23 64 10 Am-0002.pdf

HVAC Heat Pump Piping and Components Upgrade - Oahe Dam, SD OA00107

SECTION TABLE OF CONTENTS

DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING (HVAC)

SECTION 23 64 10

WATER TO WATER HEAT PUMPS, VAPOR COMPRESSION TYPE

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 CERTIFICATIONS

1.3.1 Ozone Depleting Substances Technician Certification

1.4 SAFETY REQUIREMENTS

1.5 DELIVERY, STORAGE, AND HANDLING

1.6 SYSTEM DESCRIPTION

1.6.1 General

1.6.2 Operating Conditions

1.7 PROJECT REQUIREMENTS

1.7.1 Verification of Dimensions

PART 2 PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

2.2 MANUFACTURER'S STANDARD NAMEPLATES

2.3 ELECTRICAL WORK

2.4 SELF-CONTAINED HEAT PUMPS, VAPOR COMPRESSION TYPE

2.4.1 Scroll, Reciprocating, or Rotary Screw Type

2.5 HEAT PUMP COMPONENTS

2.5.1 Refrigerant and Oil

2.5.2 Structural Base

2.5.3 Heat Pump Refrigerant Circuit

2.5.4 Controls Package

2.5.4.1 Operating Controls

2.5.4.2 Monitoring Capabilities

2.5.4.3 Configurable Setpoints

2.5.4.4 Safety Controls with Manual Reset

2.5.4.5 Safety Controls with Automatic Reset

2.5.4.6 Remote Alarm

2.5.5 Compressor(s)

2.5.5.1 Scroll Compressor(s)

2.5.5.2 Rotary Screw Compressor(s)

2.5.6 Compressor Driver, Electric Motor

2.5.7 Compressor Driver Connections

2.5.8 Water Cooler (Evaporator)

2.5.9 Water-Cooled Condenser Coil

2.5.10 Tools

2.6 ACCESSORIES

2.6.1 Refrigerant Leak Detector

2.6.2 Refrigerant Relief Valve/Rupture Disc Assembly

2.6.3 Refrigerant Signs

2.6.3.1 Installation Identification

2.6.3.2 Controls and Piping Identification

SECTION 23 64 10 Page 1

Am-0002

2.6.4 Gaskets

2.6.5 Bolts and Nuts

2.7 FABRICATION

2.7.1 Factory Coating

2.7.2 Factory Applied Insulation

2.8 CAPACITY REQUIREMENTS

2.8.1 Cooling Mode

2.8.2 Heating Mode

2.9 FACTORY TESTS

2.9.1 Heat Pumps Performance Test

2.9.1.1 Temperature Adjustments

2.9.1.2 Test Instrumentation

2.9.1.3 Equipment Adjustments

2.9.2 Heat Pumps Sound Test

2.10 SUPPLEMENTAL COMPONENTS/SERVICES

2.10.1 Chilled and Condenser Water Piping and Accessories

2.10.2 Temperature Controls

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Installation Instructions

3.1.2 Vibration Isolation

3.1.3 Posted Instructions

3.1.4 Verification of Dimensions

3.1.5 System Performance Test Schedules

3.1.6 Certificates

3.1.7 Operation and Maintenance Manuals

3.1.8 Connections to Existing Systems

3.1.9 Refrigeration System

3.1.9.1 Equipment

3.1.9.2 Field Refrigerant Charging

3.1.9.3 Oil Charging

3.1.10 Mechanical Room Ventilation

3.1.11 Field Applied Insulation

3.1.12 Field Painting

3.2 FACTORY TEST SCHEDULING AND REPORTS

3.3 MANUFACTURER'S FIELD SERVICE

3.4 CLEANING AND ADJUSTING

3.5 FIELD ACCEPTANCE TESTING

3.5.1 Test Plans

3.5.2 Testing

3.6 SYSTEM PERFORMANCE TESTS

3.6.1 General Requirements

3.6.2 Test Report

3.7 OPERATION AND MAINTENANCE

3.7.1 Operation and Maintenance Manuals

3.7.2 Operation And Maintenance Training

-- End of Section Table of Contents --

SECTION 23 64 10 Page 2

SECTION 23 64 10

WATER TO WATER HEAT PUMPS, 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 550/590 I-P (2020) Performance Rating Of Water-Chilling and Heat Pump Water-Heating Packages Using the Vapor Compression Cycle

AHRI 575 (2017) Method of Measuring Machinery Sound Within an Equipment Space

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 9 (2015) Load Ratings and Fatigue Life for Ball Bearings

ABMA 11 (2014) Load Ratings and Fatigue Life for Roller Bearings

AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING

ENGINEERS (ASHRAE)

ANSI/ASHRAE 15 & 34 (2022) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

ASHRAE 90.1 - IP (2019) Energy Standard for Buildings Except Low-Rise Residential Buildings

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME BPVC SEC VIII D1 (2019) BPVC Section VIII-Rules for Construction of Pressure Vessels Division 1

AMERICAN WELDING SOCIETY (AWS)

AWS Z49.1 (2021) Safety in Welding and Cutting and Allied Processes

ASTM INTERNATIONAL (ASTM)

ASTM A307 (2021) Standard Specification for Carbon Steel Bolts, Studs, and Threaded Rod 60 000 PSI Tensile Strength

SECTION 23 64 10 Page 3

ASTM B117 (2019) Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM E84 (2023) Standard Test Method for Surface Burning Characteristics of Building Materials

ASTM F104 (2011; R 2020) Standard Classification System for Nonmetallic Gasket Materials

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2021) Motors and Generators

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

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

40 CFR 82 Protection of Stratospheric Ozone

1.2 SUBMITTALS

Government approval is required for submittals with a "G" classification.

Submittals not having a "G" classification are for information only. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Heat Pumps; G , DO

Posted Instructions; G , DO

Refrigerant; G , DO

Heat Pumps - Field Acceptance Test Plan; G , DO

SD-06 Test Reports

Field Acceptance Testing; G , DO

Heat Pumps - Field Acceptance Test Report; G , DO

Factory Tests; G , DO

System Performance Tests; G , DO

SD-07 Certificates

Refrigeration System; G , DO

SD-08 Manufacturer's Instructions e

Heat Pumps - Installation Instructions; G , PO

SECTION 23 64 10 Page 4

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G , PO

Operation And Maintenance Training; G , PO

1.3 CERTIFICATIONS

1.3.1 Ozone Depleting Substances Technician Certification

All technicians working on equipment that contain ozone depleting refrigerants must be certified as a Section 608 Technician to meet requirements in 40 CFR 82 , Subpart F.

1.4 SAFETY REQUIREMENTS

Exposed moving parts, parts that produce high operating temperature, parts which may be electrically energized, and parts that may be a hazard to operating personnel must be insulated, fully enclosed, guarded, or fitted with other types of safety devices. Safety devices must be installed so that proper operation of equipment is not impaired. Welding and cutting safety requirements must be in accordance with AWS Z49.1 .

1.5 DELIVERY, STORAGE, AND HANDLING

Stored items must be protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Proper protection and care of all material both before and during installation will be the Contractor's responsibility. Any materials found to be damaged must be replaced at the Contractor's expense. During installation, piping and similar openings must be capped to keep out dirt and other foreign matter.

1.6 SYSTEM DESCRIPTION

1.6.1 General

This specification covers the provisions and procedures necessary for the removal of two (2) existing water-to-water heat pumps (180 tons each) and the installation of two(2) new water-to-water heat pumps with the same capacity (referred to as "heat pumps" throughout the remainder of this specification) and associated ancillary items necessary to provide a complete and functional system. The heating and cooling system must remain functional throughout the duration of work required by the contract.

Therefore the Contractor will be allowed to remove and replace only one heat pump at a time. The Contracting Officers Representative (COR) will designate the order in which the unit (s) are to be removed and replaced.

1.6.2 Operating Conditions

The heat pumps function as part of the Powerhouse heating and cooling system, which utilizes raw water from the adjacent lake. Therefore water on both the evaporator and condenser side of the heat pumps is considered to be "raw" water. This water is strained and filtered, but will still contain dirt and grit. In addition the water is not chemically treated and has not had any oxygen removed. The temperature of the water supplied from the lake will vary throughout the year (approx. 35 F to 80 F). Depending on the season, the heat pumps are used to produce heating or cooling water that is circulated through air handling unit water coils. During the heating season water from the heat pump condenser is circulated through

SECTION 23 64 10 Page 5 the air handling unit coils. During the cooling season water from the heat pump evaporator is circulated through the air handling unit coils.

Changing water flow from the evaporator to the condenser and back is accomplished through the use of external valves located in the heating and cooling system piping. As such, reversing of the refrigeration cycle in the heat pumps is not required.

1.7 PROJECT REQUIREMENTS

1.7.1 Verification of Dimensions

The Contractor must 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.

PART 2 PRODUCTS

2.1 STANDARD COMMERCIAL PRODUCTS

Materials and equipment will 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 must have a two year record of satisfactory field service prior to bid opening. The two year record of service must 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 will be acceptable if a certified record of satisfactory field service for not less than 6000 hours can be shown. The 6000 hour service record must not include any manufacturer's prototype or factory testing. Satisfactory field service must 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 heat pumps, compressors, compressor drivers, condensers, water coolers, receivers, refrigerant leak detectors, heat exchanges, fans, and motors must have the manufacturer's name, address, type or style, model or serial number, and catalog number on a plate secured to the item of equipment. Plates must be durable and legible throughout equipment life. Plates must be fixed in prominent locations with nonferrous screws or bolts.

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 the operation specified and control wiring required for controls and devices specified, but not shown, must be provided. For packaged equipment, the manufacturer must provide controllers including the required monitors and timed restart.

b. For single-phase motors, provide high-efficiency type, fractional-horsepower alternating-current motors, including motors

SECTION 23 64 10 Page 6 that are part of a system, in accordance with NEMA MG 11.

c. For polyphase motors, provide squirrel-cage medium induction motors, including motors that are part of a system, and that meet the efficiency ratings for premium efficiency motors in accordance with

NEMA MG 1.

d. Provide motors in accordance with NEMA MG 1 and of sufficient size to drive the load at the specified capacity without exceeding the nameplate rating of the motor. Motors must be rated for continuous duty with the enclosure specified. Motor duty requirements must allow for maximum frequency start-stop operation and minimum encountered interval between start and stop. Motor torque must be capable of accelerating the connected load within 20 seconds with 80 percent of the rated voltage maintained at motor terminals during one starting period. Provide motor starters complete with thermal overload protection and other necessary appurtenances.Motor enclosure type may be either TEAO or TEFC.

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

[Am#002*]

f. The Minimum required SCCR for the Heat Pumps is 11,000A.

[Am#002**]

2.4 SELF-CONTAINED HEAT PUMPS, VAPOR COMPRESSION TYPE

Unless necessary for delivery purposes, units must be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the factory.

In lieu of delivery constraints, heat pumps may be assembled, leak-tested, charged (refrigerant and oil), and adjusted at the job site by a factory representative. Unit components delivered separately must be sealed and charged with a nitrogen holding charge. Parts weighing 50 pounds or more which must be removed for inspection, cleaning, or repair, such as motors, gear boxes, cylinder heads, casing tops, condenser, and cooler heads, must have lifting eyes or lugs. Each heat pump must be provided with a single point wiring connection for incoming power supply. Heat pump's condenser and water cooler must be provided with standard water boxes with grooved mechanical, flanged, or welded connections.

2.4.1 Scroll, Reciprocating, or Rotary Screw Type

Heat pumps must be certified for performance per AHRI 550/590 I-P and minimum efficiency requirements per ASHRAE 90.1 - IP . Each heat pump must have two (2) compressors. If specified performance is outside of the Application Rating Conditions of AHRI 550/590 I-P , Table 2 then the heat pump's performance must be rated in accordance with AHRI 550/590 I-P .

heat pumps must conform to ANSI/ASHRAE 15 & 34 . As a minimum, heat pumps must include the following components as defined in paragraph HEAT PUMP

COMPONENTS.

a. Refrigerant and oil

b. Structural base

c. Heat pump refrigerant circuit

SECTION 23 64 10 Page 7

d. Controls package

e. Scroll, reciprocating, or rotary screw compressor

f. Compressor driver, electric motor

g. Compressor driver connection

h. Water cooler (evaporator)

i. Water-cooled condenser coil

j. Tools

2.5 HEAT PUMP COMPONENTS

2.5.1 Refrigerant and Oil

Refrigerants must be R-513a refrigerant (A1 Refrigerant). Refrigerants must have number designations and safety classifications in accordance with ANSI/ASHRAE 15 & 34 . CFC-based refrigerants are prohibited.

Refrigerants must have an Ozone Depletion Potential (ODP) no greater than

0.0 R-123 is prohibited. Provide SDS sheets for all refrigerants.

2.5.2 Structural Base

Heat pumps and individual heat pump components must be provided with a factory-mounted structural steel base (welded or bolted) or support legs. Heat pump and individual heat pump components must be isolated from the building structure by means of molded neoprene isolation pads.

2.5.3 Heat Pump Refrigerant Circuit

Heat pump refrigerant circuit must be completely piped and factory leak tested in accordance with ANSI/ASHRAE 15 & 34 . For multicompressor units, not less than 2 independent refrigerant circuits must be provided.

Circuit must include as a minimum a combination filter and drier, combination sight glass and moisture indicator, an electronic or thermostatic expansion valve with external equalizer or float valve, charging ports, compressor service valves for field-serviceable compressors, and superheat adjustment.

2.5.4 Controls Package

Provide heat pumps with a complete factory-mounted, microprocessor based operating and safety control system. Controls package must contain as a minimum a digital display, an on-auto-off switch, motor starters, variable frequency motor controller, disconnect switches, power wiring, and control wiring. Controls package must provide operating controls, monitoring capabilities, programmable setpoints, and safety controls as defined below. Heat pump control system, items, devices, instrumentations, components including software / applications must meet all cybersecurity requirements specified in specification section 25 05 11.00 28.

2.5.4.1 Operating Controls

Heat pumps must be provided with the following adjustable operating controls as a minimum.

SECTION 23 64 10 Page 8

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 must automatically re-cycle the heat pumps on power interruption.

f. Startup and head pressure controls to allow system operation at all ambient temperatures down to 40 degrees F.

2.5.4.2 Monitoring Capabilities

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

a. Entering and leaving chilled water temperatures

b. Entering and leaving chilled water pressure and flow

c. Entering and leaving condenser water pressure and Condenser water flow

d. Self diagnostic

e. Operation status

f. Operating hours

g. Number of starts

h. Compressor status (on or off)

i. Compressor load (percent)

j. Refrigerant discharge and suction pressures

k. Magnetic bearing levitation status (if applicable)

l. Magnetic bearing temperatures (if applicable)

m. Oil pressure

n. Condenser water entering and leaving temperatures

o. Number of purge cycles over the last 7 days

2.5.4.3 Configurable Setpoints

The control system must be capable of being configured directly at the unit's interface panel. No parameters may be capable of being changed without first entering a security access code. The programmable setpoints must include the following as a minimum:

SECTION 23 64 10 Page 9

a. Leaving Chilled Water Temperature

b. Leaving Condenser Water Temperature

c. Time Clock/Calendar Date

2.5.4.4 Safety Controls with Manual Reset

Heat pumps must be provided with the following safety controls which automatically shutdown the heat pumps 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. Magnetic bearing controller (MBC), Internal fault (if applicable)

h. MBC, High bearing temperature (if applicable)

i. MBC, Communication fault (if applicable)

j. MBC, Power supply fault (if applicable)

k. Motor current overload and phase loss protection

2.5.4.5 Safety Controls with Automatic Reset

Heat pumps must be provided with the following safety controls which automatically shutdown the heat pumps and which provide automatic reset.

a. Over/under voltage protection

b. Chilled water flow interlock

c. MBC, Vibration (if applicable)

d. MBC, No levitation (if applicable)

e. Phase reversal protection

2.5.4.6 Remote Alarm

During the initiation of a safety shutdown, a heat pump's control system must be capable of activating a remote alarm bell. In coordination with the heat pump, the Contractor must provide an alarm circuit (including transformer if applicable) and a minimum 4 inch diameter alarm bell.

Alarm circuit must activate bell in the event of machine shutdown due to the heat pump's monitoring of safety controls. The alarm bell must not sound for a heat pump that uses low-pressure cutout as an operating control.

SECTION 23 64 10 Page 10

2.5.5 Compressor(s)

2.5.5.1 Scroll Compressor(s)

Compressors must be of the hermetically sealed design. Compressors must be mounted on vibration isolators to minimize vibration and noise.

Rotating parts must be statically and dynamically balanced at the factory to minimize vibration. Lubrication system must be centrifugal pump type equipped with a means for determining oil level and an oil charging valve. Crankcase oil heater must be provided. Provide continuous compressor unloading to 10 percent of full-load capacity by way of variable speed compressor motor controller or variable unloading of the scroll.

2.5.5.2 Rotary Screw Compressor(s)

Compressors must operate stably for indefinite time periods to at least 25 percent capacity reduction without gas bypass external to the compressor.

Provision must be made to insure proper lubrication of bearings and shaft seals on shutdown with or without electric power supply. Rotary screw compressors must include:

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

b. Rotors must 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 must 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 must be provided.

SECTION 23 64 10 Page 11

2.5.6 Compressor Driver, Electric Motor

Components such as motors, starters, and wiring must be in accordance with paragraph ELECTRICAL WORK. Motor starter must be unit mounted as indicated with starter type, wiring, and accessories coordinated with the heat pump manufacturer.

2.5.7 Compressor Driver Connections

Each compressor must be driven by a V-belt drive or direct connected through a flexible coupling, except that flexible coupling is not required on hermetic units. V-belt drives must be designed for not less than 150 percent of the driving motor capacity. Flexible couplings must be of the type that does not require lubrication. Each machine driven through speed-increasing gears must be so designed as to assure self-alignment, interchangeable parts, proper lubrication system, and minimum unbalanced forces. Bearings must be of the sleeve or roller type. Gear cases must be oil tight. Shaft extensions must be provided with seals to retain oil and exclude all dust.

2.5.8 Water Cooler (Evaporator)

Cooler must be of the shell-and-coil or shell-and-tube type design.

Cooler shell must be constructed of seamless or welded steel. Coil bundles must be totally removable and arranged to drain completely. Tubes must be seamless [Am#001*] copper, plain, copper-nickel[Am#001**] integrally finned with smooth bore or integrally finned with enhanced bore. Each tube must be individually replaceable. Tubes must be installed into carbon mild steel tube sheets by rolling. Tube baffles must be properly spaced to provide adequate tube support and cross flow. Performance must be based on a water velocity not less than 3 fps nor more than 12 fps and a fouling factor per AHRI 550/590 I-P .

Brazed plate heat exchanger must be constructed of 304 or 316 stainless steel, designed to a refrigerant-side working pressure of 430 psig and a waterside working pressure of 150 psig. Evaporator must be factory tested at 1.1 times maximum allowable refrigerant side working pressure and 1.5 times maximum allowable water side working pressure. Provide cooler with factory-installed flow switches. All water connections must use either flanged or grooved-pipe connections. Factory insulate all cold surfaces.

2.5.9 Water-Cooled Condenser Coil

Condenser must be of the shell-and-coil or shell-and-tube type design.

Condenser's refrigerant side must be designed and factory pressure tested to comply with ANSI/ASHRAE 15 & 34 . Condenser's water side must be designed and factory pressure tested for not less than 150 psi.

Condensers must be complete with refrigerant relief valve/rupture disc assembly, water drain connections, and refrigerant charging valve. Low pressure refrigerant condenser must be provided with a purging device to purge non-condensibles trapped in the condenser while keeping refrigerant emissions below requirements of ASHRAE Std 147. Purge units must be certified per AHRI 580. Condenser shell must be constructed of seamless or welded steel. Coil bundles must be totally removable and arranged to drain completely. Tubes must be seamless copper, plain, [Am#001*]copper-nickel[Am#001**] integrally finned with smooth bore or integrally finned with enhanced bore. Each tube must be individually replaceable, except for the coaxial tubes. Tube baffles must be properly spaced to provide adequate tube support and cross flow. Performance must

SECTION 23 64 10 Page 12 be based on water velocities not less than 3 fps nor more than 12 fps and a fouling factor per AHRI 550/590 I-P . Water-cooled condensers may be used for refrigerant storage in lieu of a separate liquid receiver, if the condenser storage capacity is 5 percent in excess of the fully charged system for single packaged systems.

2.5.10 Tools

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

2.6 ACCESSORIES

2.6.1 Refrigerant Leak Detector

Detector must be the continuously-operating, halogen-specific type.

Detector must be appropriate for the refrigerant in use. Detector must be specifically designed for area monitoring and must include a single sampling point installed where indicated. Detector design and construction must be compatible with the temperature, humidity, barometric pressure and voltage fluctuations of the operating area. Detector must have an adjustable sensitivity such that it can detect refrigerant at or above 3 parts per million (ppm). Detector must be supplied factory-calibrated for the appropriate refrigerant(s). Detector must be provided with an alarm relay output which energizes when the detector detects a refrigerant level at or above the TLV-TWA (or toxicity measurement consistent therewith) for the refrigerant(s) in use. The detector's relay must be capable of initiating corresponding alarms and ventilation systems as indicated on the drawings. Detector must be provided with a failure relay output that energizes when the monitor detects a fault in its operation.

2.6.2 Refrigerant Relief Valve/Rupture Disc Assembly

The assembly must be a combination pressure relief valve and rupture disc designed for refrigerant usage. The assembly must be in accordance with ASME BPVC SEC VIII D1 and ANSI/ASHRAE 15 & 34 . The assembly must be provided with a pressure gauge assembly which will provide local indication if a rupture disc is broken. Rupture disc must be the non-fragmenting type.

2.6.3 Refrigerant Signs

Refrigerant signs must be a medium-weight aluminum type with a baked enamel finish. Signs must be suitable for indoor or outdoor service.

Signs must have a white background with red letters not less than 0.5 inches in height.

2.6.3.1 Installation Identification

Each new refrigerating system must be provided with a refrigerant sign which indicates the following as a minimum:

a. Contractor's name.

b. Refrigerant number and amount of refrigerant.

SECTION 23 64 10 Page 13

c. The lubricant identity and amount.

d. Field test pressure applied.

2.6.3.2 Controls and Piping Identification

Refrigerant systems containing more than 110 lb of refrigerant must be provided with refrigerant signs which designate the following as a minimum:

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

b. Pressure limiting device(s).

2.6.4 Gaskets

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

2.6.5 Bolts and Nuts

Bolts and nuts, except as required for piping applications, must be in accordance with ASTM A307. The bolt head must be marked to identify the manufacturer and the standard with which the bolt complies in accordance with ASTM A307.

2.7 FABRICATION

2.7.1 Factory Coating

Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, must be factory finished with the manufacturer's standard finish, except that items located outside of buildings must have weather resistant finishes that will withstand 500 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution. Immediately after completion of the test, the specimen must show no signs of blistering, wrinkling, cracking, or loss of adhesion and no sign of rust creepage beyond 1/8 inch on either side of the scratch mark. Cut edges of galvanized surfaces where hot-dip galvanized sheet steel is used must be coated with a zinc-rich coating conforming to ASTM D520, Type I.

2.7.2 Factory Applied Insulation

Heat pumps must be provided with factory installed insulation on surfaces subject to sweating including the water cooler, suction line piping, economizer, and cooling lines. Insulation on heads of coolers may be field applied, however it must be installed to provide easy removal and replacement of heads without damage to the insulation. Where motors are the gas-cooled type, factory installed insulation must be provided on the cold-gas inlet connection to the motor per manufacturer's standard practice. Factory insulated items installed outdoors are not required to be fire-rated. As a minimum, factory insulated items installed indoors must have a flame spread index no higher than 75 and a smoke developed index no higher than 150. Factory insulated items (no jacket) installed indoors and which are located in air plenums, in ceiling spaces, and in attic spaces must have a flame spread index no higher than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes must be determined by ASTM E84. Insulation must be tested in the

SECTION 23 64 10 Page 14 same density and installed thickness as the material to be used in the actual construction. Material supplied by a manufacturer with a jacket must be tested as a composite material. Jackets, facings, and adhesives must have a flame spread index no higher than 25 and a smoke developed index no higher than 50 when tested in accordance with ASTM E84.

2.8 CAPACITY REQUIREMENTS

2.8.1 Cooling Mode

With the heat pumps operating in the cooling mode, each heat pump shall provide a nominal capacity of 2,160,000 btu/hr with an evaporator water flow rate of 430 gpm, a condenser water flow rate of 430 gpm, an evaporator entering water temperature of 55 degrees F and a condenser entering water temperature of 80 degrees F. Due to fluctuations in the temperature of the lake water used as condenser water, the condenser water can be as low as 50 degrees F. Factory installed controls shall be capable of adjusting the operation of the heat pumps to compensate for the condenser water temperature.

2.8.2 Heating Mode

With the heat pumps operating in the heating mode, each heat pump shall provide a nominal capacity of 3,225,000 btu/hr with an evaporator water flow rate of 430 gpm, a condenser water flow rate of 430 gpm, an evaporator leaving water temperature of 40 degrees F, a condenser entering water temperature of 95 degrees F and a condenser leaving water temperature of 110 degrees F.

2.9 FACTORY TESTS

2.9.1 Heat Pumps Performance Test

The Contractor and proposed heat pump manufacturer must be responsible for performing the heat pump factory test to validate the specified full load capacity, full load EER, and IPLV in accordance with AHRI 550/590 I-P except as indicated. The Contractor and heat pump manufacturer must provide to the Government a certified heat pump factory test report in accordance with AHRI 550/590 I-P to confirm that the heat pump performs as specified. Tests must be conducted in an AHRI certified test facility in conformance with AHRI 550/590 I-P procedures and tolerances, except as indicated. At a minimum, heat pump capacity must be validated to meet the scheduled requirements indicated on the drawings. Tolerance or deviation must be in strict accordance with AHRI 550/590 I-P . Stable operation at minimum load of 15 percent of total capacity must be demonstrated during the factory test.

2.9.1.1 Temperature Adjustments

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

2.9.1.2 Test Instrumentation

The factory test instrumentation must be per AHRI 550/590 I-P and the

SECTION 23 64 10 Page 15 calibration must be traceable to the National Institute of Standards and Technology.

2.9.1.3 Equipment Adjustments

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

2.9.2 Heat Pumps Sound Test

Heat pumps must be sound tested at the factory prior to shipment to confirm the sound pressure level specified herein. Tests and data must be conducted and measured in strict accordance with AHRI 575 at the full load system operating conditions. The heat pump sound pressure level, in decibels (dB), with a reference pressure of 20 micropascals, must not exceed 85 dB, A weighted. Ratings must be in accordance with AHRI 575 .

No reduction of entering condenser water temperature or raising of leaving chilled water temperature will be allowed. A minimum of 75 percent of the sound data points must be taken along the length of the machine, and established as the minimum percentage of total possible points used to determine sound levels. In the event that the heat pump does not meet the dBA sound pressure level, the manufacturer must, at his expense, provide sufficient attenuation to the machine to meet the specified value. This attenuation must be applied in such a manner that it does not hinder the operation or routine maintenance procedures of the heat pump. The attenuation material, adhesives, coatings, and other accessories must have surface burning characteristics as determined by ASTM E84.

2.10 SUPPLEMENTAL COMPONENTS/SERVICES

2.10.1 Chilled and Condenser Water Piping and Accessories

Chilled and condenser water piping and accessories must be provided and installed in accordance with Section 23 64 26 CHILLED, CHILLED-HOT, AND

CONDENSER WATER PIPING SYSTEMS.

2.10.2 Temperature Controls

heat pump control packages must be fully coordinated with and integrated into the existing heat pump control system panels and sequence of controls as shown on the contract drawings.

PART 3 EXECUTION

3.1 INSTALLATION

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

(1) Heat Pumps - installation instructions

3.1.1 Installation Instructions

Provide manufacturer's standard catalog data, at least 5 weeks prior to the purchase or installation of a particular component, highlighted to show features such as materials, dimensions, options, performance and

SECTION 23 64 10 Page 16 efficiency. Data must include manufacturer's recommended installation instructions and procedures. Data must be adequate to demonstrate compliance with contract requirements.

3.1.2 Vibration Isolation

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

3.1.3 Posted Instructions

Provide posted instructions, including equipment layout, wiring and control diagrams, piping, valves and control sequences, and typed condensed operation instructions. The condensed operation instructions must 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 must be framed under glass or laminated plastic and be posted where indicated by the Contracting Officer.

3.1.4 Verification of Dimensions

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

3.1.5 System Performance Test Schedules

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

3.1.6 Certificates

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

3.1.7 Operation and Maintenance Manuals

Provide 3 complete copies of an operation manual in bound 8 1/2 by 11 inch booklets listing step-by-step procedures required for system startup, operation, abnormal shutdown, emergency shutdown, and normal shutdown at least 4 weeks prior to the first training course. The booklets must include the manufacturer's name, model number, and parts list. The manuals must include the manufacturer's name, model number, service

SECTION 23 64 10 Page 17 manual, and a brief description of all equipment and their basic operating features. 3 complete copies of maintenance manual in bound 8 1/2 by 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals must include piping and equipment layouts and simplified wiring and control diagrams of the system as installed.

3.1.8 Connections to Existing Systems

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

3.1.9 Refrigeration System

3.1.9.1 Equipment

Refrigeration equipment and the installation thereof must conform to ANSI/ASHRAE 15 & 34 . Necessary supports must be provided for all equipment, appurtenances, and pipe as required, including frames or supports for compressors, condensers, water coolers, and similar items.

Compressors must be isolated from the building structure. If mechanical vibration isolators are not provided, vibration absorbing foundations must be provided. Each foundation must include isolation units consisting of machine and floor or foundation fastenings, together with intermediate isolation material. Other floor-mounted equipment must be set on not less than a 6 inch concrete pad doweled in place. Isolators must be selected and sized based on load-bearing requirements and the lowest frequency of vibration to be isolated. Isolators must limit vibration to 10 percent at lowest equipment rpm. Equipment must be properly leveled, aligned, and secured in place in accordance with manufacturer's instructions.

3.1.9.2 Field Refrigerant Charging (When required)

a. Initial Charge: Upon completion of all the refrigerant pipe tests, the vacuum on the system must be broken by adding the required charge of dry refrigerant for which the system is designed, in accordance with the manufacturer's recommendations. Contractor must provide the complete charge of refrigerant in accordance with manufacturer's recommendations. Upon satisfactory completion of the system performance tests, any refrigerant that has been lost from the system must be replaced. After the system is fully operational, service valve seal caps and blanks over gauge points must be installed and tightened.

b. Refrigerant Leakage: If a refrigerant leak is discovered after the system has been charged, the leaking portion of the system must immediately be isolated from the remainder of the system and the refrigerant must be pumped into the system receiver or other suitable container. The refrigerant must not be discharged into the atmosphere.

c. Contractor's Responsibility: The Contractor must, at all times during the installation and testing of the refrigeration system, take steps to prevent the release of refrigerants into the atmosphere. The steps must include, but not be limited to, procedures which will minimize the release of refrigerants to the atmosphere and the use of

SECTION 23 64 10 Page 18 refrigerant recovery devices to remove refrigerant from the system and store the refrigerant for reuse or reclaim. At no time must more than 3 ounces of refrigerant be released to the atmosphere in any one occurrence. Any system leaks within the first year must be repaired in accordance with the specified requirements including material, labor, and refrigerant if the leak is the result of defective equipment, material, or installation.

3.1.9.3 Oil Charging

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

3.1.10 Mechanical Room Ventilation

Mechanical ventilation systems must be in accordance with Section 23 30 00

HVAC AIR DISTRIBUTION.

3.1.11 Field Applied Insulation

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

3.1.12 Field Painting

Painting required for surfaces not otherwise specified, and finish painting of items only primed at the factory are specified in Section

09 90 00 PAINTS AND COATINGS.

3.2 FACTORY TEST SCHEDULING AND REPORTS

Provide schedules which identify the date, time, and location for each test. Schedules must be submitted for the Heat pump Performance Tests and the Heat pump Sound Test.

copies of the certified test report must be forwarded to the Government for approval prior to project acceptance. Calibration curves and information sheets for all instrumentation must be included. Provide copies in bound 8 1/2 by 11 inch booklets. Reports must certify the compliance with performance requirements and follow the format of the required testing standard for the Heat pump Performance Tests and the Heat pump Sound Tests. Test report must include certified calibration report of all test instrumentation. Calibration report must 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 must be submitted 1 week after completion of the factory test.

3.3 MANUFACTURER'S FIELD SERVICE

The services of a factory-trained representative must be provided for three (3) days. The representative must advise on the following:

a. Hermetic machines:

SECTION 23 64 10 Page 19

(1) Testing hermetic water-chilling unit under pressure for refrigerant leaks; evacuation and dehydration of machine to an absolute pressure of not over 300 micrometers.

(2) Charging the machine with refrigerant.

(3) Starting the machine.

b. Open Machines:

(1) Erection, alignment, testing, and dehydrating.

(2) Charging the machine with refrigerant.

(3) Starting the machine.

3.4 CLEANING AND ADJUSTING

Equipment must be wiped clean, with all traces of oil, dust, dirt, or paint spots removed. Provide temporary filters for all fans that are operated during construction. Perform and document that proper Indoor Air Quality During Construction procedures have been followed; this includes providing documentation showing that after construction ends, and prior to occupancy, new filters were provided and installed. System must be maintained in this clean condition until final acceptance. Bearings must be properly lubricated with oil or grease as recommended by the manufacturer. Belts must be tightened to proper tension. Control valves and other miscellaneous equipment requiring adjustment must be adjusted to setting indicated or directed. Fans must be adjusted to the speed indicated by the manufacturer to meet specified conditions. At least one week before the official equipment warranty start date, all condenser coils on air-cooled water Heat pumps and split-system water Heat pumps must be cleaned in accordance with the Heat pump manufacturer's instructions. This work covers two coil cleanings. The condenser coils must be cleaned with an approved coil cleaner by a service technician, factory trained by the heat pump manufacturer. The condenser coil cleaner must not have any detrimental affect on the materials or protective coatings on the condenser coils.

3.5 FIELD ACCEPTANCE TESTING

3.5.1 Test Plans

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

(1) Heat Pumps - Field Acceptance Test Plan

Field acceptance test plans must be developed by the heat pump manufacturer detailing recommended field test procedures for that particular type and size of equipment. Field acceptance test plans developed by the installing Contractor, or the equipment sales agency furnishing the equipment, will not be acceptable.

The Contracting Officer will review and approve the field acceptance test plan for each of the listed equipment prior to commencement of field testing of the equipment. The approved field acceptance tests of the heat pump and subsequent test

SECTION 23 64 10 Page 20 reporting.

b. Coordinated testing: Indicate in each field acceptance test plan when work required by this section requires coordination with test work required by other specification sections.

c. Test procedure: Indicate in each field acceptance test plan each equipment manufacturers published installation, start-up, and field acceptance test procedures. Include in each test plan a detailed step-by-step procedure for testing automatic controls provided by the manufacturer.

Each test plan must include the required test reporting forms to be completed by the Contractor's testing representatives.

Procedures must be structured to test the controls through all modes of control to confirm that the controls are performing with the intended sequence of control.

Controller must be verified to be properly calibrated and have the proper set point to provide stable control of their respective equipment.

d. Performance variables: Each test plan must list performance variables that are required to be measured or tested as part of the field test.

Include in the listed variables performance requirements indicated on the equipment schedules on the design drawings. Heat pump manufacturer must furnish with each test procedure a description of acceptable results that have been verified.

Heat pump manufacturer must identify the acceptable limits or tolerance within which each tested performance variable must acceptably operate.

e. Job specific: Each test plan must be job specific and must address the particular cooling towers and particular conditions which exist in this contract. Generic or general preprinted test procedures are not acceptable.

f. Specialized components: Each test plan must include procedures for field testing and field adjusting specialized components, such as hot gas bypass control valves, or pressure valves.

3.5.2 Testing

a. Each heat pump system must be field acceptance tested in compliance with its approved field acceptance test plan and the resulting following field acceptance test report submitted for approval:

(1) Heat Pumps - Field Acceptance Test Report

b. Manufacturer's recommended testing: Conduct the manufacturer's recommended field testing in compliance with the approved test plan.

Furnish a factory trained field representative authorized by and to represent the equipment manufacturer at the complete execution of the field acceptance testing.

c. Operational test: Conduct a continuous 24 hour operational test for each item of equipment. Equipment shutdown before the test period is

SECTION 23 64 10 Page 21 completed must result in the test period being started again and run for the required…