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Attachment 1 - Section 15620 Centrifugal Chillers
Attachment 1 - Section 15620 Centrifugal Chillers
Centrifugal Chillers
AJ IS
01 June-2009 General revision
PART 1 - GENERAL
1.1 SUMMARY
A. Section Includes:
1. Refrigerant.
2. Compressors/motors.
3. Evaporator/condenser.
4. Control panel.
5. Purge system.
6. Pressure relief.
7. Flow switches.
8. Refrigerant management system.
9. Refrigerant monitoring system.
1.2 REFERENCES
A. Air Conditioning & Refrigeration Institute (ARI):
1. ARI 550/590-1998: Standard for Water Chilling Packages Using the Vapor Compression Cycle 2.
ARI 575: Standard for Method for Measuring Machinery Sound within an Equipment Space.
D. Performance Requirements:
1. See Part 3 of this Specification Section for performance requirements at design conditions.
2. Chiller Manufacturer shall select equipment to meet high expected efficiencies at design conditions
as well as for stable operation at off design peak extreme conditions.
3. Chiller manufacturer is responsible for the performance of all components.
4. On-site performance test is required for each chiller provided.
1.4 SUBMITTALS
A. Contractor to Comply with Tender Invitation documents. Vendor to comply with this Specification and
supply scope documents prepared by Contractor and approved by Employer.
B. Product Data: The following information shall be submitted.
1. Manufacturer's specifications and technical data including performance, construction, and
fabrication.
2. Chiller data sheets: Fill and submit attached chiller data sheets.
3. Submit product data for each manufactured component.
a. Control Panel.
b. Refrigerant Management System.
c. Electric Motors.
d. Auxiliaries.
e. Journal bearings and thrust bearings.
f. Motor heat exchanger data sheet associated with test certificate (in case of open type motors).
4. Wiring diagrams. Complete wiring diagrams of the system to be provided. Marked-up drawings of
manufacturer’s typical drawings will not be acceptable.
5. Sound power levels for each of the 8 octave bands (63 Hz through 8,000 Hz)
6. Certified test reports indicating compliance with specified performance requirements.
a. Chiller performance on Project scheduled operating conditions.
b. Chiller part load performance for 25%, 50% and 75% capacity with constant condenser water
temperature at design conditions as specified in the chillers data sheet.
c. Chiller performance when supplied with condenser water temperature 2°F higher than at
design, at both full load and at minimum stable attainable part load conditions, with chilled water
at design temperatures.
7. Complete information on heat gains to the surrounding space from machines and equipment.
8. Detailed factory test procedure proposed.
9. Compliance Statement with specifications: For each item in specification, clearly indicate
compliance, non-compliance or deviation to/from the requirements. Justify any non-compliance or
deviation and include a detailed list of all exceptions to the specifications.
10. Operating and Maintenance Manuals
11. Testing, cleaning and maintenance instructions
12. Personnel operating instructions 13. Maintenance Materials List
14. Parts List/Diagram.
15. Service Organization
16. Provide a list of spare parts required for each chiller on an annual basis and the cost of these parts
as a separate line item with the bid. Spare parts to include gaskets, seals, etc.
C. Shop Drawings: Indicate dimensions, description of materials and finishes, general construction,
specific modifications, component connections, anchorage methods, hardware, and installation
procedures, including specific requirements indicated.
1. Submit shop drawings on the following items:
D. Quality Control:
1. Source Quality Control submittals as specified in Part 2 of the Section.
2. Field Quality Control submittals as specified in Part 3 of this Section.
E. Contract Closeout:
1. Operating and Maintenance Manuals to include:
a. Instructions for testing, cleaning, maintaining and troubleshooting.
b. Operating instructions.
c. Maintenance material and equipment lists.
d. Parts lists, diagrams & exploded views.
e. Service organization for emergency support, with contact numbers.
f. Provide a list of spare parts required for each chiller on an annual basis and the cost of these
parts as a separate line item with the bid. Spare parts to include gaskets, seals, etc.
1.5 DELIVERY
A. Delivery of equipment and materials shall include the cost of freight, insurance and handling from the
manufacturer’s plant to the job site. All rigging and unloading shall be by the installing contractor on
site.
B. Chillers shall be able to be stored at temperatures of 50°C.
1.6 WARRANTY
A. The manufacturer shall guarantee the performance of the equipment and shall include guarantees and
performance data from manufacturer's vendors for all equipment that is part of the chiller package.
B. Chiller manufacturer shall warranty all equipment in his scope, including parts and labor, for the
standard warranty period after acceptance by Owner.
1. Manufacturer shall replace, without cost, any lost refrigerant exceeding 5 percent of the system
charge of an individual chiller for up to one year after acceptance by the Owner.
C. Chiller manufacturer shall submit an optional price for warranty of all equipment in his scope, including
parts and labor, for five years after acceptance by Owner.
PART 2 - PRODUCTS
2.1 MANUFACTURERS (NO SUBSTITUTES)
A. Trane
B. York
C. McQuay
D. Carrier
E. LS Cable
F. Mitsubishi
G. Axima
2.6 CAPACITIES
A. Provide capacities as described in the attached data sheets, Employer’s Requirements, and as
specified by the Contractor to meet the Project design parameters.
1. Special Requirement: Each chiller shall also be capable of providing acceptable stable operation
(at reduced capacity) with the condenser water temperature entering at 2°F higher than the design
as specified in the data sheets, when supplied with condenser water at the design flow rate, while
cooling water down to the specified chilled water temperature, at full and part load operation.
B. Chiller data plates:
1. Each chiller shall be tagged showing the serial number and the nameplate indicating the capacity,
the condenser and chilled water flows and temperatures as shown in the data sheets.
2.7 COMPRESSORS/MOTORS
A. General:
1. Chillers shall be equipped with centrifugal compressors.
2. Capacity control shall be via pre-rotation guide vanes at each compressor stage, to modulate the
unit cooling capacity for a stable machine operation from 15 percent to 100 percent of design load,
without the use of hot gas recycling.
3. Compressor impellers shall be statically and dynamically balanced.
4. Motor and compressor bearings shall have a minimum service life of 200,000 hours.
5. Thrust bearing shall be tilting pad type with babbitt-lined steel-backed shoes.
C. Lubrication System:
1. Self-contained force feed type full flow system supplying oil under pressure to all bearings, gears
and rotating surfaces, as applicable. The lubrication system shall include oil cooler (using condenser
water at design condition or refrigerant cooled), oil heater, 20 micron oil filter, and positive
displacement electric driven gear oil pump. The oil filter to be provided with isolation valves so that
the filter can be changed without having to evacuate the refrigerant charge or drain the oil. Provide
oil pressure regulator and oil filter pressure differential switch wired to an alarm indicator.
2. The oil pump shall be arranged to provide and maintain lubrication when:
a. Chiller is energized and operating at all speeds.
b. Normal start-up pre-lubrication cycle.
c. Normal compressor coast down after the compressor has been shut down.
D. Compressor Motor:
1. To be of the open or semi hermetic type, directly connected or gear driven. With starting, pull-in and
pull-out torque and running torque at rated voltage and frequency as required for the particular
centrifugal compressor furnished and in accordance with the manufacturer's recommendations.
a. Motor shall be factory mounted and connected to the compressor driveline. Assembly shall be
aligned and balanced.
b. Squirrel cage, induction type motor.
c. Suitable for reduced voltage starting.
d. Motor shall be equipped with six stator winding RTD’s (two per phase, 100 Ohm platinum),
factory wired to a dedicated terminal box.
e. Motor shall be equipped with bearing temperature RTD’s (one for each bearing, 100 Ohm
platinum), factory wired to the terminal box.
f. Manufacturers shall submit details for all utility and/or auxiliary requirements for oil coolers,
motor coolers, etc, including, but not limited to the following:
1) Water flow rates.
2) Entering/leaving temperatures.
3) Pressure drops.
4) Coordination requirements with the motor starter, etc.
2. All motors shall conform to the applicable requirements detailed in Section 15170 & Electrical
sections of this specification.
4. Open drive motors shall be totally enclosed water air cooled (TEWAC) type. The TEWAC heat
exchanger design shall be based and include:
a. Design working pressure no less than 150 psig.
b. Full motor heat removal with condenser water supplied at 95ºF and ambient air temperature of
122°F. The heat exchanger shall also be capable of acceptable performance with 97ºF entering
water for two hours of operation.
c. The heat exchanger performance shall include a fouling allowance of 0.001 ft²·Hr·ºF/BTU
d. Manufacturer to include the flow in GPM as well as the leaving water temperature for the motor
based on an indoor air temperature of 50°C maximum.
e. Motor furnished with water leak detector of the conductivity type factory wired terminating in a
terminal box.
f. Space heater with contactor wired to a dedicated terminal box.
g. Insulated non drive end bearing.
h. Grounding lugs.
i. Differential water pressure switch and thermo wells and pressure gauges shall be provided by
the installing Contractor in the motor cooling water supply & return lines.
j. Motor manufacturer shall submit details for all utility and/or auxiliary requirements for oil coolers,
motor coolers, etc, including, but not limited to the following:
1) Water flow rate.
2) Entering and leaving water temperatures.
3) Water Pressure drop.
E. Couplings:
1. Couplings shall be provided for connecting the compressor and open type electric motor. The
couplings shall be high performance type of forged alloy steel dynamically balanced; oil or grease
lubricated gear type, provided with puller holes and shrouded bolts for low noise operation.
2. The couplings shall be provided with spacers to allow coupling removal without disturbing train
component alignment or removal.
3. Couplings shall be precision bored and half couplings shall be mounted by the individual component
manufacturer. Couplings shall be keyed and locked on the respective shaft. Dry disc type coupling
on the high speed shaft may be allowed.
4. Low speed couplings shall have limited end float.
5. Removable coupling guards shall be provided.
6. A one year supply of specialty lubricant shall be provided with grease lubricated coupling types.
7. Approved manufacturers:
a. Renk, Germany
b. Kopflex, USA
c. Zurn, USA
2.8 EVAPORATOR/CONDENSER
A. Selection Information:
1. Tube Fouling Factor: Selection based on a minimum scale factor of:
a. Evaporator: 0.00025 ft2 hr.°F/BTU.
b. Condenser: 0.00025 ft2 hr.°F/BTU. In case of cooling tower make up water is potable water
2. The design tube side water velocity shall not exceed 9.0 fps nor be less than 3.5 fps, unless
determined and verified by the factory to be acceptable for unit performance.
3. Maximum allowable pressure drop to be no more than indicated in the schedule at the end of this
section.
B. Design Requirements:
1. Heat exchangers: Shell and tube construction; with integrally enhanced tube design.
2. Refrigerant in the heat exchanger shell and water in the tubes.
3. Construct in accordance with ASME Code, U stamp, ASHRAE 15/ANSI B9.1 for mechanical
refrigeration and ASME B31.5 Refrigeration Piping Code.
4. Refrigerant & water circuit components: Pressure test to 1.5 times design working pressure for
hydrostatic tests. Pressure test to 1.25 times design working pressure for pneumatic tests.
5. Evaporator tube side (water) components: 150 psig design working pressure unless otherwise
indicated in the data sheets.
6. Condenser water side components: 150 psig design working pressure unless otherwise indicated
in the data sheets.
C. Tubes: Individually replaceable copper tubing mechanically expanded or rolled into the tube sheets
and with intermediate supports. Intermediate supports shall be spaced to eliminate tube sagging and
vibration.
D. Water Boxes: Design working pressure shall be the same as that specified for the condenser and
evaporator water side circuits throughout. ASME coded for 150 psig working pressure or higher if
indicated otherwise in the data sheets.
1. Condenser: Shall be provided with Marine type water boxes with removable covers to allow access
to the tubes for cleaning and inspection without disturbing water piping connections.
2. Evaporator: Water boxes of Marine type or the nozzle in head type if so indicated in the data sheets
or Contractor’s approved design.
3. Water connections to the circumference of the water boxes, with piping connections in a direction
perpendicular to the shells, to facilitate tube cleaning and replacement without disturbing connecting
piping. Provide removable water box cover with hinges, bolts, nuts, washers and gasket for each
end of the evaporator and the condenser.
4. Provide 150 PSIG ANSI flanges or grooves for mechanical joints at chiller evaporator connections.
5. Provide 150 PSIG ANSI flanges or grooves for mechanical joints at chiller condenser connections
.
6. Each water box shall include threaded or flanged connection on the bottom for drainage connection
and the top for vent connection. Minimum size is 1” for vent and 2” for drain connections.
7. Furnish ASME Coded safety liquid relief valves to protect the water side of the evaporator. Relief
valves to be field installed by piping contractor.
E. Insulation: Thermal insulation to be furnished and installed by the Contractor in the field. Chiller
manufacturers to provide drawings and specifications for all insulation indicating location and minimum
thickness. Refer to Section 15250 Mechanical Systems Insulation for minimum insulation requirements.
Insulation material shall comply with NFPA requirements.
F. Acoustic Insulation: Shall be furnished by the manufacturer to be installed in the field on specific unit
components wherever required if the particular units proposed exceed the specified maximum allowed
noise levels. The blanketing material shall be fireproof, and shall be provided with snaps or other
devices to allow detaching for access to components requiring maintenance or inspection wherever is
necessary to be installed over such components as: Valves; Connections: Compressor: Couplings etc.
Muffler type devices making use of perforated plate internally shall not use fiberglass with loose fiber
material unless suitable treated to prevent fiber material detaching.
C. Manual Reset Safety Cutouts: Protective limits which require manual reset and cause an alarm
message informing the operator which condition caused the shutdown. Provide for each compressor-
refrigerant circuit:
1. High compressor discharge temperature.
2. High oil temperature.
3. Low or high oil pressure.
Tabreed Standard Specifications Page 8 of 21 Centrifugal Chillers
Section 15620 June 2009
4. Low evaporator pressure.
5. High condenser temperature.
6. High condenser pressure.
7. Motor controller over or under load.
8. Starter fault.
9. Refrigerant over-pressure protection.
D. Automatic Reset Safety Cutouts: Protective limits which require automatic reset and cause an alarm
message informing the operator which condition caused the shutdown.
1. Low leaving evaporator temperature.
2. Interlocks.
3. Loss of evaporator water flow.
4. Loss of condenser water flow.
5. Power failure.
2.12 INSTRUMENTATION
A. Switch Type:
1. Differential pressure type flow switches for verification of chilled water and condenser water flow.
Paddle type flow switches are not allowed. Other means of water flow verification devices shall be
approved by Tabreed.
B. Water temperature:
1. RTD with thermowells shall be provided in both return and leaving lines of the condenser and of the
evaporator (total = 4 no. per chiller).
B. Below ½ hp:
1. Type: Open drip proof (ODP), permanently lubricated.
2. Ratings: 230 volts, single-phase, 50 Hz.
2.14 ECONOMIZER
A. Type: Either refrigerant sub-cooler or flash-type intercooler, at manufacturer’s option, to improve cycle
efficiency.
B. Provide orifices, mist eliminators, thermometers, refrigerant liquid gauges, floats, and accessories as
necessary for the economizer furnished.
B. Refrigerant storage receivers shall be furnished with dual self seating ASME coded safety relief valves,
service valves, and full height refrigerant level indicator reflex type provided with isolating drain and
vent connections. Safety relief valves shall be connected to the exterior in the field by the installing
contractor.
D. Special Equipment/Requirements:
1. Self-contained breathing apparatus:
a. Provide two self contained breathing apparatus.
b. One set to be installed adjacent to the exit of the room.
c. One set to be installed just outside of the exit to the room.
2. Signs/Identification: Provide permanent sign securely attached to the Building with the following
information:
a. Name and address of installer.
b. Refrigerant number and amount of refrigerant
c. Lubrication type and amount
d. Field test pressure applied.
1. A downward temperature adjustment per Section A7.3 shall be made to the design leaving
evaporator temperature to adjust from the design fouling to the clean tube condition
2. An upward temperature adjustment per Section A7.3 shall be made to the design entering
condenser water temperature to adjust from the design fouling to the clean tube condition.
4. The factory test instrumentation shall be per ARI Standard 550/590 and with the modifications as
shown. The calibration of all instrumentation shall be traceable to the National Institute of Standards
and Technology (NIST).
5. Tests will be run for a minimum of 3 hours at steady state conditions before readings are taken.
Readings to be recorded every 15 minutes for a test run of 3 hours.
7. A certified test report shall be submitted to the Engineer and Owner. Report shall include specified
tolerance and actual test results. If the equipment fails to perform within allowable tolerances
specified, the manufacturer will be allowed to make necessary modifications to his equipment and
must retest as required. In the event that these modifications do not achieve submitted
performance, the following penalties will be imposed:
a. Capacity Test: For each ton below the nameplate capacity as set forth from testing, $1500 per
ton multiplied by the total capacity of all chillers to be provided for this project will be deducted
from the contract price.
b. Allowable capacity = ((1 - tolerance) x nameplate design capacity); tolerance per modifications
shown.
c. Power Consumption Test: The power consumption penalty for all load points shall be based
upon the tolerances set forth. The power consumption penalty (P.C.P.) will be calculated based
on the following formula:
d. P.C.P. = (Measured KW - (Measured tons x allowable KW per ton)) x $3,000 per KW.
e. Allowable KW per ton = ((1 + tolerance) x design KW per ton); tolerance per modifications.
f. Total Performance Penalty: The total performance penalty will be the sum of the capacity
penalty and power consumption penalty for all chillers provided for this project failing to meet
the test.
g. Equipment manufacturer shall not request payment for the centrifugal chillers until successful
completion of the performance test or acceptance of penalty deduction from the contract.
h. The tolerance for Capacity Test shall be minus zero to +two percent ( -0% +2%.)
i. The tolerance for Power Consumption Test shall be minus two percent (-2%) and plus zero
percent (+0% ).
j. ARI tolerance of +/- 5% is not acceptable
k. Leaving chilled water temperature allowance and entering condenser water tolerance allowed
±0.5°F of adjusted for fouling allowance values. Water flow tolerance ±3%.
l. All tests and any field tests shall be conducted under the supervision of the manufacturer’s
Service Engineers.
PART 3 - EXECUTION
3.1 SHIPPING
A. Each chiller must be protected at the factory to prevent damage during transit and to prevent the
entrance of dirt, moisture and contaminants.
B. All refrigerant circuits shall be cleaned of all debris, oil and grease, evacuated to remove all moisture
and charged with a dry nitrogen gas. The pressure of the nitrogen shall be minimum 5 psig and each
circuit shall be fitted with a pressure gauge with shut off valve reading 0-50 psig. Because the ambient
air temperature at the factory may be substantially lower than the design temperature in the U.A.E, the
manufacturer must account for the pressure rise because of the change in temperature.
G. Training:
1. Provide class room style (on-site) instruction for a minimum of 6 people. Attending will be Owner’s
operating and maintenance personnel and control system technicians.
2. Training shall be for minimum of 16 hours.
3. Provide copies of all required reference materials.
4. Minimum topics to be covered:
a. Chiller Operation.
b. Chiller Maintenance.
c. Sensor and Transducer Recalibration Procedures.
d. Use of Programmed Software.
e. Operator Interface.
5. Upon completion of Owners’ training, submit Owner’s Verification of Training Completion form
signed by Owners Representative.
3.4 FIELD QUALITY CONTROL
A. Start-up to include supervision during erection of the equipment.
B. A satisfactory unit performance at the factory alone without performance duplication on site will not
guarantee equipment acceptance.
C. Manufacturer/supplier shall prepare and submit site performance test procedure in accordance with the
latest ASHRAE / ARI standards associated with theoretical part load curves to prove fulfillment of
guarantees and conformance with the specification for full load and part load capacity, efficiency, and
proper mechanical and electrical operation. Manufacturer shall take all corrective actions required to
ensure that site performance test will be within ARI defined tolerance. In case of failure, the same
penalty described above shall be applied.
D. Manufacturer/supplier shall successfully perform and document site performance test.
Standard selection
Arrangement: Parallel
Unit Nominal Thermal Capacity - Ton:
Unit Compressor power input - KW
Unit Selected KW/Ton
Total Thermal Capacity of Fully Built plant - Ton:
Compressor
Manufacturer:
Model Number:
Country of Origin:
Semi- / Hermetic
Type:
/ Open
Number Of Compressors per Chiller:
Number of Compressor stages:
Compressor Speed - RPM
@ specified
Minimum % offloading:
conditions
Arrangement:
Suction Pressure, psia & actual temp, ºF /
Discharge Pressure, psia & actual Temp., ºF /
At 95 °F Cndr Inet
Compressor Max Capacity & % min. Off loading: & 40 F° CHW
Supply
Weight - kg (each) /
Evaporator
Model:
Coolant type: Concentration by Weight Chilled Water
Arrangement: Parallel
Chilled water Flow Rate - USgpm
Chilled water Temp: In /Out - ºF 40 / 56 ºF
Water Tube Velicity: ft/sec
Maximum Chilled water Pressure Drop- ft w.g.
Liquid Refrigerant Temperature- ºF
Fouling Factor - ft².ºF.Hr/BTU 0.00025
Tube Passes:
Tube Material: Copper
Diameter of Tubes - in.
Number of Tubes / Tube Length - feet
Tube Thickness at Fin Root - Inches 0.028
Tube Surface, Internal / External Enhanced
External Tube Heat Transfer Surface- ft²
Surface Ratio, Internal/External
Water Box Type
Water nozzle Size: Inlet / Outlet -in. /
Vessel Weight: Dry / Operating /
Water box Cover Weight: Plain / Nozzle end-kg /
Design Working Pressure: Shellside / Waterside-psig ? / 150psig
ASME, "U"
Construction & Coding Standard, Shellside.
stamp
ASME, "U"
Construction & Coding Standard, Waterside.
stamp
Condenser
Model ?
Auxiliaries Included
Lube Oil Pumps. Number & Type
TEFC for 50ºC
Oil Pump Motor, -Volt/Hz & kWatt /
ambient
Oil Cooler type: Water or Refrigerant Cooled
Oil Cooler Water Flow Rate-Usgpm / Temp ºF /
Water Cooled Oil Cooler Design Shell& Tube.
Fouling Factor - ft².ºF.Hr/BTU 0.001
Oil Heater Supply: Volt & kWatt
Refrigerant Transfer Unit:
Compressor Displacement: ft³/min at rated speed RPM / RPM
/ 415V 3ph TEFC for 50ºC
Compressor Motor Rating / Voltage: kW / Volt
50Hz ambient
Condenser Water Flow Rate: Usgpm
Condenser Water Pressure Drop: ft wg
Liquid Storage Receiver Size: O.D.in xO.A.Lng ft "/
Storage Tank net Internal Volume: ft³
Refrigerant Maximum Storage Capacity @ 50°C: Lbs
Design Working Pressure: psig
ASME "U"
Design & Construction:
stamp
Auxiliaries Unit Mounted Power Panel
Enclosure Type: Nema 4 or Equal
Factory wired Incl. Contactors and controls:
Noise Data
END OF SECTION