SECTION 15 \ 1

AIR CONDITIONING SYSTEM

PART 1 - GENERAL

1.1 SECTION INCLUDES

A. The Work shall consist of furnishing and installation of air conditioning systems as
shown on drawings and as specified herein.

1.2 REFERENCES

A. SASO – Saudi Arabian Standards Organization

SASO 35 Evaporative air coolers (Desert coolers)

SASO 36 Methods of test for evaporative air coolers (Desert coolers)

SASO 1302 Air ducts for air conditioning - Part 1: Definitions, classification and
terminology

SASO 1434 Thermal environmental conditions for human occupancy.

SASO 1435 Safety requirements for the installation on air conditioning and
ventilating systems - Part 1: Definitions and technical terms.

SASO 1436 Safety requirements for the installation on air conditioning and
ventilating systems - Part 2: Requirements of HVAC systems.

SASO 385 Methods of test for room air conditioners

SASO 772 Code of practice for mechanical ventilation and air conditioning in
buildings -Part 1: General basis of design.

SASO 773 Code of practice for mechanical ventilation and air conditioning in
buildings -Part 2: General requirements for installation.

B. ARI - Air Conditioning and Refrigeration Institute:

ARI 210 Unitary Air Conditioning Equipment.

ARI 260 Application, Installation, and Servicing of Unitary Systems.

ARI 360 Commercial and Industrial Unitary Air Conditioning Equipment.

ARI 410 Forced Circulation Air-cooling and Air-Heating Coils.

ARI 440 Room Fan Coil Air Conditioners.

ARI 520 Positive Displacement Refrigerant Compression and Condensing

Units.

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 C. ANSI - American National Standards Institute :

ANSI B9.1 Safety Code for Mechanical Refrigeration.

ANSI B15.1 Safety Standard for Mechanical Power Transmission Apparatus.

D. ASHRAE - American Society of Heating, Refrigerating and Air Conditioning

Engineers, Inc.:

ASHRAE 15 Safety Code for Mechanical Refrigeration.

ASHRAE 33 Methods of Testing Forced Circulation Air Cooling and Heating coils.

ASHRAE 37 Methods of Testing for Rating Unitary Air Conditioning and Heating
Pump Equipment.

ASHRAE 90A Energy Conservation in New Building Design.

E. NEMA - National Electrical Manufacturer's Association:

NEMA MG-1 Motors and Generators.

NEMA ICS General Standards for Industrial Control and System.

F. NFPA - National Fire Protection Association:

NFPA 70 National Electric Code.

NFPA 90.A Installation of Air-Conditioning and Ventilation Systems.

G. UL - Underwriters Laboratories Inc.:

UL-465 Central Cooling Air Conditioners.

UL-883 Safety Standards for Fan Coil Units and Room Fan Heaters Units.

H. EUROVENT: All relevant standards as applicable.

1.3 SUBMITTALS

A. Product Data: Submit manufacturer's technical product data, including rated

capacities for all air conditioning units indicated, weights (shipping, installed and
operating), supplied specialties and accessories; and installation and start-up
instructions.

B. Shop Drawings: Submit manufacturer's assembly type shop drawings indicating

dimensions, weight loadings, required clearances, methods of assembly of
components, and location and size of each field connection.
C. Wiring Diagrams: Submit manufacturer's electrical requirements for power supply
wiring to units.

D. Operation and Maintenance Data: Submit maintenance data and parts list for each
unit, control, and accessory, including Trouble-Shooting maintenance guide,
servicing guide, and preventive maintenance schedule and procedures.
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 E. As-built Drawings: A complete and up-to-date set of all mechanical work as
installed shall be maintained and submitted.

F. Spare Parts List: Submit the manufacturer's spare parts list for the air-conditioning
equipment for a period of 2 years for the Engineer's review and approval.

1.4 TRANSPORTATION, HANDLING AND STORAGE

A. Transportation, handling and storage of materials shall be in accordance with

manufacturer's recommendations regarding transportation, handling and storage of
materials.

B. Deliver materials to the site in manufacturer's original factory wrappings and

containers, clearly labeled for identification of manufacturer, brand name and
contents. Store materials off ground in original undamaged packages and
containers, inside well-ventilated area protected from weather, moisture, soiling,
extreme temperatures, and humidity.

1.5 WARRANTY

A. The entire system shall be warranted for 1 year from substantial completion.
Refrigeration compressors shall have an additional 5 year warranty starting from the
date of final acceptance by the Owner. Date of final acceptance is defined as date
of final payment to Contractor.

1.6 QUALITY ASSURANCE

A. Tests: Submit proposed testing program to the Engineer at least 2 weeks prior to
scheduled test to assure agreement and approval of personnel and instrumentation
required, and the scope of testing program. Conduct tests in the presence of
Engineer. Engineer shall be given a 2-days notice before conducting tests. Water
and electricity required for tests shall be the responsibility of the Contractor.
Materials, equipment, instruments and personnel required for the tests shall be
provided by the Contractor.

B. Testing: System testing and the submittal of reports shall comply with the applicable
ASHRAE Standards.

1.7 OPERATIONAL TESTS

A. Prior to final inspection, operate systems continuously free and stable for a
minimum of 14 consecutive days. Each day shall be a minimum of a 20-hour day.
Should a problem arise, the 14-day period shall be restarted and repeated until
successfully operated for 14 days.

1.8 OPERATING INSTRUCTIONS

A. Contractor shall provide full operating instructions to the Owner's personnel of items
of equipment that are, or have components that are motor-driven, or electric
resistance heated. Instructions are to be given at the Engineer convenience.

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PART 2 - PRODUCTS

2.1 GENERAL

A. Materials used shall be new of first quality as approved by the Engineer. Minor
items, accessories, devices reasonably inferable as necessary to the complete and
proper operation of a system shall be provided by contractor for such system
whether or not they are specifically called for by specifications or drawings.

B Air Conditioning Units: Design, manufacture and installation of mechanical

refrigeration equipment shall meet the requirements of ASHRAE 15, ARI 590 or
EUROVENT.

C. Fully guard drive mechanisms or other moving parts shall be in accordance with
ANSI B15.1.

2.2 PACKAGED SCREW TYPE LIQUID CHILLERS

A. Furnish and install complete, factory-assembled air-cooled screw type liquid chiller
units of the type, size and capacity shown on the drawings (equipment schedule).
Units shall be for outdoor use and rated in accordance with ASHRAE 15 and the Air
Conditioning and Refrigeration Institute (ARI) Standard 590.

B. Units shall be of the package air-cooled type and consist of single or multiple screw
type compressors, direct-expansion liquid cooler, air-cooled condenser and factory
wiring and piping contained within the unit enclosure. Unit shall contain a complete
operating charge of Refrigerant R-134a or R-407c and factory-installed
microprocessor system, capable of indicating status of all safeties and energizing
remote alarm. Unit construction shall comply with ANSI B9.1 Safety Code, NEC and
ASME Code. Unit shall be enclosed in a galvanized steel casing, painted with
weather resisting baked enamel finish.

C. All chillers shall be factory tested to verify capacity and electrical consumption prior
to shipping. Manufacturer shall provide such evidence.

D. .

E. Compressor:

1. The compressor shall be a field serviceable, direct drive, single screw or twin
screw type with one main screw rotor that meshes with two diametrically
opposed gaterotors. The main screw rotor shall have helical grooves and shall
be constructed of a high alloy steel. The two identical gaterotors shall be
located on opposite sides of the main screw rotor. The gaterotors shall be
constructed of a carbon impregnated engineered composite material. The
gaterotor supports shall be constructed of cast iron.

2. The semi-hermetic compressor shall utilize an internal economizer cycle to

enhance the unit's refrigeration effect and to allow the compressor to run at a
more efficient operating point.

3. A liquid refrigerant injection system shall be utilized to seal potential leakage

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 paths between high and low sides of the compressor.

4. Slide valve modulation shall be provided for unloading control. The electric
motor shall be semi-hermetic, squirrel cage induction type and cooled by
liquid refrigerant which allows the motor to operate at lower temperatures.
Compressor power factor shall be 0.90 or greater.

F. Evaporator:

1. Evaporator shall be of the direct expansion shell and tube type with carbon
steel barrel, polypropylene water baffles to resist corrosion, and seamless,
internally finned high efficiency copper tubes. Tubes shall be roll expanded
into heavy carbon steel tube sheets. Refrigerant heads shall be carbon steel
and removable to permit access to tubes from either end. For easy removal of
water, vent and drain plugs shall be provided on the shell.

2. The evaporator shall be wrapped with an electric heater cable and insulated
with 19 mm thick closed cell polyurethane insulation (K = 0.28 at 23.9 o C) to
provide freeze protection down to -10 o C ambient air temperature. The
insulation shall be fitted and cemented in place, then painted with a resilient
vinyl paint to resist cracking.

3. The evaporator shall be designed for refrigerant side working pressure of 225
psig (1552 kPa) and water side working pressure of 175 psig (1207 kPa). The
evaporator shall be designed, constructed, inspected and stamped in
accordance with ASME Code requirements.

G. Condenser: Air-cooled condenser coils shall have aluminum fins ( if not required
copper fins ) mechanically bonded to seamless copper tubes, cleaned, dehydrated,
sealed, leak tested at 1034 Kpa (150 psig) and pressure tested at 3103 kPa (450
psig). Condenser fans shall be propeller type with PVC-coated steel wire safety
guards, balanced statically and dynamically and discharge vertically. Condenser
fans shall have inherent overcurrent protection. Condenser Fan Motors shall be
TEFC with Class F insulation. Condenser coils and fins shall be coated with
manufacturer’s standard anti-corrosive coating.

H. Refrigerant Components: Refrigerant circuit components shall include hot gas

muffler, high side pressure relief device, liquid line shut off valve, replaceable core
filter drier, moisture indicating sight glass, and expansion valve. If accessory
unloaders are to be used, they shall be electrically actuated suction cutoff cylinder
unloaders.

I. Chiller Controls:

1. The chillers shall be provided with logic control system and a remote
monitoring and sequencing controller.

2. The chiller control shall have open protocol to interface with the BMS system.

3. Head Pressure Control: Each unit shall be capable of operating satisfactorily

at low indoor air temperature.

4. Capacity Control: Each unit control shall be factory equipped with

microprocessor controller and electrically-operated device for loading and
unloading compressor and a control for cycling compressors. Hot gas by-pass
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 shall be provided. Chillers shall have multiple capacity control. Chillers shall
be provided with either pressure gauges or alpha numeric display for the
following:

- Discharge pressure
- Suction pressure
- Oil pressure.

5. Unit controls, including microprocessor, shall be factory mounted and wired in

a weatherproof enclosure with hinged access doors, and shall include
automatic lead-lag, pump down at beginning and end of every circuit cycle,
low suction pressure protection, flow switch, low chilled water temperature
safety, low oil pressure protection for each circuit, low input voltage protection
for each compressor, high input voltage and single phasing and input spike
protection for each compressor, field power and control circuit terminal blocks,
fan motor circuit breakers, ON/OFF switch, replaceable relay board, individual
solid-state compressor protection, return or leaving chilled water set point
feature, a digital display module, a microprocessor board, and a temperature
reset feature. Programming of the microcomputer control panel should be
through a touch key pad system. Motors should have a three leg current
sensing system. Units should be capable of providing a hard copy of system
status and faults.

J. Electrical Requirements: Electrical requirements shall be as per schedule. Factory-

mounted control transformer shall be provided. Units shall be provided with a single
point power supply and one non-fused disconnect switch to isolate the unit.

2.3 AIR HANDLING UNITS

A. General: Provide factory-fabricated and factory-tested outdoor \ indoor type air

handling units as indicated, sizes and capacities (cooling/heating) as shown on
drawings. Units shall be tested, rated, and certified in accordance with ARI 430 or
EUROVENT. Unit shall bear ARI or EUROVENT certification label and shall be
listed in ARI directory of Certified Applied Air Conditioning Products.

B. Casings: Component modules shall be 50 mm thick constructed of sectionalized,

mill galvanized steel formed double skin insulated panels, rigidly reinforced with
external structural steel frame. Provide hinged access doors with neoprene type
door gasket for access to sections and components requiring servicing. All units
installed externally shall have close cell self-adhesive neoprene foamed gasket
joints k value of 0.4 W/m o K between panels. Externally mounted units shall have a
pitched roof with extra anticorrosive paint and self-adhesive protection foil.

C. Insulation: Coil, fan and accessory section panels shall be secured to casing with
permanent fasteners and shall meet NFPA 90A flame spread and smoke
generation requirements. All units shall be double skinned construction with 50 mm
thick thermal and acoustic insulation injected polyurethane having thermal
coefficient of 0.5 W/mo K.

D. Condensate Drain Pans: Shall be stainless steel double wall construction with
threaded drain connections on both sides and shall extend under the complete coil
section of units. Condensate drain pans shall be insulated with minimum 16 mm
thick isocyanurate foam faced with an additional aluminum foil vapor barrier and
cemented between the outer pan and the inner stainless steel pan.. Insulation
adhesive and inner coating shall comply with NFPA 90A flame spread and smoke
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 generation requirements.

E. Fan Sections: Fan sections shall be constructed of galvanized steel and have a
formed channel base for integral mounting of fan, motor and casing panels. Fan
scroll, wheel, shaft and bearings shall be mounted on structural steel frame rigidly
secured to the channel base. Fans shall be double width, double inlet type with
backward curved airfoil section blades as indicated on the schedule. Forward
curved wheels shall be bonderized steel painted with baked enamel or galvanized
steel. Airfoil wheels shall be steel painted with zinc chromate primer and an enamel
finish coat. Externally mounted AHU's shall have backward inclined or airfoil
wheels.

Motor shall be factory installed on slide rails. Motors shall be totally enclosed fan
cooled (TEFC) with Class F insulation.

Fan shafts shall be solid steel, turned, ground and polished. Fan wheels shall be
keyed to the shaft and shall be designed for continuous operation at the maximum
rated fan speed and motor horsepower. Fan wheels and shafts shall be selected to
operate at least 25% below the first critical speed, and shall be statically and
dynamically balanced as an assembly. Fan bearings shall be self-aligning, pillow
block regreaseable ball type selected for an average life of 200,000 hours at design
operation conditions, per ANSI B 3.15.

Vibration isolation of the entire fan, motor and drive assembly shall be by use of 50
mm deflection springs, internally mounted at the factory, together with fan discharge
flexible connection and thrust restraint springs.

Fan motors shall be factory mounted inside the fan section casing, on slide rails
having 2 adjusting screws. Motor capacity shall be as indicated. Fan drives shall be
factory mounted with final alignment and belt adjustment to be made by the
Contractor after installation.

Where indicated on the equipment schedules, units shall be provided with variable
frequency inverters and All (VAV) Devices Shall be Connected With (VAV) Unit.

Fan discharge dampers, with forward curved fans, shall be provided where
required. Dampers shall have opposed action damper blades, formed at the edges
and mechanically secured to steel rods rotating in bronze bushings, mounted on a
rigid, flanged, galvanized steel frame.

F. Coil Sections: Coil sections shall have heavy-duty coil tracks extending the full width
of the unit to provide slip-in, slip-out coils for ease of service and maintenance. All
coils shall be of the cartridge type, removable from coil connection side of casing.
They shall be tested at 400 psig air pressure while submerged in water. Coil
performance shall be certified in accordance with ARI 410 or EUROVENT.

Chilled water coils shall be aluminum plate fins with belled collars and bonded to
copper tubes by mechanical expansion. The fins for AHU shall have baked phenolic
or equivalent coating after production. Coils shall have galvanized steel casings and
steel headers with threaded connections. Working pressure shall be 20 bar (300
psig) at 93oC (200oF). Coils shall be drainable and shall have non-trapping circuits.
No turbulence promoting devices will be permitted inside the tubes. Headers shall
have drain and vent connections. Coils for 100% fresh air units shall be constructed
of copper tubes with copper fins.

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 An integral control box MCC panel shall be furnished by the manufacturer and shall
contain thermal cutouts, primary and secondary control, back-up contactors, sub-
circuit fusing, airflow switch and fused control transformer.

Where coils are stacked, provide intermediate drain pans with drain tubes at either
end to drain condensate to the main drain pan without flooding the lower coil. Water
traps to be designed to prevent water and odors’ ingress to the air handling units’
negative pressure section.

G. Filter Sections: Filter sections shall be supplied by the AHU unit manufacturer, with
the same casing construction as specified for other unit sections. Cartridge filter
sections for installation of fan inlet shall be capable of accepting standard 50 mm
thick cleanable prefilters and a combination of 300 mm x 600 mm and 600 mm x
600 mm cartridge filters and with minimum 85% efficiency (ASHRAE Standards 52-
76). Cartridge filter sections shall have hinged access doors on both sides for filter
replacement. Low velocity filter sections shall be capable of receiving 50 mm thick
filters of standard sizes arranged in horizontal V formation. Hinged access doors
shall be provided on both sides.

H. Mixing Boxes: Shall have motorized parallel blade, interconnected outside air and
return air dampers. Damper blades shall have parallel bends for stiffness and shall
be welded to 13 mm diameter steel rods rotating in nylon bushings and mounted in
rigid galvanized steel damper frames. Dampers shall be sectionalized to limit the
blade length to not more than 1270 mm in order to prevent excess blade warping
and to assure tight closure. All units installed externally shall have fresh air intake
with rain hood and filters.

I. Humidifier–Evaporative Sections: Humidifier section shall be supplied by the AHU

unit manufacturer with the same casing construction as specified for other unit
sections. It shall consist of an unheated fill of corrugated glass fibre for 90%
efficient. A corrosion resistant water distribution system complete with pump shall
be included. The water tank shall be stainless steel sloping to simplify cleaning
and avoid standing water during shut-off periods. The water bleed-off system
shall be to minimize water consumption and mineral salt deposits by the sensors.
The humidifier shall be equipped with a droplet eliminator to prevent water carry
over.

The control of humidification and or cooling shall be through on/off control of

pump achieved by humidity and temperature controller. All necessary contracts
for control purposes shall be provided in the panel by the manufacturer of AHU.

2.4 FAN COIL UNITS (DUCTED/NON-DUCTED TYPES)

A. Unit shall deliver published cooling capacities when tested in accordance with
current ARI Standard 441 or EUROVENT. Unit, options and accessories shall be
wired and assembled in accordance with NEC. Unit without options and
accessories shall be UL listed or as per EUROVENT standards.

B. Basic Unit shall be complete with water coil, one or more centrifugal fans with PSC
motors, 3-speed switch, condensate drain pan and 18-gage galvanize steel casing.
The cabinet shall be acoustically and thermally insulated with 12 mm thick glass
fiber insulation meeting NFPA-90A requirements. Capacity shall be as shown on
drawings.

C. Furred-in Plenum Units shall have a 62 mm return air duct collar at the bottom of
15\1-1 8-12 Air Conditioning System
 the plenum that permits removal of optional filter without removing any panels.
Removable rear panels shall provide access to the motor blower assembly, valves
and piping.

D. Units for exposed installation shall include hinged bar type return air grille on the
rear of unit with cleanable filter and integral double deflection supply grille.

E. Coils shall be (standard 4 or 6-row) with 12 mm or OD copper tubes and aluminum

fins mechanically bonded to tubes. Coils shall be leak-tested at 2.4 Mpa minimum
air pressure and shall be suitable for working pressures up to 1.72 Mpa. Each coil
shall have a manual air vent (standard) or automatic air vent (optional). Coil sweat
connections shall be OD copper of the size listed in the plans.

F. Fan Motors shall be 3-speed, permanent split capacitor type with built-in thermal
overload protection. Fans shall be centrifugal, forward curved type and shall be
both statically and dynamically balanced. Fan wheels and housings shall be of
coated steel.

G. Junction Box shall be factory installed and wired to fan motor and optional electric
valves, electric heater and aquastats.

H. Drain Pan shall be of 18 gage galvanized steel, pitched for positive drainage when
until is level. Interior and exterior surfaces shall be insulated with fire-retardant,
closed cell foam. Drain connection shall be 21.8 mm OD male sweat fitting.

I. Filters shall be 25 mm thick cleanable filter media in aluminum frame.

J. Valves: Motorized valve package, including 2-way modulating motorized valve, one
balancing valve and two gate valves; connecting piping made with copper tube;
electric cables of valve motor. Valve packages are to be provided with factory
installed unions. All units should have 3/4 inch valve packages for flow rates above
5 gpm and 1/2 inch packages for flow rates up to 5 gpm. All units to be provided
with driplips beneath the valve packages all units are to be brovided with mcc
panel factory installed .

2.5 WINDOW TYPE AIR CONDITIONING UNITS:

A. Split type air conditioning units shall be completely wall-mounted packaged units
arranged for electric cooling and heating controlled by an integral thermostat, and
shall have air exhaust, four-way air deflection, and automatic temperature control.
Units shall be of capacity (cooling and heating) as shown on drawings.

B. Units shall be factory-wired and completely enclosed. All operating controls shall be
located in a single area on the front of the units. Adjustable thermostats shall
automatically cycle compressors to maintain space conditions, and sensing
elements shall extend across the complete faces of the cooling coils. Three
position exhaust/vent control to close the vent, exhaust air from the room, or
introduce air to the room shall be included.

C. Evaporator and condenser coils shall be of all aluminum, electronically soldered

construction.

D. Compressor motors shall be two-pole, permanent split capacitor type protected

against both thermal and electrical overload.

15\1-1 9-12 Air Conditioning System

 E. Air deflection shall be horizontally variable to permit adjustment.

2.6 VIBRATION ISOLATORS AND EQUIPMENT PADS

A. Refer to Section VIBRATION ISOLATION AND NOISE CONTROL.

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PART 3 - EXECUTION

3.1 INSTALLATION

B. The entire air conditioning system installation shall conform to the requirements of
ARI 260 and ANSI B9.1

C. Equipment and components shall be completely installed in a manner to insure

proper and sequential operation of the equipment and its controls. Equipment shall
be installed in accordance with the manufacturer's recommendations. Proper
foundations for mounting of equipment, accessories, appurtenances, piping and
controls shall be provided, including supports, vibrations isolators, stands, guides,
anchors, clamps and brackets. Isolation units shall be selected and sized, based on
load-bearing requirements and lowest frequency of vibration. Foundations for
equipment shall conform to equipment manufacturer's recommendation, unless
otherwise shown on Drawings. Anchor bolts and sleeves shall be set accurately
using properly constructed templates. Anchor bolts shall be of adequate length and
provided with welded-on plates on the head end embedded in the concrete.

Equipment bases shall be leveled, using jacks or steel wedges and neatly grouted-
in using a non-shrinking type of grouting mortar. Keep equipment thoroughly clean
and free from all debris with all oil, dirt and paint spots removed until final
acceptance.

D. Chilled Water Piping: Refer to Section CHILLED WATER PIPING. Unless otherwise
indicated, connect inlet to evaporator with controller bulb ell, shut-off valve,
thermometer, strainer, flow switch, flexible pipe connector, pressure gage, and
union or flange. Connect outlet to evaporator with shut-off valve, motorized butterfly
valve, balancing valve balancing cock, thermometer, flexible pipe connection,
pressure gage, and union or flange.

E. Electrical Wiring: Install all electrical devices furnished by manufacturer but not
specified to be factory-mounted.

3.2 FIELD TEST AND INSPECTION

A. Inspection: Materials, equipment and the completed installation will be inspected by

Engineer. Equipment, materials or work rejected because of defects or non-
conformance with Drawings and Specifications shall be replaced or corrected by as
directed by Engineer.

B. Start-up air conditioning system, in accordance with manufacturer's start-up

instructions, and in presence of the manufacturer's technical representative. Test
controls and demonstrate compliance with requirements. Replace damaged or
malfunctioning controls and equipment, and retest.

C. Tests:
1. Provide materials and equipment required to perform the tests. Defects
disclosed by the test shall be corrected at no cost to Owner.

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 2. Tests after installation and prior to acceptance shall be performed in the
presence of Engineer and subject to his Approval.

3. Conform to the applicable requirements specified in Section TESTING,

ADJUSTING AND BALANCING.

4. Equipment and material certified as having complied with referenced

Specifications and Standards will not require retesting before installation.
Equipment and materials not tested at place of manufacture will be tested
before and after installation, as applicable, where necessary to determine
compliance with referenced specifications and Standards.

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