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PROJECT STANDARD SPECIFICATIONS

SECTION 15622

CENTRIFUGAL WATER CHILLER

PART 1 GENERAL

1.01 SECTIONS INCLUDES

A. Chiller Package, Charge of Refrigerant Oil, Control and


control Connections, Chilled water Connections, Condenser
Water Connections, Auxiliary Water Connection, Starters
and Electrical Power Connections.

1.02 RELATED SECTIONS

A. SECTIONS 15010 – Basic Mechanical Requirements


B. Section 15172 - Electrical Requirement of Mechanical
Equipment.
C. Section 15180 – Building Management System and Automatic
Controls.
D. Section 15500 – Heating, Ventilation and Air Conditioning.
E. Section 15513 – Noise and Vibration Controls.
F. Section 15996 – HVAC Testing, Adjusting and Balancing.
G. Section 15540 – HVAC Pump
H. Section 15640 – Mechanical Draft Cooling Towers

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1.03 CODES AND STANDARD

Unless otherwise Specified, Centrifugal Water Chiller Shall


comply with the Relevant Sections of the latest edition of each of
the following codes and standard.

A. AHRI 550 / 590 & 551 /591 – Performance Rating of Water


Chilling and Heat Pump Water heating package using the Vapor
compression cycle.
B. ASHRAE-15 – Safety code for Mechanical Refrigeration.
C. ASHRAE 90.1 – Energy Conservation in New Building Design
D. ANSI / ASME SEC 8 – Boiler and Pressure Vessel Code.
E. ANSI / UL 465 – Central Cooling Air Conditioners.
F. ASHRAE GUIDE LINE 3 – Reducing Emission of Halo
generated inn Refrigeration and Air Conditioning Equipment
and Systems
G. NFPA / NEC 70 – National Electrical Code.
H. OSHA – Occupancy Safety and Health Act.
I. NFPA 101 – Life Safety Code.

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1.04 SUBMITTALS DOCUMENTATION REQUIRED

A. Chiller performance ratings conforming to and reported in


accordance with AHRI-550/590 capacity as per given design
schedule, energy efficiency 0.7 kW/ton) Or less, Maximum
water pressure drop 30 ft. of water, 0.3292 Non-Standard Part
Load Value (NPLV)].

B. Include additional power or water sources for auxiliaries


(water for oil coolers, etc.) in all rating calculations.

C. NPLV calculated to AHRI Standard 550/590 equation.

D. Statement of Compliance with ASHRAE 90.1.

E. Unit Drawing: Indicate overall unit dimensions, key


component locations and dimensions, and field connection
details for piping and electrical wiring.

F. Floor layout drawing: Indicate centerlines; Indicate locations


and dimensions of chiller points of contact with the floor.

G. Other Diagrams: Thermal insulation requirements diagram


and vibration isolator diagrams.

H. Weights: Shipping weight, operating weight, weight of each


major component, weight load at each vibration isolator.

I. Capacities and Charges: Refrigerant and Oil (if applicable).

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J. Wiring Diagram: Including main power connections, control


wiring connections (contacts and terminations), internal
wiring schematic including transformers and other devices.

K. Electrical data: Motor full load amperage, Job full load


amperage, inrush amperage, minimum circuit amp city, max
fuse size / breaker size.

L. Electrical requirements for power supply wiring including


wiring diagrams for interlock and control wiring, clearly
indicating factory-installed and field-installed wiring.

1. Only single point chiller wiring is acceptable.

M. Control Panel Details: system operating data points, status


messages, safety shutdowns, cycling shutdowns, trending
capability, programmable set points, interface capability for
data transfer.

N. Material Safety Data Sheet (MSDS) for any refrigerants used


that is NOT classified as ‘A1’ for flammability and toxicity
by ASHRAE 34.

O. Manufacturer’s warranty certificate.

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1.05 OPERATION AND MAINTENANCE DATA

A. Submit Operation data as per Clients Project Engineer


Requirement.
B. Include Start up instructions, maintenance data, parts list,
control and accessories.
C. Submit maintenance data for preventive as well as break down.

1.06 QUALIFICATIONS

A. Manufacture – Company specializing in the manufacture of the


products specified in this section with minimum Ten Years
documented experience and minimum Ten years documents
experience with the model specified in this section.

B. Local Vendor – Local Supplier for this product or Equal must


have 10 year experience in installation, operation and
maintenance and need to verify their registration certificate from
Authorised client representative.

1.07 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and


labelled in NFPA70, article 100, by testing agency acceptable
to the engineer.

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B. ASHRAE Compliance: Comply with ASHRAE 15 latest


edition for chilled design, construction, leak testing and
installation.
C. ASME Compliance: Comply with ASME Boiler and pressure
Vessel code: Section VIII, ‘’ Pressure Vessels,’’ For
constructing and testing evaporator and condenser pressure
vessels. Stamp with ASME label.
D. UL Compliance : Comply with UL465
E. Comply with latest and Relevant IEC Standard.
F. AHRI 550 / 590 Certification for performance of chiller.

1.08 SHIPMENT , DELIVERY , STORAGE , AND HANDLING

A. Protect, pack and secure loose-shipped items and attach to


chiller. Include detailed packing list of loose-shipped items,
including illustrations and instructions for application.
B. Cap and seal water nozzle openings to prevent moisture, foreign
materials and other objects from entering heat exchangers.
C. Provide reinforced shrink-wrap around entire exterior of the
chiller. The membrane shall cover the entire top, sides and ends
to fully protect the chiller during shipping and storage. Cover
equipment, regardless of size or shape.
a. Ship units that are not shrink wrapped in an enclosed truck
or shipping container. Tarping is not acceptable.
D. Ship chiller in one major assembly
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AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

E. Follow manufacturer’s recommendations for storage, handling


and unloading.
F. Do not store equipment in wet or damp areas even when sealed
and secured.

1.09 WARRANTY

A. Provide Two year written Warranty, Signed by the manufacture


or local Vendor agreeing to repair or replace below chiller
components, including replacement of refrigerant, with in
Warranty Periods.
B. Warranty: Include Coverage for compressor, Compressor
motor, Evaporator, Condenser, Complete Chiller package as
manufactured and delivered to site including materials and
labours.
C. Warranty Periods Starts from the date of testing and
commissioning of chiller only.
1.10 MAINTENANCE SERVISE

A. Furnish service and maintenance of chiller for period of five


year from date of substantial completion.

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PART 2 PRODUCT

2.1 GENERAL

Unless otherwise noted , each water chilling unit shall be


of the hermetically sealed driven by a gas refrigerant cooled electric
motor .Compressor motor shall be of the squirrel cage induction type
and with the current and starting characteristics as specified here in
.The motor stator shall be removed for service or replacement without
breaking the main refrigerant piping connections .

Each unit shall be furnished complete with compressors , motor ,,


lubrication system , condenser , evaporator , motor starter ,
microprocessor control system suitable for connection to building
management system, panels including gauges and indicating lights ,
isolators , auxiliary components and accessories .

All there water chilling units shall have the capacities listed in the
section .Each unit shall be capable of producing the schedules leaving
chilled water temperature as design conditions.

2.2 COMPRESSOR

A. Each Compressor shall be variable speed centrifugal type or


approved equal with high energy efficient.
B. Cast Iron casing with high strength Cast aluminium alloy
impeller on stainless steel shaft; statically and dynamically

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PROJECT STANDARD SPECIFICATIONS

balanced compressor assembly; and over speed tested at 120


percent of design operating speed.
C. Motor winding shall be refrigerant cooled.
D. Rotor assembly shall be statically and dynamically balanced to
ISO 1940 / 1-1 1986.
E. Shaft bearing shall be replaceable sleeve insert type.
F. Lubrication system shall be of the forced –feed type with oil
sump, hermetically sealed motor driven positive displacement
pump, oil filter and strainer. Oil temperature shall be
thermostatically controlled. A mechanical operated oil supply
shall be provided to the bearing during spin down in event of
power interruption .A differential oil pressure cut-out shall be
interlocked with starting equipment and shall allow the
compressor to operate only when the required oil pressure is
available at the bearings .
G. Compressor shall be provided with temperature actuated capacity
reduction and shall be of multiple radial blade or butterfly damper
type VFD compressor motor control to provide automatic
capacity stopping, when load falls below 10 percent capacity
point, and automatic unloaded restarting on load demand
.Capacity modulation shall be able to maintain leaving water
temperature at plus or minus 0.25 deg. C of the set point.
H. Refrigerant: HFC-134a; Full operating charge of refrigerant oil.
I. The initial Refrigerant and oil charge shall be furnished and
installed by water chilling unit manufacture in sufficient

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PROJECT STANDARD SPECIFICATIONS

quantities to fully charge the system and leave it in complete and


satisfactory operating condition. All or any part of the refrigerant
or oil change that may be lost during the testing operation and or
during the period of the guarantee shall be replaced by the water
chilling unit manufacture under this section of this specifications
without additional cost to the Employer.
J. The refrigerant circuit shall be complete with a liquid line by –
pass angle type filter drier with replaceable core .Dryer
installation shall be complete with shutoff valves, relief valve,
moisture indicator, insulation and all interconnecting piping.
K. The water chilling unit manufacture utilizing refrigerant HFC-
134a shall provide a refrigerant transfer system to serve the water
chilling units .The transfer system shall be factory assembled with
a compressor and drive, piping, wiring, motor starter. An external
refrigerant storage vessel large enough to hold entire chiller
refrigerant charger, adequate controls for piping with all
evaporator and receiver. The compressor motor shall be at least 3
HP .The pump out receiver provided in conjunction with the
transfer system shall be horizontal type sufficiently sized to
accommodate the complete refrigerant charge of each evaporator
( Per unit not total of units ) ,, when the pump out receiver is 80%
full .The receiver shall have relief valve in accordance with the
latest edition of ANSI B 9.1 Code .Provide full length gauge glass
, Replaceable core type filter dryer and moisture indicator .Design
shall be in accordance with ASME code for unfired pressure

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PROJECT STANDARD SPECIFICATIONS

vessels. The refrigerant piping valves, etc between evaporators


and pump out receiver shall be shown on the shop drawings
.Submit complete piping diagram for review.

2.3 EVAPORATOR

A. Description: Shell –and tube design with refrigerant totally enclosed


in shell and water in tube

B. Shell Material : Rolled carbon steel plate with fusion welded seams;
have carbon steel tube sheets ;drilled and reamed to accommodate the
tubes; with minimum 6.35mm corrosion allowance epoxy coated on
water side and intermediate tube supports spaced no more than four feet
apart.

C. The refrigerant side will be designed, tested and stamped in


accordance with ASME boiler and pressure vessel code, Section VIII
Division 1.

D. Tubes shall be high efficiency, internally and externally enhanced


type having plain copper lands at all intermediate tube supports to
provide maximum tube wall thickness at the support area.

E. Each tube will be roller expanded into tube sheets providing a leak
proof seal, and be individually replaceable.

F. Coolers shall be designed for water flow velocity of at least 3 fps,


but not greater than 9 fps.

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G. Two Liquid level sight glasses will be located on the side of the shell
to aid in determining proper refrigerant charge.

H. The evaporator will have a refrigerant relief device sized to meet the
requirements of ASHRAE 15 safety code for Mechanical
Refrigeration.

I. Tubes: Seamless, Externally finned, individually replaceable tubes;


Expanded in to tube sheets.

1. Material: Copper

2. Size: 19mm OD; 0.711mm wall thickness conforming to ASTM


B359.

3. Internal Finish: Enhanced.

4. External Finish: Enhanced.

5. Intermediate tube supports shall be provided similar to condenser.

j. Water Boxes: Hinged Marine type; removable, carbon steel, with


vent and drain connection.

J.1 Temperature Sensor: Thermistor type, Factory installed in each


nozzle.

J.2 Clearance of not less than 150% of the hinged marine type water
box cover diameter shall be provide to allow free swing of the hinged
water box cover with no contact with adjacent piping or equipment or
the need to remove any piping appurtenances etc.

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AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

K. Refrigerant Working Pressure: 2070kpa or if higher, the saturation


pressure of refrigerant used at 29 deg C (85 deg. F)

L. Water – Side working pressure: 1035 Kpa.

M. Eliminators: Metal Screen mesh eliminators to prevent refrigerant


carryover in to compressor.

N. Cooler capacity shall be based on refrigerant suction temperature in


excess of 0 deg. C (32 deg. F) and fouling factor of 0.00018 m² °C / W
(0.0001 Hr-ft² - °F / BTU)

O. Waterside pressure drop shall not exceed 30 feet water gauge (13
PSI) for cooler and Manufacture shall indicate water pressure drop
through cooler.

P. A frangible carbon rupture disc safety relief device shall be provided


.Device to be piped to building exterior.

2.4 CONDENSER

A. Construction: - Shell and tube design with water enclosed in tubes


and refrigerant enclosed in shell.

B. Condenser Tubes : Condenser Tubes shall be plain bore seamless ,


90-10 copper –nickel ( UNS C 70600 ) ¾- inch O.D. ; 20 BWG ( 0.033
inches measure at root of fin enhancement ) , Externally enhanced ,
conforming to ASTM B359 .Intermediate tube support shall be
provided so that distance between supports does not exceed

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

approximately 3 feet ( 900 millimetre ) Supports shall be fitted to the


tubes in a manner that will preclude corrosion , vibration , and abrasion.

C. Design condenser water side fouling factor shall be equal to or


greater than 0.00053 m². °C/ W. (0.00025 hr. - ft² - F / BTU)

D. Condenser Tube sheets : Water side of condenser tube sheets shall


be clad with a minimum of 3.2mm of 70-30 copper nickel ( UNS
C71500 ) or Carbon steel tube sheets with a minimum 6.35mm
corrosion allowance epoxy coated on water site and need to take prior
approval from Client engineer.

E. Water Boxes: Marine type, removable, carbon steel, with vent and
drain connections.

E.1 Temperature Sensor: Thermistor type, factory installed in each


nozzle.

E.2 Refrigerant Working Pressure: 2070 kPa or if higher, the saturation


pressure of refrigerant used at 29 deg. C (85 deg. F)

E.3 Water –Side working pressure: 1035 kPa.

E.4 Pressure relief: Single or multiple, reseating type, spring – loaded


relief valves.

E.5 Condenser shall be designed for water velocity of at least 3 fps but
not greater than 9 fps.

2.5 INSULATION

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AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

2.5.1 Insulation shall be provided on all low temperature surfaces


including cooler, water boxes, compressor suction elbow, and
economizer if used, and motor cooling lines.

2.5.2 Water boxes shall be insulated to provide for ease of access to


heads for inspection and repair.

2.5.3 Cold surfaces shall have insulation designed to prevent sweating


in ambient condition of 120 °F and 80% relative humidity.

2.5.4 Chiller installed in the outdoors; the insulation shall be an


approved weather proof type or protective cladding installed to render
the installation weatherproof and suitable for outdoor installation.

2.5.4 Insulation Material

2.5.4.1 Insulation shall be flexible elastomeric unicellular sheet


covering fireproof, UL approved and meet the requirement of ANSI /
NFPA 90A.

2.5.4.2 Insulation shall be tested in accordance with ASTM C411 and


shall have maximum flame spread rating of 25 and maximum smoke
developed rating of 50.

2.6 ECONOMIZER / SUBCOOLERS

For chiller manufacture that provide economizers / sub coolers


the following shall apply:

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AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

2.6.1 The economizer / sub cooler shall be provided with the


controls necessary to regulate refrigerant flow.

2.6.2 Flash type economizers shall be used for multistage


compressors.

2.7 VIBRATION ISOLATION

2.7.1 Chiller package manufacturer shall furnish sole plates and


vibration isolation pad assembly for mounting and levelling chiller on
concrete base.

2.7.2 Vibration isolators shall be selected by the chiller package


manufacture to meet the requirements of the installation and in order
to prevent noise and vibration resulting from the operation of the unit.

2.7.3 Vibration isolators shall be as per chapter 47 of ASHRAE


Application Handbook titled ‘’ Sound and Vibration Control ‘’ of
2019 Edition.

2.7.4 Sound and vibration rating and testing shall be accordance


with AHRI 370, AHRI 530, AHRI 540 and AHRI 575.

2.8 PURGE UNIT

2.8.1 When HCFC -123 refrigerant is used , a high efficiency purge


system shall be provided and connected to the main refrigeration
system .When in operation , the purge system shall function to

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AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

automatically remove air , water vapour , and no condensable gases


from the refrigeration system and to condense , separate , and return
to the system and refrigerant present therein.

2.8.2 Purge system shall be manually or automatically started and


stopped and shall be assembled as a compact unit .Purge system shall
be complete with operating and safety devices and with an oil
separator if recommended by the manufacture.

2.8.3 When positive pressure refrigerant is used by the manufacturer


in the basic liquid chiller unit, a purge system will not be required,
Units shall purge no more than 0.1 pounds (0.045 kg) of Non
condensable.

2.8 CONTROL PANEL

2.8.1 CONROL PANEL FEATURE:

A. Type: Microprocessor based, stand alone

B. Scope: Chiller operation, monitoring of chiller sensors,


actuators, relays and switches, and display of all operating parameters.

C. Capability: Stable chiller operation at 36 °F leaving chilled


water temperature without warnings or shutdowns; no
freezing or slushing of chilled water.

D. Enclosure: Lockable, NEMA 1

E. Information Display: 10.4” (minimum) color liquid crystal


display (LCD) mounted on control panel enclosure door.
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PROJECT STANDARD SPECIFICATIONS

F. User interface: Operating parameters displayed in a user-


friendly, color and graphical format.

G. Keypad: Universal type with soft-keys or touchable screen as


option.

H. Height: Eye level and readable and operable without the need
for ladder or stool.

I. Temperature rating: 0 to 46°C

J. Security Access: Through ID and password recognition


defined by a minimum of three different levels of user
capability:

1. View: prevent unauthorized changing of set points

2. Operator: allow local or remote control of chiller

K. Chiller information screen including on-screen display of the


following, as a minimum:

1. Model number

2. Chiller serial number

3. Control panel serial number

4. Manufacturer contract number

5. Design voltage

6. Refrigerant type

7. Starter type

8. Original factory chiller rating information


WATER COOLED CHILLING UNITS
AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

L. Data tracking and trend display including on-screen


graphical display of the following, as a minimum:

1. Parameters selected from a list of a minimum of 140


possibilities

2. Data collected once per second up to once per hour for each
parameter

3. Data trend lines displayed for a minimum of 5 parameters


at once

2.8.2 Status Display: Including, but not limited to the following


conditions:

2.8.2.1 Date and time

2.8.2.2 Operating or alarm status

2.8.2.3 Operating hours

2.8.2.4 Entering and leaving chilled water temperature

2.8.2.5 Evaporator refrigerant temperature

2.8.2.6 Entering and leaving condenser Water Temperature.

2.8.2.7 Condenser refrigerant temperature.

2.8.2.8 Oil Supply temperature.

2.8.2.9 Oil sump Temperature

2.8.2.10 Percent motor amperage.

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PROJECT STANDARD SPECIFICATIONS

2.8.2.11 Purge suction temperature if purge system is provided (For


chiller using HFC – 123)

2.8.2.12 Purge Elapsed time if purge system is provided (For chiller


using HFC-123)

2.8.3 Control Function: Including but not limited to the


followings:

2.8.3.1 Manual or automatic start up and shut down time schedule.

2.8.3.2 Leaving and Entering chilled water temperature, control set


points, and motor load limit.

2.8.3.3 Current – limit and demand limit.

2.8.3.4 Condenser water temperature.

2.8.3.5 External chiller emergency stop.

2.8.4 Manual reset safety controls: The following condition shall


shut down chiller and require manual reset:

2.8.4.1 Evaporator low pressure

2.8.4.2 Evaporator low temperature

2.8.4.3 Low oil flow.

2.8.4.4 Low oil pressure

2.8.4.5 High oil temperature.

2.8.4.6 High condenser pressure.


WATER COOLED CHILLING UNITS
AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

2.8.4.7 High compressor – discharge temperature.

2.8.4.8 No chilled water flow

2.8.4.9 High Bearing Temperature

2.8.4.10 No condenser water flow

2.8.4.11 Sensor or detection – circuit fault.

2.8.4.12 Processor communication loss

2.8.4.13 Starter Fault

2.8.4.14 Extended Compressor Surge

2.8.5 Interface Panel: Factory supplied interface panel to


communicate and transmit data between the chillers and BMS .All
required data as from chillers as specified to be transmitted to BMS
.Interface panel to be capable for communication with the specified
BMS System.

2.8.6 Remote Alarm: During the initiation of a safety shutdown, a


chiller’s control system shall be capable of activating a remote alarm
bell .In coordination with the chiller manufacture, the contractor shall
provide an alarm circuit (including transformer if applicable) and a
minimum 100mm (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 that uses low pressure cut-out as an
operating control.

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AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

2.8.7 Chiller system controller:

2.8.7.1 A chiller system controller shall communicate with the


individual chiller unit controllers’ .The chiller system controller shall
supervise all of the chiller unit controller and shall determine which
chillers are to start and stop.

2.8.7.2 The chiller unit controller shall:

2.8.7.2.1 Initiate the chiller start up routine when it receives a


request to start from the chiller system controller.

2.8.7.2.2 Open the isolation valves on the condenser water and


chiller water lines.

2.8.7.2.3 Start and stop the condenser water and chilled water
pumps.

2.8.7.2.4 Once chilled water and condenser water flow is proven


the chiller shall be started if all safeties (minimum off time, flow
switches, etc.) permit.

2.8.7.2.5 The chiller unit controller shall undertake the chilled


water supply temperature control.

2.8.7.3 When request to stop is received from the chiller system


controller the chiller unit controller shall:

2.8.7.3.1 Stop the chiller, if the minimum run time has been
exceeded.

WATER COOLED CHILLING UNITS


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PROJECT STANDARD SPECIFICATIONS

2.8.7. 3.2 Stop the chilled water pump and close the chilled water
isolation valve.

2.8.7. 3.3 stop the condenser water pump after a predetermined


period of time.

2.8.7.3.4 Close the condenser water isolation valve when the


condenser water pump has stopped.

2.8.7.4 The chiller system controller shall have a data port to enable
the exchange of data from the chiller unit controllers with the BMS.

2.8.7.5 The Chiller system controller shall communicate the


following information to the BMS via the gate way for each chiller.

2.8.7.5.1 Entering chilled water temperature (monitoring point)

2.8.7.5.2 Leaving chilled water temperature (Monitoring Point)

2.8.7. 5.3 Evaporator pressure (monitoring Point)

2.8.7.5.4 Auxiliary oil pressure (Monitoring point)

2.8.7.5.5 Bearing Pressure (Monitoring Point)

2.8.7. 5.6 Gear Pressure (Monitoring Point)

2.8.7. 5.7 Evaporator Differential Pressure (Monitoring Point)

2.8.7. 5.8 Evaporator Temperature (Monitoring Point)

2.8.7.5.9 Suction Temperature (Monitoring Point)

2.8.7.5.10 Pre Alarm (Monitoring Point)


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PROJECT STANDARD SPECIFICATIONS

2.8.7. 5.11 Gear Box High Temperature (Monitoring Point)

2.8.7. 5.12 Gear Box low temperature Setting (Monitoring Point)

2.8.7. 5.13 Oil compressor Status (Monitoring Point)

2.8.7.5.14 Flow safety (Monitoring Point)

2.8.7.5.15 Motor Safety (Monitoring Point)

2.8.7.5.16 Motor Run Status (Monitoring Point)

2.8.7.5.17 Rear Thrust Bearing Temperature (Monitoring Point)

2.8.7.5.18 Front Thrust Bearing Temperature (Monitoring Point)

2.8.7. 5.19 Gear Oil Temperature (Monitoring Point)

2.8.7.5.20 Current Limit (Control Point)

2.8.7.5.21 Chilled water supply temperature (Control Point)

2.8.7.5.22 Chilled water pump run status (Monitoring Point)

2.8.7.5.23 Chilled water Pump Alarm Status (Monitoring Point)

2.8.7.5.24 Condenser Water Pump Alarm Status (Monitoring


Point)

2.8.7. 5.25 Entering Condenser Water Temperature (Monitoring


Point)

2.8.7.5.26 Leaving condenser water Temperature (Monitoring


Point)

2.8.7.5.27 Shut down / Cycling Message.

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PROJECT STANDARD SPECIFICATIONS

2.8.7.5.28 A record of the last 4 NO. Cycling or safety shutdowns


of each chiller.

2.9 Electrical

2.9.1 GENERAL

2.9.1.1 Electrical / Electronic diagram shall indicate all factory and


field wirings.

2.9.1.2 Equipment name plate voltage shall be in accordance with


AHRI 110

2.9.1.3 Al electrical wiring shall be run in approved water tight PVC


Conduit or approved equivalent.

2.10 Motors

2.10.1 Hermetically sealed motors shall confirm NEMA MG 1,


AHRI 520 or IP20 to IEC 60529 and to requirements of motors as
specified herein.

2.10.2 Bearing shall be oiled – lubricated, replaceable, inserted type


or permanent lubricated, rolling element type .Magnetic Bearings
shall be as per 2.10.3.

2.10.3 Magnetic Bearings

2.10.3.1 Levitated shaft position shall be actively controlled


and monitored by an X- , Y- and Z- axis digital position sensor.
WATER COOLED CHILLING UNITS
AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

2.10.3.2 The compressor shall be capable of coming to a


controlled, safe stop in the event of a power failure by diverting stored
power from the DC bus to the magnetic bearing control system.

2.10.4 If water chilled unit or any components could be damaged


by reverse water – chiller unit contains a mechanically driven
lubricating –oil pump, the manufacturer’s responsibility shall include
providing reverse phase rotation protection.

2.11 MOTOR STARTER: VARIABLE SPEED DRIVE OR


APPROVED EQUAL

A. General: Variable Speed Drive (VSD) compressor motor


starter to start motor and control motor speed by controlling
the frequency and voltage of the electrical power supplied to
the motor.

B. Drive type: Pulse width modulated (PWM) utilizing insulated


gate bipolar transistors (IGBTs).

C. Control Logic: Independently control motor speed and pre


rotation vane (PRV) position for optimum efficiency and
operational stability. Base motor speed and PRV position on
a minimum of 4 inputs: leaving chilled water temperature,
return chilled water temperature, evaporator refrigerant
pressure, condenser refrigerant pressure; Verify motor speed
and PRV position and also use as inputs to the control logic.

WATER COOLED CHILLING UNITS


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PROJECT STANDARD SPECIFICATIONS

D. Power Factor: At all loads and speeds, provide a minimum of


a .97 power factor.

E. Capacitors shall not require scheduled replacement. If


capacitors do not meet this requirement, the chiller
manufacturer shall provide three spare sets of capacitors per
compressor for the building owner’s stock.

F. Enclosure: NEMA-1 type with hinged access door with door


interlock, lock and keys, and pad lockable

G. Packaging: Factory mounted on chiller, piped to cooling


circuit; wired to control panel and compressor motor; entire
package (including active harmonic filter) shall be UL listed.

H. Cooling: Cool drive pole assembly components and internal


ambient air via fluid-cooled, closed loop; all starter
components accessible for service and replacement without
opening the chiller’s main refrigerant circuit.

I. Factory run test: Perform an electrical and mechanical run test


of VSD starter prior to shipment to verify proper wiring and
phasing.

J. Factory settings: Set starting design current and current


overload settings prior to shipment.

K. Harmonic Distortion: Provide a drive and chiller system with


an integrated active harmonic filter mounted inside the starter
cabinet. System must generate harmonic distortion levels less
than the following, measured at the input side of the drive:
WATER COOLED CHILLING UNITS
AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

1. Current: 5% maximum current total demand distortion

L. Inrush amperage: Limited to the design full load amperage of


the chiller.

M. Protective devices: provide the following, as a minimum:

1. Electronic current-sensing overloads (1 per phase) – with


indicating message on the control panel and reset button;
shut down chiller upon detection of operating current
exceeding 105% full load amperage.

2. High instantaneous current overload – with indicating


message on the control panel and reset button; shut down
chiller upon detection of starting current exceeding 115%
of design inrush starting current for 1 second.

3. Phase rotation insensitivity

4. Single phase failure protection circuit with indicating light


– shut unit down if power loss occurs in any phase at
startup.

5. High temperature safety protection system on IGBTs with


indicating light and reset button; via thermistors embedded
on IGBT heat sinks – shut unit down if IGBT temperature
exceeds acceptable limits.

6. Power fault protection for momentary power interruptions


– interrupt power to the compressor motor within 4 line

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

cycles upon detection of power interruptions longer than


¾ of a line cycle.

7. High and low line voltage protection.

N. Features: Factory mount and wire the following as a minimum:

1. Control transformer: 115volt and sized to power control


panel and all unit controls.

2. Electrical lugs: Sized to accept the copper power lines


required by the chiller.

3. Single point power: From electrical lugs at starter, power


all powered devices on the chiller including control panel,
control devices, oil pump (if applicable) and refrigerant
purge.

4. Circuit-breaker disconnect: Door interlocked; ground fault


protection; minimum 65,000A short circuit withstand
capacity per UL 508.

O. Control panel readouts: Display on the control panel and


provide to BMS via communication port the following as a
minimum:

1. Output frequency

2. Output voltage

3. Output current (each phase)

4. Input power (kW)

5. Energy consumption (kWh)


WATER COOLED CHILLING UNITS
AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

6. Elapsed running time

7. Three phase voltage total harmonic distortion (THD)

8. Three phase current total demand distortion (TDD)

9. Total unit power factor

10. Total supply KVA

2.12 FINISHES

A. Dry chiller components for shipment, including inside of water


boxes and tubes.

B. Blast and clean chiller surfaces thoroughly. Apply prime coat


for painting.

C. Paint all exposed surfaces with alkyd-modified, vinyl enamel


machinery paint, including all factory-applied insulation for
consistent color matching. If not painted in the factory, paint
over insulation in the field with manufacturer’s standard paint
and color.

2.14 ACCESSORIES

A. Refrigerant recovery unit consisting of the following as a


minimum:

1. Portable, self-contained package, lawn mower configuration

2. Refrigerant compressor

3. Oil separator and heater (if applicable)

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

4. Water-cooled condenser

5. Refrigerant filter drier

6. Suction and discharge pressure gauges

7. Refrigerant isolation valves

8. Relief valves

9. Two 8-foot long hoses

10. Controls: Permanent circuit with all safety devices

11. Wheels and swivel casters with lock brakes

12. AHRI certified

B. Refrigerant receiving tank consisting of the following as a


minimum:

1. Self-contained package

2. Receiving tank: Horizontal, pitched toward tank drain

3. Capacity: Hold the charge of largest chiller with 20%


capacity remaining at 90°F

4. Two sight glasses

5. Pressure gauge

6. Refrigerant isolation valves

7. Relief valves

8. Float cutoff switch

9. Oil heater (if applicable)

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

10. ASME stamped

C. Refrigerant storage and recycling system (Section 230160):

1. Self-contained package

2. Receiving tank: Horizontal, pitched toward tank drain

3. Capacity: Hold the charge of largest chiller with 20%


capacity remaining at 90°F

4. Two sight glasses

5. Refrigerant compressor

6. Oil separator and heater (if applicable)

7. Water-cooled condenser

8. Refrigerant filter drier

9. Suction and discharge pressure gauges

10. Refrigerant isolation valves

11. Relief valves

12. Two 8-foot long hoses

13. Float cutoff switch

14. Controls: permanent circuit with all safety devices

15. AHRI certified and ASME stamped

16. Warranty: 1 year parts, starting from date of shipment

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

D. Spring vibration isolators (for above-grade floor


installations): Provide four spring-type, level-adjusting, 1” deflection
vibration isolators with non-skid pads for each support point

2.13 REFRIGERANT LEAK DETECTOR

2.13.1 Detector shall be infrared system in NEMA 250, Type 4


enclosure of the continuously, halogen specific type .Detector shall be
appropriate for the refrigerant in use. Detector shall be specifically
designed for area monitoring and shall include a single sampling point
installed where indicated.

2.13.2 Detector design and construction shall be compatible with the


temperature, humidity, barometric pressure and voltage fluctuations
of the operating area. Detector shall have an adjustable sensitivity
such that it can detect refrigerant at or above 3 parts per million
(PPM)

2.13.3 Detector shall be supplied factory calibrated for the appropriate


refrigerant .Detector shall be provided with an alarm relay output
which energizes when detector detects a refrigerant level at or above
the TLV –TWA ( or toxicity measurement consistent therewith ) for
the refrigerant(s) in use. The detector’s relay shall be capable of
initiating corresponding alarms and ventilation system as indicated on
drawings.

2.13.4. Detector shall be provided with a failure relay out put that
energizes when the monitor detects a fault in its operation. Detector
shall be compatible with the Building Management system and shall
WATER COOLED CHILLING UNITS
AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

be capable to interface with the chiller plant manager system as well


as the BMS .The BMS shall be capable of generating an electronic log
of the refrigerant level in the operating area, monitoring for detector
malfunction, and monitoring for any refrigerant alarm conditions.

2.14 FACTORY TEST

2.14.1 The proposed chiller manufactures shall be responsible


for performing chilled factory test to validate the specified full load
capacity , full load EER , and ( IPLV ) , ( NPLV ) in accordance with
AHRI 550 / 590 excepts as indicated .

2.14.2 The chiller factory test shall be carried out design ambient
temperature of 46 °C DB and 30°C WB, as well as 52°C DB with
reduced capacity without mechanical failure.

2.14.3 The chiller factory test shall be performed in the presence of the
client’s and engineer representative .The team will comprise maximum
2 representatives. All expenses to be borne on the Manufacture.

2.14.4 Chiller manufacture shall provide to the Engineer a certified


chiller factory test report in accordance with AHRI 550 / 590 to confirm
that the chiller performs as specified .Test shall be conducted in an
AHRI certified test facility in conformance with AHRI 550 / 590
procedures and tolerances.

2.14.5 At a minimum, chiller capacity shall be validated to meet the


scheduled requirements indicated on the drawings. Tolerance or

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

deviation shall be in strict accordance with AHRI 550 / 590 .Stable


operation at minimum load of 10 percent of total capacity shall be
demonstrated during factory test.

2.14.6 Temperature Adjustments: Temperature adjustment shall adhere


to AHRI 550 / 590 to adjust from the design fouling factor to the clean
tube conditions. Test temperature adjustments shall be verified prior to
testing by the manufacture .There shall be no exceptions to conducting
the test with clean tubes with the temperature adjustments per AHRI
550 / 590 .The manufacture shall clean the tubes , if necessary , prior
to testing to obtain a test fouling factor of 0.0000.

2.14.7 Test Instrumentation: The factory test instrumentation shall be


as per AHRI 550 / 590 and the calibration shall be traceable to the
National institute of standards and Technology. All instrumentation
shall have been calibrated within 6 month of the test date.

2.14.8 Test Report: A certified test report of all data shall be forwarded
to the Engineer for approval prior to project acceptance .Calibration
curves and information sheets for all instrumentation shall be provided.

2.14.9 Equipment Adjustments: If the equipment fails to perform with


in allowable tolerances, the manufacture shall be allowed to make
necessary revisions to his equipment and resets as required .The
manufacture shall assume all expenses incurred by the Client / Engineer
to witness retest.

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

2.14.10 Chiller shall be sound tested at the Factory prior to shipment to


confirm the sound pressure level as per project requirement. Test and
data shall be conducted and measured in strict accordance to the AHRI
575 at the full load system operating conditions.

PART 3: EXECUTION
3.01 INSTALLATION

A. General Requirements: Install per industry standards,


applicable building codes and manufacturer’s written
instructions.

B. Refrigerant: Rig refrigerant into equipment room and place


next to what will be the final location of the chiller.
Manufacturer will be responsible for charging the machine.

C. Temporary use: Use of any chiller for temporary heating,


cooling or ventilation is strictly prohibited unless a complete
inspection and startup has been performed by manufacturer’s
factory-trained and factory-employed service personnel.

D. Concrete base: Install chiller on a minimum 4” thick reinforced


concrete pad, designed to support the operating weight of the
unit.

E. Level the chiller to within ¼” in both directions (end-to-end


and side-to-side).

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

F. Access clearance: For regular service and tube pull clearances,


install chiller with the following minimum recommended
clearances:

1. End of unit: distance equal to the length of the heat


exchanger shell

2. Front of unit (control panel side): 3 feet minimum

3. Rear of unit: 2 feet minimum

4. Top of unit: 2 feet minimum

3.02 FIELD QUALITY CONTROL

A. Storage: Store per chiller manufacturer’s written


recommendations. Store chiller indoors in a warm, clean, dry
place where the chiller will be protected from weather,
construction traffic, dirt, dust, water and moisture. If chiller
will sit idle for more than 3 months, purchase long-term
storage service from the manufacturer to ensure warranty
coverage.

B. Rigging: Follow manufacturer’s written instructions for


rigging, off-loading, and use of rigging tools such as spreader
bars, forklifts, come-a-longs, and shackles.

3.03 STARTUP SERVICE

3.03.1 Chiller manufacture to provide a factory trained


representatives to perform following services:

a. Leak testing

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

b. Refrigerant Pressure Testing


c. Evacuation.
d. Dehydration.
e. Charging the chiller with refrigerant in needed.
f. Check and record performance of chiller protection
devices
g. Check and record performance of chilled and condenser
water flow and low temperature interlock.
h. Operate chiller for run in period as recommended by
manufacture.
i. Check static deflection of vibration isolators, including
deflection during chiller start up and shut down.
j. Check refrigerant Charge.
k. Check oil level.

3.04 OWNER INSTRUCTION

A. Provide training of the owner’s personnel. Cover startup,


shutdown, general maintenance and troubleshooting. Review
operating and maintenance manual and familiarize personnel
with control panel, including its special features and
capabilities.

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

B. After the above services have been performed, the same


factory trained representative shall be available for 15 days to
instruct the owner’s personnel in the proper operation and
maintenance of the chiller.

C. Training shall include control panel, motor starter / VSD,


lubrication system (if applicable), operation, and
maintenance requirements.

D. Training shall include startup and shutdown procedures as well


as regular operation and maintenance requirements.

3.05 CLEANING

A. Clean exterior prior to transfer to owner.

3.06 FINAL ASSEMBLY, TESTING AND START UP

A. Manufacture shall be responsible for supervising the installation


of the shop loose components of the chiller on site.
B. Manufacture is responsible for the reconnection of all control
wiring from the chiller to the chiller control panel and starter.
C. Manufacture shall perform the onsite pre commissioning,
commissioning ad startup of the new chiller .These activity
include the 48 hour pressure test of refrigerant side components
at factory specified pressure. Manufacture must provide two

WATER COOLED CHILLING UNITS


AL SHUBAILY GRAND MALL, KHOBAR, KSA –REV.00
PROJECT STANDARD SPECIFICATIONS

evacuation and dehydration test, to be signed off by the owner /


Engineer before charging of system. The pressure level achieved
by each evacuation shall not exceed 100 milli –bar absolute
.charging of refrigerant and oil to be performed by manufacturer.

D. Manufacture shall reconfirm the proper operation of the chillers


control system in all mode of operation, including all shutdowns.

3.06 DOCUMENTATION

A. Provide Installation, Operation & Maintenance Manual(s)


in each chiller’s control panel door. Provide six additional
copies for owner’s project system manual.
B. Provide six copies of Spare Parts Manual for owner’s
project system manual.

3.07 SEASIONAL PERFOMANCE TEST

A. During the defect liability period, when instructed by


the Engineer, engage a factory authorized service
representative to conduct a seasonal performance test
according to requirements of the Engineer. Report
results in writing.

WATER COOLED CHILLING UNITS


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