SUNCOR ENERGY Technical Standard No. FB-R-5639 FIREBAG PROGRAM HVAC AIR HANDLING UNITS SUNCOR ENERGY INC. CANADA 1_|_ ‘-Feb-06 _|Issued for Implementation Bevender A. Devender is Rev | __ Date Document Status Originator | Engineer | Reviewor UNGONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004.001 244.7 File Name: FE-R-6639_- Rev_1_- HVAC_Air Handling Units, 0C Page 1 of 10SUNCOR TECHNICAL STANDARD ‘Subject ‘Number; Revision: HVAC AIR HANDLING UNITS FB-R-5639 4 10 2.0 3.0 4.0 5.0 6.0 7.0 8.0 ‘This standard is based on Suncor Energy Inc. Specification No. SP91-R-10 Rev, {1A and has bean developed special fr use on Frobag Projects. ‘TABLE OF CONTENTS SCOPE OF STANDARD INTRODUCTION 24 2.2 2.3. Terms and Definitions 2.4 Units of Measurement 25 Exceptions CODES, STANDARDS AND REGULATORY REQUIREMENTS PROJECT STANDARDS OPERATING CONDITIONS TECHNICAL REQUIREMENTS, 6.1 General 6.2 Unit Construction 6.3. Fans and Motors 64 Vibration Isolation 65 66 Coils 67 —Pre-Wired Equipment and Factory Installed Controls 68 __ Installation INSPECTION AND TESTING SHIPPING, HANDLING AND STORAGE ‘UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JPIEWR 100-2004-001 2-447 File Name: FB-R-5639_- Rev WAC. A Handling. Units.00C Page 2 of 10Suncor) TECHNICAL STANDARD SubiecE Taber aso HVAG AIR HANDLING UNITS FB-R-5639 4 1.0 SCOPE OF STANDARD 1.0.1 This document presents the minimum requirements for the design, manufacturing, supply and installation of HVAC Air Handling Units for Suncor Firebag Projects. 2.0 INTRODUCTION 24 LOCATION 24.1 The HVAC systems will be installed in the Suncor Energy Firebag Facility located approximately 45 km NE of existing Suncor upgrader plant near Fort McMurray, Alberta, Canada. 2.2 RESPONSIBILITY 2.4.1 Compliance by Contractor with this standard does not relieve Contractor of his responsibility {for furnishing and installing equipment of proper design, mechanically suited for the specified service conditions. 2.2.1 Any conflict between this document, codes, standards, regulatory requirements or other contractual documents shall be brought to Suncor’s attention for resolution before proceeding. 2.3. TERMS AND DEFINITIONS 2.3.1 “Suncor” means owner or purchaser and is defined as Suncor Energy Ine. 2.3.2 “Contractor” means vendor, supplier or manufacturer that supplies the materials and services. 24 UNITS OF MEASUREMENT 2.4.1 All units of measure shall be reported in the International System of units (SI) in accordance with CAN/CSA Z234.1-89, Canadian Metric Practice Guide. Dimensions shall be presented first in SI units followed by the equivalent value in imperial units shown in parentheses. Where imperial-sized materials such as plate are used (or where imperial dimensions are controlling), dimensions shall be first specified in SI units (after hard conversion), with equivalent imperial sizes specified in parentheses. Piping flanges and bolting shall be shown in imperial units only (Le. NPS 4). ‘UNCONTROLLED DOCUMENT WHEN PRINTED ({-Feb-06) CONTROLLED DOCUMENT IN JPI EWR 100-2006001 —2-447 Fle Namo: FB-R-5639_- Rev_1_- HVAC. Air Handing Unis. DOC Page 3 of 10Suncor) TECHNICAL STANDARD ‘SubecE Naniber Revision HVAC AIR HANDLING UNITS FB-R-5639 1 2.5 EXCEPTIONS 2.5.1 Any exceptions to this standard shall be made in writing at the time of quotation submission. All exceptions shall be clearly identified and explained in Contractor's proposal. Exceptions shall be permitted only after Suncor has given written approval. 3.0 CODES, STANDARDS AND REGULATORY REQUIREMENTS 3.0.1 The HVAC Air Handling Units shall be designed, fabricated, tested and inspected in accordance with the latest applicable edition and addenda’s of the following in effect at contract award date: ARI 430-85 Air Conditioning and Refrigeration Institute — Standard for Central Station Air Handling Units AMCA Air Movement and Control Association ASHRAE American Society of Heating, Refrigeration and Air Conditioning Engineers ceC Canadian Electrical Code CEMA Canadian Electrical Manufacturers Association CGSB 1-GP-181M Coating, Zinc-Rich, Organic Ready Mixed CSA Canadian Standards Association OHSA Occupational Health and Safety Act NEMA National Electrical Manufacturers Association SMACNA Sheet Metal and Air Conditioning Contractors’ National Association uLc Underwriters Laboratories of Canada ‘UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004.001 -2-44-7 Fle Name: FB-R-5639_- Rev_1_- HVAC_Air Handling. Units, DOC Page 4.of 10Suncor) TECHNICAL STANDARD Saber Nomber Revision HVAC AIR HANDLING UNITS FB-R-5639 4 4.0 PROJECT STANDARDS 4.0.1 The latest version of the following Firebag Projects standards shall be complied with for the HVAC Air Handing Units. FB-A-5672 Plant Noise Level Control FB-A-5673 Equipment Protection During Transit and Storage at Jobsite FB-P-5552 Induction Motors 600 Volts and Below FB-R-5632 HVAC Mechanical General Requirements and Testing FB-R-5640 HVAC Supply & Exhaust Fans FB-R-5642 HVAC Ductwork FB-R-5644 HVAC Components 5.0 OPERATING CONDITIONS 5.0.1 Refer to the Site Conditions Data Sheet for outdoor conditions and the contract for indoor conditions. 6.0 TECHNICAL REQUIREMENTS 61 GENERAL 6.1.1 The noise level of the Air Handling Units shall meet the requirements of Firebag Projects standard FB-A-5672. 6.1.2 Contractor shall supply components assembled and tested in the factory to build units supplying air at design conditions mentioned in Section 5.0. 6.1.3 The air handling units shall be outdoor, horizontal type, having air tight modular components, consisting of casing, fan section with motors and drives, filter sections, glycol heating coil and intake hood with motorized damper. 6.1.4 Contractor shall supply air handling units from Engineered Air, Trane, Hakon or LPG, unless otherwise approved by Suncor. 6.1.5 Contractor supplied air handling units shall be CSA approved and labeled. The units located in electrical classified areas shall be approved for the area in which they are located. UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED OOCUMENT IN JPI EWR 100-200-001 Fle Namo: FB-R-5639_- Rev_1_. HVAC_Air Handing Units, DOCSuncor) TECHNICAL STANDARD Subject Tiamiber Revision HVAC AIR HANDLING UNITS: FB-R-5639 4 62 6.21 622 6.23 6.24 6.25 6.26 6.27 6.28 6.29 UNIT CONSTRUCTION Unit casings shall be of minimum 1.3mm gauge satin coat galvanized sheet metal. Surfaces shall be cleaned with a degreasing solvent to remove oil and metal oxides and primed with a two-part acid based etching primer. Finish coat shall be electrostatically applied enamel to all exposed surfaces. All unprotected metal and welds shall be factory coated. Walls, roofs and floors shall be of formed construction, with at least two breaks at each joint. Joints shall be secured by sheet metal screws or pop rivets. Wall and floor joints shall be broken in and roof joints broken out (exposed) for rigidity. All joints shall be caulked with a water resistant sealant. Internal insulation shall be provided with 0.85 mm solid galvanized metal liner. Units shall be provided with access doors to all components requiring regular maintenance. Hinged access doors, large enough for easy access, with zinc plated piano hinges and brass pins, in welded steel frames shall be provided. Doors shall be fully lined with automotive bulb gasket and Ventlock 310 handles, operable from both sides. Casings shall be supported on formed galvanized steel channel or structural channel supports, designed and welded for low deflections. Integral lifting lugs shall be provided for hoisting. Units shall be internally insulated with 50mm thick 48 kg/m*. density acoustic insulation. Unit casing floors in walk-in sections shall be fabricated with 2 mm galvanized checker plate steel. Floors shall be insulated with 50mm thick 48 kg/m? density acoustic insulation. Reinforcing channels shall be furnished under the floor to minimize deflection. Bird screen shall be attached to reinforcing channels to protect the exposed insulation. Air handling units shall be weatherproofed and equipped for outdoor installation. ‘Weatherproofing shall be included for the prevention of rain infiltration and snow infitration into the unit: hoods on air intakes and exhaust openings with 25 mm galvanized screens, rain gutters over all access doors, all joints caulked with water resistant sealant, roof joints turned up 50 mm with three break interlocking design, outer wall panels extending a minimum of 6 mm below the floor panel, drain traps for field installation. The units shall be equipped with a convenience outlet, 115V, 1ph for maintenance. UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004.001 — 2-447 File Name: FB-R-5639_- Rev_1_- HVAG_Air Handling Units.006 Page 6 of 10oR) "FREENS PROGRNH- MECANICALDEPARTENT SUNCOR TECHNICAL STANDARD ‘Subject Tanber Revision: HVAG AIR HANDLING UNITS FB-R-5639 4 6.3 FANS AND MOTORS 6.3.1 Fans shall be airfoil type in accordance with Firebag Projects standard FB-R-5640. 6.3.2 Motors shall be furnished in accordance with Firebag Projects standard FB-P-5552. 6.3.3. For electrical unclassified buildings, motors shall be TEFC type with high efficiency. 6.3.4 For electrical classified buildings, non-arcing (non-sparking) fans with aluminum wheels, aluminum inlet cones and explosion proof motors shall be installed. 6.4 VIBRATION ISOLATION 6.4.1 Flexible connections at inlets and outlets of fan sections shall be installed in accordance with Firebag Projects Standard FB-R-5642, para 6.4 “HVAC Duct Accessories”. 6.4.2 Vibration isolators shall be 50 mm deflection as per Firebag Projects standard FB-R-5644, section 10, "HVAC Vibration Isolators”. 65 FILTER BOX 6.5.1 Material shall match that of the casing. Access shall be provided to filters through hinged doors with suitable hardware. 6.5.2 Space shall be provided for winter and summer positions. 6.5.3 Blank-off plates and gaskets shall be equipped to prevent air bypass. 6.5.4 Pre-filters shall be 50 mm thick and 30% efficient. Filters and filter gauges shall be in accordance with Firebag Projects standard FB-R-5644, section 9, “HVAC Filters and Filter Gauges’ 6.5.5 Low leakage dampers shall conform to Firebag Projects standard FB-R-5644, para 6.2, “Operating Dampers". Damper actuators will be provided by others. 66 COILS 6.6.1 Coils shall be constructed of steel tube, aluminum fin, schedule 40 steel! headers with ANSI class 150 flanged connections. Fins shall be rippled for maximum heat transfer and shall be mechanically bonded to the tubes by mechanical expansion of the tubes. The coils shall have a galvanized steel casing. All coils shall be factory tested with air at 2070 kPag while immersed in an illuminated water tank. 'UNGONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JP EWR 100-2004.001 -2-44-7 File Name: FB-R-5639_- Rev_1_- HVAC_Ale Handling Units. 0¢ age 7 of 10Suncor) [ Presa rncor- waco ce | EWERGY TECHNICAL STANDARD ‘Subject Naber Revision HVAC AIR HANDLING UNITS FB-R-5639 4 6.6.2 Coils shall be removable from the unit at the header end, unless shown otherwise on the drawings. All water coils shall be equipped with a capped vent tapping at the top of the return header, and a capped drain tapping at the bottom of the supply header. 6.6.3 Outdoor units shall be provided with fully insulated and weatherproofed piping vestibule to allow for the entry of piping from the building into the air-handling unit and for connections to the coils. Piping vestibules shall be designed to accommodate piping, valves and controls. 6.7 — PRE-WIRED EQUIPMENT AND FACTORY INSTALLED CONTROLS 6.7.1 Air handling units shall be factory wired and tested, and shall be certified by C-ETL. 6.7.2 Pre-wired air handling units shall bear an approved label with all the necessary identification marks, electrical data, and any necessary cautions as required by the Canadian Electrical Code, Part 2. 6.7.3 Units shall be equipped with necessary terminal blocks, motor contactors, motor overload protection, grounding lugs, control transformers, auxiliary contactors and terminals. 67.4 Factory installed and wired non-fused disconnect switches shall be in NEMA 4X configuration, or shall disconnect with integral door closure mounted on face of control panel. 68 INSTALLATION 6.8.1 General 6.8.1.1 Manufacturer's instructions shall be followed for the installation of air handling units. 6.8.1.2. Installation work shall be performed in a safe manner and shall be subject to all OHSA safety requirements. 68.2 Fan 6.8.2.1. Fan sheaves shall be installed for final air balance where required. 6.8.2.2 Flexible connections shall be installed at fan inlets and outlets. 6.8.2.3. Vibration isolators shall be installed. UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JPI EWR 100-2004-001 ~2-44-7 File Name: FB-R-6639_- Rev_1_- HVAC_Air Handling Units.D0C Page 8 of 10Suncor) ng ROGERSON GET ENERGY, TECHNICAL STANDARD | Subject Nomiber Rovio HVAC AIR HANDLING UNITS FB-R-5639 4 68.3 Ce 6.8.3.1 Coils shall be installed with necessary connections as valves, air vents, test plugs, flanges and connections from drip pans. 6.8.3.2. Isolation valves shall be installed on supply lines and control and balancing valves shall be installed on return lines to each glycol coil. For units with split coils, piping connections shall be arranged for balanced flow to each split coil. Valves shall be factory installed in piping vestibules. 6.8.3.3 Each glycol coil shall be equipped with combination pressure and temperature test plugs on both inlet and outlet. 6.8.3.4 Final connections to glycol piping, will be performed by others. 6.8.3.5 Water supply shall be located at bottom of supply header and return water connection shall be located at the top to provide self-venting and reverse return arrangement. Manual air vents shall be provided at high points complete with stop valves. Water coils shall be drainable and shall be installed with drain connections at low points. 6.8.3.6 Contractor shall protect fins and flanges from damage. Loose and damaged fins shall be replaced. Deformed fins shall be combed out unless required to be replaced. 7.0 INSPECTION AND TESTING 7.0.1 All equipment must be tested in the factory. The tests shall include: a. Adjustment of all dampers and damper linkages. b. Leak test on all coils, ¢. Static and dynamic balance of fan clw belts and drives. d. Pressure test of cabinet to ensure no more than 1% (of specified air volume of unit) air leakage at 20% above specified static pressure. @. Ensure even air flow across all filters and coil banks. f. Performance test to ensure specified airflow and static pressure can be met. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOGUMENT IN JPIEWR 100-2004.001 —2-44.7 Fle Name: FB-R-5639_- Rev_1_- HVAC_Alr Handling. Units. DOC Page 9 of 10or) ‘PREBAG PROGR WECHANCAL DEPARTWENT Sun COR TECHNICAL STANDARD Sibjeck Nomber Revision] HVAC AIR HANDLING UNITS FB-R-5639 4 7.0.2 Electrical circuits shall undergo a dielectric strength test, and shall be factory tested and checked for proper function. 7.0.3 A certified report showing all details of factory tests shall be included in the maintenance manuals. 8.0 SHIPPING, HANDLING AND STORAGE 8.0.1 Shipping, Handling and Storage of unit heaters shall meet the requirements of Suncor Firebag Projects standard FB-A-5673. UNCONTROLLED DOCUMENT WHEN PRINTED (1-Feb-06) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 - 244-7 Fle Name: FB-R-5639_- Rev_1_. HVAC_Air Handling_Unis DOC Page 10 of 10TFRERAG PROGRAM ~ENGWEERNG GENERAL TECHNICAL STANDARD SUNCOR REVISION REVIEW AND APPROVAL Nos, FIREBAG PROGRAM TECHNICAL STANDARD REVISION REVIEW AND APPROVAL Doc. No. FB-R-5639 Current Rev.No.: 1 Date: 1-Feb-06 Document Title: HVAC Air Handling Units Issuing Department: "Mechanical Date: _1-Feb-06 To: From: DESCRIPTION OF CHANGE (Attach the draft/revised Technical Standard) * Reasons for Change — Creation of a Firebag Program Technical Standard ‘* Revisions: * Additions: (Refer to paragraph number of this new standard) * Deletions: (Refer to paragraph number of the old specification SP91-R-10, Rev.1A) ‘Comments Roarova7) Date 1. | Originator Wi 7 : Arcot Devender fff. Viol kee b Firebag Mechanical Program Lead Wore (Aloo sion re age of et 2. | Engineer ‘Arcot Devender More , deca [Feh Roo b Firebag Mechanical Program Lead (oo son ont ge of 3. | Reviewer Dave Tullis _ . wed on Febhfo Firebag Engineering Manager 4 i / le 4, | Approval Authority B Ken Hart neal Firebag Operations Manager a wmrosonigieomt | feb 1 [pe 5. | Return to Rita Lewis Jacobs Canada Heritage Square Attachment — Firebag Projects Standard Number FB-R-5639 - Rev. No. 1 - Issue Date 1-Feb-06 i TNCONTROLLED DOCUMENT WHEN PRINTED ({-FEB-08) CONTROLLED DOCUMENT IN EWR FILE LOCATION. J (Fou: — EWR 1002008001244 -FB Rev. = “Page: Toft]TECHNICAL STANDARD SUNCOR REVISION REVIEW AND APPROVAL Doc. No.: FB-R-5639 Current Rev.No.: Date: 6-Jan-06 Document Title: HVAC Air Handling Units Issuing Department: chanical Date: _6-Jan-06 To: From: DESCRIPTION OF CHANGE No:, FIREBAG PROGRAM TECHNICAL STANDARD REVISION REVIEW AND APPROVAL (Attach the draft/revised Technical Standard) ‘> Reasons for Change — Creation of a Firebag Program Technical Standard ‘* Revisions: Reformatted and reworded Updated reference standards * Additions: (Refer to paragraph number of this new standard) 6.1.4 — Add Trane, Hakon, LPG ‘Deletions: (Refer to paragraph number of the old specification SP91-R-10, Rev.1A) 2.2.10 - Delete entire para 2.6.1 — Delete “Ultrafin and/or Superfin, as manufactured by Engineered Air" 3.3.2 - Delete “Balancing valves” on each split coil in a coil section 3.3.3 - Delete entire para 3.3.4 — Delete the second sentence Comments ‘Approval Date 2 1. | Originator 7, ‘Arcot Devender : / Heh B0/1/2ood Firebag Mechanical Program Lead | vt Wo son tort page of f 2. | Engineer Arcot Devender La of /206 Firebag Mechanical Program Lead Nive 0 sign front page of 3) ears. DIVE | eshlon Firebag Engineering Manager (Also sign front page of 18) Form TRIGONTROLLED DOCUMENT WHEN PRINTED (26-JAN-06) CONTROLLED DOCUMENT IN EWR FILE LOCATION EWR 100-2008-001 — 2 - FS Far = ] Ta?)Suncor) TECHNICAL STANDARD REVISION REVIEW AND APPROVAL 4. | Approval Authority Ken Hart (Aso sign font page of Jacobs Canada Heritage Square Firebag Operations Manager Pei te a avsofoo 5. | Return to Rita Lewis Attachment ~ Firebag Projects Standard No. FB-R-5639 - Rev. No. B - Issue Date 6-Jan-06 c TNCONTROLLED DOCUMENT WHEN PRINTED (26-IANO8) CONTROLLED DOCUMENT IN EWR FILE LOCATION. (Fem BWR to.2008 007 — rer re rR FER RR Fey Page: 1 Zotz]