and zero tolerance data for full load operation as previously outlined.

b. Testing data for all conditions outlined in the sections above,

c. Detailed shop drawings indicating dimensions, configurations, piping connections and arrangement of chiller being manufactured. Typical catalog cuts not indicating exact machine fabrication are not acceptable.

d. Equipment support requirements.

e. Functional and ancillary provisions being provided such as relief valves, isolations valves, strainers, etc. required for a complete system and

f. Options and Auxiliary devices like specialized coatings, insulation

(thickness, location, application requirements and procedures).

g. Utilities including all power connections required by electrician.

2. Submit integrated electrical drawings indicating power, control and instrument wiring interfacing with field work both under this contract (i.e. manufacturer provided service tech installation of devices in the field) and under separate contracts as well as factory assembled work. Wiring diagrams shall clearly identify:

a. Pump Interlocks

b. Cooling Tower interlocks

c. Refrigerant Leak detection interface with monitoring system (provided by others).

d. Flow proving sensors.

e. Site BMS system connections and monitoring.

f. Integration of GE starters with all necessary control devices.

g. Vibration switch wiring connection point.

h. Safety interlock connection points (i.e. E-stop)

3. Sequence of operation.

4. Installation details for construction field conditions including rigging and start-up procedures.

5. Vibration amplitude limits for the chiller.

6. Submit compressor and product data in table form indicating impeller speed (RPM), number of bearings, type of bearings, high speed impeller shaft RPM, sound pressure level per AHRI 575-2017 (dB), number of stages, number of sets of inlet guide vanes, amount of refrigerant charge (lb), and amount of oil required (gal).

D. Acceptable refrigerant on which chiller performance is based is R-514A. All proposals for chiller performance must include an AHRI approved selection method for the specified refrigerant.

E. Submit manufacturer’s data report, Form U-1 for compliance to ASME.

1.05 OPERATIONS AND MAINTENANCE DATA

A. Operations and Maintenance Information and Manuals including but not limited to the following:

1. Specific installation, operation, lubrication and maintenance instructions for the equipment purchased under this contract. Extraneous information for “typical” chillers shall not be accepted.

2. Spare parts data for the chiller and all ancillary devices provided under this contract.

3. Maintenance manuals shall include the following at a minimum:

a. All diagrams required as part of the Shop Drawing requirements.

b. System OEM components and assembly drawings as-built.

c. Equipment data including:

i. Performance data – normal and abnormal conditions.

ii. Installation requirements

iii. Operations requirements and procedures

iv. Trouble Shooting

v. Safety Precautions

vi. Maintenance and repair

vii. Contact information for authorized service technicians and stock parts source.

viii. Recommended spare parts.

PART 2 - PRODUCTS

2.01 SUMMARY

A. Description: Factory-assembled and tested water chiller complete with compressor, evaporator, condenser, controls, interconnecting unit piping and wiring, indicating accessories, and mounting frame. Minimum performance shall be per specification section 4.01 SCHEDULE.

B. The units shall produce the specified tonnage per the scheduled data in accordance with the latest revision of AHRI 550/590. The unit shall bear the AHRI certification label as applicable.

C. The chiller basis of design is a CenTraVac™ model CVHF as manufactured by Trane. Job awarded on basis of conformance to specified machine performance and dimensional characteristics.

D. Unit shall be painted in accordance with the manufacturer's standard procedures and practices.

E. Chiller shall be supplied with and shall operate based on the use of R-514A or 513A.

2.02 COMPRESSOR AND MOTOR

A. The compressor shall be direct driven centrifugal with multiple stages with interstage flash refrigerant economizer.

B. Rotor shall be cast, high strength aluminum, statically and dynamically balanced and tested to a minimum of 25% above maximum operating speed. There shall be no critical speed within the operating range of the compressor.

C. Chiller should be able to unload to 10 % of design tonnage with constant entering water temperature. The minimum unloading point shall be demonstrated as part of witnessed factory performance test.

D. Compressor assembly shall be vibration tested at the factory. Vibration shall not exceed

0.15 inches per second at full load design compressor speed as measured on the motor housing. The test data shall be recorded and provided to the customer for approval.

E. The motor shall be hermetic and either suction or liquid refrigerant cooled. Hot gas motor cooling is not acceptable.

F. Provide a self-contained, forced-feed lubrication system with oil sump, mechanically driven positive displacement lube oil pump, heater, oil cooler, level gauge, thermostatically controlled oil temperature, pressure regulator all required strainers, filters, piping, fittings and control valves. Lubrication system shall supply the proper oil pressure to bearings under all conditions of operation including total loss of power. Provide interlock and differential oil pressure cutout with starting equipment to allow the compressor to operate only when the required oil pressure is available at the bearings. Provide oil pump starter factory mounted and wired.

G. Provide stable operation, modulating capacity from 10% to 100% of design capacity utilizing multiple radial vanes (inlet guide vanes) and hot gas bypass (as needed) to maintain stable operation. Control shall include automatic stopping when load falls below

10% capacity point and automatic, unloaded starting on load demand.

H. Capacity modulation shall be based on chiller leaving water temperature. The chiller shall be capable of maintaining the leaving chilled water setpoint within +/- ½ °F.

I. Compressor shall be provided with a discharge line isolation valve.

J. Motors shall be high efficiency type rated for 4160 V, 3 phase, 60 Hz.

K. Motors shall have winding 100 ohm platinum RTDs for temperature sensing on each phase. Thermistors and thermal overloads are not acceptable. These temperatures shall be furnished to the unit control panel for monitoring and alarm.

L. The motor speed shall not exceed 3600 rpm.

M. Provide reverse phase rotation protection to preclude damage to any component due to reverse rotation.

N. Provide motor bearing temperature sensing connected to the chiller control circuit.

O. The impellers shall be fully shrouded and made of a high strength aluminum alloy.

Impellers shall be dynamically balanced and over-speed tested at 1.25 times impeller shaft speed.

2.03 EVAPORATOR (CHILLER BARREL)

A. The evaporator shall be built in accordance with ANSI/ASHRAE 15-2019 Safety Code for

Mechanical Refrigeration and ASME Unfired Pressure Vessel Code section VIII regarding the quality of materials used, methods of construction, design of components and testing of materials, assemblies, connections and appurtenances. Provide an ASME “U” stamp accordingly.

B. Evaporator tubes shall be internally and externally enhanced with a 0.75" outer diameter.

The tubes shall be securely supported at intermediate supports and physically expanded into both ends of the tube sheets. The evaporator tubes must also be removable from both ends to provide easy access for tube cleaning.

1. The minimum evaporator tube wall thickness, root-to-root across the entire tube length shall be 0.035". It is unacceptable to provide this thickness at the intermediate supports only.

C. The evaporator water piping connections shall be grooved to work specifically with couplings as manufactured by Victaulic.

D. Evaporator shall be designed to prevent liquid refrigerant from entering the compressor.

Evaporator shall include a suction baffle or mesh eliminator, located above the tube bundle, to prevent refrigerant carry-over into the compressor.

E. The evaporator water boxes shall be hinged marine style with stainless steel baffles. Water boxes shall contain rigging points or hooks for lifting of covers off hinges.

Provide water boxes with drains and high point air vents. Provide ¾ ” ball valves for vents and drains (air vents and drain hoses shall be provided by others). The water boxes’ maximum allowable working pressure shall match the rating for the evaporator bundle at

150 psig. Side connections shall be provided such that the water piping of both the entering and leaving sides shall not be disconnected for mechanical. The water piping connections shall be in a direction perpendicular to the shells to allow full unblocked access to the tubes – final angle shall be confirmed during shop drawing process.

F. Entire evaporator shall be hydrostatically tested to 1.5 times the working pressure of 150 psig and vacuum.

G. Units shall incorporate an interstage flash vessel "economizer".

H. Insulation will be ¾ " closed cell foam type with 25/50 flame / smoke index rating and cover all low-temperature surfaces to include the evaporator, water boxes, and suction elbow and economizer.

I. Internal Shell Coating: Belzona high-performance epoxy coating applied to interior surfaces of both evaporator and condenser water boxes and tube sheets.

J. Internal Baffles: Stainless steel construction for all internal waterbox baffles.

K. Waterboxes: Standard marine hinged waterboxes with 12 in. Victaulic groove pipe connections.

L. Flow Switch: IFM thermal dispersion flow switch, factory-furnished for field installation.

2.04 CONDENSER

A. The condenser shall be built in accordance with ANSI/ASHRAE 15-2019 Safety Code for

Mechanical Refrigeration and ASME Unfired Pressure Vessel Code section VIII regarding the quality of materials used, methods of construction, design of components and testing of materials, assemblies, connections and appurtenances. Provide an ASME “U” stamp accordingly.

B. Condenser tubes shall be internally and externally enhanced with a 1.00" outer diameter.

The tubes shall be securely supported at intermediate supports and physically expanded into both ends. The condenser tubes must also be removable from both ends to provide easy access for tube changeouts or tube cleaning.

1. The minimum condenser tube wall thickness, root-to-root across the entire tube length shall be 0.035". It is unacceptable to provide this thickness at the intermediate supports only.

C. The condenser water piping connections shall be grooved for use with couplings as manufactured by Victaulic.

D. The condenser shall be proved with marine style hinged water boxes with stainless steel baffles rated for a maximum allowable working pressure of 150 psig. The water boxes shall also include ¾ ” ball valves for drains and a high point air vents (air vent and drain hoses shall be provided by others). Side connections shall be provided such that the water piping of both the entering and leaving sides shall not be disconnected for mechanical cleaning. The water piping connections shall be in a direction perpendicular to the shells to allow full unblocked access to the tubes (angle shall be confirmed during shop drawing process).

E. Hydrostatically test the entire condenser assembly in the factory for 1.5 times the maximum design pressure of 150 psig and full vacuum.

F. The condensor tube sheets and water box interiors shall be factory finished with a Belzona epoxy coating.

G. Internal Shell Coating: Belzona high-performance epoxy coating applied to interior surfaces of both evaporator and condenser water boxes and tube sheets.

H. Internal Baffles: Stainless steel construction for all internal waterbox baffles.

I. Orifice Sizing: 1,890 nominal ton refrigerant expansion orifice.

J. Flow Switch: IFM thermal dispersion flow switch, factory-furnished for field installation.

2.05 REFRIGERANT

A. Refrigerant shall be R-514A, or as necessary, environment-friendly refrigerant, factory supplied by Trane for field charging.

B. Refrigeration Transfer: Provide service valves and other factory-installed accessories required to facilitate transfer of refrigerant from the chiller to remote systems.

1. See Section 1.05 for additional details on refrigerant shipment.

C. Refrigerant Flow Control: Fixed orifice plates at the entrance and exit of the economizer shall be used to control refrigerant flow.

D. Chillers shall have a high efficiency purge system (i.e., Trane EarthWise Purge) to ensure that any potential non-condensable leakage into the vessel is immediately eliminated. The purge run time shall be monitored by the main unit controller to act as a leak detector if required, and must have the following specifications:

1. The purge efficiency must meet ASHRAE Standard 147-2013 and all addenda.

2. The purge shall be capable of operating when the chiller is idle in accordance with

ASHRAE Standard 147-2013 and all associated addenda.

3. The purge shall be certified to meet AHRI 580 requirements.

2.06 REFRIGERANT RELIEF VALVES

A. Provide refrigerant relief valves factory sized and installed per ASHRAE 15 requirements.

B. Valves to be combination reverse buckling, non-fragmenting rupture disk and resetting valve in series appropriate for use with R514A.

2.07 ELECTRICAL

A. Chiller shall be installed, wired, and functionally tested at the factory before being shipped.

B. Single point power connection - A control power transformer internal to the motor controller and of sufficient size to power all chiller mounted auxiliary loads shall be supplied. No separate power connection shall be required for chiller mounted equipment.

The CPT shall tap from the main power connection.

C. Terminal blocks numbered to match the wiring diagram must be included.

D. A remote starter shall be provided by others. For the chiller to properly integrate into the

BNL required starter sequencing and monitoring the following shall be provided by the manufacturer as part of their scope and all labor for installation and testing shall be included whether factory or field (See reference drawing ECN-56-E1 for reference to previously installed chiller starter wiring on site). The following functionality must be integrated to the BNL Starter:

1. Chiller Start / Stop / Status.

2. Shorting Capability across primary and secondary

3. Secondary Power Transformers for controls

4. Emergency Stop

2.08 CONTROLS

A. The chiller shall be controlled by a unit mounted, stand-alone Direct Digital Control (DDC) system.

B. Enclosure shall be unit mounted NEMA 250 Type 1.

C. The chiller manufacturer shall include a pressure, non-mechanical based flow switch that is of the thermal dispersion type for each evaporator and condenser to verify flow through the unit.

D. A color, touch sensitive liquid crystal display (LCD) shall be unit mounted and a minimum of 12.1" diagonal. The display shall be fully adjustable in height and viewing angle.

Animated graphical representations of chiller subsystem operation shall be used to enhance the user interface.

E. Display shall consist of a menu driven interface with easy touch screen navigation to organized sub-system reports for compressor, evaporator, condenser, purge and motor information as well as associated diagnostics. The controller shall display all active diagnostics and a minimum of 20 historical diagnostics.

F. The chiller control panel shall provide control of chiller operation and monitoring of chiller modules, sensors, actuators, relays and switches. The chiller control panel shall include controls to safely and efficiently operate the chiller.

G. Control authority must be capable of handling at least four conditions: Off, local manual at the chiller, local automatic at the chiller and automatic control through a remote source.

H. Capability to connect a laptop to service utility with applicable software from manufacturer and obtain enhanced set-up and diagnostics.

I. The front of the chiller control panel shall display the following in clear language, without the use of codes, look-up tables, or gauges:

1. Run time.

2. Number of starts.

3. Current chiller operating mode.

4. Chilled water set point and set point source.

5. Electrical current limit set point and set point source.

6. Entering and leaving evaporator water temperatures.

7. Entering and leaving condenser water temperatures.

8. Saturated evaporator and condenser refrigerant temperatures.

9. Evaporator and condenser refrigerant pressure.

10. Oil tank temperature.

11. Oil tank pressure.

12. Oil pump discharge pressure.

13. Differential oil pressure.

14. Compressor motor current per phase.

15. Compressor motor percent RLA.

16. Compressor motor voltage per phase.

17. kW energy consumption and power factor.

18. Compressor motor winding temperatures per phase.

19. Purge operating mode.

20. Purge operating status.

21. Time until next purge run.

22. Daily pumpout - 24 hours.

23. Average daily pumpout - 7 Days.

24. Purge refrigerant compressor suction temp.

25. Purge liquid temp (chiller condenser saturated refrigerant temperature).

26. Daily pumpout limit/alarm.

27. Bearing oil temperatures.

28. Discharge temperature (compressor).

J. The chiller control panel shall provide password protection of all setpoints.

K. The controller shall have the ability to display all primary sub-system operational parameters on dedicated trending graphs. The operator must be able to create up to 6 additional custom trend graphs, choosing up to 10 unique parameters for each graph to trend log data parameters simultaneously over an adjustable period and frequency polling.

L. The chiller control panel shall provide individual relay outputs to start/stop the evaporator and condenser water pumps. The condenser water pump relay output can be used to enable the cooling tower temperature controls.

M. The chiller control panel shall provide leaving chilled water temperature reset based upon return water temperature.

N. The chiller control panel shall be capable of displaying system data in I-P or SI units.

O. Safeties - the chiller control panel shall provide the following safeties:

1. Low chilled water temperature.

2. Low evaporator refrigerant temperature or pressure.

3. High condenser refrigerant pressure.

4. Evaporator and condenser water flow status.

5. Low oil pressure.

6. Low oil temperature.

7. High oil temperature.

8. High motor winding temperatures.

9. High motor current.

10. Starter faults.

11. Sensor faults.

12. Unit controls operation.

13. The chiller control panel or starter shall incorporate advanced motor protection to safeguard the motor throughout the starting and running cycles from the adverse effects of:

a. Current phase loss.

b. Current phase unbalance.

c. Current phase reversal.

d. Under/Over voltage.

e. Motor current overload.

f. Distribution fault protection with auto restart consisting of three-phase current sensing devices that monitor the status of the current.

g. Starter contactor fault protection.

h. Starter transition failure.

14. Compressor discharge temperature.

15. High bearing temperatures.

a. Each of the compressor and motor bearings (including high speed, low speed, and thrust bearings) shall have factory installed, separate temperature sensors installed on the bearing or in the oil return line of each separate bearing.

b. If any oil temperature reaches or exceeds a set value, the chiller control panel shall shut down the chiller, display the diagnostic, and activate the front panel alarm indicator.

P. The chiller control panel shall provide evaporator freeze protection and low limit control to avoid low evaporator refrigerant temperature trip-outs during critical periods of chiller operation. Whenever this control is in effect, the controller shall indicate that the chiller is in adaptive mode. If the condition exists for more than 30 seconds, a limit warning alarm relay shall energize.

Q. The chiller control panel shall be capable of providing short cycling protection.

R. The chilled water controller of each chiller shall include variable water-flow capability to allow the chiller to respond quickly to accelerating or decelerating water, and have the following features:

1. The variable water-flow compensation capability shall allow control of the leaving chilled water temperature to within +/- 1.0°F (0.6°C) at a water flow rate change of

10% per minute and will stay online at a water flow rate change of 30% per minute.

S. The chiller, upon power loss restoration, must be able to start the compressor within 60 seconds. The chiller time to fully load up to 80% shall be no longer than 3 minutes. The chiller shall be capable of handling full load within 5 minutes. This shall be demonstrated at the factory as part of the witnessed performance testing. Documentation of this test shall be provided with delivery of the chiller.

T. The chiller control panel shall provide hardwire connections for the following binary and analog signals:

1. Compressor Running.

2. Detection by the panel of a fault requiring manual reset.

3. Chiller operation at maximum capacity.

4. Chiller operation in condenser limit mode and thereby requesting condenser water temperature relief.

5. Contact for alarm conditions

6. Contact for operating status

7. Remote Start / Stop (not permitted under safety shutdown).

8. Remote chilled water reset.

U. The chiller control panel shall provide an analog 2 - 10VDC output signal that shall indicate the Compressor Motor Percent RLA.

V. The chiller should have a condenser pressure output signal of 0 - 10VDC that may be used for head pressure control if required.

W. The chiller control panel shall allow for an analog input for a chilled water setpoint and an electrical current limit set point. These setpoints can be in the form of 4-20 mA or 2-10

Vdc signals from a remote source (i.e. generic building automation system).

X. The chiller control panel shall provide condenser limit control by including a condenser

(refrigerant side) pressure transducer and interconnecting piping and wiring. This control shall be used to avoid high condenser refrigerant pressure tripouts. The control shall take action in response to the condenser refrigerant pressure. Whenever this control is in effect, the panel will automatically indicate that the chiller is in adaptive mode and if the condition exists for more than 30 seconds, a limit warning alarm shall energize.

Y. The chiller controller must be able to communicate and be controllable directly from the

CCWF building automation system using BACnet protocol through ethernet connection.

2.09 TESTING

A. GENERAL

1. For witness tests, BNL or their representative shall be notified 14 days in advance to witness the factory performance test. The manufacturer shall assume all costs necessary to set up a virtual witness test by BNL and/or their representative(s).

2. The chiller shall be factory performance tested with the proposed refrigerant under full-load conditions in an AHRI certified test facility. The manufacturer shall supply a certified test report to confirm performance as specified. Proper AHRI certification documents for the manufacturer's test loop shall be made available for inspection upon request.

3. The factory test instrumentation shall be per AHRI Standard 550/590, and the calibration of all instrumentation shall be traceable to the National Institute of

Standards and Technology (NIST).

4. The performance test shall be run with clean tubes in accordance with AHRI

550/590 to include the following:

a. A downward temperature adjustment per AHRI 550/590 shall be made to the design leaving evaporator water temperature to adjust from the design fouling factor (per sections 4.01 SCHEDULE) to the clean tube condition.

b. An upward temperature adjustment per AHRI 550/590 shall be made to the design entering condenser water temperature to adjust from the design fouling factor (per sections 4.01 SCHEDULE) to the clean tube condition.

c. There shall be no exceptions to conducting the performance test with clean tubes and with temperature adjustments in (1) and (2). The manufacturer shall clean tubes, if necessary, prior to test to obtain a test fouling factor of .0000 h·ft²·°F/Btu.

B. VERIFICATION TEST OF CHILLER CAPACITY AND EFFICIENCY

1. The chiller shall be witness tested in the manufacturer's factory on an AHRI certified test loop.

a. The chiller must be tested with AHRI tolerances, except as otherwise indicated within this specification.

b. Evaporator and Condenser water flows shall be held constant as indicated in Section 4.01 SCHEDULE for all test points.

2. The performance test point minimums shall be as follows:

% Load Entering CWT Expected Maximum kW/ton

100% 85° F 0.57 kW/ton (zero tolerance allowed)

100% 90.9° F 0.63 kW/ton

100% 65° F 0.46 kW/ton

75% 85° F 0.57 kW/ton

75% 90.9° F 0.61 kW/ton

75% 65° F 0.42 kW/ton

50% 85° F 0.60 kW/ton

50% 90.9° F 0.67 kW/ton

50% 65° F 0.45 kW/ton

25% 85° F 0.78 kW/ton

25% 90.9° F 0.88 kW/ton

25% 65° F 0.56 kW/ton

3. A certified test report of all data shall be submitted to the Contracting Officer prior to completion of the project. The factory certified test report shall be signed by an officer of the manufacturer's company.

4. If the equipment fails to perform within proposed tolerances, the manufacturer will be allowed to make necessary revisions to their equipment and retest as required.

5. BNL will not accept equipment that does not meet the required specified performance. If these revisions do not achieve submitted performance, the chiller shall not be accepted and any delays to the construction schedule will be monetarily assessed against the manufacturer.

a. Equipment manufacturer shall not invoice for the chillers until successful completion of the performance test.

C. SOUND DATA DEMONSTRATION

1. The Centrifugal Chiller Sound Pressure Level (SPL), in decibels (dB), with a reference pressure of 20 micropascals (µPa), shall not exceed Sound Levels in the following table:

% Load Decibels (A Weighted) Entering CWT

100 % 90 90.90 F

2. In order to indicate actual sound pressures at a given chiller's load and conditions, a reduction in the temperature of the entering condenser water and/or raising the leaving chilled water temperature shall not be allowed when determining the Sound

Pressure Levels.

3. Sound Pressure Test - One of each size chiller shall have a sound test conducted at the factory prior to shipment to confirm the submitted Sound Pressure Levels. All data must be measured and presented in strict accordance with AHRI Standard

575-2017.

a. The sound data points shall be measured simultaneously during the verification of capacity and efficiency as outlined in Section 2.09.

b. If liquid-refrigerant injection is used for reducing the sound pressure level, then liquid injection is to be used when conducting the performance test, noting that liquid-refrigerant injection penalizes the chiller performance.

PART 3 - EXECUTION

3.01 INSTALALTION OF CHILLER COMPONENTS

A. Manufacturer’s authorized service technicians shall provide all labor for installation of loosely shipped items from chiller manufacturer including but not limited to:

1. All electrical items needed for remote starter integration outlined in section 2.07

ELECTRICAL.

2. Installation of relief valves.

3.02 FIELD QULAITY CONTROL

A. Pre-Check, Test and Start-up

1. Provide all labor and materials for equipment checkout and testing by factory trained and authorized service technicians prior to starting the chiller. This shall include all required prechecks per the manufacturer’s IOM including a leak test in the field prior to refrigerant charging. The authorized service technicians shall also be responsible for charging the chiller with the manufacturer supplied refrigerant and shall have sufficient supply on hand should it be necessary to supplement the factory provided supply to complete the full charge. Upon successful completion of check out and testing the service technicians shall provide a complete written report to the CCWF Chief Engineer, the BNL Technical Authority and the construction team.

2. Upon completion of all prechecks and tests signed off by the field service technician confirming proper installation and chiller condition, as well as acceptance by BNL personnel, and under coordination with the construction team the factory authorized service shall provide start-up services for the installed chiller under strict adherence to the manufacturer’s requirements. These shall include at a minimum:

a. Provide all necessary standard start-up testing.

b. Make all critical adjustments of equipment calibration of controls.

c. Ensure integration of remote starter has been completed and is functioning properly with Chief Engineer.

d. Confirm actual performance matches with submitted and approved manufacturer generated selections and submittals.

e. Provide a log of all operating parameters

f. Provide completed logs to Chief Engineer, construction team and BNL

Technical Authority.

3. After successful completion of start-up the factory authorized service technician shall perform a field vibration test using a certified calibrated vibrometer readable to 0.0001 inch displacement.

a. Readings shall be taken at steady state conditions of 100%, 75%, 50%

25%, 10% and 0% (for baseline only) loads, as well as under the transition period from load point to load point in the presence of BNL field personnel or their authorized representative.

b. The readings shall be compared to the factory provided vibration tests.

c. A full report shall be delivered to BNL and the construction team for review and approval.

4. See Section MAINTENANCE / INSTALLATION SERVICES of this specification for additional requirements.

3.03 OWNER TESTING DURING WARRANTY PERIOD.

A. BNL at their discretion shall have certified third party testing performed during the warranty period as follows:

1. Performance testing

2. Vibration testing

B. Should the chiller’s operation be found to be out of acceptable operational parameters the cost of the tests shall be borne by the manufacturer and the manufacturer shall engage its factory service personnel, at no cost to BNL, to investigate and mitigate any possible parameters affecting the chiller’s performance as part of the normal warranty claim.

C. Tests shall be repeated until chiller is deemed acceptable by BNL.

PART 4 - PERFORMANCE REQUIREMENTS (BASIS OF DESIGN)

4.01 SCHEDULE

Equipment Tag CH-3

Basis Manufacturer: Trane

Model Number: CVHF

Nominal Cooling Capacity: 1250.00 tons

Evaporator:

Flow Rate: 2985.00 gpm

Entering Fluid Temp: 52.00 F

Leaving Fluid Temp: 42.00 F

Pressure Drop: 21.6 ft H2O

Fouling Factor: 0.000100 hr-sq ft-deg F/ Btu

Fluid Type: water

Condenser:

Flow Rate: 3750.00 gpm

Entering Fluid Temp: 85° and 90.9° F

Leaving Fluid Temp: 95° and 100.4° F

Pressure Drop: 12.9 ft H2O

Fouling Factor: 0.000250 hr-sq ft-deg F/ Btu

Fluid Type: water

Compressor:

Maximum Power Input: 768.9 kW

Voltage, 3 Phase: 4160. V kW/ton

0.57 kW/ton @ 85°F

0.6253 kW/ton @ 90.9°F

Starter:

Incoming RLA: 125.90 A

REFERENCE ATTACHMENTS:

1. REFERENCE WIRING DIAGRAM WITH REMOTE STARTER (ECN-56-E1)

2. MAXIMUM UNIT DIMENSIONS

END OF SECTION

Job N am e: B rookhaven N ational Lab C hiller

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Q uantity: 1

S ales O ffice: Long Island

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T rane S elect A ssist

V ersion N um ber:

552604 D ata G eneration D ate:

4/19/2026

12" Connections To Be Provided e: B rookhaven N ational Lab C hiller

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e: B rookhaven N ational Lab C hiller

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Site Coordination Required. Hinge Might Need To Relocate To Opposite Side e: B rookhaven N ational Lab C hiller

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Q uantity: 1

S ales O ffice: Long Island

2026/08/25 12:00:49 P age 9 of 26

T rane S elect A ssist

V ersion N um ber:

552604 D ata G eneration D ate: