23 64 10_refrig leak detector removed.pdf

CBP IDC-DLC SPECIFICATIONS

HARPERS FERRY, WV 09/19/22

SECTION 23 64 10

WATER CHILLERS, VAPOR COMPRESSION TYPE

11/16, CHG 2: 08/18

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 (2015; ERTA 2016) Performance Rating Of Water-Chilling and Heat Pump Water-Heating Packages Using the Vapor Compression Cycle

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 (2013) ANSI/ASHRAE Standard 15-Safety Standard for Refrigeration Systems and ANSI/ASHRAE Standard 34-Designation and Safety Classification of Refrigerants

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 (2012) 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

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

ASTM D520 (2000; R 2011) Zinc Dust Pigment

ASTM E84 (2020) Standard Test Method for Surface Burning Characteristics of Building

SECTION 23 64 10 Page 1

Materials

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2018) 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" or "S" classification. Submittals not having a "G" or "S" 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

Posted Instructions

Verification of Dimensions

Factory Tests

System Performance Tests

Demonstrations

Refrigerant

Water Chiller - Field Acceptance Test Plan

SD-06 Test Reports

Field Acceptance Testing

Water Chiller - Field Acceptance Test Report

Factory Tests

System Performance Tests

SD-07 Certificates

Refrigeration System; G, RO

Ozone Depleting Substances Technician Certification

SD-08 Manufacturer's Instructions

SECTION 23 64 10 Page 2

Water Chiller - Installation Instructions; G, RO

SD-10 Operation and Maintenance Data

Operation and Maintenance Manuals; G, RO

SD-11 Closeout Submittals

Indoor Air Quality During Construction; S

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. Provide copies of technician certifications to the Contracting Officer at least 14 calendar days prior to work on any equipment containing these refrigerants.

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 PROJECT REQUIREMENTS

1.6.1 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

SECTION 23 64 10 Page 3 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 chillers, compressors, compressor drivers, condensers, water coolers, receivers, heat exchangers, 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.

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

2.3 ELECTRICAL WORK

a. Provide motors, controllers, integral disconnects, contactors, and controls with their respective pieces of equipment, except controllers indicated as part of motor control centers. Provide electrical equipment, including motors and wiring, as specified in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. Manual or automatic control and protective or signal devices required for 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 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.

SECTION 23 64 10 Page 4

2.4 SELF-CONTAINED MODULAR HEAT RECOVERY WATER CHILLERS, 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, 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 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. Chiller must be provided with a single point wiring connection for incoming power supply. Chiller's condenser and water cooler must be provided with standard water boxes with flanged or welded connections.

2.4.1 Scroll, Reciprocating, or Rotary Screw Type

Chiller must be certified for performance per AHRI 550/590 I-P. If specified performance is outside of the Application Rating Conditions of AHRI 550/590 I-P, Table 2 then the chiller's performance must be rated in accordance with AHRI 550/590 I-P. Chiller must conform to ANSI/ASHRAE 15 & 34. As a minimum, chiller must 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

g. Compressor driver connection

h. Water cooler (evaporator)

i. Air-cooled condenser coil

2.4.2 Centrifugal or Rotary Screw Type NOT USED

2.5 SPLIT-SYSTEM WATER CHILLER, VAPOR COMPRESSION TYPE NOT USED

2.5.1 Compressor-Chiller Unit NOT USED

2.5.2 Condensing Unit NOT USED

2.5.3 Remote Water Cooler (Evaporator) NOT USED

2.5.4 Remote Air-Cooled Condenser

2.5.4.1 Fans

Provide centrifugal or propeller type fans as best suited for the application. Fans must be direct or V-belt driven. When belt drive is

SECTION 23 64 10 Page 5 provided, an adjustable sheave to furnish not less than 20 percent fan-speed adjustment must be provided. Sheave sets must be matched and selected to provide the capacity indicated at the approximate midpoint of the adjustment. Fans must be statically and dynamically balanced.

2.5.4.2 Condenser Sizing

Size condensers for full capacity at 30 degrees F temperature difference between entering outside air and condensing refrigerant. Subcooling must 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.

2.5.4.3 Low Ambient Control

Provide factory mounted head pressure control for operation during low ambient conditions. Head pressure must be controlled by fan speed control.

Low ambient control must permit compressor operation below40 degrees F.

2.5.4.4 High Ambient Unloading

Provide unloading capability to allow operation in high ambient conditions 20 degrees F above design conditions.

2.5.5 Remote Water-Cooled Condenser NOT USED

2.6 CHILLER COMPONENTS

2.6.1 Refrigerant and Oil

Refrigerants must be one of the fluorocarbon gases. 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, with the exception of R-123. Provide SDS sheets for all refrigerants.

2.6.2 Structural Base

Chiller and individual chiller components must be provided with a factory-mounted structural steel base (welded or bolted) or support legs.

Chiller and individual chiller components must be isolated from the building structure by means of vibration isolators with published load ratings. Vibration isolators must 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 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.

SECTION 23 64 10 Page 6

2.6.4 Controls Package

Provide chillers 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, variable frequency motor controller, disconnect switches, power wiring, and control wiring.

Controls package must provide operating controls, monitoring capabilities, programmable setpoints, safety controls, and BAS interfaces as defined below.

2.6.4.1 Operating Controls

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

a. Leaving chilled and heating 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 chiller on power interruption.

f. Startup and head pressure controls to allow system operation at all ambient temperatures down to 10 degrees F.

2.6.4.2 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 and heating water temperatures

b. Entering and leaving chilled and heating water pressure and flow

c. Self diagnostic

d. Operation status

e. Operating hours

f. Number of starts

g. Compressor status (on or off)

h. Compressor load (percent)

i. Refrigerant discharge and suction pressures

j. Magnetic bearing levitation status (if applicable)

k. Magnetic bearing temperatures (if applicable)

SECTION 23 64 10 Page 7

l. Oil pressure

2.6.4.3 Configurable Setpoints

The control system must be capable of being configured directly at the unit's interface panel. The programmable setpoints must include the following as a minimum:

a. Leaving Chilled and Heating Water Temperature

2.6.4.4 Safety Controls with Manual Reset

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

a. Low chilled and heating water temperature protection

b. High condenser refrigerant discharge pressure protection

c. Low evaporator pressure protection

d. Chilled and heating 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

2.6.4.5 Safety Controls with Automatic Reset

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

a. Over/under voltage protection

b. Chilled and heating water flow interlock

c. MBC, Vibration (if applicable)

d. MBC, No levitation (if applicable)

e. Phase reversal protection

2.6.4.6 Remote Alarm

During the initiation of a safety shutdown, a chiller's control system must be capable of activating a remote alarm bell. In coordination with the chiller, 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

SECTION 23 64 10 Page 8 chiller's monitoring of safety controls. The alarm bell must not sound for a chiller that uses low-pressure cutout as an operating control.

2.6.4.7 Utility Monitoring and Control System Interface

Provide a Utility Monitoring and Control System (UMCS) interface meeting the requirements of Section 23 09 00 INSTRUMENTATION AND CONTROL FOR HVAC and the requirements of Section 23 09 23.02 BACNET DIRECT DIGITAL CONTROL FOR HVAC AND OTHER BUILDING CONTROL SYSTEMS. The interface must provide all system operating conditions, capacity controls, and safety shutdown conditions as network points. In addition, the following points must be overridable via the network interface:

a. Unit Start/Stop

b. Leaving Chilled and Heating Water Temperature Setpoint

2.6.5 Compressor(s)

2.6.5.1 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.

2.6.5.2 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.

SECTION 23 64 10 Page 9

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

i. Crankcase oil heaters must be provided.

2.6.5.3 Centrifugal Compressor(s)

Centrifugal compressors may be either single or multistage, having dynamically balanced impellers, either direct or gear driven by the compressor driver. Impellers must be over-speed tested at 1.2 times the impeller-shaft speed. Impeller shaft must be steel with sufficient rigidity for proper operation at any required operating speed. Compressors must be capable of variable speed operation and may have either oil-free bearing drives or oil-lubricated bearing drives. Centrifugal compressors must include:

a. Shaft main bearings that are either oil lubricated, oil free ceramic or magnetic levitated. The oil lubricated bearings must be 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. Oil lubricated or oil free ceramic bearings must be rated for an L(10) life of not less than 200,000 hours. Magnetic levitated main shaft bearings must be in accordance with ISO 14839-1, ISO 14839-2, ISO 14839-3, ISO 14839-4, and provided with radial and axial magnetic levitated bearings (combination permanent and electro magnets) to levitate the shaft thereby eliminating metal to metal contact and thus eliminating the need for oil. The active magnetic bearings must be equipped with an automatic vibration reduction and balancing system.

Each bearing position must be sensed by position sensors and provide real time positioning of the rotor shaft, controlled by on-board digital electronics. In the event of a power failure, the magnetic bearings will remain in operation throughout the compressor coast-down using a reserve power supply. Provide mechanical bearings designed for emergency touchdowns, as a backup to the magnetic bearings.

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 (if applicable). On units providing forced-feed lubrication prior to starting, a differential oil pressure cutout interlocked with the compressor starting equipment must allow the compressor to operate only when the required oil pressure is provided to the bearings (if applicable).

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

f. Temperature-or pressure-actuated prerotation vane, variable geometry diffuser or suction damper to provide automatic capacity modulation from 100 percent capacity to 25 percent capacity. If operation to 25 percent capacity cannot be achieved without providing gas bypass

SECTION 23 64 10 Page 10 external to the compressor, then the Contractor must indicate in the equipment submittal the load percent at which external hot gas bypass is required to prevent surge and to provide the specified capacity reduction and its impact on performance.

2.6.6 Compressor Driver, Electric Motor

Components such as motors, variable speed drives and wiring must be in accordance with paragraph ELECTRICAL WORK. Variable frequency drive must be unit mounted or remote mounted as indicated with variable frequency drive type, wiring, and accessories coordinated with the chiller manufacturer.

2.6.7 Compressor Driver, Gas-Engine NOT USED

2.6.8 Compressor Driver, Steam Turbine NOT USED

2.6.9 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.

2.6.10 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 copper, plain, 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.

2.6.11 Air-Cooled Condenser Coil

Condenser coil must be of the extended-surface fin-and-tube type and must be constructed of seamless copper or aluminum tubes with compatible copper or aluminum fins. Fins must be soldered or mechanically bonded to the tubes and installed in a metal casing. Coils must be circuited and sized for a minimum of 5 degrees F subcooling and full pumpdown capacity. Coil must be factory leak and pressure tested after assembly in accordance with

ANSI/ASHRAE 15 & 34.

2.6.12 Water-Cooled Condenser Coil NOT USED

2.6.13 Heat Recovery Condenser Coil NOT USED

2.6.14 Receivers NOT USED

SECTION 23 64 10 Page 11

2.6.15 Chiller Purge System

Chillers which operate at pressures below atmospheric pressure must be provided with a purge system. Purge system must automatically remove air, water vapor, and non-condensible gases from the chiller's refrigerant while keeping refrigerant emissions below requirements of ASHRAE Std 147. Purge units must be certified per AHRI 580. Purge system must condense, separate, and return all refrigerant back to the chiller. An oil separator must be provided with the purge system if required by the manufacturer.

Purge system must not discharge to occupied areas, or create a potential hazard to personnel. Purge system must include a purge pressure gauge, number of starts counter, and an elapsed time meter. Purge system must include lights or an alarm which indicate excessive purge or an abnormal air leakage into chiller.

2.6.16 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.

2.7 ACCESSORIES

2.7.1 Refrigerant Leak Detector NOT USED

2.7.2 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.

2.7.3 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.

2.7.3.1 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.

c. The lubricant identity and amount.

d. Field test pressure applied.

2.7.3.2 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:

SECTION 23 64 10 Page 12

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

b. Pressure limiting device(s).

2.7.4 Automatic Tube Brush Cleaning System NOT USED

2.7.5 Gaskets

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

2.7.6 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.

2.8 FABRICATION

2.8.1 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 125 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.

2.8.2 Factory Applied Insulation

Chiller 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 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.

SECTION 23 64 10 Page 13

2.8.3 Coil Corrosion Protection

Provide coil with a uniformly applied epoxy electrodeposition type coating to all coil surface areas without material bridging between fins. Submit product data on the type coating selected, the coating thickness, the application process used, the estimated heat transfer loss of the coil, and verification of conformance with the salt spray test requirement. Coating must be applied at either the coil or coating manufacturer's factory.

Coating process must ensure complete coil encapsulation. Coating must be capable of withstanding a minimum 3,000 hours exposure to the salt spray test specified in ASTM B117 using a 5 percent sodium chloride solution.

2.9 FACTORY TESTS

2.9.1 Chiller Performance Test

The Contractor and proposed chiller manufacturer shall be responsible for performing the chiller factory test to validate the specified full load capacity, full load EER, and IPLV in accordance with AHRI 550/590 I-P except as indicated. The Contractor and chiller manufacturer must provide to the Government a certified chiller factory test report in accordance with AHRI 550/590 I-P to confirm that the chiller performs as specified.

Tests 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, chiller 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 10 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 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 Chiller Sound Test NOT USED

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

SECTION 23 64 10 Page 14

CONDENSER WATER PIPING SYSTEMS.

2.10.2 Refrigerant Piping NOT USED

2.10.3 Cooling Tower NOT USED

2.10.4 Temperature Controls

Chiller control packages must be fully coordinated with and integrated into the temperature control system indicated in Section 23 30 00 HVAC AIR DISTRIBUTION and Section 23 09 23.02 BACNET DIRECT DIGITAL CONTROL FOR HVAC

AND OTHER BUILDING CONTROL SYSTEMS.

PART 3 EXECUTION

3.1 INSTALLATION

Installation of water chiller 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) Water chiller - 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 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

SECTION 23 64 10 Page 15 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 Six 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 manual, and a brief description of all equipment and their basic operating features. Six complete copies of maintenance manual in bound 8 1/2 by 11 inch booklets listing routine maintenance procedures, possible breakdowns and repairs, and a trouble shooting guide. The manuals must include piping and equipment layouts and simplified wiring and control diagrams of the system as installed.

3.1.8 Connections to Existing Systems NOT USED

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, pumps, cooling towers, 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. Concrete foundations for floor mounted pumps must have a mass equivalent to three times the weight of the components, pump, base plate, and motor to be supported. In lieu of concrete pad foundation, concrete pedestal block with isolators placed between the pedestal block and the floor may be provided. Concrete pedestal block must be of mass not less than three times the combined pump, motor, and base weights. Isolators must be selected and sized based on load-bearing requirements and the lowest frequency of vibration to be isolated. Isolators must limit

SECTION 23 64 10 Page 16 vibration to 20 percent at lowest equipment rpm. Lines connected to pumps mounted on pedestal blocks must be provided with flexible connectors.

Foundation drawings, bolt-setting information, and foundation bolts must be furnished prior to concrete foundation construction for all equipment indicated or required to have concrete foundations. Concrete for foundations must be as specified in Section 03 30 00 CAST-IN-PLACE CONCRETE. Equipment must be properly leveled, aligned, and secured in place in accordance with manufacturer's instructions.

3.1.9.2 Field Refrigerant Charging

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 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.

SECTION 23 64 10 Page 17

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 Chiller Performance Tests.

Six 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 Chiller Performance Tests and the Chiller 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 1 day.

The representative shall advise on the following:

a. Hermetic machines:

(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

SECTION 23 64 10 Page 18 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 chillers and split-system water chillers must be cleaned in accordance with the chiller 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 chiller manufacturer. The condenser coil cleaner must not have any detrimental affect on the materials or protective coatings on the condenser coils.

Testing, adjusting, and balancing must be as specified in Section 23 05 93

TESTING, ADJUSTING, AND BALANCING FOR HVAC.

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) Water chiller - Field Acceptance Test Plan

Field acceptance test plans must be developed by the chiller 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 chiller and subsequent test 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. Furnish test procedures for the simultaneous or integrated testing of tower system controls which interlock and interface with controls for the equipment provided under Section 23 09 23.02 BACNET DIRECT DIGITAL CONTROL FOR HVAC AND OTHER

BUILDING CONTROL SYSTEMS.

c. Prerequisite testing: Chillers for which performance testing is dependent upon the completion of the work covered by Section 23 05 93 TESTING, ADJUSTING, AND BALANCING FOR HVAC must have that work completed as a prerequisite to testing work under this section.

Indicate in each field acceptance test plan when such prerequisite work is required.

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

Each test plan 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.

SECTION 23 64 10 Page 19

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

e. Performance variables: Each test plan 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. Chiller manufacturer must furnish with each test procedure a description of acceptable results that have been verified.

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

f. 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.

g. 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 water chiller 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) Water chiller - Field Acceptance Test Report

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

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

c. Operational test: Conduct a continuous 24 hour operational test for each item of equipment. Equipment shutdown before the test period is completed shall result in the test period being started again and run for the required duration. For the duration of the test period, compile an operational log of each item of equipment. Log required entries every two hours. Use the test report forms for logging the operational variables.

d. Notice of tests: Conduct the manufacturer's recommended tests and the operational tests; record the required data using the approved reporting forms. Notify the Contracting Officer in writing at least 15 calendar days prior to the testing. Within 30 calendar days after acceptable completion of testing, submit each test report for review and approval.

e. Report forms: Type data entries and writing on the test report forms.

Completed test report forms for each item of equipment must be reviewed, approved, and signed by the Contractor's test director. The manufacturer's field test representative must review, approve, and sign

SECTION 23 64 10 Page 20 the report of the manufacturer's recommended test. Signatures must be accompanied by the person's name typed.

f. Deficiency resolution: The test requirements acceptably met;

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

3.6 SYSTEM PERFORMANCE TESTS

Six copies of the report must be provided in bound 8 1/2 by 11 inch booklets.

3.6.1 General Requirements

Before each refrigeration system is accepted, tests to demonstrate the general operating characteristics of all equipment must…