USACE / NAVFAC / AFCESA / NASA UFGS-42 22 16 (August 2008)
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Preparing Activity: NASA Superseding
UFGS-42 22 16.00 40 (April 2008)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 42 22 16
RECIPROCATING PROCESS CHILLERS AND COOLERS
08/08
NOTE: This specification covers the requirements for water cooled reciprocating
water chillers for refrigerating and air conditioning applications.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
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(2003) Standard for Water-Chilling Packages Using the Vapor Compression Cycle][AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)ASHRAE EQUIP IP HDBK(2004) Handbook, HVAC Systems and Equipment (IP Edition)ASHRAE EQUIP SI HDBK(2004) Handbook, HVAC Systems and Equipment (SI Edition)ASHRAE HVAC APP SI HDBK(2007) HVAC Applications Handbook, SI Edition][INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)ISO 1940-1(2003; Corrigendum 2005) Mechanical Vibration - Balance Quality Requirements for Rotors in a Constant (Rigid) State - Part 1: Specification and Verification of Balance Tolerance - International Restrictions][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA MG 1(2007; Errata 2008) Standard for Motors and Generators][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 70(2007; AMD 1 2008) National Electrical Code - 2008 Edition][U.S. DEPARTMENT OF ENERGY (DOE)DOE CE-6(2000) How to Buy an Energy-Efficient Air-Cooled Electric Chiller]1.2 SUBMITTALS
NOTE: Review Submittal Description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Keep submittals to the minimum required for adequate quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are [for Contractor Quality Control approval.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for the Government.] Submit the following
in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Submit connection diagrams indicating the relations and connections of the following items.
The drawings shall indicate the general physical layout of all controls, and internal tubing
and wiring details.
Compressor
Motor
Control Panel
Condenser
Evaporator
Refrigerant Circuit
Alarm Systems
Vibration Isolators
Gages
Submit Control Diagrams for water-cooled reciprocating chiller units in accordance with paragraph
entitled, "Control," of this section.
SD-03 Product Data
Submit Equipment and Performance Data for the following items indicating use life, system functional
flows, safety features, and other features such as electrical system protective device ratings.
Chiller Unit
Compressor
Condenser
Submit manufacturer's catalog data for the following items:
Accessories
Spare Parts
Vibration Isolators
SD-07 Certificates
Submit certificates for following items showing conformance with the referenced standards contained
in this section.
Compressor
Motor
Control Panel
Condenser
Evaporator
Refrigerant Circuit
Alarm Systems
Vibration Isolators
Gages
SD-08 Manufacturer's Instructions
Submit Manufacturer's Instructions for water-cooled reciprocating chiller units in accordance
with paragraph entitled, "General Requirements," of this section.
SD-10 Operation and Maintenance Data
Submit Operation and Maintenance Manuals in accordance with paragraph entitled, "Manufacturer's
Field Service," of this section.
1.3 GENERAL REQUIREMENTS
Submit Manufacturer's Instructions for water-cooled reciprocating chiller units including manufacturer's style
or catalog numbers, specification and drawing reference numbers, warranty information, and fabrication site information.
1.3.1 Mechanical
NOTE: If Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST
SYSTEMS is not included in the project specification, applicable requirements
therefrom should be inserted and the following paragraph deleted. If Section
23 05 48 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT is not
included in the project specification, applicable requirements therefrom should
be inserted and the second paragraph deleted.
[Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEMS applies to work specified in this
section.]
[Section 23 05 48 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT applies to work specified in this
section.]
1.3.2 Electrical
Rate motors in accordance with Section 26 60 13.00 40 LOW-VOLTAGE MOTORS.
Provide solid state sensors and protection in accordance with Section 26 05 70.00 40 HIGH-VOLTAGE OVERCURRENT
PROTECTIVE DEVICES and Section 26 05 71.00 40 LOW-VOLTAGE OVERCURRECT PROTECTIVE DEVICES.
PART 2 PRODUCTS
NOTE: Compressor and motor balance shall conform to ISO Std. 1940/1 - (1986)
Balance Quality Requirements of Rigid Rotors - Determination of Permissible
Residual Unbalance unless otherwise noted. Motor vibration levels shall conform
to NEMA Specification MG-1, Motors and Generators, Part 7 unless otherwise noted.
2.1 MANUFACTURED CHILLER UNIT
NOTE: For descriptive specification, edit this article to suit project conditions.
If performance specification is used for the project, delete this article.
Provide factory assembled water cooled liquid chiller unit, consisting of [two] [_____] [semi-] hermetic reciprocating,
motor-driven compressor[s] mounted on [spring] [_____] vibration isolators, [hot gas muffler,] condenser, insulated
evaporator, [independent refrigerant circuits,] thermal expansion valves, refrigeration accessories, and control
panels.
Except as specified, ensure unit and spare parts are the manufacturer's standard product, designed for the service
indicated, and tested and rated in accordance with AHRI 550/590.
Factory run-test(s) prior to shipment, with capacity, current draw, and control operation monitored, recorded,
and submitted. Ship unit(s) with a full operating charge of [R-22] or other suitable refrigerant with ODP=0.0,
and oil. Operate the unit with [230] [208] [480] volt 3-phase, 60 Hertz power.
"Energy efficiency ratings shall meet or exceed the full-load efficiency and the integrated part-load value (IPLV)
efficiency ratings as described in ARI Standard 550/590-98 and DOE CE-6."
2.2 LIQUID CHILLER
NOTE: Performance specification for one, or identical units. Use schedule
to specify units of different sizes.
Reciprocating water chiller unit shall have minimum capacity of [_____] watt tons of refrigeration when delivering
[_____] cubic meter per second gpm of chilled water at [_____] degrees C degrees F when supplied with [_____]
cubic meter per second gpm of condenser water at [_____] cubic meter per second [_____] degrees F. For determining
this capacity, ensure the fouling factor for evaporator and condenser is no less than 0.0005. Water head loss
shall not exceed [_____] millimeter [_____] feet through condenser, or [_____] millimeter [_____] feet through
evaporator.
2.3 COMPONENTS
NOTE: The following article may be deleted, or edited as necessary to suit
project conditions and to further describe the Manufactured Chiller Unit.
2.3.1 Compressor
Construct the compressor(s) with heat treated [forged steel] [ductile iron] crankshafts, aluminum alloy connecting
rods, cast aluminum pistons fitted with one compression ring and one oil ring, replaceable cylinder liners, and
double mesh suction inlet screens. Housing, cylinder heads, liners, and handhole covers shall be close grain
cast iron. Suction and discharge valves shall be high strength, non-flexing, ring type. Valve plates shall
be of cast iron, with ground and lapped seats. Rotating parts shall be statically and dynamically balanced to
ISO 1940-1-1986, [G16] [G6.3] [_____]. Mount compressors on [spring] [_____] vibration isolators. Provide isolation
service valves on inlet and outlet lines of each compressor.
2.3.1.1 Lubricating System
Provide lubricating system with positive displacement oil pump, oil charging valve, oil level sight glass, oil
filter, and magnetic-plug on strainer, arranged to be self relieving to the suction side, and to ensure adequate
lubrication during starting, stopping, and normal operation.
2.3.1.2 Capacity-Reduction
Provide automatic capacity-reduction equipment consisting of suction valve unloaders. Operate the lifting mechanism
by [oil pressure] [gas discharge pressure] [solenoid valve]. Provide for unloaded compressor start.
2.3.1.3 Motor
Compressor shall conform to NEMA MG 1, be direct-driven by [1800] [3600] rpm, [230] [_____] volt, 3-phase, 60
Hertz, constant speed motor, UL listed, and designed for [across-the-line] [part-winding] [_____] starting. Motor
shall have copper windings and be suction gas cooled. Provide solid state sensor and electronic winding overheating
protection.
2.3.1.4 Crankcase Heater
Crankcase heater shall be immersible type. Energize heater [continuously] [_____]. [Mount a "DANGER - EXTERNAL
POWER SUPPLY" sign having 10 millimeter 3/8-inch white letters with red background on the junction box for the
crankcase heater.]
2.3.2 Condenser
Condenser shall be shell-and-tube type, of [seamless] [welded] steel construction, with removable [cast iron]
[fabricated steel] heads [and independent, dual refrigerant circuits].
Tubes shall be cleanable [and] [replaceable] [seamless copper] [_____], with integral fins, [expanded] [_____]
into tube sheets.
Design, test, and stamp refrigerant side for [2050] kilopascal [300] psig [_____] working pressure in accordance
with ASHRAE HVAC APP SI HDBK and ASHRAE EQUIP SI HDBK ASHRAE EQUIP IP HDBK, Chapter 13.
Provide [2050] kilopascal [300] psig [_____] safety relief valve on condenser shell.
Design, test, and stamp water side for [1030] kilopascal [150] psig [_____] working pressure in accordance with
ASHRAE HVAC APP SI HDBK and ASHRAE EQUIP SI HDBK ASHRAE EQUIP IP HDBK, Chapter 13. Provide drain connection.
2.3.3 Evaporator
Evaporator shall be shell-and-tube type, of [seamless] [welded] steel construction, with removable [cast iron]
[fabricated steel] heads [and independent, dual refrigerant circuits].
Tubes shall be cleanable [and] [replaceable] [seamless copper] [_____], with integral fins, [expanded] [_____]
into tube sheets.
Design, test, and stamp refrigerant side for [1550] kilopascal [225] psig [_____] working pressure, and water
side for [1030] kilopascal [150] psig [_____] working pressure, in accordance with ASHRAE HVAC APP SI HDBK and
ASHRAE EQUIP SI HDBK ASHRAE EQUIP IP HDBK, Chapter 13. Provide water drain connection.
Insulate with [_____] [25] millimeter [_____] [100] inch thick flexible [expanded polyvinyl chloride] [polyurethane
foam] insulation with maximum K value of [0.037] watt per meter per degree Kelvin [0.26] Btu per hour per foot
square per degree F [_____].
2.4 ACCESSORIES
2.4.1 Refrigerant Circuit
Each independent refrigerant circuit shall be factory supplied and piped, and complete with liquid line solenoid
valve, filter dryer, liquid line sight glass and moisture indicator, thermal expansion valve, [charging valve][
8 millimeter 1/4-inch flare charging ports], insulated suction line, compressor discharge service valve, [discharge
line check valve.]
2.4.2 Control
Submit Control Diagrams for water-cooled reciprocating chiller units showing the physical and functional relationship
of equipment. Electrical diagrams shall show size, type, and capacity of the systems.
Power and control devices, including but not limited to motor starters, relays, timers, fuses, circuit breakers,
shall be in accordance with Section 26 05 70.00 40 HIGH-VOLTAGE OVERCURRENT PROTECTIVE DEVICES and Section
26 05 71.00 40 LOW-VOLTAGE OVERCURRECT PROTECTIVE DEVICES.
Components of the control panel, and external control devices, shall be UL listed. Designate all components
with a code, and called out by that code on the wiring diagrams and schematics.
Timers shall be electronic, with adjustable settings. Indicating lights shall be push-to-test type and easily
replaceable from the front of the panel.
2.4.2.1 Sequence Panel
NOTE: Include this paragraph only if multiple units are provided.
Provide a [remote mounted] sequence panel, with sequence switch, temperature controller, and low temperature
cutout, to permit operation in [series] [parallel] with lead-lag switching.
2.4.2.2 Control Panel
Control panel, having separate sections for starter and refrigeration controls, shall be furnished for each compressor
and located [on] [near] chiller unit. Starter section shall have internal access door and customer connection
junction box with knockouts for remote interlocks.
Ensure control panels are factory assembled, and wired in accordance with UL and NFPA 70 requirements, with single
point power connection. Identify each wire at every termination with a wire number matching the wiring diagram
and control schematic. Wire identification shall utilize preprinted heat-shrink wire sleeves. Hand lettering
or marking is not acceptable.
For each control panel, the starter section shall have:
Circuit breaker type combination starter.
Power controls for [across-the-line] [part winding] [_____] starting.
Control power [fuse] [circuit breaker].
Control power transformer for [115] [_____]-volt control voltage.
Terminal blocks, having terminals for the main power supply and all auxiliary connections clearly identified.
Pumpdown control relay.
Compressor starter relay.
Reset relay.
Non-recycling compressor overload relay.
Anti-recycle timer.
For each control panel, the refrigeration section shall have:
High pressure control.
Low pressure control.
Motor protection.
Oil pressure control.
Mount the following devices on the control panel face:
Compressor run lights.
System start-stop switch.
Hand, Off, Auto switch.
[Suction and Discharge Pressure Gages.]
[Compressor lead-lag switch.]
Demand limit switch.
2.4.2.3 Operating Controls
Provide the following operating controls:
[Multi] [_____]-step capacity control in response to [leaving] [return] chilled water temperature.
Five minute off timer to prevent short cycling.
[Part-winding start timer.]
Periodic pump-out timer, to pump down on chilled water flow and high evaporator refrigerant pressure.
Load limit thermostat to limit compressor loading on high return chilled water temperature.
Three phase monitor to protect unit by stopping compressor on phase loss, phase reversal, phase unbalance,
or under voltage.
Cycle counter and operating hour meter.
Computer switching circuit.
2.4.3 Alarm Package
Furnish an alarm package for alarm systems with test button. Furnish lights to indicate when control circuit
is energized and compressors are running. Provide an audible alarm and indicating lights to indicate compressor
malfunction, low chilled water temperature, and evaporator water flow failure.
2.4.4 Hot Gas Bypass
Provide hot gas bypass valve, and associated control panel wiring and piping, to allow operation of unit below
the minimum step of unloading.
2.4.5 Gage Board
Provide factory piped gage-board for each compressor, with pressure gages for suction and discharge refrigerant
pressures, and oil pressures.
2.4.6 Vibration Isolators
Provide vibration isolators as recommended by the manufacturer to support complete chiller unit. Refer to Section
23 05 48 VIBRATION AND SEISMIC CONTROLS FOR HVAC PIPING AND EQUIPMENT for vibration isolation considerations.
PART 3 EXECUTION
3.1 INSTALLATION
Install chiller assembly in accordance with manufacturer's instructions. [Provide connection for electrical
service.]
Provide connections for chilled water piping, condenser water piping, and auxiliary water piping. [Arrange piping
for easy dismantling to permit tube cleaning.] Provide piping from safety relief valve to outdoors.
Chilled water inlet piping shall have [thermometer,] [strainer,] [flow switch,] [flexible pipe connector,] [pressure
gage,] [and] shut-off valve.
Chilled water outlet piping shall have [flexible pipe connector,] [thermometer,] [pressure gage,] [and] [shut-off]
[balancing] valve.
Condenser inlet piping shall have [thermometer,] [strainer,] [flow switch,] [flexible pipe connector,] [pressure
gage,] [and] shut-off valve.
Condenser outlet piping shall have [flexible pipe connector,] [thermometer,] [pressure gage,] [and] [shut-off]
[balancing] valve.
3.2 MANUFACTURER'S FIELD SERVICE
Contractor shall submit [6] [_____] copies of the Operation and Maintenance Manuals 30 calendar days prior to
testing the water-cooled reciprocating water chiller units. Update and resubmit data for final approval no later
than 30 calendar days prior to contract completion.
Furnish service by factory-trained representative for a period of [_____] calendar days, to conduct training
and supervise [dehydration and charging,] testing, and start-up.
3.3 DEMONSTRATION
Demonstrate system operations and verify specified performance.