OMA-SPECS_23 64 10_Chiller.pdf

2014 O&MA SPECIFICATIONS

REVISION 1 - 20151030

SECTION 23 64 10

WATER CHILLERS, VAPOR COMPRESSION TYPE

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 450 (2007) Water-Cooled Refrigerant Condensers, Remote Type

AHRI 480 (2007) Refrigerant-Cooled Liquid Coolers, Remote Type

AHRI 550/590 I-P (2011) 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

AHRI 740 (1998) Refrigerant Recovery/Recycling Equipment

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 2014) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 64 (2011) Methods of Testing Remote Mechanical-Draft Evaporative Refrigerant Condensers

SECTION 23 64 10 Page 1

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

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 11 (1977; R 2012) Energy Management Guide for Selection and Use of Single Phase Motors

NEMA SM 23 (1991; R 2002) Steam Turbines for Mechanical Drive Service

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 37 (2015) Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines

NFPA 54 (2015) National Fuel Gas Code

SECTION 23 64 10 Page 2

SOCIETY OF AUTOMOTIVE ENGINEERS INTERNATIONAL (SAE)

SAE J537 (2011) Storage Batteries

UNDERWRITERS LABORATORIES (UL)

UL 1236 (2006; Reprint Jul 2011) Standard for Battery Chargers for Charging Engine-Starter Batteries

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Water Chiller; G

Manufacturer's standard catalog data, at least highlighted to show material, size, options, performance charts and curves, 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.

Posted Instructions

Posted instructions, including equipment layout, wiring and control diagrams, piping, valves and control sequences, and typed condensed operation instructions. The condensed operation instructions shall include preventative maintenance procedures, methods of checking the system for normal and safe operation, and procedures for safely starting and stopping the system. The posted instructions shall be framed under glass or laminated plastic and be posted where indicated by the Contracting Officer.

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

SECTION 23 64 10 Page 3

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. The Chiller Performance Test schedule shall also allow the witnessing of the test by a Government Representative.

System Performance Tests

A schedule, at least 2 weeks prior to the start of related testing, for the system performance tests. The schedules shall identify the proposed date, time, and location for each test.

Demonstrations

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

Water Chiller - field acceptance test plan

SD-06 Test Reports

Field Acceptance Testing

Water Chiller - field acceptance test report

Factory Tests

One hard copy & one digital copy (.pdf - text searchable) of the report shall be provided. Reports shall certify the compliance with performance requirements and follow the format of the required testing standard for both the Chiller Performance Tests and the Chiller Sound Tests. Test report shall include certified calibration report of all test instrumentation. Calibration report shall include certification that all test instrumentation has been calibrated within 6 months prior to the test date, identification of all instrumentation, and certification that all instrumentation complies with requirements of the test standard.

Test report shall be submitted 1 week after completion of the factory test.

System Performance Tests

One hard copy & one digital copy (.pdf - text searchable) of the report shall be provided.

SD-07 Certificates

Refrigeration System; G

Where the system, components, or equipment are specified to comply with requirements of AGA, NFPA, ARI, 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 ARI rating conditions, computer printouts, catalog, or other application data certified by ARI or a nationally recognized laboratory as described above shall be included. If ARI does not have a current certification program that encompasses such application data, the manufacturer may self certify that his application data complies with project performance requirements in accordance with the specified test standards.

SD-08 Manufacturer's Instructions

Water Chiller - Installation Instruction; G

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G

Provide one hard copy & one digital copy (.pdf - text searchable) of an operation manual, 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. Provide one hard copy & one digital copy (.pdf - text searchable) of maintenance manual, 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.

SECTION 23 64 10 Page 5

1.5 PROJECT REQUIREMENTS

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 5 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 5 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 one hard copy & one digital copy (.pdf - text searchable) of 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

SECTION 23 64 10 Page 6 shall be attached with copper 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

Major equipment including chillers, compressors, compressor drivers, condensers, water coolers, receivers, refrigerant leak detectors, heat exchanges, fans, and motors shall have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment. Plates shall be durable and legible throughout equipment life. Plates shall be fixed in prominent locations with nonferrous screws or bolts.

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.

SECTION 23 64 10 Page 7

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, 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 11.

d. Provide motors in accordance with NEMA MG 11 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. Motor bearings shall be fitted with grease supply fittings and grease relief to outside of the enclosure.

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

f. Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers may be provided to accomplish the same function. Use solid-state variable-speed controllers for motors rated 7.45 kW (10 hp) or less and variable frequency drives for larger motors.

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 23 kg (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, or welded connections.

SECTION 23 64 10 Page 8

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

f. Compressor driver, electric motor or gas-engine

g. Compressor driver connection

h. Water cooler (evaporator)

i. Air or water-cooled condenser coil

j. Heat recovery condenser

k. Receiver

l. Tools

2.4.2 Centrifugal or Rotary Screw Type

Chiller shall be constructed and 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. Centrifugal or rotary screw compressor

f. Compressor driver, electric motor, gas-engine, or steam turbine

g. Compressor driver connection

h. Water cooler (evaporator)

i. Air or water-cooled condenser coil

j. Heat recovery condenser coil

k. Receiver

SECTION 23 64 10 Page 9

l. Purge system for chillers which operate below atmospheric pressure

m. Tools

2.5 SPLIT-SYSTEM WATER CHILLER, VAPOR COMPRESSION TYPE

Total chiller system shall be constructed and rated in accordance with ARI 550/590. Individual chiller components shall be constructed and rated in accordance with the applicable ARI standards. Chiller system shall conform to ANSI/ASHRAE 15 & 34. The chiller shall be ASHRAE 90.1 - SI ( ASHRAE 90.1 - IP) complaint and 10 CFR Part 433, 434 and 435 efficiency performance standards for federal construction. The manufacturer shall provide certification of compliance. Chiller shall be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the job site in strict accordance with manufacturer's recommendations. Unit components delivered separately shall be sealed and charged with a nitrogen holding charge. Unit assembly shall be completed in strict accordance with manufacturer's recommendations. Chiller shall operate within capacity range and speed recommended by the manufacturer. Parts weighing 50 pounds or more which must be removed for inspection, cleaning, or repair, shall have lifting eyes or lugs. Chiller shall include all customary auxiliaries deemed necessary by the manufacturer for safe, controlled, automatic operation of the equipment. Chiller's condenser and water cooler shall be provided with standard water boxes with grooved mechanical, flanged, or welded connections. Chillers shall operate at partial load conditions without increased vibration over normal vibration at full load, and shall be capable of continuous operation down to minimum capacity. 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. Receiver

f. Tools

2.5.1 Compressor-Chiller Unit

As a minimum, the compressor-chiller unit shall include the following components as defined in paragraph CHILLER COMPONENTS.

a. Scroll, reciprocating, or rotary screw compressor

b. Compressor driver, electric motor

c. Compressor driver connection

d. Water cooler (evaporator)

2.5.2 Condensing Unit

As a minimum, the condensing unit shall include the following components as defined in paragraph CHILLER COMPONENTS.

SECTION 23 64 10 Page 10

a. Scroll, reciprocating, or rotary screw compressor

b. Compressor driver, electric motor

c. Compressor driver connection

d. Air or water cooled condenser

2.5.3 Remote Water Cooler (Evaporator)

2.5.3.1 Shell and Tube Type

Cooler shall be constructed and rated in accordance with AHRI 480. Cooler shall be of the shell-and-coil or shell-and-tube type design. Cooler's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Cooler's water side shall be designed and factory pressure tested for not less than 1035 kPa (150 psi), unless otherwise indicated. 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. Cooler shall be skid-mounted. Refrigerant circuit shall be complete with liquid solenoid valve and expansion device capable of modulating to the minimum step of capacity unloading. For the water side of water cooler, performance shall be based on a water velocity not less than .91 mps (3 fps) and not more than 3.7 mps (12 fps) and a fouling factor of 0.00025. Evaporator shall be provided with electric freeze protection type.

2.5.3.2 Brazed Plate Type

Cooler shall be constructed and rated in accordance with AHRI 480. Cooler shall be of the brazed plate design. Cooler's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34.

Cooler's water side shall be designed and factory pressure tested for not less than 1035 kPa (150 psi), unless otherwise indicated. Cooler shell shall be constructed of stainless steel plates brazed together with copper. Refrigerant circuit shall be complete with liquid solenoid valve and expansion device capable of modulating to the minimum step of capacity unloading. For the water side of water cooler, performance shall be based on a water velocity not less than .91 mps (3 fps) and not more than 3.7 mps (12 fps) and a fouling factor of 0.00025. Evaporator shall be provided with electric freeze protection type.

2.5.4 Remote Air-Cooled Condenser

Condenser shall be a factory-fabricated and assembled unit, consisting of coils, fans, and condenser fan motors. Condenser shall be constructed and rated in accordance with ANSI/AHRI 460. Unless the condenser coil is completely protected through inherent design, louvered panel coil guards shall be provided by the manufacturer to prevent physical damage to the coil. Manufacturer shall certify that the condenser and associated equipment are designed for the submitted condensing temperature. For design conditions, if matched combination catalog ratings matching remote condensers to compressors are not available, the Contractor shall furnish a crossplotting of the gross heat rejection of the condenser against the

SECTION 23 64 10 Page 11 gross heat rejection of the compressor, for the design conditions to show the compatibility of the equipment furnished.

2.5.4.1 Condenser Casing

Condenser casing shall be aluminum not less than 0.040 inch or hot-dip galvanized steel not lighter than 18 gauge. Condensers having horizontal air discharge shall be provided with discharge baffle to direct air upward, constructed of the same material and thickness as the casing.

2.5.4.2 Coil

Condenser coil shall be of the extended-surface fin-and-tube type and shall be constructed of seamless copper or aluminum 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.

2.5.4.3 Fans

Fans shall be centrifugal or propeller type as best suited for the application. Fans shall be direct or V-belt driven. Belt drives shall be completely enclosed within the unit casing or equipped with a guard. When belt drive is provided, an adjustable sheave to furnish not less than 20 percent fan-speed adjustment shall be provided. Sheaves shall be selected to provide the capacity indicated at the approximate midpoint of the adjustment. Fans shall be statically and dynamically balanced.

2.5.4.4 Condenser Sizing

Size condensers for full capacity at -1.1 degrees C (30 degrees F) temperature difference between entering outside air and condensing refrigerant. Subcooling shall not be considered in determining compressor and condenser capacities. For design conditions, submit a cross-plot of net refrigeration effect of compressor to establish net refrigeration effect and compatibility of equipment furnished.

2.5.4.5 Low Ambient Control

Provide factory mounted head pressure control for operation during low ambient conditions. Head pressure shall be controlled by fan cycling, fan speed control, or condenser refrigerant flooding. Low ambient control shall permit compressor operation below -17.7 degrees C (0 degrees F).

2.5.4.6 High Ambient Unloading

Provide unloading capability to allow operation in high ambient conditions

40.6 to 51.7 degrees C (105 up to 125 degrees F) above design conditions.

2.5.5 Remote Water-Cooled Condenser

Condenser shall be a factory-fabricated and assembled unit constructed and rated in accordance with AHRI 450. Condenser shall be of the shell-and-coil or shell-and-tube type design. Condenser's refrigerant side shall be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34. Condenser's water side shall be designed and factory

SECTION 23 64 10 Page 12 pressure tested for not less than 1035 kPa (150 psi), unless otherwise indicated. Condensers shall be complete with pressure relief valve or rupture disk, water drain connections, refrigerant charging valve, refrigerant valves, liquid-level indicating devices, and stand or saddle.

Low pressure refrigerant condenser shall be provided with a purge valve located at the highest point in the condenser to purge non-condensibles trapped in the condenser. Condenser 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, except for the coaxial tubes. 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. Condenser performance shall be based on water velocities not less than .91 mps (3 fps) and not more than 3.7 mps (12 fps) and a fouling factor of 0.00025. Water-cooled condensers may be used for refrigerant storage in lieu of a separate liquid receiver, if the condenser storage capacity is 20 percent in excess of the fully charged system for remote water cooled condensers. As a minimum, the condenser shall include the following components as defined in paragraph "Chiller Components".

a. Liquid-level indicating devices.

b. Companion flanges, bolts, and gaskets for flanged water connections.

2.5.6 Remote Evaporatively-Cooled Condenser

Condenser shall be rated and tested in accordance with the requirements of ASHRAE 64. Condenser shall include fans, water pump with suction strainer, electric motor and drive equipment, water eliminators if required, condensing coil, liquid receiver if required, water pan or sump, spray nozzles or water-distribution pan, water strainer, water make-up assembly, bleeder with flow valve of the needle valve type sized for the flow required or a fixed orifice, enclosure with suitable access doors, and air-inlet and outlet openings. No water shall carry over into the unit discharge outlet.

2.5.6.1 Condenser Casing

Enclosure shall be constructed of not lighter than 18 gauge hot-dip galvanized steel or 0.080 inch aluminum, reinforced and braced. Access doors or panels suitably sized and located shall be provided for access to water nozzles or distribution pan, coils, and valves for cleaning, repair, or removal of the item. Access doors or panels shall be gasketed with synthetic rubber, or equivalent gasket material, and locked in place with thumb screws or catches. One-half inch mesh hot-dip galvanized steel or copper air-inlet screens shall be provided on each air inlet.

2.5.6.2 Refrigerant Section

Condenser coil shall be constructed of unfinned copper or steel tubes hot-dip galvanized after fabrication. The receiver shall be welded steel and shall be fitted and tested in accordance with ANSI/AHRI 495. A refrigerant charging valve shall be installed in the liquid line between the receiver cut-off valve and the expansion device. Refrigerant section shall be tested in accordance with ASHRAE 15 for the refrigerant employed in the system.

SECTION 23 64 10 Page 13

2.5.6.3 Fans

Fans shall be centrifugal or propeller type as best suited for the application. Fans shall be direct or V-belt driven. Belt drives shall be completely enclosed within the unit casing or equipped with a guard. When belt drive is provided, an adjustable sheave to furnish not less than 20 percent fan-speed adjustment shall be provided. Sheaves shall be selected to provide the capacity indicated at the approximate midpoint of the adjustment. Fans shall be statically and dynamically balanced. Fan motor shall be totally enclosed type or open drip-proof and located within an enclosure to be fully protected from the weather.

2.5.6.4 Water Section

Water eliminators shall be constructed of nonferrous metal, of an approved nonmetallic material, or of not lighter than 24 gauge steel, hot-dip galvanized after fabrication. Spray nozzles shall be brass nonclogging type designed to permit easy disassembly, and shall be arranged for easy access. Water pump shall be bronze-fitted centrifugal or turbine type, and may be mounted as an integral part of the evaporative condenser or remotely on a separate mounting pad. Pump suction shall be fully submerged and provided with screened inlet. Water pan or sump shall be constructed of not lighter than 14 gauge steel, hot-dip galvanized after fabrication, or molded acid-resistant glass-fiber-reinforced polyester.

Water distribution pan shall be constructed of not lighter than 16 gauge steel, hot-dip galvanized after fabrication. Joints shall be watertight.

Water pan or sump shall be provided with drain, overflow, and make-up water connection with stop valve and float valve. A bleed line with a flow valve of the needle type sized for the flow required or fixed orifice shall be provided in the pump discharge line and shall be extended to the nearest drain for continuous discharge.

2.6 CHILLER COMPONENTS

2.6.1 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 shall have an Ozone Depletion Potential (ODP) of 0.055 or less. Refrigerants classified by the EPA as Class 2 shall not be allowed with the exception of R-123. The ODP shall be in accordance with the "Montreal Protocol On Substances That Deplete The Ozone Layer," September 1987, as amended through 2000, sponsored by the United Nations Environment Programme.

2.6.2 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.

2.6.3 Chiller Refrigerant Circuit

Chiller refrigerant circuit shall be completely piped and factory leak

SECTION 23 64 10 Page 14 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, charging ports, compressor service valves for field-serviceable compressors, and superheat adjustment.

2.6.4 Controls Package

Chiller shall be provided with a complete factory-mounted or remote-mounted, as indicated, 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, motor starters, disconnect switches, power wiring, and control wiring.

Controls package shall provide operating controls, monitoring capabilities, programmable set-points, safety controls, and EMCS interfaces as defined below.

2.6.4.1 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

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. Fan sequencing for air-cooled condenser

2.6.4.2 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

SECTION 23 64 10 Page 15

h. Oil pressure

i. Condenser water entering and leaving temperatures

j. Number of purge cycles over the last 7 days

2.6.4.3 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

b. Leaving Condenser Water Temperature

c. Time Clock/Calendar Date

2.6.4.4 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

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. Motor current overload and phase loss protection

2.6.4.5 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. Phase reversal protection

2.6.4.6 Remote Alarm

During the initiation of a safety shutdown, a chiller's control system shall be capable of activating a remote alarm bell. In coordination with the chiller, the Contractor shall provide an alarm circuit (including transformer if applicable) and a minimum 100 mm (4 inch) diameter alarm bell. Alarm circuit shall activate bell in the event of machine shutdown due to the chiller's monitoring of safety controls. The alarm bell shall not sound for a chiller that uses low-pressure cutout as an operating

SECTION 23 64 10 Page 16 control.

2.6.4.7 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

c. Remote Condenser Water Reset

2.6.5 Compressor(s)

2.6.5.1 Reciprocating Compressor(s)

Rotating parts shall be statically and dynamically balanced at the factory to minimize vibration. Compressors shall be capable of operating at partial-load conditions without increased vibration over the normal vibration at full load operation and shall be capable of continuous operation down to the lowest step of unloading as specified. Compressors of size 7.45 kW (10 horsepower) and above shall have an oil lubrication system of the reversible, forced-feed type with oil strainer. Shaft seal in open-type units shall be mechanical type. Piston speed for open-type compressors shall not exceed the manufacturer's recommendation or 6 m/s (1200 fpm), whichever is less. Compressors shall include:

a. Vertical, V, W, or radial cylinder design

b. Oil lubrication

c. Integrally cast block of close-grained iron or cast aluminum block with hardened steel cylinder sleeves

d. Oil-level bull's eye

e. Cast cylinder heads

f. Cast-aluminum or forged-steel connecting rods

g. Cast iron or forged-steel crankshaft

h. Main bearings of the sleeve-insert type

i. Crankcase oil heaters controlled as recommended by the manufacturer

j. Suction and discharge refrigerant service valves that are flange connected, wrench operated, with cap

k. A strainer on the suction side of the compressor

l. A hot-gas muffler to reduce vibration and noise from pulsations

SECTION 23 64 10 Page 17

2.6.5.2 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.

2.6.5.3 Rotary Screw Compressor(s)

Compressors shall operate stably for indefinite time periods at any stage of capacity reduction without hot-gas bypass. Provision shall be made to insure proper lubrication of bearings and shaft seals on shutdown with or without electric power supply. Rotary screw compressors shall include:

a. An open or hermetic, positive displacement, oil-injected design directly driven by the compressor driver. Compressor shall allow access to internal compressor components for repairs, inspection, and replacement of parts.

b. Rotors shall be solid steel, possessing sufficient rigidity for proper operation.

c. A maximum rotor operating speed no greater than 3600 RPM. provide cast iron rotor housing

d. Casings of cast iron, precision machined for minimal clearance about periphery of rotors with minimal clearance at rotor tops and rotor ends.

e. A lubrication system of the forced-feed type that provides oil at the proper pressure to all parts requiring lubrication.

f. Bearing housing shall be conservatively loaded and rated for an L(10) life of not less than 200,000 hours. Shaft main bearings of the sleeve type with heavy duty bushings or rolling element type in accordance with ABMA 9 or ABMA 11.

g. A differential oil pressure or flow cutout to allow the compressor to operate only when the required oil pressure or flow is provided to the bearings.

h. A temperature- or pressure-initiated, hydraulically actuated, single-slide-valve, capacity-control system to provide minimum automatic capacity modulation from 100 percent to 15 percent.

i. An oil separator and oil return system to remove oil entrained in the refrigerant gas and automatically return the oil to the compressor.

j. Crankcase oil heaters controlled as recommended by the manufacturer.

2.6.5.4 Centrifugal Compressor(s)

Centrifugal compressors shall be single or multistage, having dynamically balanced impellers, either direct or gear driven by the compressor driver. Impellers shall be over-speed tested at 1.2 times the

SECTION 23 64 10 Page 18 impeller-shaft speed. Impeller shaft shall be heat-treated alloy steel with sufficient rigidity for proper operation at any required operating speed. Centrifugal compressors shall include:

a. Shaft main bearings that are the rolling element type in accordance with ABMA 9 or ABMA 11, journal type with bronze or babbitt liners, or of the aluminum-alloy one-piece insert type. Bearings shall be rated for an L(10) life of not less than 200,000 hours.

b. Casing of cast iron, aluminum, or steel plate with split sections gasketed and bolted or clamped together.

c. Lubrication system of the forced-feed type that provides oil at the proper pressure to all parts requiring lubrication.

d. Provisions to ensure proper lubrication of bearings and shaft seals prior to starting and upon stopping with or without electric power supply. On units providing forced-feed lubrication prior to starting, a differential oil pressure cutout interlocked with the compressor starting equipment shall allow the compressor to operate only when the required oil pressure is provided to the bearings.

e. Oil sump heaters controlled as recommended by the manufacturer.

f. Temperature-or pressure-actuated prerotation vane or suction damper to provide automatic capacity modulation from 100 percent capacity to 10 percent capacity. If operation to 10 percent capacity cannot be achieved without providing hot-gas bypass, then the Contractor shall indicate in the equipment submittal the load percent at which hot gas bypass is required.

2.6.6 Compressor Driver, Electric Motor

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

2.6.7 Compressor Driver, Gas-Engine

Gas-engine compressor driver shall operate on natural gas and be in accordance with NFPA 37 and NFPA 54. Engine shall be designed for stationary applications and include all ancillaries necessary for operation. Engine shall be a manufacturer's standard production model and be specifically designed for chiller operation. Engine shall include as a minimum a heavy duty industrial or standard automotive grade block, starting system, lubrication system, coolant system, engine heat exchanger, engine cooling radiator, fuel supply system, electronic ignition, and controls package. Engine shall be naturally aspirated, supercharged, or turbocharged and include appropriate air filters. Engine shall be 2- or 4-stroke-cycle and compression-ignition type. Engine shall be vertical in-line, V- or opposed-piston type, with a solid cast block or individually cast cylinders. Engine shall have a minimum of 2 cylinders.

Opposed-piston type engines shall have not less than 4 cylinders. Engine block shall have a coolant drain port.

SECTION 23 64 10 Page 19

2.6.7.1 Starting System

Engine starting system shall be the electric type, unless otherwise indicated, and be of sufficient capacity, at the maximum temperature specified, to crank the engine without damage or overheating. Electric starting system shall operate on a 24-volt DC system utilizing a negative circuit ground. A starting battery system shall be provided and shall include the battery, corrosion resistant battery rack, intercell connectors, spacers, automatic battery charger with overcurrent protection, metering and relaying. Battery shall be in accordance with SAE J537. Battery charger shall conforming to UL 1236 and be the current-limiting type with overcurrent protection. Pneumatic starting system, if indicated, shall be as specified in Section 22 00 00 PLUMBING, GENERAL PURPOSE, for a working pressure of 1.03 MPa (150 psi).

2.6.7.2 Lubrication System

Engine shall be provided with a pressurized oil lubrication system.

System shall include a lubrication oil pump that is engine driven. One full-flow filter shall be provided for each pump. Filters shall be readily accessible and capable of being changed without disconnecting the piping or disturbing other components. System pressure shall be regulated as recommended by the engine manufacturer. A pressure relief valve shall be provided on the crankcase. Crankcase breathers shall be piped to the outside. System shall be readily accessible for servicing such as draining, refilling, and overhauling.

2.6.7.3 Coolant System

Engine shall include an automatic engine jacket water cooling system.

Water shall be circulated through the system with an engine-driven circulating pump. System coolant shall use a combination water and ethylene-glycol sufficient for freeze protection at the minimum temperature specified.

2.6.7.4 Engine Heat Exchanger

Engine heat exchanger shall be of the shell-and-tube type construction and be in accordance with ASME BPVC SEC VIII D1. Shell material shall be carbon steel. Tubes shall be seamless copper or copper-nickel. Tubes shall be individually replaceable. Unit's waterside working pressure shall be rated for not less than 1,000 kPa (150 psig) and factory tested at 150 percent of design working pressure. Water connections larger than 75 mm (3 inches) shall be ASME Class 1500 flanged. Unit shall be provided with gasketed removable covers, drains, and vents.

2.6.7.5 Engine Cooling Radiator

Heat exchanger may be factory coated with corrosive resistant film, provided that correction measures are taken to restore the heat rejection capability of the radiator to the initial design requirement via over sizing, or other compensating methods. Internal surfaces shall be compatible with liquid fluid coolant used. Materials and coolant are subject to approval by the Contracting Officer. Heat exchangers shall be the pressure type incorporating a pressure valve, vacuum valve and a cap.

Caps shall be designed for pressure relief prior to removal. Each heat exchanger and the entire cooling system shall be capable of withstanding a minimum pressure of 48 kPa (7 psi) and shall be protected with a strong grille or screen guard. Each heat exchanger shall have at least 2 tapped

SECTION 23 64 10 Page 20 holes; one shall be equipped with a drain cock, the rest shall be plugged.

2.6.7.6 Fuel Supply System

Engine fuel supply system shall be factory mounted. System shall include as a minimum a solenoid shut-off valve, a gas pressure regulator, and carburetors (including a throttle body assembly) or fuel injectors.

2.6.7.7 Controls Package

The controls for the gas-engine shall be incorporated into the overall controls package for the water chiller. The engine controls shall be capable of monitoring, displaying, and controlling, as applicable, the following conditions.

a. Coolant-fluid inlet and outlet temperatures

b. Lubricating-oil inlet and outlet temperatures and pressures

c. Engine run-time hours

d. Engine current status mode (on/off)

e. Engine speed

f. Percent engine load

g. Engine jacket temperature

2.6.7.8 Exhaust Piping

Exhaust piping shall be ASTM A53/A53M Schedule 40 seamless black iron, exhaust piping installation shall be per the engine manufacturer's recommendations, except as modified herein. Horizontal sections of exhaust piping shall be sloped downward away from the engine to a drip leg for collection of condensate with drain valve and cap. Changes in direction shall be long radius.