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KENCANA SQUARE

WATER-COOLED LIQUID CHILLER


SECTION AC-300
Page 1

1.0

GENERAL

1.1

DESCRIPTION
.1

1.2

1.3

1.4

Work of this Section shall conform to the requirements of the Contract


Documents.

WORK INCLUDED
.1

Water Cooled Liquid Chiller.

.2

Factory-Mounted Microcomputer Unit Control Panel.

.3

Chiller Plant Manager (Multiple Chiller Sequencer Control Panel. Chiller


visual control, Integrated Starter Module)

.4

Chiller Factory Performance Test certified

SUBMITTALS
.1

Catalogue Data: Manufacturers Catalogue And Equipment Data

.2

Computer print out of equipment selection shall be comply to MS 1525 and


the latest ARI certified software version

.3

Sound Power characteristic ratings

.4

Wiring diagram of pre-wired controllers, required control wiring and power


wiring diagrams

.5

Installation: Manufacturers installation instructions

.6

Operation Instruction: Written operating instruction including start-up and


shutdown

.7

Maintenance Data: Written instruction on items requiring periodic


maintenance and Part List

.8

Factory Tests and Certificates certified by ARI lab.

QUALITY ASSURANCE
.1

Comply with the following standards:


.1

ARI Standard 1550/590 (2003)

.2

ASME Standard 15 Safety Code for Mechanical Refrigeration


(latest edition)

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 2

.2

.3

ASME Boiler and Pressuree Vessel Code, Section VIII Division 1


Unfired Pressure Vessels (latest edition).

.4

All governing local codes and all regulation of Jabatan Kesihatan &
Keselamatan Pekerja-pekerja (JKKP).

.5

Malaysian Standard MS 1525:2007 Code of Practice on Energy


Efficiency and Use of Renewable Energy for Non-Residential
Buildings (First Edition)

.6

GBI Assessment Criteria for Non-Residential New Construction


(NRNC)

To provide Certificate of origin by manufacturer.

2.0

PRODUCTS

2.1

GENERAL
.1

The proposed plant layout must be considered as an outline of intent and


the equipment offered must not significantly change the intended plant
layout. Great importance is attached to good pipe work arrangement and
installation to enable maintenance and repair works to be carried-out
properly and efficiently.

.2

It is not the intent of this part of the Specification to specify completely all
the details of design and construction of the equipment but the type, size
and materials of the offered equipment shall be subjected to approval.

.3

The water cooled liquid chiller shall be completely factory (factory shall
have ISO 9000 series standard) assembled, piped, wired, fully charged with
refrigerant and delivered complete with all starting gear, controls,
instruments and safety devices. It includes one or more compressors,
evaporators, water cooled condensers, starter and control panel, all
mounted on a continuous structural base for proper support and ease of
rigging. The only field connections required are external control circuitry,
system water piping and electrical power supply.

.4

The water cooled liquid chiller shall be certified in conformance with the
latest ARI Standard 550 and manufactured to conform ASME Standard 15
Safety Code for Mechanical Refrigeration or approved Local Code, National
Electric Code, Underwriters Laboratories Standard UL508 Industrial Control
Panels. The cooler and condenser shall include ASME U Stamp and
nameplate certifying compliance to ASME Boiler and Pressure Vessel
Code, Section VIII Division 1 Unfired Pressure Vessels or approved Local
Code (JKKP).

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 3

2.2

LIQUID CHILLER
.1

The chillers shall be designed to operate on R134a refrigerant.

.2

Unless otherwise specified the cooling of each liquid chiller shall be based
on the following conditions:
Liquid to be chilled

Pipe water (SYABAS water)

Fouling factor for cooler

to comply ARI std

Fouling factor for

to comply ARI std

Cooler leaving water

6.7C (44F)

Cooler entering water

14.4C (58F) temperature

Cooler max. pressure drop

90 kPa (30 ft)

Cooler min. working pressure


(Water side)

1035 kPa (150 psig)


(Refrigerant Side)

1800 kPa (260psig)

Condenser leaving water

35.56 C (96F) temperature

Condenser entering water

30.0C (86F) temperature

Condenser max. pressure

90 kPa (30 ft) drop

Condenser min. working pressure


(Water side)

1035 kPa (150 psig)


(Refrigerant Side)

2076 kPa (300 psig)

kW/ton (Full Load Conditions)

0.55 KW/RT

Power Supply

415V, 3 Ph, 50Hz

temperature

Notes:
NPLV denotes Non-standard Part Load Value where for part-load entering condenser
water temperatures (ECWT), the temperature should be constants at selected ECWT
(870F) from 100% load to 0% load, and is defined by the following formula:
NPLV = 1 / [(0.01 / A) + (0.42 / B) + (0.45 / C) + (0.12 / D)]

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 4

Where,
A = kWe/RT at 100% at 860F ECWT
0
B = kWe/RT at 75% at 86 F ECWT
C = kWe/RT at 50% at 860F ECWT
D = kWe/RT at 25% at 860F ECWT
2.3

COMPRESSOR
.1

HERMETICALLY OR OPEN DRIVE CENTRIFUGAL


.1

The compressor shall be of hermetically sealed refrigerant cooled or


open-drive water cooled centrifugal type (to include the energy
required to cool down the motor) to follow manufacturer standard.
The motor must be dynamically and statically balanced after
fabrication and tested to minimum 20% over speed. The motor
shall also be sufficiently rigid to prevent any vibration at operation
speed. The operating speed shall be below the first critical speed.
The casing shall be of close grain cast iron or approved equivalent
material.

.2

The forced feed circulation lubricating system shall be complete with


main oil pump driven either by motor or through gears from
compressor shaft. When the compressor starts and comes to
speed, main oil pump shall assume lubrication duty and
automatically shut down the auxiliary pump. Should oil pressure
developed by main oil pump fail, auxiliary oil pump shall
automatically cut-in to ensure continuous compressor operation.
The oil system shall be complete with pressure-relief valves, oil
piping, gauges, sight ports, thermometers, oil pressure switches, oil
cooler that is designed for use with chilled water, condenser water
or directly cooled by refrigerant. Oil filter, oil reservoir, oil heater
shall be provided to prevent oil from absorbing refrigerant during
shutdowns. When single-stage compressor is employed, liquid subcooling shall be provided in the refrigerant condenser.

.3

The compressor shall also be provided with automatic capacity


control with variable inlet guide vanes operating through an arc of
90 degrees. The vanes shall be of stainless steel or non-ferrous
alloy and supported by high-quality, heat-treated stainless steel or
non-ferrous alloy shafts. Approved type positive seal shall be used
at point where vane operating mechanism transmits motion to
linkage. Lifting devices such as eyebolt or other approved device
shall be provided to permit lifting of compressor. Compressor shall
be capable to operate without surge, cavitations or undue vibration
from full load to 20% load without hot gas bypass when supplied
with design entering water quantities and temperature. Refrigeration
solating valves to be installed in chiller.

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 5

.2

2.4

SCREW COMPRESSOR
.1

The packaged chiller shall be furnished with single-stage direct


connected positive displacement rotary screw compressor(s) as
required, of the oil injected type, driven by a 2950 RPM motor. The
rotors (male and female) of each compressor shall be precision
made from special quality hot rolled steel with laser heat treated
pitch line. The main housing shall be constructed from a high grade,
low porosity gray iron casting, having reinforced double wall
construction, to provide a rigid structure and minimize noise
transmission.

.2

The motor shall be a two-pole hermetic squirrel cage type and


concentric wound double-delta suitable for all three phase
operation. Each compressor shall be provided with a dust-proof
terminal box, located in an accessible location on the
compressor(s), containing all wiring connection terminals.

.3

Each compressor shall include an integral oil separation system, oil


sump and oil filter. The oil temperature shall be controlled during
operation to maintain proper oil temperatures throughout the
lubrication system. An electric oil heater shall be supplied with each
compressor to maintain oil temperature during shutdown period.

.4

Each compressor shall have suction check valve, suction filter,


suction service valve and discharge check valve. Compressor
capacity control shall be obtained by electrically initiated,
hydraulically actuated slide valve within each compressor housing.
Provide isolation valves on all connection to compressor to allow
condenser to be used as a pump-down receiver.

CONDENSER
.1

.2

Condenser vessel shall be cleanable shell and tube type with integral finned
copper water tubes mechanically expanded into heavy fixed steel tube
sheets. The shell shall be of carbon steel construction.
The vessel shall be available in one, two or three pass design as required
on the drawings with mechanical coupling or flanges connections. The
condenser shall have dual pressure relief valves with provision for
refrigerant venting. The condenser shall be sized for full pump-down
capacity.

.3

The top of the flooded condenser shall have a built-in refrigerant distribution
baffle to redirect the hot discharge gas from the compressor along the
length of the condenser, lowering its velocity and minimizing vibration noise.

.4

Water heads shall be removable for tube cleaning. Vent and drain plugs
shall be provided in each head.

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 6

2.5

2.6

2.7

COOLER
.1

Cooler vessel shall all be cleanable flooded shell and tube type with
intergral finned copper water tubes mechanically expanded into heavy fixed
steel tube sheets. The shell shall be of carbon steel construction.

.2

The cooler shall be available in one, two or three pass design as required
on the drawings with mechanical coupling or flanges connections. The shell
side of cooler is to have a single relief valve.

.3

The flooded cooler shall have a built in distributor for feeding refrigerant
evenly under the tube bundle to produce a uniform boiling action and baffle
plates shall be provided to ensure vapor separation.

.4

Water heads shall be removable for tube cleaning. Vent and drain plugs
shall be provided in each head. All low temperature surfaces shall be
factory insulated.

.5

The flooded cooler shall be fitted with an oil recovery system. The oil
recovery system will insure that the cooler is operating at peak efficiency at
all times and provide optimal energy efficiency during extended periods of
part load. Units without oil recovery systems mounted on the cooler will not
be acceptable.

EQUIPMENT BASE
.1

The unit casing or framework shall be constructed from painted, heavy


gauge, steel structural sections with lifting holes.

.2

Components shall be arranged for easy access and all compressors and
heat exchangers shall easily removed and replaced.

INSULATION
.1

The cooler shall be factory insulated with 50mm thick insulation applied in
two 25mm layers with all joints offset.

.2

Insulation shall be polyethylene foam or equivalent (CFC free) type of the


self extinguishing type in accordance with AS 1366 Part 3, having a thermal
conductivity after six months ageing of not greater than 0.036w/mC at a
mean temperature of 25C

.3

Prior to application of the insulation, the vessel shall be thoroughly cleaned,


free of scale, rust, grease and dirt. A bedding/filler material such as Fosters
Foamseal 30-45 shall then be applied to both the vessel and the insulation
to a thickness of 2mm to 3mm. The insulation shall then be applied, with all
joints butted together and sealed to ensure that no air space or gaps are
left.

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 7

2.8

.4

After filling all gaps and smoothing off the surface a vapor barrier
comprising two coats of hand wiped sealant shall be applied.

.5

The whole of the insulation shall be metal sheathed, with easily removable
boxes at the chilled water connections and water boxes. The insulation
vapour barrier at these boxes shall be of a type that does not stick to the
metal cladding.

FACTORY-MOUNTED MICROCOMPUTER UNIT CONTROL PANEL


.1

Every chiller unit shall be complete with factory wired microcomputer control
panel mounted on the unit. The Control shall provide for compressor
loading based on leaving chilled water temperature and start and stop of
chilled liquid and condenser pumps.

.2

The Control Center shall be fully enclosed steel cabinet with hinged access
doors. Dual compartments, separating safety and operating controls from
the power controls, shall be provided. Controls shall include:
.1

Compressor, solid state, thermal sensing overloads, manual reset

.2

High refrigerant discharge temperature, manual reset

.3

Phase failure protection against low voltage, phase imbalance or


phase reversal

.4

Separate power terminal blocks for main power, 115 VAC control
power and 115 VAC chiller heater power

.5

Compressor starter including current sensing overload protection

.6

Microcomputer controller with factory installed sensors including


integral anti-cycle protection

.7

Complete labeling of all control components

.8

Numbered terminal strips for easier wire tracing

.9

Operating and safety lights visible from unit exterior including:

.10

i)

Power on

ii)

Individual compressor operation

iii)

Safety failure for each refrigerant circuit

Control panel solenoid door latch to prevent opening before turning


off power to the unit

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 8

.3

The Control Centers individual microcomputer shall provide compressor


staging based on entering water temperature. It shall have a two line 80
character display and input shall be through a 20 character touch-pad
keyboard through menu-driven prompts. It shall be proactive in control and
accommodate system anomalies such as high condenser temperature and
high entering water temperature by controlling loading and refrigerant flow
to keep the machine on line but at reduced capacity until the fault is fixed.

.4

The unit microcomputer shall provide for:


.1

Three hundred sixty five day clock function

.2

Leaving chilled water temperature control

.3

Alarm upon leaving temperature above set point

.4

High pressure protection

.5

Low pressure protection

.6

Evaporator freeze protection

.7

Compressor current limiting

.8

Anti-recycling protection

.9

High motor temperature protection

.10

Overcurrent protection

.11

Overload protection

.12

Phase loss, or reversal protection

.13

Contactor status

.14

Compressor status

.15

Flow switch status

.16

External start/stop status

.17

Compressor staging

.18

Capacity control

.19

Lead/Lag status

.20

Staggered compressor start

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 9

2.9

Evaporator and condenser pressure readout

.22

Power supply volts and amps readout

.23

RS232 communication port for direct computer communication or


remote monitoring via modem

.24

Communication with a remote building management system to


accept a remote start and stop signal, 0 to 5vDC chilled water
temperature reset signal and 0 to 5vDC demand limiting signal.

.25

Computer graphics software package allowing operator to view


operation of unit remotely via modem or hard wired terminal that
displays temperature, pressures and status of equipment

.26

Control via a twisted-shielded pair of wires to control multiple chiller


units

.27

Factory installed modem

MULTIPLE CHILLER SEQUENCER CONTROL PANEL


.1

2.10

.21

Multiple Chiller Control


.1

The chillers shall come with a Multiple Chiller sequencer control


which does not require another extra control box for controlling the
sequencing of chillers interlocking with their own dedicated chilled
water and condenser water pumps and cooling tower fan motor.

.2

The sequencer control shall be integrated within each chillers


micro-computer and requires only some interconnection wiring
between chillers. All interconnection wiring within the chillers shall
be factory-supplied and ready for field interconnection.

.3

Please refer to page 11 for Input and Output schedule.

INTERFACING WITH BUILDING CONTROL SYSTEM (BCS)


.1

Gateway
.1

A gateway to ASHRAE 135 (IEEE802.3) Local Area Network


System can be performed via the open protocol Gateway. The
open protocol Gateway shall be linked to any Building Supervisory
System that is operating within the specification approved

.2

The Gateway shall enable but not limited to the following functions
to be performed by Building Supervisory System Contractor:

Schedule control based on yearly and weekly calendar.


Interlock with the security system.

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 10

2.11

CHILLER FACTORY PERFORMANCE TEST


.1

The chiller manufacturer will be required to conduct witnessed performance


test for the chiller to verify the performance submitted at the original
manufacturer. The test will be in accordance with ARI 550/590-2003.
-

2.12

Test shall be conducted at an approved Test Facility certified by ARI of


Manufacturers factory. Performance test shall be at least two-point test for
one chiller. Points to be tested shall decided by the SO of capacity per the
job schedule conditions.

.3

After testing, the chiller shall be packed and shipped in one single piece.

ELECTRICAL WORKS
Refer to Section on Electrical Works : AC-948 Electrical Works

VIBRATION ISOLATION
.1

3.0

Part-load conditions will be tested at Constant Condenser Water


entering temperature down to 25% of full load capacity. The chiller
manufacturer must demonstrate that the chillers can operate at
25% of full capacity at constant entering condenser water
0
temperature of 30.55 C without surging.

.2

.1
2.13

Energy and power savings control.


Monitoring and control of airconditioning systems.
Emergency stop control when fire alarm is detected.

Refer to Section on Vibration Isolation : AC-241 Vibration Isolation

EXECUTION
.1

Supervision of the positioning on plinths, pressure testing, evacuation,


dehydration, charging and the initial start up shall be factory trained
representatives of the equipment manufacturer, who have had extensive
experience with the particular type of machine being installed.

.2

This representative shall start up the equipment, adjust and calibrate


controls and rectify any fault which may be found. Concurrently he shall
fully instruct the Officer(s) who will later be in charge of the operation and
maintenance of the plant.

.3

This representative shall remain on site a minimum time of 30 consecutive


working days. Should the refrigeration machines be found not working
satisfactorily by the end of this period this representative shall remain on
site until in the opinion of the S.O the refrigeration machines are operating
satisfactorily.

KENCANA SQUARE
WATER-COOLED LIQUID CHILLER
SECTION AC-300
Page 11

.4

.5

Evacuation of Refrigeration Machine that are shipped without refrigerant


charge
.1

The refrigeration system shall be evacuated by means of a suitable


vacuum pump to a pressure of not greater than 0.7 kPa (0.1 psi)
(equivalent of approximately 1.7C (35F) wet bulb temperature)
after which it shall be closed off and left to stand for 10 hours.

.2

The vacuum pump shall then be started and run for approximately
two minutes and a reading taken on the vacuum dehydration
indicator. No appreciable change in temperature should be
observed. Dehydration shall continue until identical readings are
obtained before and after a 10 hour shutdown period.

Commissioning Tests
.1

While the manufacturers technician is on site, commissioning test


shall be carried out and witnessed by the S.O.

.2

The commissioning tests shall involve a complete check of the


operation of all parts and safety controls associated with the
chilled water machines, including associated pumps, autostart/stop controls such as return water thermostats and step
controllers, chilled water bypass valve controls, electrical supply
and starter, cooling tower and any associated alarm control
systems.

.3

The commissioning check of the chiller shall include check of


evacuation, refrigerant and oil charge, electrical starter and
associated control functions, motor windings, thermistor strips,
bearings, water flow quantities, flow switch functions, electrical
wiring interlocks, refrigeration HP/LP controls, refrigeration low
temperature thermostat, low oil pressure cut-out, oil level safety cutout, high discharge temperature safety cut-out, leaving water
thermostat and controls, load limit controller, motor windings,
insulation tests, oil pump functions, recycle timer/programmer
functions, and then a check of running pressures, temperatures,
fluid levels, amps, motor overload trip settings, vane controls
function, to establish that proper operation is achieve.

END OF SECTION AC-300