WATER-COOLED HELICAL ROTARY CHILLER
1.0
GENERAL REQUIREMENTS
1.1
Application. This technical specification applies to equipment and materials
furnished and installation work performed by the Contractor.
1.2
Jobsite: The State of Florida, Dept. of Children and Families (Owner) is
procuring one replacement chiller for the following state-owned building:
Emmett S. Roberts Building
5920 Arlington Expressway, Jacksonville, FL 32211
Site Contact: Chuck Johnson, Tel. (904) 485-9485
Alternate Site Contact: Larry Lemelin, Tel. (904) 485-9484
1.3
1.4
1.5
Scope of Work. Work included under this specification includes:
A.
Furnishing one new water-cooled helical rotary water chiller as specified
herein.
B.
Removal and disposal of existing Chiller #2 and starter/control cabinet.
C.
Installation of the new chiller, including chilled water and condenser water
piping connections inside the mechanical room; re-routing and insulating
chilled water piping inside the mechanical room; installation of water flow
switches; and, verification of proper water treatment for the new chiller.
D.
Providing electrical power and control wiring connections (including water
flow interlocks), and building automation system (BAS) programming to
interface with the new chiller.
System Description. The chiller to be replaced (Chiller #2) fits into the HVAC
systems as follows:
A.
Chiller evaporators are piped in series (∆T=5°F each per original design).
CHW flows sequentially through chillers at 600 gpm, leaving Chiller #2 at
44°F supply setpoint.
B.
Each chiller has its own cooling tower and condenser water pump.
Condenser water flow is 450 gpm, designed for 85°F supply water under
full-load conditions.
C.
Each chiller reports its operational parameters to an existing Trane Tracer
Summit building automation system (BAS). The BAS operator, in turn, is
capable of starting and stopping each chiller (manually or by daily
schedule), and can remotely adjust the chilled water supply temperature
for each chiller.
Documentation. The Contractor shall submit the following:
Technical Specification -- Page 1
A.
Chiller shop drawings shall be submitted and approved by the Owner
before equipment is ordered. Shop drawings shall indicate components
and their assembly; control features; weights and dimensions; and,
operational and performance data.
1.
Operational data shall include: rated capacities, refrigerant type,
electrical requirements, performance specifications, control system
operation, and other such information.
2.
Performance data (energy input versus cooling load output) based
on ANSI/AHRI Standard 550/590 conditions, shall be plotted from
10 percent to 100 percent of full load.
B.
Shop drawings for installation materials shall be submitted before
ordering. Submittals shall include diagrams showing intended routing of
new conduit above the floor, and new chilled water piping routing to
accommodate 2-pass evaporator configuration.
C.
Performance test results shall accompany or precede chiller delivery to
the jobsite. (Performance test shall be conducted by the chiller
manufacturer in accordance with ANSI/AHRI Standard 550/590.)
D.
Three copies of operating and maintenance instructions shall be provided
to the Owner upon completion of the job.
E.
Copies of both the Manufacturer's warranty and the Contractor's warranty
shall be delivered to the Owner at completion of the job.
1.6
Coordination. All on-site activity shall be coordinated with the Site Contact or his
designee.
1.7
Installation work shall be conducted such that system downtime is minimized.
1.8
Acceptance. Work not conforming to specified requirements, or any work for
which approval has not been obtained, shall be rejected.
1.9
Warranty. Provide a one-year Contractor’s Warranty on all installation
workmanship and materials.
2.0
ACCEPTABLE PRODUCTS
2.1
The Contractor shall furnish one Trane Model RTHD water-cooled helical rotary
water chiller with Adaptive Frequency Drive, B2-B2-B2 configuration (Product
Version #167), conforming to Owner’s Basis of Design.
2.2
Basis of Design. Specified unit shall be certified in accordance with ANSI/AHRI
Standard 550/590 at the following conditions:
Technical Specification -- Page 2
Trane Model
Compressor/Evaporator/Condenser
Evaporator Leaving water temp
Evaporator Entering water temp
Evaporator Flow (gpm)
Evaporator passes
Evaporator pressure drop
Condenser Entering water temp
Condenser Leaving water temp
Condenser Flow (gpm)
Condenser passes
Cond pressure drop (max)
Full Load Capacity
Full Load Efficiency
NPLV
IPLV
Electrical
Minimum Ckt. Ampacity (MCA)
Max. Overcurrent Protection (MOCP)
Factory Refrigerant Included
Dimensions
2.3
RTHD w/ Adaptive Frequency Drive
B2-B2-B2 Configuration
44 °F
51.7 °F
600 gpm
2
7.00 ft.
85 °F
97.4 °F
450 gpm
2
8.30 ft.
194.4 Tons
0.691 kW/Ton
0.417 kW/Ton
0.408 kW/Ton
480v / 3ph / 60Hz
240.2 amperes
400 amperes
R-134A
125.4"L x 64.9"W x 74.4"T
Factory-supplied Accessories. The chiller manufacturer shall provide each of the
following features, without exception:
Factory Adaptive Frequency Drive
Factory mounted circuit breaker
Factory insulation (all cold surfaces)
7" Color touch screen control panel
LonMark control interface
Factory charge of R-134A refrigerant
Shrink wrap packing for shipment
Two (2) flow switches (shipped loose for contractor installation)
Factory start-up
5 year factory warranty - Whole unit - including parts, labor & refrigerant
2.4
Performance requirements. The Manufacturer will be required to conduct a
factory performance acceptance test to verify performance figures submitted with
the shop drawings. Chiller performance shall be tested in accordance with
ANSI/AHRI Standard 550/590. Certified performance shall be equal to
performance claimed by the Manufacturer.
2.5
Condition of Equipment Furnished. The furnished equipment shall be shipped,
delivered, and set in place, free of internal and external physical damage. The
owner shall have the right to refuse any equipment set in place with obvious
physical damage.
Technical Specification -- Page 3
2.6
Internal control features. The new chiller shall be furnished with an integral
programmable control system with display panel front. Panel shall feature a
display readout for pressures, temperatures, setpoints, etc., plus keypad(s) for
programming setpoints and calling up data for display. Control system shall
provide the following key features, as a minimum:
A.
Programmable setpoints: leaving chilled water temperature, electrical
demand limit.
B.
Selectable display of operating parameters: Chilled water temperatures,
condenser water temperatures, refrigerant pressures, percent motor
current draw, oil pressure, operating hours.
C.
Display of safety/cycling shutdown messages providing the day and time
of shutdown, cause of shutdown, and type of restart required.
D.
A time delay to prevent compressor restart within fifteen minutes of
shutdown.
E.
Anti- single phase and phase reversal protection.
F.
High condenser refrigerant pressure cutout.
G.
Low evaporator refrigerant temperature cutout.
H.
Low oil pressure and high oil temperature trips.
I.
Waterflow interlocks (to prove chilled water and condenser water flow via
external flow switches) as a condition for chiller operation).
3.0
EXECUTION
3.1
Release for Manufacture. Contractor shall obtain Owner approval of shop
drawing submittal before ordering any equipment. (Release for Manufacture is
contingent upon release of appropriated funds by the Office of the Governor.)
3.2
Demolition. The Contractor shall remove existing Chiller #2 and dispose offsite.
The Contractor shall also remove the chiller starter/control cabinet (mounted on
a separate concrete pad behind the chiller), preserving the underfloor conduit
stub coming up through the pad for pulling new power conductors.
3.3
Chiller delivery to Jobsite. The Contractor shall provide offloading, crane and
rigging as needed to unload the delivery truck, and shall assure protected
storage if the chiller is not immediately set in place on the mounting pad. (The
Owner, with advance notice, will make storage space inside the loading dock
available for temporary storage of the new chiller on the date of delivery to the
jobsite.) Provide the Owner with documentation of certified performance test
results.
Technical Specification -- Page 4
3.4
Installation of new equipment. The new chiller shall be set on the equipment pad
vacated by the old machine. The Contractor shall provide loading, lifting,
disassembly/reassembly, and rigging as needed to install the new chiller on the
equipment pad. Follow Manufacturer’s procedures for mechanical installation
(Trane Document #RTHD-SVX01D-EN). The Contractor is responsible for
restoring & reconnecting building fixtures requiring temporary relocation to clear
a travel path for chiller equipment.
3.5
Pipe Fabrication and Installation:
A.
Modify existing piping & valves as necessary to reconnect to new chiller.
Connections shall be in accordance with approved shop drawings.
B.
Per the original design, Chiller #2 had a 1-pass evaporator with left-hand
inlet and right-hand outlet. Shop drawings should describe a rerouting of
chilled water piping to accommodate 2-pass evaporator connections.
Recommended: Left-hand inlet & outlet connections, with CHW outlet
piping routed through space vacated where existing starter/control cabinet
was removed (see Paragraph 3.2 above). Coordinate with new power
conduit routing (see Paragraph 3.7B below).
C.
Make piping layout and installation in the most advantageous manner
possible with respect to headroom, valve access, opening and equipment
clearance for other work. Give particular attention to piping in the vicinity
of equipment. Preserve the maximum access to various equipment parts
for maintenance.
D.
Chilled water and condenser water piping shall be Schedule 40 black
steel per ASTM A120 Gr. A or ASTM A53 Gr. A or B. Fittings shall be
Schedule 40 black steel seamless butt-welded per ASTM A234 and ANSI
B16.9 to match pipe wall thickness. Flanges shall be ANSI 16.5, 150-lb.
rated, black steel, flat-faced, welding neck to match pipe wall thickness.
E.
Fabricate sections having butt-welded joints offsite, to the greatest extent
possible, to minimize welding activity inside the building.
F.
Install pipe neatly, free from unnecessary traps and pockets. Work into
place without springing or forcing. Align piping to eliminate strain on
evaporator and condenser heads. Use fittings to make all changes in
direction (i.e., field bending and mitering are prohibited). Make reducing
connections with reducing fittings only. Make all connections to
equipment using flanged joints or unions. Arrange piping to permit
removal of evaporator and condenser heads with minimal disassembly of
piping.
G.
Flush dirt, scale and other foreign matter from inside piping before tying in
sections, fittings, valves or equipment.
H.
Whenever practical, install piping close to walls, ceilings and columns, so
as to minimize space requirements. Provide proper clearances for pipe
insulation, for offsets, and for operation and maintenance of fittings.
Technical Specification -- Page 5
3.6
3.7
I.
Support pipe adequately to maintain line and grade, with due provision for
expansion and contraction. Support piping so that no piping weight is
supported by equipment.
J.
Provide anchors as required. Use pipe anchors consisting of heavy steel
collars with lugs and bolts for clamping to pipe and attaching anchor
braces. Install anchor braces in the most effective manner to secure the
desired results. Do not install supports, anchors or similar devices where
they will damage construction during installation or because of the weight
or the expansion of the pipe. If necessary, insulate anchors sufficiently to
prevent moisture condensation problems.
K.
Install 3/4" drain valves at all low points of water piping systems so that
these systems can be drained completely.
L.
Install Factory-provided flow switches in the chilled water and the
condenser water piping per Manufacturer’s instructions.
M.
Clean or flush piping systems thoroughly. Purge pipe of construction
debris and contamination before placing the systems in service. Remove
temporary piping and jumpers when cleaning and flushing is complete.
Use temporary strainers on initial start-up, to protect the new shell-andtube exchangers on the new chiller. Remove temporary strainers before
completion of job.
N.
Furnish suitable water treatment for the chilled water loop.
Pipe Insulation. Provide cellular glass piping insulation on all new chilled water
piping.
A.
Cellular glass insulation shall be preformed, water retardant, closed cell
composition, complying with ASTM C 552, “Specification for Cellular
Glass Thermal Insulation”. Thermal conductivity “k” rating shall be less
than 0.30 Btu-in/hr•ft²•°F at 75°F. Flame-spread/smoke-developed ratings
shall be 0/0. Equal to Pittsburgh-Corning Foamglas.
B.
Pipe jacketing and fitting covers shall be aluminum, minimum 0.016-inch
thick, with laminated or baked moisture retardant.
C.
Insulate with bore-coated prefabricated cellular glass pipe insulation.
Apply thickness of insulation equal to the existing insulation to which it is
joined. Coat joints with joint sealant and secure each new section with not
less than two 16-gauge stainless steel wires. Finish with jacketing
secured with straps. Finish elbows and fittings with mastic reinforced with
fabric, or finish with fitting covers.
D.
Apply insulation and finish materials in strict accordance with all
manufacturers’ recommendations.
Electrical Hookup. The Contractor shall provide a complete electrical installation,
as follows:
Technical Specification -- Page 6
A.
All wiring shall be copper, sized per NEC.
B.
Provide properly-supported rigid conduit to the chiller for power wiring.
Extend new conduit to the chiller from the conduit stub left penetrating
through pad where existing starter/control cabinet was removed. (See
Paragraph 3.2 above.) Verify grounded continuity of entire conduit run, or
alternatively, provide an equipment grounding conductor sized per NEC
Article 250 (Table 250.122) within the conduit.
C.
New power conductors shall be minimum 250 kcmil, Type THW, rated
75°C. Pull new power conductors through new conduit in a continuous
run from existing fused switch. Verify existing or provide new 400-amp
fuses in existing fused disconnect.
D.
The chilled water and condenser water flow switches shall be wired to
internal controls per Manufacturer's instructions. Flow switches shall be
checked to confirm that they are installed and wired correctly, and that
they are functioning properly to prove condenser- and chilled-water flow.
E.
Contact Trane Factory Service to reconnect disconnected BAS wiring.
3.8
Start-Up and test. Contact Trane Factory Service for factory startup.
3.9
Final acceptance. The completed installation shall be inspected by the Owner’s
designee. Final payment shall not be authorized until:
A.
All building fixtures temporarily relocated to clear a path for equipment are
fully restored & reconnected.
B.
All noted deficiencies are corrected.
C.
All required documentation has been delivered to the Owner.
D.
Necessary water treatment systems are in place and functioning.
E.
Full BAS control of chiller operation and chilled water setpoint is tested
and confirmed.
Technical Specification -- Page 7