USACE / NAVFAC / AFCESA / NASA UFGS-23 64 00 (August 2008)
--------------------------------
Preparing Activity: NAVFAC Superseding
UFGS-23 64 00.00 10 (January 2008)
UFGS-23 66 00.00 20 (July 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL July 2008
SECTION 23 64 00
PACKAGED WATER CHILLERS, ABSORPTION TYPE
08/08
NOTE: This guide specification covers the requirements for packaged water chillers,
absorption type equipment.
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.
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
CAMP LEJEUNE NOTE: Do not specify packaged water chiller absorption type for
Camp Lejeune projects without specific approval from the base
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 560(2000) Absorption Water Chilling and Water Heating Packages][AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS (ASHRAE)ASHRAE 15 & 34WARNING: Text in tags exceeds the maximum length of 300 characters][AMERICAN WELDING SOCIETY (AWS)AWS Z49.1(2005) Safety in Welding, Cutting and Allied Processes][ASME INTERNATIONAL (ASME)ASME BPVC SEC VIII D1(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section VIII, Pressure Vessels Division 1 - Basic Coverage][ASTM INTERNATIONAL (ASTM)ASTM A 307(2007b) Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile StrengthASTM B 395/B 395M(2008) Standard Specification for U-Bend Seamless Copper and Copper Alloy Heat Exchanger and Condenser TubesASTM E 84(2008a) Standard Test Method for Surface Burning Characteristics of Building MaterialsASTM F 104(2003) Standard Classification System for Nonmetallic Gasket Materials][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA MG 1(2007; Errata 2008) Standard for Motors and GeneratorsNEMA MG 11(1977; R 2007) Energy Management Guide for Selection and Use of Single Phase Motors][NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)NFPA 54(2008) National Fuel Gas Code]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. Submittals should be kept 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.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Drawings[; G][; G, [_____]]
Drawings provided in adequate detail to demonstrate compliance with contract requirements,
as specified.
SD-03 Product Data
Absorption Water Chiller[; G][; G, [_____]]
Manufacturer's standard catalog data, prior to the purchase or installation of a particular
component, highlighted to show material, size, options, performance charts and curves, etc.
in adequate detail to demonstrate compliance with contract requirements. Data shall include
manufacturer's recommended installation instructions and procedures. Data shall be adequate
to demonstrate compliance with contract requirements as specified within the paragraphs:
a. Packaged Water Chiller, Absorption Type
b. Chiller Components
c. Accessories
If vibration isolation is specified for a unit, vibration isolator literature shall be included
containing catalog cuts and certification that the isolation characteristics of the isolators
provided meet the manufacturer's recommendations.
NOTE: Choose this bracketed section for Army projects only.
[Posted Instructions[; G][; G, [_____]]
Posted instructions including equipment layout, wiring and control diagrams, piping, valves
and control sequences, and typed condensed operation instructions. The condensed operation
instructions shall 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 shall be framed under glass or laminated plastic and be posted where
indicated by the Contracting Officer.]
Verification of Dimensions[; G][; G, [_____]]
A letter including the date the site was visited, conformation of existing conditions, and
any discrepancies found.
System Performance Tests[; G][; G, [_____]]
A schedule, at least [2] [_____] weeks prior to the start of related testing, for the system
performance tests. The schedules shall identify the proposed date, time, and location for each
test.
Demonstrations
A schedule, at least [2] [_____] weeks prior to the date of the proposed training course,
which identifies the date, time, and location for the training.
[Absorption water chiller - field acceptance test plan]
SD-06 Test Reports
Field Acceptance Testing[; G][; G, [_____]]
[Absorption water chiller - field acceptance test report][; G][; G, [_____]]
System Performance Tests[; G][; G, [_____]]
SD-07 Certificates
Absorption Water Chiller[; G][; G, [_____]]
Where the system, components, or equipment are specified to comply with requirements of AGA,
NFPA, ARI, ASHRAE, ASME, or UL, proof of such compliance shall be provided. The label or listing
of the specified agency shall 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 shall 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.
SD-08 Manufacturer's Instructions
[Water chiller - installation instructions][; G][; G, [_____]]
SD-10 Operation and Maintenance Data
Operation and Maintenance Manuals
1.3 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 shall be insulated, fully enclosed, guarded, or fitted
with other types of safety devices. Safety devices shall be installed so that proper operation of equipment
is not impaired. Welding and cutting safety requirements shall be in accordance with AWS Z49.1. Fuel-fired
equipment shall be in accordance with NFPA 54.
1.4 DELIVERY, STORAGE, AND HANDLING
Stored items shall 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 shall be the Contractor's
responsibility. Any materials found to be damaged shall be replaced at the Contractor's expense. During installation,
piping and similar openings shall be capped to keep out dirt and other foreign matter.
1.5 PROJECT REQUIREMENTS
1.5.1 Verification of Dimensions
The Contractor shall 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.
1.5.2 Drawings
Because of the small scale of the drawings, it is not possible to indicate all offsets, fittings, and accessories
that may be required. The Contractor shall carefully investigate the plumbing, fire protection, electrical,
structural and finish conditions that would affect the work to be performed and shall arrange such work accordingly,
furnishing required offsets, fittings, and accessories to meet such conditions. The Contractor shall submit
detailed drawings consisting of:
a. Equipment layouts which identify assembly and installation details.
b. Plans and elevations which identify clearances required for maintenance and operation.
c. Wiring diagrams which identify each component individually and all interconnected or interlocked
relationships between components.
d. Foundation drawings, bolt-setting information, and foundation bolts prior to concrete foundation
construction for all equipment indicated or required to have concrete foundations.
e. Details, if piping and equipment are to be supported other than as indicated, which include
loadings and type of frames, brackets, stanchions, or other supports.
NOTE: Warranties on Navy construction: Warranties for equipment, materials,
or design furnished, or workmanship performed by the Contractor or any subcontractor
or supplier, has a duration of one year from the date of final acceptance of
the work. An exception is in normal commercial practice longer warranty period
for particular construction are given.
An example of a typically longer duration period is the warranty for the chiller
refrigeration compressor, is typically good for five years. The Contractor
submits to the Contracting Officer all applicable warranties signed and official
prior to project closeout.
If a longer than one year warranty duration is desired, it is recommended that
the specifier/designer survey the chiller market to determine if the chiller
industry normally provides a longer warranty for all of the subject chiller
or for any major components.
A warranty duration of longer than a year, and not covered normally by the industry,
requires a Level III Contracting Officer's written determination documenting
that the extra warranty protection is needed.
1.6 Warranty
In addition to the warranty requirements specification in Division 00, Contract Requirements, the following major
components of the chiller shall be covered by a warranty of a duration period of five years: [solution pump,]
[heat exchanger,] [burner,] and [______].
PART 2 PRODUCTS
Minimum chiller efficiencies will either be presented in this specification
or on the design drawings. Delete chiller efficiencies in the specification
if efficiencies are shown on the drawings. If the efficiencies are shown on
the drawings, reference the applicable ARI standard.
The following is a list of terms which are commonly used in regard to efficiency
ratings of equipment defined within this specification.
COP - Coefficient of Performance (dimensionless)
EER - Energy Efficiency Ratio (Btuh/Watt)
IPLV - Integrated Part Load Value
(dimensionless or kW/ton)
NPLV - Non-Standard Part Load Value
(dimensionless or kW/ton)
Note that the IPLV ratings presented by manufacturers are based upon standard
rating conditions established by ARI. NPLV ratings on the other hand are based
upon site specific rating conditions. NPLV ratings should be specified in most
applications. NPLV ratings will be coordinated with ARI and with the chiller
manufacturers.
Minimum efficiency ratings for absorption chillers are defined under paragraph
ABSORPTION LIQUID CHILLER.
2.1 STANDARD COMMERCIAL PRODUCTS
Materials and equipment shall be standard products of a manufacturer regularly engaged in the manufacturing of
such products, which are of a similar material, design and workmanship. The standard products shall have been
in satisfactory commercial or industrial use for 2 years prior to bid opening. The 2 year use shall include
applications of equipment and materials under similar circumstances and of similar size. The 2 years experience
shall be satisfactorily completed by a product which has been sold or is offered for sale on the commercial market
through advertisements, manufacturer's catalogs, or brochures. Products having less than a 2 year field service
record shall be acceptable if a certified record of satisfactory field operation, for not less than 6000 hours
exclusive of the manufacturer's factory tests, can be shown. System components shall be environmentally suitable
for the indicated locations.
2.2 NAMEPLATES
NOTE: In a salt water environment, substitute acceptable non-corroding metal
such as but not limited to nickel-copper, 304 stainless steel, or monel. Aluminum
is unacceptable. Nomenclature (or system identification) should be established
by the designer.
Major equipment including chillers, water coolers, heat exchanges, and motors shall 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 shall be durable and legible throughout equipment life and made of [anodized aluminum] [stainless steel]
[_____]. Plates shall be fixed in prominent locations with nonferrous screws or bolts.
2.3 ELECTRICAL WORK
NOTE: Show the electrical characteristics, motor starter type(s), enclosure
type, and maximum rpm on the drawings in the equipment schedules.
Where reduced-voltage motor starters are recommended by the manufacturer or
required otherwise, specify and coordinate the type(s) required in Section
26 20 00 INTERIOR DISTRIBUTION. Reduced voltage starting is required when full
voltage starting will interfere with other electrical equipment and circuits
and when recommended by the manufacturer. Where adjustable speed drives (SD)
are specified, reference Section 26 29 23 VARIABLE FREQUENCY DRIVE SYSTEMS UNDER
600 VOLTS. The methods for calculating the economy of using an adjustable speed
drive is described in UFC 3-520-01 INTERIOR ELECTRICAL SYSTEMS.
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 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, shall
be provided. For packaged equipment, the manufacturer shall 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.
NOTE: Bracketed sentence "Motor bearings..." to be used for Army projects only.
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 shall be
rated for continuous duty with the enclosure specified. Motor duty requirements shall allow
for maximum frequency start-stop operation and minimum encountered interval between start and
stop. Motor torque shall 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 bearings shall be fitted with grease supply fittings and grease relief to outside of
the enclosure.]
e. [Where two-speed or variable-speed motors are indicated, solid-state variable-speed controllers
may be provided to accomplish the same function. Use sold-state variable-speed controllers
for motors rated. 7.45 kW10 hp or less and adjustable frequency drives for larger motors.]
[Provide variable frequency drives for motors as specified in Section 26 29 23 VARIABLE FREQUENCY
DRIVE SYSTEMS UNDER 600 VOLTS.]
2.4 CHILLER COMPONENTS
NOTE: Coordinate the type of chiller components required with the type of chiller
specified in the previous paragraphs. Components define under this paragraph
do not apply to absorption type chillers. Delete this paragraph if only absorption
type chillers are specified.
NOTE: Paragraph "Tools" to be used in Army projects only.
2.4.1 Tools
One complete set of special tools, as recommended by the manufacturer for field maintenance of the system, shall
be provided. Tools shall be mounted on a tool board in the equipment room or contained in a toolbox as directed
by the Contracting Officer.
2.5 ABSORPTION WATER CHILLER
2.5.1 General
Chiller shall be designed, constructed tested, and rated in accordance with AHRI 560, ASHRAE 15 & 34 and
shall bear the appropriate underwriter's laboratories (UL) label. [Integrated Part Load Value (IPLV)] [Application
Part Load Value (APLV)] of [_____] COP in accordance with AHRI 560. Chiller shall have a minimum cooling COP
of [_____] at part load conditions in accordance with AHRI 560. Chiller shall be the [single-stage] [two-stage]
hermetic, water-cooled type design. Chiller shall be [indirectly-fired with [steam] [hot water]] [directly-fired
with a [single] [dual] fuel burner]. [For direct-fired units, ratings for cooling capacity, fuel consumption,
and COP shall be based on the higher heating value (HHV) or the specific type of fuel utilized.] Chiller exterior
surfaces shall be factory painted, finished, and insulated as applicable.
2.5.2 Assembly
Unless necessary for delivery purposes, chiller shall be assembled, leak-tested, charged, and adjusted at the
factory. In lieu of delivery constraints, a chiller may be assembled, leak-tested, charged, and adjusted at
the job site by a factory representative. Unit components delivered separately shall be sealed and charged with
a nitrogen holding charge. Unit assembly shall be completed in strict accordance with manufacturer's recommendations.
2.5.3 Operation
Chiller shall operate within capacity range and speed recommended by the manufacturer. Parts weighing 50 pounds
or more which must be removed for inspection, cleaning, or repair shall have lifting eyes or lugs. Chiller shall
be provided with insulation on surfaces subject to sweating including the water cooler and water boxes. Chiller
shall be provided from the factory with a single point wiring connection for incoming power supply. Magnetic
across-the-line motor starters with overload protection shall be provided for each factory supplied pump. Chiller
shall include all customary auxiliaries deemed necessary by the manufacturer for safe, controlled, automatic
operation of the equipment. Unit shall be capable of operating automatically and continuously between 10 percent
and 100 percent of full load.
2.5.4 Components
Chiller shall include the following as a minimum:
a. Absorber, evaporator, and condenser
b. [Generator] [First and second stage generators]
c. Refrigerant, absorber, and inhibitor solutions
d. [Low] [Low and high] temperature heat exchanger(s)
e. Self-contained, hermetically sealed, self lubricating, water cooled, refrigerant and solution
pumps. Pumps shall be direct coupled with the motor and shall include isolation valves.
f. Anticrystallization or automatic decrystallization system
g. [Factory-installed combustion burner assembly and pre-piped fuel train]
h. [Cooling/heating switch valve]
i. [Exhaust gas economizer]
j. [Automatic][Manual] purge system
k. Chiller controls package
l. Interconnecting piping and wiring
m. [Grooved mechanical] [Flanged] [Welded] connections for water boxes
n. Refrigerant spray nozzles
o. Factory-mounted structural steel base (welded or bolted) or support legs
p. Thermometers and sight glasses to allow visual inspection of unit operation. Mercury shall
not be used in thermometers.
2.5.4.1 Absorber, Evaporator, Condenser & Generator
The absorption unit shall be of the shell-and-tube type construction which shall be designed, constructed, tested,
and certified in accordance with ASME BPVC SEC VIII D1. The absorber, evaporator, and condenser shall be suitable
for not less than [150] [250] working pressure. The generator shall have a heating medium of [steam] [hot water].
The absorption unit may be enclosed in one or two shells with removable water boxes or heads. Condenser tubes
shall be seamless copper or copper-nickel. Generator tubes shall be seamless copper-nickel. Absorber and evaporator
tubes shall be either seamless copper or seamless copper-nickel. Tube ends shall be rolled into or silver brazed
to tube sheets. All copper or copper-nickel tubes shall be seamless and be in accordance with ASTM B 395/B 395M
.. [For double effect absorption chiller[/heaters], first stage concentrator tubes shall be titanium and the
steam circuit shall comply with ASME BPVC SEC VIII D1. Double effect absorption chillers[/heaters] shall be
equipped with capacity modulation to control solution flow entering and leaving the first stage concentrator.]
2.5.4.2 Tube Bundles
Provide sufficient clearance between tubes and an adequate number of support sheets, with tubes fitted in the
sheets, to prevent chafing of tubes or crevice corrosion due to uneven tube expansion, vibration, or pulsation.
Holes in the tube sheets shall not have sharp corners. Each tube shall be removable, in one piece, through holes
individually provided for it in tube and support sheets. Water velocities through cooler, condenser and absorber
tubes shall range from less than 3 to 12 fps. Condenser shall be [single] [double]-tube bundle type.
2.5.4.3 Heads
Provide removable, welded-steel or cast-iron heads for external steam and water connections to permit access
to tubes for inspection and cleaning. Design and test water spaces for a working pressure of not less than 150
psig. Water spaces that are not subject to the ASME Code, due to the size or other limitations, shall be tested
at a pressure of not less than 1.5 times the working pressure.
2.5.4.4 Purge System
Provide chiller with an [automatically] or [manually] controlled purge system consisting of a motor driven, jet
type, or viscosity type, high vacuum pump with separators, pipe connections, and controls. Provide positive
protection against return air to unit when evacuator is not in operation.
2.5.4.5 Crystallization
Provide for automatic decrystallization or anti-crystallization, in accordance with manufacturer's standard.
If decrystallization is used, provide and arrange for supplemental heating elements if required for automatic
operation.
2.5.4.6 Refrigerant and Absorber
Refrigerants shall be distilled or deionized water. Absorbent shall be lithium bromide.
Absorber unit shall be fully charged with water and a nontoxic absorber after installation. Refrigerant and
inhibitors shall not generate films that would reduce machine efficiency by coating tubes. The corrosion inhibitor
shall not cause the solution to be classified as hazardous waste under the Resource Conservation and Recovery
Act.
2.5.5 Component Construction
2.5.6 Combustion Burner Assembly
Chiller shall be provided with a forced draft, flame retention type burner and fuel train assembly. Burner shall
be the [single] [dual] fuel type capable of burning [natural gas] [propane] [and] [number 1 fuel oil] [number
2 fuel oil] [diesel]. Burner and fuel train shall be listed by the underwriters laboratories (UL). Burner assembly
shall be provided with all pressure regulators, switches, controls, ignition system, blower fans, and other devices
required for proper and safe operation of the burner. Burner assembly shall be equipped with an external primary-secondary
air ratio adjustment that allows adjustment without dismantling the burner. Burner controls shall allow either
manual or automatic burner operation. Fuel changeover shall be accomplished [by a manual fuel changeover switch]
[automatically as indicated].
2.5.7 Controls Package
Chiller shall be provided with a complete factory mounted and prewired electric or microprocessor based control
system. Controls package shall be [unit-mounted] [floor-mounted where indicated] which contains as a minimum
a digital display or acceptable gauges, an on-auto-off switch, motor starters, power wiring, control wiring,
and disconnect switches. Controls package shall provide operating controls, monitoring capabilities, programmable
setpoints, safety controls, and EMCS interfaces as defined below.
2.5.7.1 Operating Controls
Chiller shall be provided with the following adjustable operating controls as a minimum.
a. Leaving chilled water temperature control
b. System capacity control to adjust the unit capacity in accordance with the system load and
the programmable setpoints. Controls shall automatically re-cycle the chiller on power interruption.
2.5.7.2 Monitoring Capabilities
During normal operations, the control system shall be capable of monitoring and displaying the following operating
parameters. Access and operation of display shall not require opening or removing any panels or doors.
a. Entering and leaving chilled water temperatures
b. Entering and leaving condenser water temperatures
c. Refrigerant and solution temperatures
d. Generator pressures and temperatures
e. Self diagnostic
f. Operation status
g. Operating hours
h. Number of starts
i. Number of purge cycles over the last 7 days
2.5.7.3 Programmable Setpoints
The control system shall be capable of being reprogrammed directly at the unit. No parameters shall be capable
of being changed without first entering a security access code. The programmable setpoints shall include the
following as a minimum.
a. Leaving Chilled Water Temperature
b. Leaving Condenser Water Temperature
c. Time Clock/Calendar Date
2.5.7.4 Safety Controls with Manual Reset
Chiller shall be provided with the following safety controls which automatically shutdown the chiller and which
require manual reset.
a. Refrigerant or solution pump thermal or current overload
b. Low refrigerant temperature
c. Loss of chilled water
d. Loss of condenser water
e. High or low condenser water temperatures
f. Power failure
g. Generator high temperature or pressure
h. Low solution level
i. [Burner or related combustion malfunction]
NOTE: Safeties shall be per UL Standards 795 Oil for Heating Equipment and
726 Oil for Direct-Fired Water Chilling-Heating Units]
j. [Burner controls and [gas] [oil] train.]
2.5.7.5 Remote Alarm
During the initiation of a safety shutdown, the control system shall be capable of activating a remote alarm
bell. In coordination with the chiller, the Contractor shall provide an alarm circuit (including transformer
if applicable) and a minimum 4 inch diameter alarm bell. Alarm circuit shall activate bell in the event of machine
shutdown due to the chiller's monitoring of safety controls. The alarm bell shall not sound for a chiller that
uses low-pressure cutout as an operating control.
2.5.7.6 Energy Management Control System (EMCS) Interface
The control system shall be capable of communicating all data to a remote integrated DDC processor through a
single shielded cable. The data shall include as a minimum all system operating conditions, capacity controls,
and safety shutdown conditions. The control system shall also be capable of receiving at a minimum the following
operating commands.
a. Remote Unit Start/Stop
b. Remote Chilled Water Reset
c. Remote Condenser Water Reset
2.6 ACCESSORIES
2.6.1 Cleaning Brushes
Furnish chiller with two brushes, having jointed rods, suitable for cleaning evaporator and condenser tubes.
2.6.2 Gaskets
Gaskets shall conform to ASTM F 104 - classification for compressed sheet with nitrile binder and acrylic fibers
for maximum 700 degrees F service.
2.6.3 Bolts and Nuts
Bolts and nuts, except as required for piping applications, shall be in accordance with ASTM A 307. The bolt
head shall be marked to identify the manufacturer and the standard with which the bolt complies in accordance
with ASTM A 307.
2.7 FABRICATION
2.7.1 Factory Coating
Unless otherwise specified, equipment and component items, when fabricated from ferrous metal, shall be factory
finished with the manufacturer's standard finish.
2.7.2 Factory Applied Insulation
Chiller shall 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 shall be installed to provide easy removal and replacement of heads without damage to the insulation.
As a minimum, factory insulated items installed indoors shall 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 shall have a flame spread index no higher
than 25 and a smoke developed index no higher than 50. Flame spread and smoke developed indexes shall be determined
by ASTM E 84. Insulation shall 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 shall be tested as a composite
material. Jackets, facings, and adhesives shall have a flame spread index no higher than 25 and a smoke developed
index no higher than 50 when tested in accordance with ASTM E 84.
2.8 SUPPLEMENTAL COMPONENTS/SERVICES
2.8.1 Charging and Testing
Unless fully assembled, tested, evacuated, and charged at factory, components shall be dried and sealed to prevent
corrosion of internal surfaces prior to field assembly. Assemble, test, evacuate, and charge units under supervision
of manufacturer's representative. Periodic tests shall be readily made on the concentration of the inhibitor
and lithium bromide solution with a field test kit furnished by the manufacturer, or as recommended by the manufacturer.
2.8.2 Chilled and Condenser Water Piping and Accessories
Chilled and condenser water piping and accessories shall be provided and installed in accordance with Section
23 64 26 CHILLED, CHILLED-HOT, AND CONDENSER WATER PIPING SYSTEMS.
2.8.3 Cooling Tower
Cooling towers shall be provided and installed in accordance with Section 23 65 00 COOLING TOWER.
2.8.4 Temperature Controls
Chiller control packages shall be fully coordinated with and integrated [into the temperature control system
specified in Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION, AND EXHAUST SYSTEM, 23 09 23.13 20 BACnet
Direct Digital Control Systems for HVAC and 23 09 23 DIRECT DIGITAL CONTROL FOR HVAC AND OTHER LOCAL BUILDING
SYSTEMS] [into the existing air-conditioning system].
PART 3 EXECUTION
3.1 INSTALLATION
Installation of absorption chiller systems including materials, installation, workmanship, fabrication, assembly,
erection, examination, inspection, and testing shall be in accordance with the manufacturer's written installation
instructions, including the following:
[(1) Water chiller - installation instructions]
3.1.1 Connections to Existing Systems
Notify the Contracting Officer in writing at least 15 calendar days prior to the date the connections are required.
Obtain approval before interrupting service. Furnish materials required to make connections into existing systems
and perform excavating, backfilling, compacting , and other incidental labor as required. Furnish labor and
tools for making actual connections to existing systems.
3.1.2 Mechanical Room Ventilation
Mechanical ventilation systems shall be in accordance with Section 23 00 00 AIR SUPPLY, DISTRIBUTION, VENTILATION,
AND EXHAUST SYSTEM.
3.1.3 Field Applied Insulation
Field installed insulation shall be as specified in Section 23 07 00 THERMAL INSULATION FOR MECHANICAL SYSTEMS,
except as defined differently herein.
3.1.4 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 MANUFACTURER'S FIELD SERVICE
The services of a factory-trained representative shall be provided for [_____] days. The representative shall
advise on the following:
a. Absorption Units:
(1) Testing and evacuation.
(2) Charging the machine with lithium bromide solution and refrigerant water (distilled or
demineralized water).
(3) Starting the machine.
3.3 CLEANING AND ADJUSTING
Equipment shall be wiped clean, with all traces of oil, dust, dirt, or paint spots removed. Temporary filters
shall be provided for all fans that are operated during construction, and new filters shall be installed after
all construction dirt has been removed from the building. System shall be maintained in this clean condition
until final acceptance. Bearings shall be properly lubricated with oil or grease as recommended by the manufacturer.
Belts shall be tightened to proper tension. Control valves and other miscellaneous equipment requiring adjustment
shall be adjusted to setting indicated or directed. Fans shall be adjusted to the speed indicated by the manufacturer
to meet specified conditions. Testing, adjusting, and balancing shall be as specified in Section 23 05 93
TESTING, ADJUSTING AND BALANCING.
3.4 FIELD ACCEPTANCE TESTING
3.4.1 Test Plans
a. Manufacturer's Test Plans: Within [120] [___] calendar days after contract award, submit
the following plans:
[(1) Absorption water chiller - field acceptance test plan]
Field acceptance test plans shall be developed by the absorption 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 absorption 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 factory prewired or external controls for the equipment
provided under [Section 23 09 23 DIRECT DIGITAL CONTROL FOR HVAC AND OTHER LOCAL BUILDING SYSTEMS][Section
23 09 53.00 20, SPACE TEMPERATURE CONTROL SYSTEMS] [Section 23 09 23.13 20, BACNET DIRECT DIGITAL
CONTROL SYSTEMS FOR HVAC].
c. Prerequisite testing: Absorption chillers for which performance testing is dependent upon
the completion of the work covered by Section 23 05 93 TESTING, ADJUSTING, AND BALANCING 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 shall include the required test reporting forms to be completed by the Contractor's
testing representatives. Procedures shall be structured to test the controls through all modes
of control to confirm that the controls are performing with the intended sequence of control.
Controller shall 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 shall 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 shall furnish with each test procedure a description
of acceptable results that have been verified.
Chiller manufacturer shall identify the acceptable limits or tolerance within which each tested
performance variable shall acceptably operate.
f. Job specific: Each test plan shall be job specific and shall 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 shall include procedures for field testing and field
adjusting specialized components, such as hot gas bypass control valves, or pressure valves.
3.4.2 Testing
a. Each absorption chiller system shall 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. Absorption 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 shall be reviewed, approved, and signed by the Contractor's
test director. The manufacturer's field test representative shall review, approve, and sign
the report of the manufacturer's recommended test. Signatures shall be accompanied by the person's
name typed.
f. Deficiency resolution: The test requirements acceptably met; deficiencies identified during
the tests shall be corrected in compliance with the manufacturer's recommendations and corrections
retested in order to verify compliance.
3.5 SYSTEM PERFORMANCE TESTS
3.5.1 General Requirements
Before each refrigeration system is accepted, tests to demonstrate the general operating characteristics of all
equipment shall be conducted by a registered professional engineer or an approved manufacturer's start-up representative
experienced in system start-up and testing, at such times as directed. Tests shall cover a period of not less
than [48] [_____] hours for each system and shall demonstrate that the entire system is functioning in accordance
with the drawings and specifications. Corrections and adjustments shall be made as necessary and tests shall
be re-conducted to demonstrate that the entire system is functioning as specified. Prior to acceptance, service
valve seal caps and blanks over gauge points shall be installed and tightened. Any refrigerant lost during the
system startup shall be replaced. If tests do not demonstrate satisfactory system performance, deficiencies
shall be corrected and the system shall be retested. Tests shall be conducted in the presence of the Contracting
Officer. Water and electricity required for the tests will be furnished by the Government. Any material, equipment,
instruments, and personnel required for the test shall be provided by the Contractor. Field tests shall be coordinated
with Section 23 05 93 TESTING, ADJUSTING, AND BALANCING.
3.5.2 Test Report
The report shall document compliance with the specified performance criteria upon completion and testing of the
system. The report shall indicate the number of days covered by the tests and any conclusions as to the adequacy
of the system. The report shall also include the following information and shall be taken at least three different
times at outside dry-bulb temperatures that are at least 3 degrees C 5 degrees F apart:
a. Date and outside weather conditions.
b. The load on the system based on the following:
(1) For absorption units, the cooling water pressures and temperatures entering and exiting
the absorber and condenser. Also the refrigerant solution pressures, concentrations, and temperatures
at each measurable point within the system.
(2) Running current, voltage and proper phase sequence for each phase of all motors.
(3) The actual on-site setting of all operating and safety controls.
(4) Chilled water pressure, flow and temperature in and out of the chiller.
(5) The position of the [capacity-reduction gear] [gas supply control valve] [fuel oil supply
valve] at machine off, one-third loaded, one-half loaded, two-thirds loaded, and fully loaded.
3.6 DEMONSTRATIONS
Contractor shall conduct a training course for the operating staff as designated by the Contracting Officer.
The training period shall consist of a total [_____] hours of normal working time and start after the system
is functionally completed but prior to final acceptance tests. The field posted instructions shall cover all
of the items contained in the approved operation and maintenance manuals as well as demonstrations of routine
maintenance operations.