Rotary Screw Water Chillers ME- Building Group

SECTION 236426 – ROTARY-SCREW WATER CHILLERS

PART 1 - GENERAL

1.1  RELATED DOCUMENTS

  1. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division01 Specification Sections, apply to this Section.

1.2  SUMMARY OF WORK

  1. Provide Microprocessor controlled, twin-screw compressor, air-cooled, liquid chillers of the scheduled capacities as shown and indicated in this specification section, including but not limited to:
  2. Chiller package
  3. Charge of refrigerant and oil
  4. Electrical power and control connections
  5. Chilled water connections
  6. Factory start-up
  7. Factory Test: Chiller shall be pressure-tested, evacuated and fully charged with refrigerant and oil, and shall be factory operational run tested with water flowing through the vessel. Load testing of the equipment package will be witnessed by the owner at the factory.
  8. Chiller manufacturer shall have a factory trained and supported service organization that is within a 50 mile radius of the site.
  9. Submit shop drawings to include weight, assembly, dimensions and valves for the complete equipment package. Submit product data indicating rated capacities, weights, and written certifications that non-manufacturer supplied components of the package are in accordance with manufacturer’s requirements.

1.3  GENERAL NOTES

  1. All work shall conform to applicable federal, state and local codes and regulations.
  2. All work shall conform to all applicable Chrysler Corporation requirements. It is understood and agreed that this Supplier is familiar with all applicable Chrysler Corporation requirements.
  3. Submit shop drawings showing in sufficient details all items pertaining to this Work to the Owner and obtain said approval prior to fabrication. See paragraph 1.6.
  4. Whenever in the following specifications an article, material, or equipment is defined by describing a proprietary product or the use of the manufacturer or vendor, it shall be the basis of bid. Any offered equal must have Owner approval prior to submission of bid.

1.4  ELECTRICAL

  1. Unit manufacturer shall provide a control panel containing unit package power wiring, main disconnect switch, motor starters, main drive motor including terminal boxes, oil pump separator, oil pump, oil heater, control devices and auxiliaries, together with over-current protective devices, control transformers and control wiring system.
  2. Wiring for external connections shall be brought to readily accessible terminal strips for connection thereto.
  3. Electrical work excluded:
  4. Motor control centers for chillers,.
  5. Power wiring to chiller package will be furnished and installed by the installation Contractor.
  6. Interlock and interface wiring from the chiller master system control panel to the chiller unit microprocess control panels, to energy center PC, and to the motor control center will be furnished and installed by the installation Contractor. Design of all power and control wiring 480 V, 115 V, etc., however is the responsibility of the chiller manufacturer.

1.5  QUALITY ASSURANCE

  1. ARI Compliance: Rate chiller according to ARI 550.
  2. ASHRAE Compliance: Conform to ASHRAE 15 for chiller design, construction, leak testing, and installation.
  3. ASME Compliance: Comply with ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, for construction and testing of evaporator pressure vessel. Label evaporator with ASME mark.
  4. NEC Compliance: Comply with applicable NEC requirements for electrical power and control wiring.
  5. UL Listing label.
  6. Factory Test: Chiller shall be pressure-tested, evacuated and fully charged with refrigerant and oil, and shall be factory operational run tested with water flowing through the vessel.
  7. Provide sound data for refrigerant compressors measured in accordance with ARI 530 and Chrysler Sound Level Specification.

1.6  DELIVERY AND HANDLING

  1. Unit shall be delivered to job site fully assembled and charged with refrigerant and oil by the Manufacturer. If not practical, minimize shipping split and field connections all fluids shall be factory charged. NOTIFY OWNER OF SHIPPING REQUIREMENTS AT TIME OF BID.
  2. During shipment, provide protective covering over vulnerable components. Fit nozzles and open ends with plastic enclosures.
  3. Protect the chiller and its accessories from the weather and dirt exposure during shipment.
  4. Provide services of local manufacturer’s representative for supervision of rigging, unloading and setting of units.
  5. For Mexico, units are shipped free of refrigerant and oils; refrigerant and oils are to be supplied separately.

1.7  SUBMITTALS

  1. Shop drawing to include product data for each chiller and the following
  2. Chiller refrigerant and quantity.
  3. Chiller capacity at design conditions.
  4. Condenser pressure drop.
  5. Cooler pressure drop.
  6. Furnished accessories.
  7. Installation and start-up instructions.
  8. Chiller APLV in accordance with ARI rating procedures.
  9. Chiller power consumption per ton at design conditions.
  10. Part load performance data.
  11. Weight, assembly, dimensions and valves for the complete equipment package.
  12. Electrical requirements and wiring diagrams.
  13. LEED Submittals:
  14. Product Data for CreditEA4: Documentation indicating that equipment and refrigerants comply.
  15. Shop drawings detailing fabrication and installation of chiller, including plans, elevations, sections, component details, attachments, and other construction elements including dimensions, weight loadings and distribution, maintenance and operational clearances, field connections, structural supports, lockout tagging, and field mounted device tagging.
  16. Chiller performance ratings conforming to and reported in accordance with ARI-550/590 and to include capacity (tons), energy efficiency (kW/ton), water pressure drop (ft of water), Integrated Part Load Value (IPLV) efficiency or Non-Standard Part Load Value (NPLV). Chiller performance testing will be witnessed ob the owner. Adequate notice will need to be given for the test for schedule coordination.
  17. Include additional power or water sources for auxiliaries (water for oil coolers, etc.) and the effect of compressor motor heat losses to the refrigerant stream in all rating calculations.
  18. NPLV calculated to ARI Standard 550/590 equation.
  19. Statement of Compliance with ASHRAE 90.1.
  20. Sound power and pressure level ratings expected from measurements performed in accordance with ARI-370 and Chrysler Sound Level Specification. Include estimates for each octave band at each of the four standard ARI points.
  21. Unit Drawing: Indicate overall unit dimensions, key component locations and dimensions, required clearances and field connection details for piping and electrical wiring and unit access.
  22. Floor layout drawing: Indicate centerlines; Indicate locations and dimensions of chiller points of contact with the floor.
  23. Other Diagrams: Thermal insulation requirements diagram and vibration isolator diagrams.
  24. Weights: Shipping weight loadings and distribution, operating weight, weight of each major component, weight load at each vibration isolator.
  25. Capacities and Charges: Refrigerant and Oil.
  26. Electrical and Control Wiring Drawings
  27. General Requirements: A complete set of control wiring drawings and physical layout of the multi-chiller system (P & ID drawing) and associated control and sensing devices (temperature, pressure, flow sensors, end switches, etc. on the chiller unit and/or in the field piping) shall be submitted to the Owner and engineer prior to start of fabrication. Drawings shall include:
  28. Schematic and interconnection diagrams shall have each point numbered including the schematic of the starter and annunciator panel and internal wiring of relays. Wire sizes to be indicated.
  29. Bill of material showing the manufacturer, rating, catalog number and identification symbol of each component, including relays, meters, fuses, timers, contactors, resistors, capacitors, control and sensing devices, etc. Supplier to include in the bill of materials whether the control and sensing devices are "furnished and installed", or "furnished by chiller manufacturer and installed by others", or "furnished by others and installed by others".
  30. A complete sequence of operation.
  31. Electrical and control drawings are to be presented in ladder logic format to JIC and Chrysler standards.
  32. Drawings are to be done with a Chrysler approved title block and numbering sequence.
  33. Electrical and control drawings shall incorporate all aspects of the chiller plant including the chiller, all field devices (pressure temperature and flow transmitters, etc.), pumps, starters plus monitoring of certain aspects of the system including interface to the PC workstation.
  34. Electrical and control drawings shall include power wiring, 480 Volts, and control wiring 115, and 24 Volt etc., AC and DC.
  35. Drawings Required:

1)  Chiller unit electrical and control drawings.

2)  Master control panel, field wiring, and starter drawings.

3)  Low voltage 480 volt starter drawings.

4)  Electrical/control riser diagrams.

5)  Sequence of operation.

6)  Input/output list and addresses.

  1. Software: Manufacturer shall provide the following software packages:
  2. System Graphics
  3. System Graphics - PC
  4. Program for Intellution PC
  5. Certification of performance from the factory.
  6. Certification letter from manufacturer stating that the chiller has been through start-up procedures and that it is functioning properly.
  7. Material Safety Data Sheet (MSDS) for any refrigerants used that is NOT classified as ‘A1’ for flammability and toxicity by ASHRAE 34. MSDS for Mexico shall be in Spanish.
  8. Manufacturer’s warranty certificate.

1.8  OPERATION AND MAINTENANCE MANUALS

  1. 90 days prior to start-up of equipment, submit to the Owner with 10 copies of operating and maintenance instruction manuals bound in durable stiff covers.
  2. Instruction manuals shall contain the following:
  3. Index on book form of component and diagram data sheets.
  4. Description and assembly drawings of each item of equipment.
  5. Parts nomenclature.
  6. Wiring and piping drawings.
  7. Procedures for start-up and operation of unit.
  8. Instructions for disassembly and reassembly of all items of equipment furnished, as required for normal operation and maintenance.
  9. Sequence of operation for the equipment.
  10. Normal set points and limits for controls.
  11. Final settings and adjustments established for start-up tests.
  12. Preventative maintenance schedule and checklist including daily, weekly, monthly, and annual schedules.
  13. Operating checklists.
  14. Spare parts list.
  15. Special tools list.
  16. Total Maintenance System list.
  17. Start-up report.
  18. In addition to the folded insert drawings, (11 inches by 17 inches) and data sheets incorporated in each copy of the manual, large diagrams and schematics shall be furnished in as-built condition on mylar reproducible sheets and electronically on disc.
  19. Provide software and related back-up diskettes for control systems.

1.9  SPARE PARTS LISTS

  1. Supplier shall submit a list of parts recommended to maintain units in full operation under normal operating conditions, including long lead time items in excess of 1 week delivery such as vacuum contractors, spare motors and spare compressors. List should include expected life and recommended replacement schedule for furnished equipment. Selection shall take into account vulnerability to normal wear, availability and expected shelf life. Supplier shall also advise special devices and tools required for maintenance and calibration of all equipment furnished. Lists shall indicate current total prices of recommended and optional parts and materials.

1.10  REFRIGERANT AND LUBRICATING OIL CHARGE

  1. Refrigerant and lubricating oils needed to satisfy the initial start-up and testing needs of the equipment shall be provided.

1.11  WARRANTY

  1. Warranty: Manufacturer shall Warrant in writing and signed all equipment and material of its manufacture against defects in workmanship and material for a period of twenty-four (24) months from date of start up or Substantial Completion, whichever occurs later.
  2. Perform warranty work with manufacturer’s factory-trained and factory-employed service technicians.

PART 2 - PRODUCTS

2.1  MANUFACTURERS

  1. Manufacturers: Subject to compliance with requirements, provide chillers by one of the following:
  2. Trane Company (The)
  3. United Technologies Corp.; Carrier Corporation Subsidiary
  4. York International Corporation
  5. Daikin-McQuay
  6. Thermal Care

2.2  MANUFACTURED UNIT

  1. Description: a packaged factory assembled, charged and operational tested air-cooled screw chillers as specified herein. Chiller shall include, but is not limited to: a complete system with multiple independent refrigerant circuits, semi-hermetic twin screw compressors, shell and tube type evaporator, air-cooled condenser, R134a refrigerant, lubrication system, interconnecting wiring, safety and operating microprocessor controls including capacity controller, control center, motor starting components, and special features as specified herein or required for safe, automatic operation.
  2. Operating Characteristics:
  3. Provide low ambient control and high ambient options as required to ensure unit is capable of operation from 0°F to 125°F (-18°C to 52°C) ambient.
  4. Provide capacity control system capable of reducing unit capacity to 10% of full load. Compressor shall start in unloaded condition. Application of factory installed hot gas bypass shall be acceptable as required to meet specified minimum load.
  5. Sound pressure level, resulting from centrifugal refrigeration machine operation, shall not exceed 80 dBA. When measured in accordance with ARI Standard 575 and the National Machine Tool Builders Association (NMTBA) Noise Measurement Techniques latest edition. Data shall comply with the requirements of Chrysler’s sound level specification for industrial machinery and equipment.
  6. Bids shall clearly state exceptions regarding the ability of the proposed vendor in complying with this requirement.
  7. If Bidders cannot meet the specified noise level and the manufacturer of the proposed equipment is capable of demonstrating that engineering solutions have been fully explored without positive results, the bidder shall furnish with the bid, the minimum sound level that can be achieved (not to exceed 85 dBA), manufacturer's complete octave-band analysis, together with his identification of probable noise sources. Data shall include readings at each test point from each load condition in sufficient detail to permit calculation of associated noise exposure. Furnish manufacturer's information as to nature, construction type, and expected noise reduction for corrective schemes such as enclosures and include cost of such corrective schemes in bid.
  8. Compressor and compressor inlet and discharging piping shall have sound blanketing as required to meet the specified criteria.
  9. Pressure Limiting and Relief Devices: Manufacturer's standard complying with ASHRAE 15, including rupture disc. Provide refrigerant charging and transfer connections, pressure relief device (per BSR/ASHRAE 15 safety code) on the evaporator to prevent over-pressurization of the refrigerant, and to sense refrigerant pressure or temperature. System shall incorporate as a minimum the following indicating, warning and shut-down protective devices and shall include wiring:

Sensor / Warning / Shutdown /
Oil pressure / X / X
High lube oil temperature / X / X
Low lube oil temperature / X / X
High condenser head pressure / X / X
High evaporator head pressure / X / X
Low evaporator temperature / X / X
Vibration / X / X
High electrical motor current / X / -
Hours run totalizing meter / - / -
Compressor bearing temperature sensor / X / X
Surge / X / X
Compressor contactor failure / X / X
  1. Refrigerant Flow Control Devices: Provide refrigerant flow control devices between evaporator and condenser (and as required elsewhere) to regulate refrigerant flow at volume and pressure required to maintain evaporator liquid refrigerant at level sufficient to keep cooler tubes adequately wetted through full range of chiller operation.
  2. Cabinet: Unit panels, structural elements, control boxes and heavy gauge structural base shall be constructed of galvanized steel. Unit panels, control boxes and structural base are finished with a baked on powder paint. All painted surfaces shall be coated with baked on powder paint which, when subject to ASTM B117, 1,000 hour, 5% salt spray test, yields minimum ASTM D1654 rating of “6”.
  3. Unit shall ship in one piece and shall require installer to provide onlya single evaporator inlet and outlet pipe connection.Chiller model that ships in multiple pieces shall NOT be acceptable. Trim kits and multiple evaporator inlet and outlet pipe connections shall NOT be acceptable to meet the single piece shipment requirement of this specification.

2.3  COMPRESSORS AND MOTORS