MNA Heat Pump Retubing PWS.pdf

TECHNICAL SPECIFICATIONS

MCNARY HEAT PUMP #1 AND #2 RETUBING CONDENSER AND EVAPORATOR

INTENT

The following specifications pertain to the repair of TWO 200-ton capacity Trane Water-Cooled Chillers Model RTHD. This is an in-house repair of TWO existing chillers that work together to regulate the temperature of McNary’s powerhouse and generating units. Items listed under Specifications 1.1 are the current configuration.

Incorrect tube material was used in the original Contract, W912EF-12-C-0027. The intent is to replace all defective tubes in both chillers (heat pump #1 and #2) following the successful installation and commissioning of Chiller #3 (heat pump #3).

SCOPE

The successful contractor shall be required to furnish all labor, tooling, and miscellaneous equipment to set up and extract the Two Hundred and Ninety-Eight (298) condenser and evaporator tubes from one chiller. Thoroughly clean all tube sheets holes in preparation for new tubes. Furnish and install new condenser and evaporator tubes. Use correct sealant(s) and installation methods. Stand by and observe the USACE lead pressure test and assist in leak checks. Upon completion of pressure and leak testing, the contractor will recommission the heat pump chillers.

SPECIFCATIONS

1.1. The Heat Pumps currently have the following model number and associated characteristics:

Model Number Selection: RTHDUB1FX**UAC1W2LALD1C2LCLAVCQAEXADDCY***FCUT522XRXXXH

Digit # Digit Option Digit Selection Digit Selection Description

Basic Product Line

R

RTHD

2 T

3 H

4 D

5 Manufacturing Plant U Water Chiller Business Unit, Pueblo, CO USA

6 Compressor Frame B B compressor

7 Compressor Capacity 1 Small capacity for frame

8 Unit power supply F 460V/60Hz/3Ph power

9 Design Specials X No Specials

Design sequence

Factory Assigned

11 *

12 Agency Listing U UL Listed to US and Canadian Safety Standard

13 Pressure Vessel Code A ASME Pressure Vessel Code

Evaporator

C C1 Evaporator

15 1

16 Evaporator Tube Type W Enhanced fin copper (water only)

17 Evaporator Water Pass Conf. 2 2 Pass

18 Evaporator Water L Left Hand

19 Evaporator Connection Type A Standard Grooved Pipe

20 Evaporator Water Side Pressure L 150 psi

Condenser

D D1 Condenser

22 1

23 Condenser Tube Type C Smooth Bore CuNi

24 Condenser Water Passes 2 2 Pass

25 Condenser Water Connection L Left Hand

26 Condenser Connection Type C Marine

27 Condenser Waterside Pressure L 150 psi

28 Condenser Leaving Water Temp. A Standard

29 Refrigerant Isolation Valves V With Refrigerant Isolation Valves

30 Oil Cooler C With Oil Cooler

31 Thermal Insulation Q Factory Installed Insulation

32 Acoustic Insulation A Standard attenuator

33 Label and Literature Language E English

34 Safety Devices X Standard

35 Factory Charge A Refrigerant Charge R-134a

36 Shipping Package D Skid + Shrink Wrap

37 Flow Switch D Evaporator and Condenser (NEMA 4)

38 Factory Test C Witness Test

39 Starter Type Y Wye-Delta Closed Transition Starter

Design RLA

Design RLA 41 *

42 *

43 Power Line Connection Type F High Interrupt Circuit Breaker

44 Max RLA (Starter) C 277 max RLA (Fixed Speed)

45 Under/Over Voltage Protection U With Under/Over Voltage Protection

46 Operator Interface T Tracer AdaptiView™ TD7 Display

47 Digital Communication Interface 5 LCI-C (LonTalk®) Interface

48 External Water & Current-Limit Setpoint 2 2-10 Vdc input

49 External Base Loading 2 2-10 Vdc input

50 Ice Making X None

51 Programmable Relays R With Programmable Relays

52 Chilled Water Reset X Chilled Water Reset - Return Water

53 Control Outputs X None

54 Refrigerant Monitor Input X None

55 Condenser Leaving Hot Water Temp Control H Hot Water Temp Control

1.2. Condenser Tubes.

1.2.1. Tubes shall be new. Not used or recycled.

1.2.2. Cupronickel or copper-nickel (CuNi).

1.2.3. Alloy UNS No C70600 (90-10).

1.2.4. 0.750” Outside Diameter (OD) x 0.035” UF Wall Thickness x One Hundred Seventeen and three-quarters Inches (117-3/4") Long.

1.2.5. Continuous Fin and smooth bore Tube.

1.2.6. Quantity – One Hundred Sixty-Nine (169) Tubes per condenser. 338 tubes total for this contract.

1.3. Evaporator Tubes.

1.3.1. Tubes shall be new. Not used or recycled.

1.3.2. Cupronickel or copper-nickel (CuNi).

1.3.3. Alloy UNS No C70600 (90-10).

1.3.4. 1.000” Outside Diameter (OD) x 0.035” UF Wall Thickness x One Hundred Twenty-Six Inches

(126") Long.

1.3.5. Continuous Fin and ID Enhanced Tubes.

1.3.6. Quantity – One Hundred Twenty-Nine (129) Tubes per condenser. 258 tubes total for this contract.

1.4. Tube Sheet Holes.

1.4.1. Tube sheet holes shall only be cleaned using stainless steel brushes.

1.5. Tube Installation.

1.5.1. Contractor shall provide method of sealant(s) used to seal the tubes to the tube sheets.

1.5.2. Contractor shall provide method and instrumentation used to roll the tubes into place on the tube sheets.

1.6. Testing.

1.6.1. Contractor shall stand by for the pressure tests and leak checks.

1.7. Controls currently used on both chiller units.

1.7.1. LonWorks technology and conform to the ANSI/CEA-709.1 control-networking protocol.

• LonMark Interoperability Guide:

o (2005) LonMark Application-Layer o Interoperability Guide and LonMark Layer o 1-6 Interoperability Guide; Version 3.4 (This remains the same, the version is still applicable)

• LonMark SCPT List:

o Version 15 Revision 00 November 2014 SCPT Master List

• LonMark SNVT List:

o Version 15 Revision 00 November 2014 SNVT Master List

• LonMark XIF Guide:

o LONMARK® Device Interface File Reference Guide Revision 4.501 December

1.8. McNary Personnel responsibility.

1.8.1. Completely drain chiller units of chiller water.

1.8.2. Remove obstructive insulation and tube sheet heads.

1.8.3. Evacuate the chillers.

1.8.4. Provide clear access for removal and replacement of the condenser and evaporator tubes.

1.8.5. Off-loading and pre-staging of condenser and evaporator tubes next to each chiller.

1.8.6. Provide and witness pressure and leak checks upon contractor completion.

1.8.7. Reinstall tube sheet heads, recharge the chillers with freon.

1.9. Insulation

Evaporator shell and suction piping between evaporator and first stage of the compressor shall be insulated, including the water headers or boxes of the evaporator. Where motors are the gas-cooled type, insulation shall be provided on the cold-gas inlet connection to the motor per manufacturer's standard practice. Condenser water boxes shall be insulated. Insulation shall be closed cell elastomeric foam not less than 3/4" thick. Insulation shall have a maximum thermal conductivity of

0.28 Btu/(hr.)(sq. ft.)(°F). Insulation on heads of evaporators shall be installed to provide easy removal and replacement of heads without damage to the insulation.

1.10. Nameplates

TRANE contractor to update the current data plate to conform with new tubes. In lieu of a nameplate, the manufacturer's name or trademark may be cast integrally or stamped, or otherwise permanently marked.

OPERATION SECURITY

• General security requirements and guidance: The security requirements described below apply to all contract personnel (including employees of the prime Contractor ("Contractor") and all subcontractor employees) supporting the performance requirements of this contract. The Contractor is responsible for compliance with these security requirements. Questions regarding security matters shall be addressed to the designated Government representative (e.g., Contracting Officer Representative (COR), Requiring Activity (RA) representative, or Contracting Officer (if a COR or other RA representative is not appointed)). Contract personnel are critical to the overall security and safety of US Army Corps of Engineers (USACE) installations, facilities and activities, and security awareness training contributes to those efforts. The Department of Defense (DOD) and Army security training requirements specified below, if applicable, are performance requirements; all applicable contract personnel shall complete initial training within 30 days of contract award or the date new contract personnel begin performance on the contract. Within five business days from the completion of training, the Contractor shall provide written documentation (e.g., email or memorandum) to the Government representative. The documentation shall include the names of contract personnel trained and which training they completed; the Contractor shall maintain training records as part of their contract files and be prepared to provide copies of training certificates to the Government representative. Contractor personnel and vehicles are subject to search when entering federal installations. Additionally, all contract personnel shall comply with Force Protection Condition (FPCON) measures, Random Antiterrorism Measures (commonly referred to as "RAMs"), and Health Protection Condition (HPCON) measures. The Contractor is responsible for meeting performance requirements during elevated FPCON and/or HPCON levels in accordance with applicable RA plans and procedures --this includes identifying mission essential and non-mission essential personnel. In addition to the changes otherwise authorized by the changes clause of this contract, should the FPCON or HPCON levels at any individual facility or installation change, the Government may implement security changes that affect contract personnel. The Contractor shall ensure all contract personnel are aware of their security responsibilities, including any site-specific requirements identified in local policies or procedures.

• Physical security and access control requirements: All contract personnel requiring physical access to a federal installation or facility shall comply with the access control procedures of that location.

Contract personnel requiring unescorted access to meet contract performance requirements on a DoD installation in the US shall be vetted by the installation/facility Provost Marshal/Directorate of Emergency Services/Security Office using the National Crime Information Center-Interstate Identification Index (commonly referred to as "NCIC-111") and Terrorist Screening Database (commonly referred to as "TSDB"). Contract personnel shall comply with all personal identity verification requirements specified in installation/facility policies and procedures. Contract personnel who do not meet requirements for unescorted access to USACE facilities shall coordinate escorted access with the Government representative, as needed. Contract personnel who receive keys, access cards, or lock combinations that provide access to government-owned property shall comply with key and lock control procedures of the RA.

• Suspicious Activity Reporting training (e.g. iWATCH, CorpsWatch, or See Something, Say

Something): All contract personnel shall receive initial and annual refresher training from the RA representative on the local suspicious activity reporting program. This locally developed training provides contract personnel with general information on suspicious behavior, and guidance on reporting suspicious activity to the project manager, security representative or law enforcement entity.

• Escorting in classified and/or sensitive areas: In accordance with applicable regulations, all contract personnel who do not possess the appropriate security clearance or access privileges will be escorted in areas where they may be exposed to classified information or operations, sensitive information or activities, or restricted areas.

• Pre-screen candidates using E-Verify Program: Contractors shall comply with the requirements set forth in FAR clause 52.222-54 Employment Eligibility Verification and FAR Subpart 22.18 in using the E-Verify Program at (https://w„wv e-verify.gov/) (website subject to change) to meet the contract employment eligibility requirements. Contractors are encouraged to cooperate with Federal and State agencies responsible for enforcing labor requirements to include eligibility for employment under United States immigration laws in accordance with FAR 22.102-1 (i). An initial list of verified/ eligible candidates shall be provided to the COR no later than three business days after the initial contract award. When contracts are with individuals, the individuals will be required to complete a Form 1-9, Employment Eligibility Verification, and submit it to the Contracting Officer to become part of the official contract file.

HECP TRAINING: LOCK-OUT/TAG-OUT

Contractor, subcontractor, vendors and visitors shall take the appropriate level of HEC Program training commensurate with their job duties. Contractor Personnel on-site for Start-Up Support (Section 6.0) shall have, at a minimum, awareness level training. Training and written tests for the modules below shall be completed on-line prior to commencing on-site work.

Time estimates for Awareness Level Training: Approximately 1 hour (vendors and visitors).

A copy of the Safe Clearance Program for the Control of Hazardous Energy (NWWP 385-1-20) can be found on the Walla Walla District Internet site at:

http://www.nww.usace.army.mil/Portals/28/docs/contracting/OP385120.pdf .

Vivid Training/Testing modules can be found at:

http://engineerstrainingonline.com/ .

All costs for this training shall be considered incidental to the work, and therefore, no additional payment will be made. Training is an annual requirement and will expire one year from completion date. Training is provided by Vivid Learning Systems and is available on line at http://Hecp.vividlms.com.

Cost for the training is displayed on the home page. Submit the training completion certification a minimum of seven days prior to the individual’s arrival at site. Maintain training documentation on site, including the individual's name and date of training completion, in accordance with NWWP 385- 1-20. Submit Contractor Employee names and level of required training a minimum of one week prior to commencing on-site work to the COR.

START-UP SUPPORT

Commissioning and start up support provided by manufacturer specialist once installation is complete. Support will be coordinated with the McNary Contract Performance Specialistafter installation, approximately one month after delivery.

SUBMITTALS

Before final acceptance, the following must be submitted to the Contract Specialist:

• Manufacturer’s Cut Sheets

• Chiller Service Report

• Refrigerant Area Monitor Test Report

• Water Cooled Run Facility Test Report

• Installation, Operation and Maintenance Manual

WARRANTY

Each component shall be covered by a minimum one-year warranty on all parts, refrigerant, and workmanship from factory defects.

SHIPMENT AND DELIVERY

http://hecp.vividlms.com/

All equipment and materials delivered and placed in storage shall be stored with protection from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Materials shall be delivered in the manufacturer's unopened containers. Any materials or equipment damaged during delivery, storage, and handling will not be accepted. The Contracting Officer's Representative may reject insulation material and supplies that become dirty, dusty, wet, or otherwise contaminated.

Packaging and handling shall be adequate to prevent contamination, mechanical damage, or deterioration of the item supplied. All openings into items shall be sealed or plugged until ready for use or connection. The outer-most covering shall be clearly marked with the complete vendor identification that shall include weight, lifting points, and written instructions covering the location and stacking limits of the packaging on the transport vehicle. This information shall be utilized for all handling procedures.

All items shall be delivered FOB Destination to McNary Lock and Dam.

No shipments are allowed other than during normal business hours of Monday-Thursday, 7:00AM-4PM, excluding federal holidays.

All shipments shall be delivered to:

McNary Lock and Dam 82790 Devore Rd.

Umatilla, OR. 97882