Section 230500 - Modular Central Plant Doc with... · Web viewHydraulic Institute standards shall be followed for the calibration procedures of all testing instrumentation. Prior

SECTION 230500 – MODULAR UTILITY PLANT

PART 1 – GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. General description.2. Manufacturers.3. Qualifications.4. Performance testing.5. Mechanical equipment.6. Electrical and controls equipment.7. Project execution.

B. Related Sections:

1. [Section 230513 “Common Motor Requirements for HVAC Equipment.”]2. [Section 230519 “Meters and Gages for HVAC Piping.”]3. [Section 230523 “General-Duty Valves for HVAC Piping.”]4. [Section 230533 “Heat Tracing for HVAC Piping.”]5. [Section 230553 “Identification for HVAC Piping and Equipment.”]6. [Section 230716 “HVAC Equipment Insulation.”]7. [Section 230719 “HVAC Piping Insulation.”]8. [Section 230900 “Instrumentation and Control for HVAC.”]9. [Section 230993 “Sequence of Operations for HVAC Controls.”]10. [Section 232113 “Hydronic Piping.”]11. [Section 232123 “Hydronic Pumps.”]12. [Section 232500 “HVAC Water Treatment.”]13. [Section 235200 “Heating Boilers.”]14. [Section 235700 “Heat Exchangers for HVAC.”]15. [Section 236416 “Centrifugal Water Chillers.”]16. [Section 236426 “Rotary-Screw Water Chillers.”]17. [Section 236500 “Cooling Towers.”]18. [Section 260519 “Low-Voltage Electrical Power Conductors and Cables.”]19. [Section 260523 “Control-Voltage Electrical Power Cables.”]20. [Section 260526 “Grounding and Bonding for Electrical Systems.”]21. [Section 260533 “Raceways and Boxes for Electrical Systems.”]22. [Section 260553 “Identification for Electrical Systems.”]23. [Section 262419 “Motor-Control Centers.”]24. [Section 262923 “Variable-Frequency Motor Controllers.”]25. [Section 283500 “Refrigerant Detection and Alarm.”]

C. References:

1. AHRI – Air-Conditioning, Heating, and Refrigeration Institute.2. AISC – American Institute of Steel Construction.3. ANSI – American National Standards Institute.4. ASCE – American Society of Civil Engineers.5. ASHRAE – American Society of Heating, Refrigerating, and Air-Conditioning

Engineers.6. ASME – American Society of Mechanical Engineers.7. ASTM – American Society for Testing and Materials.8. ETL – Electrical Testing Laboratories.9. Hydraulic Institute.10. IBC – International Building Code.11. IEEE – Institute of Electrical and Electronics Engineers.12. NEC – National Electrical Code.13. NEMA – National Electrical Manufacturers Association.14. NIST – National Institute of Standards and Technology.15. OSHA – Occupational Safety and Health Administration.16. UL – Underwriters Laboratories

1.3 GENERAL DESCRIPTION

A. Provide a factory assembled modular central plant as specified herein and according to plan drawings. 1. The modular central plant shall be no smaller than specified on the plan drawings.2. The modular central plant shall match general orientation and component location as

shown on the plan drawings.

B. The modular central plant after assembly shall require only the following connections for the chilled water portion:1. Chilled water suction and discharge pipe connections.2. Cooling tower water suction and discharge pipe connections.3. <Insert number> make-up water connection(s).4. <Insert number> electrical power connection(s).5. Terminal contacts to field mounted devices and building automation system (BAS).

C. The modular central plant after assembly shall require only the following connections for the hot water portion:1. Hot water suction and discharge pipe connections.2. One (1) make-up water connection.3. <Insert number> electrical power connection(s).4. Terminal contacts to field mounted devices and building automation system (BAS).5. Natural gas connection [with gas system regulator, if required]6. [Flue piping, when plant does not include an enclosure from the MUP

manufacturer]

1.4 MODULAR CENTRAL PLANT COMPONENTS

A. The modular central plant’s chilled water portion shall consist of the following components: [Outdoor equipment enclosure,] structural base, chiller(s), [cooling tower(s),] [cooling tower support structure,] chilled water pump(s)/motor(s),

MODULAR CENTRAL PLANT 230500 - 2

condenser water pump(s)/motor(s), power distribution, controls, valves, and all necessary piping and components as listed in the specification for a complete system.

B. The modular central plant’s hot water portion shall consist of the following components: [Outdoor equipment enclosure,] structural base, boiler(s), hot water pump(s)/motor(s), power distribution, controls, valves, air intake venting, exhaust flu venting, unit gas regulators and condensate neutralization and all necessary piping and components as listed in the specification for a complete system.

1.5 MODULAR CENTRAL PLANT DESIGN CONDITIONS

A. Chiller Plant:1. Total cooling load at present: <Insert number> tons, <Insert number> chiller(s) at

<Insert number> tons each.2. Total cooling load in future: <Insert number> tons, <Insert number> additional

chiller(s) at <Insert number> tons each.3. Chilled water system: <Insert number> GPM at present, <Insert number> GPM in

future, <Insert number> pump TDH.4. Condenser water system: <Insert number> GPM at present, <Insert number>

GPM in future, <Insert number> pump TDH.

B. Boiler Plant:1. Total heating load at present: <Insert number> MBH, <Insert number> boiler(s) at

<Insert number> MBH each.2. Total heating load at future: <Insert number> MBH, <Insert number> boiler(s) at

<Insert number> MBH each.3. Hot water system: <Insert number> GPM at present, <Insert number> GPM in

future, <Insert number> pump TDH.

1.6 MANUFACTURER

A. Subject to full compliance with the specification, provide a complete modular central plant by one of the following manufacturers:

1. Base Bid: Systecon (www.systecon.com).2. Stellar (www.stellar-energy.net).3. TAS Energy (www.tas.com).

Alternate manufacturers must submit 2 weeks before the bid date following data for the engineer's review. Failure to provide the information below will result in a disqualification:

1. Preliminary 3D layout & P&ID for this project2. Complete control sequence.3. Pumping energy analysis.4. System performance data.5. Documentation of proposed equipment with flow diagrams.6. At least five successful variable primary flow jobs with contact name and phone number.7. Itemized list of any exceptions taken to the base bid specification.8. Provide a letter from an officer of the packaged plant manufacturer stating that the exceptions listed are the only deviations from the specifications.


http://www.tas.com/

http://www.stellar-energy.net/

http://www.systecon.com/

1.7 QUALIFICATIONS

A. The modular central plant manufacturer shall be listed by ETL or UL as an approved manufacturer of factory assembled modular central plants. The equipment shall bear the listing and label before shipment from the factory.

a. The listing must cover the entire modular central plant as assembled. b. An individual listing for components is unacceptable.c. If the manufacturer does not carry a listing, they must pay UL or ETL to field

label the entire modular central plant system.

B. The modular central plant manufacturer must be the manufacturer of the controls and control panel used for the system.

a. The control panel shall be listed by UL as an approved manufacturer of industrial control panels under UL508A.

b. Upon request from the engineer, the manufacturer shall furnish proof of listing.

c. Use of commercial grade controllers from the building automation contractor is not acceptable.

C. The modular central plant manufacturer shall have a quality assurance program. a. The manufacturer shall provide documentation of this program in the

submittal. b. The manufacturer shall provide a description of the performance test

procedure. c. The manufacturer shall provide current (within last 9 months) independent

testing certifying the performance test stand instrumentation is NIST traceable.

D. The modular central plant manufacturer shall of a minimum of fifteen (15) years of manufacturing and application experience.

E. The modular central plant manufacturer shall provide all mechanical drawings in a three-dimensional format.

a. These drawings shall be reviewed utilizing a 3D viewer with the owner and engineer.

b. The use of 3D design software is required to ensure the design adequately provides for maintenance and angle clearance.

c. CAD files of the modular plant shall be provided in Autodesk Revit upon request of the engineer for no additional cost.

1.8 PERFORMANCE TESTING

A. Factory Performance Test Standards

1. Field performance testing of the modular central plant is not acceptable.2. Factory performance tests to be witnessed by the owner, consulting engineer,

commissioning agent, installing contractor and equipment representative.3. The entire testing facility shall be independently certified and traceable to NIST or

ASME PTC 18.1 calibration procedures. a. Certification shall be kept on file for inspection.


b. Hydraulic Institute standards shall be followed for the calibration procedures of all testing instrumentation.

4. Prior to factory assembly of the modular central plant, each pump or pumping system shall be performance tested as per 1.8B.

5. After factory assembly of the modular central plant, the entire system shall be hydrostatically tested with water to 150 PSIG for ANSI class 150 for a minimum of thirty (30) minutes.

6. The performance test stand must have a tank that will limit the water temperature rise from the beginning to the end of the test to 10 degrees F.

a. Flow test data must be provided showing the tank temperature.7. As a minimum requirement, the following test equipment must be utilized and shall

be within the following accuracies:

a. Flow meter: ±4% of rated flow, 0 to full range.b. Pressure gauges and sensors: ±2% based upon independent dead weight test.c. Tachometer: ±1% of rated speed, 0 to full range.d. Multimeter: for readings of supply voltage, input amperage, input kilowatts, and

power factor ±1% of selected reading, 0 to full range.

B. Pumping System Factory Performance Test

1. Prior to testing of the complete modular central plant, the manufacturer shall perform a factory efficiency test for each variable speed pumping system at 25%, 50%, 75% and 100% of the design flow of the pump and pumping system. Constant speed pumps shall be tested by the pump manufacturer at a minimum of four (4) flow points.

2. Flow, system total dynamic head, kW and efficiency to be recorded for each of the above percentages of design system flow

a. All performance data shall be recorded and signed by the testing agent.b. Any performance deviations are to be corrected at the expense of the

manufacturer.3. As part of the test procedure, the manufacturer shall demonstrate the transition

points at which standby variable speed pump(s) are added and subtracted to achieve optimum system efficiency.

4. The control system for each pump set shall be tested and all sequences and alarms shall be simulated.

C. Functional System Test

1. Prior to shipment, the complete system (including the chiller(s) and the pumping systems) shall be completely assembled and tested at the factory by the modular central plant manufacturer.

2. Prior to the test date, the manufacturer shall develop and distribute a performance test agenda, complete with procedures and tables for data. These forms will be filled out during the execution of the test.

3. The control systems shall be tested and all sequences and alarms shall be simulated.

4. A complete description of operations as submitted shall be reviewed point by point to ensure that the system operates as specified.


D. Performance Test Under Load. [OPTIONAL]

1. All equipment shall be operated under load and be fully energized.2. The complete system shall be piped to a certified test stand. The test stand shall be

capable of supplying an air conditioning load sufficient to operate the modular plant system for a minimum of thirty (30) minutes.

3. Instrumentation to measure flow, pressure and temperature shall be provided in order to determine that all equipment is operating properly and within range.

4. The pumping systems shall be tested as specified herein in 1.8B. 5. The pumps shall be water balanced to provide the specified flows. 6. The testing shall measure kilowatts and power factor for each pump and chiller.7. A qualified representative of the chiller manufacturer shall start up and operate the

chillers, recording a log of operating pressure and temperatures. 8. All chiller compressors shall be operated.

1.9 SUBMITTALS

A. Submittals shall include the following as a minimum:

1. Title page with job name, location, and equipment title.2. Table of contents with document index.3. System design information sheet.4. Description of system operation.5. Modular central plant general arrangement and dimensioned drawing(s).6. Modular central plant schematic showing all pipe sizes, location of reducers,

components, specialties, and instrumentation.7. Structural base drawings showing number and size of members.8. Structural base deflection calculations.9. Electrical power and control wiring drawings.10. HVAC Load Calculations (if enclosure is provided).11. Enclosure Structural Calculations (if enclosure is provided, after submittal approval).12. Refrigerant Ventilation Calculations.13. Pump(s) material and construction drawing(s).14. Pump(s) performance curve showing design point.15. A predictive pumping energy analysis showing system efficiency and kW.16. [Complete chiller submittal.]17. [Complete cooling tower submittal.]18. [Complete boiler submittal.]19. Complete variable frequency drive(s) submittal.20. Catalog information on valves, strainers, and control components.21. Name and address of local factory trained service company.22. Performance test procedure and performance test stand drawing.

B. Provide electronic download of submittal for approval.

C. Submittals that are generic and not specifically designed to meet the requirements of this specification section will be immediately rejected and are not acceptable.


D. Submittal shall be assembled in an organized manner with proper index.

E. If the submittal is rejected more than once, upon the third submission the manufacturer shall pay the engineer $5,000.00 for each instance for their service before the third or subsequent submittal is reviewed.

1.10 OPERATION AND MAINTENANCE MANUALS

A. Operation and Maintenance (O&M) Manuals shall include the following as a minimum:

1. Title page with job name, location, and equipment title.2. Table of contents with document index.3. System design information sheet.4. Description of system operation.5. Modular central plant general arrangement and as-built dimensioned drawing(s).6. Modular central plant schematic showing all pipe sizes, location of reducers,

components, specialties, and instrumentation.7. Electrical power and control wiring drawings.8. Bill of material.9. Modular central plant component’s operation and maintenance instructions.

B. Provide electronic download of operation and maintenance manual.

C. Operation and maintenance manuals that are generic and not specifically designed to meet the requirements of this section are not acceptable.

D. Operation and maintenance manuals shall be assembled in an organized manner with proper index.

PART 2 – PRODUCTS

2.1 MECHANICAL

A. [Outdoor Equipment Enclosure]

1. A pre-insulated architectural metal panel outdoor equipment enclosure shall be provided as specified below. The enclosure size and color, quantity and location of doors, louvers, and miscellaneous fixtures shall be as shown on submitted general arrangement drawing. The interior of multiple enclosure modules shall be open and provide continuous clearance between components. Doorways or partitions between modules are not acceptable.

2. Enclosure construction and materials

a. Outdoor equipment enclosure shall be fabricated as a single assembly or in separate shipping sections as required for shipping or installation purposes. Each section shall include means by which the unit is to be lifted and include a label indicating proper lifting instructions.

b. All dissimilar materials shall be properly isolated. All floor, wall, and roof deflections shall be less than 1”/360” span including internal compartment


pressures. Structure shall be designed for a <90> mph wind load, <30> lbs./sq.ft. snow load on roof & <100> lbs./sq.ft. live load for interior floor. Roof shall be slant type and slope a minimum of ¼” per foot.

c. Wall construction to consist of flat insulated embossed architectural metal wall panel.

d. Roll-formed exterior and interior steel sheet faces chemically bonded to continuously foamed-in-place polyurethane core; laminated panels are not acceptable.

e. Exterior Face: G-90 galvanized embossed painted steel, minimum Grade 33 in 22ga (0.0312").

f. Interior Face: G-90 galvanized unembossed painted steel, minimum Grade 33, 22ga (0.0312”).

g. Wall & Roof Core Insulation: Foamed-In-Place, Non-CFC, FM Class I approved, polyurethane. Minimum R value required to be <21>. The enclosure shall not contain any exposed insulation. Foil backed or rigid board exposed “stick-on” insulation shall not be acceptable.

h. Exterior Finish: Exterior face sheet shall be treated with a nominal 0.2 mil (5 microns) base primer, followed by a nominal 0.7 mil (17.5 microns) finish coat of full strength PVF2 fluoropolymer in manufacturer’s standard colors.

i. Interior Finish: The interior face sheet shall be a nominal 0.2 mil (5 microns) primer followed by a nominal 0.7 mil (17.5 microns) polyester coating in USDA compliant Blizzard White.

j. Panels shall be fastened to heavy gauge formed steel structure.k. Structural Tests: The design load/deflection criteria shall be verified from tests

per ASTM E 72 “Air Bag Method” using a 20 psf (.96 kPa) simulated wind load. A deflection limit of L/180 shall apply to wall panel.

l. Thermal Transmission: Testing in accordance with ASTM C 518, “measurement of steady state thermal transmission", the panels shall provide a K-factor of .140 btu/sf/hr/deg. F at 75º F (24º C) mean temperature (air films are not included).

m. Vapor BarrierAir Infiltration: Air infiltration shall not exceed .06 cfm per square foot of wall area when tested per ASTM E 283 at a static pressure of 12.0 psf (.576 kPa).Static Water Penetration: There shall be no uncontrolled water penetration through the panel joints at a static pressure of 20.0 psf (.96 kPa) when tested per ASTM E 331.Dynamic Water Penetration: There shall be no uncontrolled water penetration through the panel joints when subjected to a 95 mph (153kph) slipstream airflow and application of water for a 15 minute period in accordance with AAMA 501.1.

n. FireSurface Burning Characteristics: The insulated core shall have been tested in accordance with ASTM E 84 and CAN/ULC S102 for surface burning characteristics. The core shall have a maximum flame spread of 25 and a maximum smoke developed rating of 450.Factory Mutual Research Corporation (FMRC) Standard 4880, 50’ (15.24 m) High Corner Test for Unlimited Height Structures: The panel assembly shall not support a self-propagating fire which reaches any of the limits of the 50’(15.24 m) high corner test structure as evidenced by flaming or material damage of the ceiling of the assembly. Note: Approval is applicable to structures of unlimited height.


Factory Mutual Research Corporation (FMRC) Standard 4881, Standard for Class 1 Exterior Wall Systems. Note: Panels to be installed per Factory Mutual guidelines for required listings.

o. Bond StrengthFatigue Test: The panel shall withstand deflection cycling at L/180 to two (2) million alternate cycles with no evidence of delamination, core cracking or permanent bowing.Freeze/Heat Cycling: The panel shall exhibit no delamination, surface blistering or permanent bowing when subjected to cyclic temperature extremes of –20º F (-28º C) to +180º F (+82º C) for twenty-one (21) eight- hour cycles.Humidity Test: The panel shall exhibit no delamination or metal corrosion at interface when subjected to a +140º F (+60º C) temperature and 100% relative humidity for a total of 1200 hours.Autoclave Test: The panel shall exhibit no delamination of the foam core from metal skins when exposed to 2 psi (.122 kg/sq. cm) pressure at a temperature of +212º F (+100º C) for a total of 2½ hours.

p. State of Florida Building Code Product Approved Panel System.q. System shall be Large Missile Impact tested and approved by Miami-Dade per

the following tests: TAS 201-94, 202-94, 203-94.

3. Doors

a. All egress doors shall be equipped with emergency door opening hardware and emergency lights, with signage indicating egress

b. All doors are to have a common key, and as well as stainless steel hardware with door closure and opening stops.

c. Exterior doors shall be of the same color and material as the enclosure. All doors shall conform to ASTM Standards C236, E283-91, and E331-86. Each door shall have a .080-6063-T5 extruded aluminum frame with mitered and welded corners, 304 stainless steel continuous hinge, and extruded EPDM gasket in the door frame.

d. Single doors shall be 36” wide by 84” high or as indicated on the drawings. e. Double doors shall be 72” wide by 84” high or as indicated on the drawings.

Double doors shall be arranged side by side with removable center divider. f. Roll-up doors for chiller tube pull access shall be sized as indicated on the

drawings. All roll-up doors shall be a chain-operated rolling curtain type. Doors shall be constructed of roll-formed 26 gage super-hard galvanized steel sheeting that is primed white on both sides. In lieu of roll up doors, double or bi-fold doors may be used.

4. Modular Central Plant HVAC

NOTE TO SPECIFIER: Choose a. or b.

a. Self-contained, wall-mounted HVAC unit(s) shall be provided to condition the interior space of the plant. Unit(s) shall be factory assembled, pre-charged, pre-wired, tested and ready to operate. Each unit shall provide heating, ventilation, and air-conditioning designed to maintain a maximum indoor temperature of <85> degrees F and minimum indoor temperature of <50> degrees F.


Acceptable Manufacturer: Bard Manufacturing Company, Model WA-602 or Approved Equal.

OR

b. HVAC fan coil unit(s) shall be provided to condition the interior space of the plant. The plant manufacturer shall provide calculations to determine appropriate plant loads, with unit(s) designed to maintain a maximum indoor temperature of <85> degrees F and minimum indoor temperature of <50> degrees F. Provide with <5> kW Unit Heater. Provide fan coil drain piped to nearest floor drain.

c. Acceptable Manufacturer: Larkin Manufacturing Company, or Approved Equal.

5. Ventilation

a. Two (2) or more framed louvers shall be provided for the forced draft ventilation system. The louvers shall be of the type and size shown the drawings. One louver shall be for the intake air and the other for exhaust air. All louvers shall be installed in an accessible, non-restricted location. Bird screens and 3 break moisture elimination shall be provided for all louvers

b. The intake louver shall be provided with a motor operated shutter and #4 galvanized hardware screen.

c. The exhaust louver shall be provided with a plenum, motor operated fan, and automatic shutter. The exhaust louver components shall be zinc-coated steel. The ventilation fan shall be of a capacity to maintain adequate cooling and ventilation for the locale in which the equipment is to operate.

6. Refrigerant Monitoring and Removal

a. Follow minimum standards for refrigeration systems as required by ANSI/ASHRAE Standard 15 paying special attention to requirements for air monitoring, ventilation, and leak detection to assure the safety of personnel. Optional: self-contained breathing apparatus.

b. Install proper outside exhaust of chiller refrigerant relief device and purge unit(s) complete with dirt leg, blow down valve, and flexible connector. Purge system shall include motorized intake complete with exterior indication and control. Route exhaust to the exterior of the building and away from all air intakes in compliance with ANSI/ASHRAE 15.

c. Install a refrigerant monitor that can be calibrated for appropriate refrigerant. Unit shall be capable of detecting concentrations of minimum parts per million (ppm) for low level leak detection to assure the safety of personnel.

d. Install suitable audible and visual alarms that activate well below the Acceptable Exposure Level (AEL) of the specific refrigerant to alert persons inside and outside of the equipment room that a refrigerant leak condition exists.

e. Acceptable Manufacturer: Honeywell, Model 301 or Approved Equal.

7. Electrical and Lighting

a. An electrical receptacle on 10 ft. centers shall be provided on each wall. Each receptacle shall be equipped with a ground fault interruption (GFI) device.


Outdoor receptacles shall be provided for maintenance considerations. Each receptacle shall be equipped with GFI and outdoor-rated enclosure.

b. LED lighting fixtures shall be provided for adequate lighting for maintenance and operation of the plant. Light switches shall be provided at each door used for normal egress. Three-way light switches shall be provided with adjustable timers and motion detectors. Outdoor lights shall be provided above the main entry door(s).

8. TPO Roof Membrane

a. If the enclosure roof is flat or non-standing seam construction, the modular central plant manufacturer shall provide a 60-mil white TPO roof membrane system to cover the roof.

b. The TPO roof membrane system shall include a color coordinated steel drip edge.

c. The TPO roof membrane system shall include wood blocking and polyisocyanurate insulation, to provide a taper of ¼” per foot.

d. The modular central plant manufacturer shall hire a local roofing contractor to furnish and install the TPO roof membrane system at the job site.

B. Structural Base

1. A pre-engineered structural steel base shall be provided by the modular central plant manufacturer to support all equipment and facilitate lifting, shipping, and the proper installation of the plant.

i. All major equipment, including chiller(s), boiler(s), pump(s), and heat exchanger(s), shall be supported directly with full height structural steel members underneath the floor.

ii. All equipment shall be welded to the floor. Bolting equipment is not acceptable. Supporting pipe from the enclosure is not acceptable due to complications with transit to site.

2. Structural base shall be supported on a maximum of 24” centers to the structural intermediate support channels.

3. Structural base shall be lifted with a maximum of 4 lifting lugs. 4. Structural base shall not deflect more than the allowable strain at the allowable

design stress or 1/360th of the length of the base, whichever is less. 5. Floor decking shall be provided and be made from solid welded 3/16” hot rolled steel

diamond plate sheets. 6. Floor decking shall be 1” stitch welded, every 12” from the bottom and continuously

welded from above. 7. Floor decking shall be turned upward at the perimeter a minimum of 2” to provide for

proper containment (if enclosure is provided). 8. Module sections shall be provided with clips used to pull sections together, as well as

base bolts to fasten modules together. 9. Jacking bolts shall also be present on either side of base bolts on each module

section.10. Drains shall be specifically located at major equipment throughout the plant.

i. All drains shall be collected in the base and brought out in a single 3” line through the base channel near the main building sewer line.

ii. Trough drains to be provided at both ends of chiller(s).


iii. Drains to have sloped bottoms and stainless steel or epoxy lined steel construction.

iv. Removable galvanized steel gratings to be mounted flush with finished floor.

v. Drains to have ball valves at all low points, and air releases must have ball valves at all high points

C. [Chiller(s)]

1. Chiller(s) shall be provided by the modular central plant manufacturer.2. [Refer to Section 236416 “Centrifugal Water Chillers.”]3. [Refer to Section 236426 “Rotary-Screw Water Chillers.”]4. Chiller(s) shall be restrained for shipment with welded anchoring to floor and tie

downs to prevent load shifting.5. Chiller(s) shall be provided with hinged water box covers on evaporator and

condenser for ease of maintenance and tube pull on non-connection end.6. Chiller(s) shall be factory insulated by the chiller manufacturer.7. Chiller(s) shall be isolated from floor using chiller manufacturer provided isolation

pad.8. Chiller(s) shall be provided with a thermal displacement flow detection device.9. Chiller(s) shall be provided with ball valves with plugs or caps for drain and vent

connections. i. 1-1/2” chiller evaporator by-pass line with blow down valve on system

side of isolation valves for system flushing. ii. Drain must be included.

10. Individual chiller lead detection shall be provided.11. Emergency break glass stop to be provided.

D. [Cooling Tower(s)]

1. [Cooling tower(s) shall be provided by the modular central plant manufacturer.]

2. Refer to Section 236500.0 “Cooling Towers.”

E. [Cooling Tower Support Structure]

1. A pre-engineered, prefabricated, heavy-duty, industrial grade steel support structure shall be provided by the modular central plant manufacturer to mount, support, and service the cooling tower(s).

i. Support structure shall include integrated pipe supports for condenser water piping.

ii. Support structure shall include space for mounting cooling tower equipment.

2. Support structure base plates shall be designed in accordance with AISC ASD 9th

edition. i. Foundation loads and design guidelines shall be provided to facilitate the

anchor design process. ii. Anchor rods, nuts, and washers shall be provided by installing contractor. iii. Anchor rods, nuts, and washers shall conform to ASTM F1554 Grade 55

and hot-dip galvanized to conform to ASTM 153.


iv. Each anchor rod shall be provided with a leveling nut. v. A 2” grout space shall be provided to allow for turning of the leveling nuts

under the base plate.3. Support structure steel framing shall be designed according to the requirements of

the latest editions of AISC, IBC, and ASCE. i. Design calculations are based on the operating loads supplied by cooling

tower manufacturer, wind and other lateral loads. ii. Apply zinc coating by the hot-dip process to structural steel indicated for

galvanizing according to ASTM A 123.4. Support structure shall be compliant with OSHA requirements for personnel access

and egress. i. Provide a galvanized stair and railing with self-closing safety gate.

Provide 1-1/4” x 3/16” galvanized grating around the parameter of the cooling tower(s) to provide access with a single climb.

ii. Provide toe kick, knee rail, and handrail for platforms greater than 6’ above grade.

5. The modular central plant manufacturer shall provide separate PE stamped drawings for the cooling tower support structure.

F. [Boiler(s)]

1. Boiler(s) shall be provided by the modular central plant manufacturer.i. As required by state code provide CO sensor for shutdown

2. Refer to Section 235200 “Heating Boilers.”

G. [Heat Exchanger(s)]

1. Heat exchanger(s) shall be provided by the modular central plant manufacturer.2. Refer to Section 235700 “Heat Exchangers for HVAC.”

H. Pump(s) and Motor(s)

1. [Chilled water pump(s) and motors(s) shall be provided by the modular central plant manufacturer.]

2. [Condenser water pump(s) and motors(s) shall be provided by the modular central plant manufacturer.]

3. [Hot water pump(s) and motors(s) shall be provided by the modular central plant manufacturer.]

4. Refer to Section 232123 “Hydronic Pumps.”5. Refer to Section 230513 “Common Motor Requirements for HVAC Equipment.”

I. Pipe, Manual Valves, Fittings, and Hydronic Specialties1. All pipe, manual valves, fittings, and hydronic specialties as shown on the bid

drawings within the boundaries of the plant enclosure shall be provided by the modular central plant manufacturer.

2. All pipe, manual valves, and fittings as shown on the bid drawings between the boundaries of the plant enclosure and the cooling tower(s) shall be provided by the modular central plant manufacturer. Piping shall ship loose in sections.

3. Refer to Section 230516 “Expansion Fittings and Loops for HVAC Piping.”4. Refer to Section 230523 “General-Duty Valves for HVAC Piping.”5. Refer to Section 230529 “Hangers and Supports for HVAC Piping and Equipment.”


6. Refer to Section 232113 “Hydronic Piping.”7. Pipe shall be fabricated welded steel headers using manufactured fittings conforming

to ASME Section 9 Code B.31.1, 150# ANSI class. Pipe shall be sized for a maximum velocity of 10 feet/second and maximum head loss of 8.5 feet per 100 feet of pipe. Branch piping shall be sized for the design capacity of each component.

8. Grooved couplings shall be limited to connections between modules, chiller evaporator and condenser connections, and connections through enclosure walls. A modular central plant assembled entirely of grooved couplings is unacceptable.

9. All pipe inside the plant shall be supported from the structural base and be independent of component connections. Pipe shall be isolated from supports using a non-metallic spacer. Pipe welded directly to supports is unacceptable.

10. When copper pipe is used, it shall be Type L and Pro Press fittings shall be used.

J. Actuated Control Valves

1. The modular central plant manufacturer shall provide automatic, two-way, two-position, control valves with electric actuator for the following functions, at a minimum:

a. Chiller evaporator isolation.b. Chiller condenser isolation.c. Chiller bypass isolation.d. Cooling tower inlet and outlet isolation. Ship loose for field installation.e. Heat exchanger inlet isolation, if applicable.f. Heat exchanger bypass isolation, if applicable.g. Boiler inlet isolation, if applicable.h. Make-up water to cooling towers.

2. The modular central plant manufacturer shall provide automatic, two-way, modulating, control valves with electric actuator for the following functions, at a minimum:

a. Chiller condenser isolation and flow control.b. Chilled water bypass loop, for minimum flow control.c. Cooling tower bypass loop. d. Hot water bypass loop, when design is variable primary pumping.

3. All valves indicated above shall be provided as an integral part of the modular central plant.

i. All valves shall be designed for quarter turn operation. ii. Three-way assemblies shall consist of two butterfly valves with integral

linkage and tee. iii. All butterfly valve shall be constructed with a ductile iron lug body, EPDM

seat, stainless steel disc, 416 stainless steel shaft, and copper and brass bushings.

iv. The actuator shall be mounted on a bracket, which is coupled to the valve shaft.

v. The actuators for two position operation shall have a split phase capacitor AC reversing motor with 25% duty.

vi. The actuators for modulating operation shall have a split phase capacitor AC reversing motor with 100% duty.


vii. Actuators shall be housed in an aluminum NEMA 4 enclosure with integral 115 VAC condensate heater.

viii. Two-position valve actuators shall have end switches. ix. All valves shall be provided with position indication displays on HMI. x. All electric actuated control valves shall be provided with manual override

clutch and wheel hand operator. xi. Brass isolation valves shall be present at headers for equipment tie-in

K. Hoist and Trolley System(s)

1. Mono-directional package hoist and trolley system shall be provided by the modular central plant manufacturer for each pump set that uses motors 15 HP or larger. The purpose is to facilitate removal and/or installation of pumps and/or motors.

2. The hoist and trolley shall be completely supported from the base structure and shall be constructed of structural steel tube for vertical support and structural steel I-beam for horizontal cross members.

i. The main hoist trolley beam shall be constructed of tapered flange I-beam.

ii. All structural steel shall be ASTM A-36. iii. The trolleys shall be constructed of heavy-duty design complete with

hardened pressed steel wheels with double row ball bearings. iv. Side plates shall extend beyond wheels to act as a bumper. v. The chain hoist shall be constructed of a hardened steel housing with a

two-stage hardened spur gear reduction system and grease lubrication. vi. The hoist shall also be equipped with mechanical load brakes and

bearing mounted pinions.3. Hoists and monorail systems shall have a marked capacity of (1/2) Ton or (1) Ton,

as required to lift the heaviest pump or motor.4. All Hoists and monorail systems shall comply with all state and federal regulations

and be constructed per ASME B29.24M, HST-2M, B30.11 and ANSI MH27.1 as directed for hand operated hoists.

i. All design calculations shall comply with the MANUAL OF STEEL CONSTRUCTION.

ii. All hoists and monorails shall be tested at 125% of the rated maximum capacity.

iii. A certified test report shall be provided for each hoist and monorail.

L. Filtration

1. Filtration equipment for the [condenser water system] [cooling tower(s)] shall be provided by the modular central plant manufacturer and shall be mounted inside of the plant enclosure. Lakos TBX package, or Approved Equal.

2. Refer to Section <Insert number> “<Insert name>”

M. Water Treatment

1. Water treatment equipment for the condenser water system shall be provided by the modular central plant manufacturer and shall be mounted inside of the plant enclosure. Connection points in piping with brass isolation valves at header for


equipment tie-in shall be provided. Shot feeder for chilled water loop piped across common suction and discharge headers of chilled water pumps shall also be provided

2. Refer to Section 232500 “HVAC Water Treatment.”3. The modular central plant manufacturer is not responsible for providing any water

treatment chemicals or any routine testing of the water quality.

N. Piping Insulation

1. The modular central plant manufacturer shall provide and install piping insulation with service jacket, aluminum or PVC, for all chilled water system components which are included within the interior of the plant enclosure. Components include pumps, piping, valves, fittings, and air separators. Interior insulation shall be painted white.

2. The modular central plant manufacturer shall provide and install piping insulation with service jacket for all hot water system components which are included within the interior of the plant enclosure. Components include pumps, piping, valves, fittings, and air separators.

3. Expansion tanks/associated piping and water make-up pipes shall be insulated4. Refer to Section 230716 “HVAC Equipment Insulation.”5. Refer to Section 230719 “HVAC Piping Insulation.”6. All piping insulation and heat trace required for piping that will be installed exterior to

the plant enclosure shall be provided and installed by the installing contractor.

O. Fit and Finish

1. Paint: All exposed steel components shall be cleaned, degreased and painted with a rust preventive primer, and shall be painted the same color as the base.

2. Base and pipe components shall be mechanically cleaned per SSPC – surface preparation specification No. 2.

3. The structural base, exposed steel, pipe, pump(s), motor(s), and valves shall be painted with a consistent color and two-part epoxy.

4. All other major equipment shall be in original condition and not painted. Provide touch up paint as part of the shipment.

5. Tagging: All mechanical components, electrical devices (including switches and receptacles), transmitters, and control devices shall be tagged.

i. Provide phenolic name tags with chains for all control valves and transmitters and non-potable water.

ii. Provide type tagging in circuit breaker panels. iii. Tagging to be the same as shown on the submitted flow diagram. Refer

to Section 230553 “Identification for HVAC Piping and Equipment. 6. Pipe marking: All pipe shall be marked with pipe markers to indicate type of fluid and

flow direction. i. Markers to have 2-inch letters with colored background. Locate marker

before and after major components. ii. Use different colors for each system.

7. Caution markers: Provide caution markers for all hazards. i. Markers to include hoist ratings, shock hazards and burn hazards.ii. Provide tagging on exterior doors for refrigerant and hearing protection.

8. Conduit and Pipe: i. All horizontal conduit and pipe shall be installed level.


ii. All vertical conduit and pipe shall be installed vertical. iii. Pipe and conduit shall be arranged not to impede access. iv. Pipe and conduit to be arranged so that it does not become a trip hazard

or hazard for bumping one’s head.

2.2 ELECTRICAL

A. Electrical Distribution

1. A switchboard shall be provided by the modular central plant manufacturer for distribution of power for the entire modular central plant. This shall include power for [chiller(s),] [cooling towers,] [boilers,] pump(s), valve(s), and controls.

2. [Chiller(s) to be feed with individual power feed(s).]3. Power Supply: 460/3/60. 4. The switchboard shall be package mounted and wired. The switchboard shall comply

with all applicable codes and braced for 65,000 AIC. Switchboard shall include the following: a. Main plant circuit breaker.b. [Chiller circuit breaker.]c. Chilled water pump circuit breakers.d. Condenser water pump circuit breakers.e. [Cooling tower fan circuit breakers.]f. [Boiler water pump circuit breakers.]g. Load center 30 circuit panel board with 45 kVA 480v/120v step-down

transformer. Serves 120/1/60 utilities in the enclosure.h. Transient Voltage Surge protection.i. NEC clearance required for all electrical components.

5. Conduit shall be provided for all electrical wiring.a. Electrical metallic conduit (EMT) constructed of galvanized steel with a minimum

trade size of 1/2.” UL listed split type fittings shall be used. Enclose conductor exterior to all enclosures, panels, and motor terminator boxes.

b. UL listed liquid tight flexible metallic conduit may be used for across package splits, motor connections and all control devices with a maximum length of three feet without a g rounding conductor and unlimited length with a grounding conductor. Application and installation in accordance with all requirements of NEC articles 300, 348 and 351.

c. Galvanized rigid conduit with Meyers hubs shall be required conduit style for outdoor use.

d. Connectors to be watertight where conduit crosses the floor. Where the conduit is not a trip hazard raise conduit a minimum of 1-5/8” above floor using Unistrut stand off to allow drainage.

e. Control device wiring shall be run in conduit.f. When conduit or cable trays run through walkways, minimum height from finished

floor to bottom of conduit/tray shall be 6’6”g. When sensor wiring does not have a junction box, run conduit to minimize

exposed wire.h. Draping of control wire, other than those included on chillers, is not acceptable.i. Main power wiring to be color tagged at each end.

a. All power wiring to be phased correctly. b. All 115-volt wiring to be tagged at each end. c. All control wiring to be tagged at each end.


d. Control wires to be continuous except across package splits. e. Use shielded cable as required for transmitters.f. Power wiring and control wiring shall not be run in the same conduit

B. Variable Frequency Drives

1. The modular central plant manufacturer shall provide a variable frequency drive for each chilled water pump, condenser water pump, [cooling tower fan,] [hot water pump].

2. Refer to Section 262923 “Variable-Frequency Motor Controllers”.3. Provide with adjustable frequency, which employ a pulse width modulated inverter. 4. Each drive shall have its own, individual disconnect5. Drives for cooling tower fans and single pump applications shall have manual by-

pass starters.6. To insure safety of the equipment, the VFD shall include these protective features

and options:a. NEMA 1 enclosure.b. Static instantaneous over-current and over-voltage trip.c. Static over-speed (over-frequency) protection.d. Line or fuse loss and under-voltage protection.e. Power unit over-temperature protection.f. Motor inverse time overload protection.g. Input line reactor or DC choke. AC or DC sized for a minimum of 1-½%

impedance.h. Ammeter.i. Speed meter.j. Automatic restart after power failure or minor drive fault. The drive shall attempt a

minimum of two restarts before a complete drive shut-down.k. Power on light.l. Manual speed potentiometer or control capability through the keypad.m. Hand/Off/Automatic Switch or Manual/Automatic Switch with start/stop

pushbutton.n. VFD fault light and reset.o. The drive shall include built in diagnostics. Diagnostics shall be annunciated

through the alpha numeric keypad. The drive shall be listed UL, ETL and/or CSA.

p. All drive information shall be transmitted to the BAS through an interface with the master control panel. Multiple BAS connections are not acceptable.

C. Heat Tracing

1. The modular central plant manufacturer shall provide heat tracing for all exposed outdoor cooling tower pipe between the plant enclosure and the cooling towers.

2. Refer to Section 230533 “Heat Tracing for HVAC Piping.”3. Provide a separate heat trace panel with test circuits and contactors, installed inside

of the plant enclosure. Provide a master heat trace thermostat for control. 4. In addition, electrical provision shall be provided for all required heat tracing of chilled

water and condenser water piping. 5. Installation of heat tracing tape on the piping to be provided by the installing

contractor.


6. All other required heat trace systems (for outdoor chilled water piping and outdoor hot water piping) to be provided by others.

2.3 CONTROLS

A. Hardware

1. All controls hardware required for the operation of the modular central plant to be provided by the modular central plant manufacturer.

2. The central plant control enclosure to conform to NEMA 1 type construction.3. Control panel to be UL 508A listed under CULUS.4. The modular central plant control panel to include:

a. Disconnect switch.b. Control circuit transformer 480/120 with primary and secondary fuses.c. System Local-Off-Remote selection.d. System Initialized indication.e. Run indication for each pump and chiller.f. Pump failure alarm indication and reset.g. Lead selector for manual alternation of each pump set.h. Lead selector for manual alternation of chillers.i. Open-close-auto switch for each control valve.j. Position indication for each control valve.k. Failure alarm indication for each control valve.l. Chiller failure alarm indication with cut-off.m. Programmable Logic Controller (PLC).n. Human Machine Interface (HMI).o. Interface controls for variable frequency drives.

5. Programmable Logic Controller (PLC).a. Industrial PLC based control system shall be used.b. Manufacturer: Allen-Bradley [CompactLogix (Standard)] [ControlLogix].c. Memory: Expandable to 64K.d. PLC to have built in communication for peer-to-peer, DH 485, device net or

RS232.e. I/O points: 4096.f. Provide built in security with multiple levels of passwords.g. PLC is to be mounted in the cabinet to avoid accidental damage. Damage to the

HMI shall not affect the operation of the PLC.h. Individual remote I/O panels to be provided for each equipment module.i. Commercial grade DDC systems are not acceptable.

6. All analog and digital inputs and outputs to be supplied with compatible programmable logic controller interface (either individually or in clustered groups).

7. Human Machine Interface (HMI)a. The operator display is to be provided in a single integrated graphic display

screen with a separate processor for the controls.b. The HMI to be suitable for mounting in the door of a NEMA 1 enclosure so that it

will maintain the enclosure’s NEMA 1 rating.c. Mount at a suitable height to assure proper visibility and easy access by the

operator.


d. Display shall be a 15” color STN display and a resistive touch screen rated for at least 5,000,000 touches.

e. The HMI includes the following:1. CPU: Minimum 5x86/133 MHz.2. System memory: Minimum 8 MB.3. Storage Memory: Compact FLASH Cartridge (minimum 8 MB). Rotating

media devices and mechanical hard drives are not acceptable.4. Serial ports: Total 2, with at least one (1) port configurable for

RS232/422/486.5. Ethernet port: NE 2000 compatible, 10 MBPS / 10 Base-T with RJ45

connector.6. Expansion Slots: Minimum one (1) PC/104 slot

f. The HMI will be provided with a full color graphic display. A separate screen shot will be provided for the following:1. Master screen.2. Chilled water schematic.3. Chilled water pump(s).4. Chiller(s).5. Heat exchanger(s).

g. Each screen will have a touch button to relocate the screen to any of the main screens. On each screen the touching of the individual component will take you to a component screen. The component screens to consist of:1. Chiller(s).2. Pump(s).3. Valve(s).

h. The master screen will display the active tons, kW, flow and kW/ton.i. All screens shots to be provided digitally to the building automation for their use

in monitoring the controls.8. Transmitters

a. Differential Pressure Transmitters1. Provide <Insert number> complete, self-contained, variable capacitance

type differential pressure transmitters. DPT’s shall be hard wired back to the control system for pump monitoring and failure sequencing.

2. The following are to be remote mounted by others:Chilled water system zones (at load) <Insert number>Hot water system zones (at load) <Insert number>

3. The following are to be mounted inside the plant:Chiller chilled water (across evaporator) <Insert number>Condenser water system (across chiller headers) <Insert number>

4. Manufacturer: Rosemount “Smart Transmitter” No. 2051 or equal.5. Wiring terminals and electronics to be in separate compartments, so the

electronics remain sealed during installation.6. Provide reverse polarity protection to keep wiring mishaps from damaging the

transmitter.7. Wiring Manufacturer: Belden 9320, two wire, shielded twisted cable between

the control system and the transmitters, and installed separate from any conduit containing AC circuit wiring.

8. Design range shall be as required by system. External zero and span adjustments, over-pressure to 2,000 PSI, and no humidity effects.


9. Minimum accuracy: 0.25% of calibrated span. Includes combined effects of linearity, hysteresis and repeatability.

10. Stability: 0.25% of upper range limit for six months.11. Internal mechanical linkages are not allowed in the transmitter(s).

b. Turbine Type Flow Meters1. Provide <Insert number> dual turbine, insertion type flow meter(s) for the

chilled water system.2. Provide <Insert number> dual turbine, insertion type flow meter(s) for the hot

water system.3. Manufacturer: Onicon SF1210 or equal.4. Wiring Manufacturer: Belden 9364, three wire, shielded twisted cable

between the control system and the transmitters, and installed separate from any conduit containing AC circuit wiring.

5. Provide 15 straight pipe diameters for installation. Provide additional straight pipe diameters as necessary.

6. Provide hot tap installation, in order to be both insertable and removable through a ball valve when the pipe is under pressure.

c. Electromagnetic Type Flow Meters1. Provide <Insert number> electromagnetic, insertion type flow meter(s) for

the condenser water system.2. Manufacturer: Onicon SF3500 or equal.3. Wiring Manufacturer: Belden 9364, three wire, shielded twisted cable


4. Provide 15 straight pipe diameters for installation. Provide additional straight pipe diameters as necessary.

5. Provide hot tap installation, in order to be both insertable and removable through a ball valve when the pipe is under pressure.

d. Water Temperature Transmitters1. Provide <Insert number> self-contained RTD type temperature transmitters.2. Manufacturer: Rosemount 248 or equal.3. Provide for supply and return temperatures of chilled water and hot water

systems.4. Provide for inlet and outlet temperatures on each chiller evaporator and

condenser.5. Provide for inlet and outlet temperatures on each heat exchanger.6. Power input and current output (4-20mA) through the same pair of low

voltage wires.7. Each transmitter head to be explosion proof.8. Temperature Probe: Provide a platinum, wire wound, sensing element in a

316SS sheath, spring loaded, and inserted into a ¾” NPT stainless steel thermowell with explosion proof process fittings and connection head. The thermowell to penetrate one-half the pipe diameter.

9. Temperature Range: 32-122ºF (0-50ºC) for chilled or condenser water. For applications measuring the supply and return temperatures for a loop type water system, the two probes to be a matched pair.

e. Pressure Transmitters1. Provide across any device that has a pressure drop including chiller barrels,

heat exchangers, boilers, pumps and suction diffusers. Pressure to be displayed after compensation for elevation.


2. Manufacturer and Product: Dyer Model 626-12.f. Outdoor We tbulb Temperature Transmitter

1. Provide one wet bulb temperature transmitter with radiation shield.2. Manufacturer: Vaisala Model HMT330 or equal.3. Wiring Manufacturer: (3) Belden 9320, two wire, shielded twisted cables


4. Power input and current output (4-20mA) through the same pair of low voltage wires.

5. The humidity range shall be 0-100% RH. The temperature range shall be up to up to 356 Deg F.

6. The accuracy of the temperature transmitter shall be +/-0.36 Deg F at 68 Deg F. The accuracy of the analog output shall be +/-0.05% of full scale at 68 Deg F.

7. Temperature transmitter shall be field installed outdoors and wired by the temperature controls contractor.

B. Control Sequencing

1. All controls sequencing of pumps, chillers, cooling towers, heat exchangers, and boilers required for the operation of the modular central plant to be provided by the modular central plant manufacturer. Use of a third-party control vendor is not acceptable.

2. The control logic center shall include a Central Plant Optimization sequencing routine as manufactured by Systecon, or a licensed equivalent by Hartman Loop or Johnson Controls CPO-30.

3. Refer to Section 230993 “Sequence of Operations for HVAC Controls”.

C. Communications

1. Modular central plant shall include full integration of all components to single BAS interface of the protocol [BACnet MS/TP] [BACnet Ethernet] [BACnet IP] [Modbus] [LON].

2. The communication interface shall be native to the existing building management system. a. Communication gateways shall not be acceptable

3. The installation of the communication cabling to the main building shall be included in another contract.

4. The communication interface shall transmit and receive the following points:a. Transmit:

1. Chilled Water System Request to Start/Stop (Digital)2. Hot Water System Request to Start/Stop (Digital)

b. Receive:1. Equipment on/off status (Each pump, chiller, tower, boiler) (Digital)2. Equipment failure alarms (Each pump, chiller, tower, boiler) (Digital)3. Valve failure alarm (Each control valve) (Digital)


4. Valve position (Each 2-way control valve) (Digital)5. Valve position (Each modulating control valve) (Analog)6. Pump speed (Each pump) (Analog)7. Pump suction pressure (Each pump) (Analog)8. Pump discharge pressure (Each pump) (Analog)9. Suction header pressure (Each connection) (Analog)10. Discharge header pressure (Each connection) (Analog)11. Chilled water system flow (Analog)12. Chilled water system zone differential pressure (Analog)13. Chiller evaporator differential pressure (Analog)14. Chilled water system supply temperature (Analog)15. Chilled water system return temperature (Analog)16. Condenser water system flow (Analog)17. Condenser water system zone differential pressure (Analog)18. Chiller condenser differential pressure (Analog)19. Condenser water system supply temperature (Analog)20. Condenser water system return temperature (Analog)21. Chiller inlet temperature (Analog)22. Chiller outlet temperature (Analog)23. Chiller inlet pressure (Analog)24. Chiller outlet pressure (Analog)25. Heat exchanger inlet temperature (Analog)26. Heat exchanger outlet temperature (Analog)27. Heat exchanger inlet pressure (Analog)28. Heat exchanger outlet pressure (Analog)29. Hot water system flow (Analog)30. Hot water system zone differential pressure (Analog)31. Hot water system supply temperature (Analog)32. Hot water system return temperature (Analog)33. Boiler inlet temperature (Analog)34. Boiler outlet temperature (Analog)35. Boiler inlet pressure (Analog)36. Boiler outlet pressure (Analog)37. Wire-to-water efficiency (Each variable speed pump set) (Analog)38. Chilled water system KW (Analog)39. Hot water system KW (Analog)40. Chilled water system KW/Ton (Analog)41. Hot water system KW/MBH (Analog)

PART 3 – EXECUTION

3.1 DELIVERY OF EQUIPMENT

A. Prior to Shipment:

Manufacturer is required to disassemble modular central plant into subassembly form. Subassemblies shall be authorized by the engineer. Manufacturer is required to weatherize subassemblies for shipment. This shall include exterior equipment and exposed sections of the subassemblies. Manufacturer is required to completely drain system of water and remove drain plugs where the possibility of freeze damage may exist.


B. Upon Delivery at Jobsite:

Reassembly of the modular central plant is the responsibility of the installing contractor. Reassembly of the subassemblies shall be coordinated between the manufacturer and installation contractor, with the manufacturer providing a technician for supervision. Installation contractor shall comply with the manufacturer’s instructions for rigging, unloading, and transporting equipment.

3.2 INSTALLATION

A. Responsibilities of the Manufacturer:

1. Provide detailed instruction manual on the reassembly of the modular central plant. 2. Provide two (2) visits for the supervision of the installation of the modular central

plant. 3. Inspect installed modular central plant including field assembled components and

connections.

B. Responsibilities of the Installation Contractor:

1. Install the modular central plant in accordance with the manufacturer’s instructions.2. Receive and inspect the interior and exterior of the modular central plant and report

damage accordingly. 3. Provide temporary protection of individual enclosure and equipment sections from

the elements before roofing and final section connections can be finalized.4. Hoist and rig all subassemblies into final locations.5. Reassemble equipment sections including reconnections at the section spits for

the base, house enclosure, and piping. Caulking and sealing as required.6. Level and shim structural base as needed per manufacturer’s recommendations.7. Supply and install all roof finishing materials including caulking and sundry items

needed to complete modular central plant installation.8. Realign and level all equipment within recommended tolerances including pumps

and motors. 9. Check and tighten all mechanical connections that may have vibrated loose during

shipment.10. Reconnect all internal electrical power and control conduit between subassemblies

as required. 11. Install equipment accessories that are shipped loose from the manufacturer.12. Install control instrumentation that is shipped loose from the manufacturer. This may

include pressure transmitters, temperature transmitters, flow meters, and the associated wiring for each device.

13. Install all field connections to the modular central plant. This shall include all system, electric, domestic water, drainage, and control connections.

14. Reassemble and install cooling tower(s), cooling tower support structure, outdoor piping, electrical, and control wiring.


15. Provide and install all outdoor piping and valves required for the cooling tower make-up water systems between the modular central plant and the cooling towers.

16. Provide and install all required power and control wiring and conduit between the modular central plant and the cooling towers.

17. Install safety disconnect switches near the cooling tower fan motors.18. Install heat tracing as required. Electrical power shall be provided by the

manufacturer.19. Reassemble and install all boiler exhaust stacks.20. Touch-up and paint scratches and minor dents that may occur during hoisting and

rigging.21. Flush and fill each system.22. Obtain all pertinent inspections and permits required to start-up modular central

plant.

3.3 DEMONSTRATION

A. Commissioning and Start-up: Manufacturer to provide two (2) visits for commissioning and start-up. Each visit will require a minimum of three (3) days on-site. Installation contractor to complete and sign off on all items listed on the start-up request form (SRF). Commissioning shall include final checkout, adjustment, and start-up of the complete system.

B. Training: Manufacturer or representative will provide a minimum of eight (8) hours of training for the owner’s personnel on the operation and maintenance of the modular central plant. Chiller manufacturer’s representative will provide four (4) hours of training for the owner’s personnel on the operation and maintenance of the chiller. Chiller manufacturer’s representative shall advise owner of upcoming O&M sessions two (2) weeks in advance.

3.4 WARRANTY

A. Manufacturer shall provide parts and labor warranty coverage for all components for a period of 12 months from start-up or 18 months from installation, whichever occurs first.

END OF SECTION 230500


Compliance Checklist

General and Equipment EnclosuresComp

ly

Do Not

Comply

Pipe component drains to floor drains. This includes pump drain pans, air gap drain on back flow preventer, pressure relief exhaust, and tower sweeper system. Manifold where possible, except for relief valves and any blow downs.

Dielectric fittings are used where copper and steel pipes are connected. A brass fitting is used, where possible, to eliminate the need for dielectric fittings.

Trough drains at both ends of the chillers. Drains to have sloped bottoms and be constructed of stainless steel or epoxy lined steel. Removable galvanized steel gratings are flush with the finished floor.

Floor drain located near each set of pumps (avoiding walkways). Full height structural base members under all major equipment and chillers. Structural members under all major components. Floor drains tied together for a single 3” connection. Components welded to 3/16” diamond plate. Continuously welded ¼” diamond plate floor deck with 2” turn up around

perimeter and other openings.

Floor deck is 1” stitch welded to the structural members every 12” from below and seal welded on top.

Emergency door opening hardware with emergency lights at means of egress. Stainless steel door hardware with door closure and opening stops. All doors

have a common key.

Service doors (roll-up, double, or bi-fold) for chiller maintenance. Three-way light switches at each means of egress. (not required at service

doors)

LED interior lighting. Equipment sections designed for no more than a four-point lift with removable

lugs.

Lifting lugs provided. Module sections provided with base pull together clips and base bolts. Jacking bolts on either side of base bolts on each module section. Base and pipe components mechanically cleaned per SSPC – surface

preparation specification No. 2.

Components will be primer coated prior to finish coat. Internal components, except insulated components, will be painted with factory

standard enamel.

Exterior lighting at each means of egress. Factory hydrostatic pressure test of all chilled and condenser piping loops. Factory pressure testing of all other piping systems.


Factory performance flow test with verification of flow, head, and kW for all variable volume systems.

Factory performance flow test with certified curve for each constant volume pump.

Functional testing of all control functions including equipment sequencing and alarm functions.

The complete package is listed by ETL under UL-778 listing. Drains with ball valves at all low points. Air release with ball valves at all high points. Provide brass isolation valves at headers for equipment tie-in (shot feeder,

chemical treatment, etc.).

Temporary construction power connection (pigtail) for enclosure lights

Chillers and BoilersComp

ly

Do Not

Comply

Chiller and boiler restraints with shipping tie downs to prevent load shifting. Hinged water box covers on the evaporator and condenser on non-pipe

connection end.

Thermal displacement flow detection device located on the chiller side of the isolation valve.

Refrigerant relief lines piped to the exterior of the enclosure, complete with dirt leg, blow down valve, and flexible connector.

Ball valves with plugs or caps for drain and vent connections on chiller end bells. Valves and plugs are removed from end bells prior to shipment.

Pressure gauges and thermometers at the inlet/outlet of each chiller evaporator and condenser barrel. Any sensing lines are provided as stainless steel braided hose.

Neoprene vibration dampeners, provided under all centrifugal and screw compressor chillers.

Chillers must be factory insulated by the chiller manufacturer. 1-½” chiller evaporator barrel bypass line with blow down valve located on

system side of isolation valves. Drain included.

ASHRAE Standard 15 compliant, with the following features:• Individual chiller leak detection• Emergency break glass stop• Interior/exterior audible and visual alarm indications• Main egress signage• Refrigerant exhaust with motorized intake complete with exterior indication & control• Louvers with bird screen and 3 break moisture elimination

When boilers are provided with an enclosure, exhaust flue, sealed combustion piping (for some high efficient boilers), combustion air and individual or main gas regulators will be provided by manufacturer.

Pumping Equipment Comply

Do Not


Comply

Maintenance rail with hoist/trolley system provided for service removal over pumps with motors 15 HP and higher. Rail extends beyond pump set end. Rail to be set at a minimum height of 80” above finished floor.

Pumps on sub bases with decking for rigidity. Drain pans under each pump piped to main drain. Ball valve and hose bib with cap on suction diffuser. Laser alignment of all pumps. Shims put under both pump and motors. Pump shaft couplings shall be paired at opposite ends to balance the weight. Adjustable pipe supports with thermal break to assure no weight on pumps.

Pipe supports to lift pipe for service.

Electronic pressure transmitters with ball valve and clean out port. Jacking bolts on pipe supports for pump headers.

Hydronic SpecialtiesComply

Do Not Comply

Pete’s plugs on header, as well as air separators. Air separator air vent piped to drain. Expansion tank with associated piping.

Make Up Water SystemsComply

Do Not Comply

Make up water assembly with PRV (Pressure Reducing Valve), isolation valves, bypass, and pressure relief for closed loop systems. Optional back flow preventer.

Type L copper pipe with ProPress™ fittings.

Closed Loop Chemical TreatmentComply

Do Not Comply

Connection points in piping with brass isolation valves at headers for equipment tie-in.

Shot feeder for chilled water loop piped across common suction and discharge headers of chilled water pumps.

Shot feeder supply and return piping is type L copper with Pro Press fittings.

Open Tower Water Filtration for Basin Sweeper Systems

Comply

Do Not

Comply


Water filtration system with circulating pump, solid separator, and closed solid recovery vessel for tie-in to the tower basin sweeper system.

Monitoring of the solid recovery vessel. Full service valves. Separate blow down lines. CPVC pipe between the filtration system and tower basin connections. Suction

line to be upsized to increase NPSH available to the filter pump.

Pipe ConstructionComply

Do Not Comply

ASME Section 9 B31.1 compliant, 150 # ANSI class Butt weld fittings with slip-on and/or weld neck flanges. Indirect saddle welds on branches less than 2/3 the size of the main header. All vertical flanges are two-hole center. All valves (butterfly/ball) provided with handle extensions to accommodate

pipe insulation.

No pipe spacer required on condenser water piping unless more convenient for shop assembly. (project dependent)

Exterior piping: Cold climate – heat traced and insulated; Warmer climate – non-insulated and painted

Minimal use of grooved end/couplings except section splits; wall penetrations; chiller and cooling tower connections; chiller branch to header (when required for expansion compensation)

Schedule 40 pipe up to and including 10”, standard weight 12” and larger. Type L copper for all applicable lines. ProPress™ fittings on copper piping systems.

Pipe InsulationComply

Do Not Comply

1” Armaflex pipe insulation for interior chilled water pipe and components. Painted white. Optional PVC or aluminum jacketing.

Minimum 1 ½” pipe spacer for thermal break. Uninsulated make-up water pipe. Expansion tanks and associated piping will not be insulated. Free cooling heat exchangers with chilled water side piping up to the

exchanger.

Exterior insulation to be PVC jacketed unless otherwise specified. More than likely, this will be done in the field.

Make accommodations for insulation on all pipe penetrations through enclosure.

Enclosure HVAC Requirements Comp Do


ly

Not Comply

Bard self-contained air conditioning units with strip heaters and ventilation where required.

Enclosure internal temperature will be maintained as 50˚F minimum for heating; 85˚F maximum for cooling; 100˚F maximum for ventilation

Occupancy ventilation as required. The interior of multiple enclosure modules is open and provides continuous

clearance between components, unless required by code.

All floor, wall, and roof deflections shall be less than 1”/360” span including internal compartment pressures. A deflection limit of L/180 shall apply to wall panel.

Wall & Roof Core Insulation: Foamed-In-Place, Non-CFC, FM Class I approved, polyurethane. R-Value to be determined.

An electrical receptacle on 10 ft. centers shall be provided on each wall; each equipped with a ground fault interruption (GFI) device. Outdoor receptacles shall be provided for maintenance considerations; each equipped with GFI and outdoor-rated enclosure.

A 60-mil white TPO (thermoplastic polyolefin) roof membrane roof system shall be used when the roof is flat or non-standing seam. Wood blocking and polyisocyanurate insulation used to provide a taper of ¼” per foot. Standing seam is acceptable in warm weather areas or when a high pitch on the roof is available.

ElectricalComp

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Do Not

Comply

Panelboard with main lugs are a minimum 65,000 AIC. 1200 amps or above requires two (2) means of egress. Stand-alone VFD reduces line length and allows for heat dissipation.

• Drive parameters set up for pump operation.• Hardwired stop, start and failed.• Separate communication link.• Carrier frequency tuned for low noise with lowest carrier frequency.• Drives with individual disconnects.• Drip pan installed over VFD’s when pipe runs exist above them• Drives provided with manual bypass starters for cooling tower fans applications.

NEC (National Electric Code) clearance on all electrical components. No trip hazards in front of electrical panels. Equipment disconnect height shall not exceed 78” above the finished floor. Pipe cannot be routed over MCC’s (Motor Control Center), panel boards, load

centers, or switch boards.

Large 115-volt junction boxes with terminal strip used for splits. Segregate the 120 VAC -powered circuits from the 24 VAC powered circuits in the box.


All power wires are tape color coded as a minimum. All control wires are numbered. Provide a 2” minimum separation between Class 1 and Class 2 wiring in open

cable trays. Class 1 and Class 2 wiring cannot reside in the same closed conduit. Provide separate conduits.

Separate circuit breaker panels for all 115-volt loads. Avoid running conduit on the floor. In cases where this is unavoidable, the

conduit must be raised off the floor a minimum of 1-⅝”.

When dry rooms are required by specification:• 1200 amp and larger feeds require two (2) means of egress.• Line of site disconnects are required for each motor.• If commercial market, no open tray power distribution.

Standard power distribution arrangement is:• Individual power feed to each chiller.• Common feed for remaining loads to a switchboard with a main lug minimum.• Switchboard will have a single breaker for each set of pumps, fans, etc., so that a single power feed is provided to a power distribution lug located near the set of motors that it feeds. The line power to the motor controller comes from the lug.

Compression fittings are used for all EMT (Electrical Metallic Tubing) conduit connections.

EMT is standard conduit for indoor use. Galvanized rigid conduit with Meyers™ hubs is standard conduit for outdoor

use.

Depending on the connected load, Meltric™ plugs* are utilized to facilitate package splits for higher voltages (460 VAC), while junction boxes with terminal strips are utilized for lower voltages.

3’ maximum length of flexible Seal-Tite® runs to final, end device. Three-way light switches at each means of egress. LED interior lighting. Weather rated receptacles for outside service. Electrical conduits will be at least 1 5/8” above the finished floor. Where conduit or cable tray runs through walkways, the minimum height from

the finished floor to the bottom of the conduit/tray is 6’-6”.

ControlsComp

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Do Not

Comply

Individual remote I/O panels at section splits. Rosemount™ RTD (Resistive Temperature Device) temperature transmitters

for supply/return temperature indication for the chilled water and condenser water loops.

Rosemount differential pressure transmitters for zone loop control and minimum flow control.

Onicon™ SF1210 insertion type flow meter for chilled water flow monitoring.


Pressure transmitters hard wired back to the control system for pump monitoring, failure sequencing at the suction, discharge of each pump, and at the inlet/outlet of each chiller evaporator/condenser, and heat exchangers.

Pressure transmitters hard wired back to the control system for pressure monitoring at the main supply and return header connections for the chilled and condenser water loops.

All actuated control valves with all aluminum NEMA 4 enclosure and heaters to avoid condensation. Valves with opening and closing switches, as well as, visual location arrow.

All actuated control valves provided with manual override clutch and wheel handle operator.

Valve control relays in control panel with individual disconnecting service circuit breaker for both control and power. Light indicating DC voltage relays.

All valves have HOA (Hand-Off-Auto) switch or potentiometers for override. Switches are mounted in the control panel door. Main control enclosure valve HOA switch operation is integrated into control logic.

Industrial PLC (Programmable Logic Controller) based control system. Full 15” color graphic screen. Control panel with color coded and tagged wires. Individual control power disconnect. External receptacle and service port for computer connection to controls. Full integration of all components to single BAS interface (BacNet Ethernet,

BacNet MSTP, BacNet IP, Modbus, LON).

Spare control and signal conductors are provided as follows:• VFD – 2 sets for control, 1 set for signal• Chillers – 4 sets for control, 1 set for signal

Interactive Optimization with Wire-to-Water efficiency optimization of the entire central plant and full equipment sequencing and failure routines.

Minimum of six (6) each DI (Digital Input), DO (Digital Output), and AI (Analog Input) and two (2) AO (Analog Output) spare I/O, wired to terminal strips.

Control panel UL 508A listed under cULus. NEMA 1 enclosures provided with gasketed doors.

OptionsComp

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Do Not

Comply

Fire suppression system with sprinkler heads to match existing. Fire pull boxes and conduit to central junction box for fire protection alarm and

monitoring. (Systecon never provides the wiring for these systems since this falls under the fire protection contractor scope.)

Fiberglass pipe insulation with fitting covers. (PVC fitting cover and a fiber glass insert)

Electrical dry room with air conditioner. Interior hose bibs for maintenance of equipment. 2” make-up water connection to the cooling towers.


Make-up water metering. Exterior windows. Perforated interior wall and ceiling panels for sound absorption. Exit lights at each exterior door. LED lighting. Exterior paint and siding options. Chiller vibration elimination options. Wingert two (2) coupon rack for chilled water loop. PVC piping to and from

rack (no copper).

Non-chemical treatment systems for open towers. Solid separator purge systems. Equipment installation supervision is provided for all central plants and an

option for pump modules.

Space for future equipment. Chiller VFD refrigerant service valves. Flexible pipe connectors at the inlet/outlet of each chiller evaporator and

condenser barrel.

Roll up maintenance doors. Removable wall panels. Color graphics exportable to BAS. Main breaker. Internet router. OSHPD (Office of Statewide Health Planning & Development) compliant

equipment, state of California. Seismic approval for hospitals & other human services buildings

Enclosure to be large Missile Impact tested and approved by Miami-Dade per the following tests: TAS 201-94, 202-94, 203-94.

Insulated pump boxes. Fan coils and associated insulated piping for enclosure cooling. Calsil spacer/oversized U-bolt for vapor barrier. 300 PSIG high pressure piping. Bypass filter feeder with insulation. Heat traced and insulated exterior cold climate piping. Glycol feed units. Aegis grounding rings on pump motors. Gutters and downspouts on multi-section assemblies. Emergency eye wash and shower station.

Open Tower Chemical Treatment (when required by specifications)

Comply

Do Not

Comply

Nalco is the preferred vendor. Injection pumps.


Coupon rack w/PVC piping.

Physical ConstraintsComply

Do Not Comply

Maximum size and weight restraints for any equipment section:• Height - 12’-6”• Length - 40’• Width - 12’• Weight - 80,000 lbs.

Optional horizontal split for enclosures over 12’-6” in height.

Seismic RequirementsComply

Do Not Comply

Category A. Equipment and anchoring only. Beyond our standard requires additional analysis.

Exceptions (but not limited to)Comply

Do Not Comply

Life safety, smoke alarms, etc. Lightning rods. Traps on sanitary lines. Overflow and drain lines on cooling towers. Conduits for outside signals.


Documents

Section 230500 - Modular Central Plant Doc with... · Web viewHydraulic Institute standards shall be followed for the calibration procedures of all testing instrumentation. Prior