1.

0 SPECIFICATION OF EQUIPMENT / MATERIAL AND INSTALLATION STANDARDS

1.1 SPECIFICATIONS FOR WATER COOLED CENTRIFUGAL CHILLER

Performance Parameters
1. Cooling capacity at design conditions: 450 TR
2. Unit power input at design conditions: Not More Than 293 kW
3. Full load energy efficiency (AHRI) (COP): 5.90 or Better
4. Full load energy efficiency (DESIGN) (COP): 5.50 or Better
5. Part load energy efficiency (AHRI IPLV) (COP): ≥ 0.36 IK/TR
6. Part load energy efficiency (DESIGN NPLV) (COP): ≥ 0.38 IK/TR
7. Design Evaporator entering/leaving water temperature: 55.4 / 44.6°F
8. Design Condenser entering/leaving water temperature: 89.6 / 98.6°F
9. Design Fouling Factor Evaporator in FPS : 0.005 FPS
10. Design Fouling Factor Condenser in FPS : 0.001 FPS

General

System Description

Water-cooled chiller utilizing centrifugal compressor 2960 rpm (50 HZ) semi-
hermetic sealed compressor using refrigerant 134A.

Quality assurance

Unit shall be rated in accordance with ARI / Eurovent standard.

Unit construction shall comply with European directives-

- Machinery directive 98/37/EC, modified.
- Low voltage directive 73/23/EEC, modified.
- Electromagnetic compatibility directive 89/336/EEC, modified, and the
applicable recommendation of European standards-
- Machine safety-electrical equipment in machines, general regulations,
EN 60204-1.
- Electromagnetic emission EN 50081-2.
- Electromagnetic immunity EN 50082-2.

Unit shall be designed, manufactured and tested in a facility with a quality

assurance system certified ISO 9001.

Unit shall be manufactured in a facility with an environment management

system certified ISO 14001. Unit shall be tested at the factory.

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Delivery, storage and handling-

Unit controls shall be capable of withstanding 55°C storage temperatures in

the control compartment.

Products-
Equipment-
General-

Factory assembled, single-piece, air-cooled liquid chiller contained within

the unit cabinet shall be all factory wiring, piping, controls, refrigerant charge
(HFC – 134a), required prior to field start-up.

Unit Cabinet-

- Frame shall be made of U steel beam and protected by three layers of

paint.
- The control box plates shall be steel with an oven-baked polyester-
paint finish, and be capable of withstanding a 500-hour salt spray test
in accordance with the ASTM B-117 standard (U. S. A.).

Compressors-

- Unit shall have semi-hermetic sealed compressors with internal muffler

and check valve.
- Each compressor shall be equipped with a discharge shut-off valve.
- Capacity control shall be provided by pilot-operated solenoid valve,
capable of reducing unit capacity to 20% of full load. Compressor shall
start in unloaded condition.
- Motor cooling shall be provided by direct liquid injection and
protected by internal overload thermistor.
- Lube oil system shall include pre-filter and internal filter capable of
filtration to 3 microns.

Evaporator-

Unit shall be equipped with a single evaporator.

- Evaporator shall be tested and stamped in accordance with

applicable European pressure code for a refrigerant side operating
pressure of 1700 kPa (service des Mines units) and for a maximum
water-side pressure of 1000 kPa.
- Shall be mechanically cleanable shell-and-tube type with removable
heads.
- Tubes shall be internally-enhanced, seamless-copper type, and shall
be rolled into tube sheets.

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- Shall be equipped with Victaulic water connections (accessory flanges
on request).
- Shell shall be insulated with 19 mm closed-cell, polyvinyl-chloride foam
with a maximum K factor of 0.28.
- Shall incorporate two independent refrigerant circuits.
- Shall have an evaporator drain and vent.
- Shall incorporate a refrigerant level control system.

Condenser-

- Coil shall be Water-cooled with integral sub cooler and shall be

constructed of aluminium fins mechanically bonded to internally
finned copper tubes. The tubes are then cleaned, dehydrated and
sealed.
- Condenser tubes shall be leak tested and shall be pressure tested at
3400 kPa.

Refrigeration Circuits-

Refrigeration circuit components shall include oil separators, high and low
side pressure relief devices (according to applicable standards), discharge
and liquid line shutoff valves, filter driers, moisture indicating sight glasses,
electronic expansion devices, refrigerant economizers and complete
operating charges of both refrigerant and compressor oil.

Controls, Safeties and Diagnostics-

1. Controls-

a. Unit controls shall include as a minimum; the microprocessor board,

and a 6-digit diagnostic display with keypad.

b. Shall be capable of performing the following functions -

- Automatic changeover between compressors.

- Capacity control based on leaving chilled fluid temperature with
return fluid temperature sensing.
- Limiting the chilled fluid temperature pull-down rate at start-up an
adjustable range of 0.1°C to 1.1°C per minute to prevent excessive
demand spikes at start-up.
- Enable adjustment of leaving chilled water temperature according to
the return water temperature or by means of a 0 – 10 V signal to the
outdoor temperature.
- Provide a dual set point for the leaving chilled water temperature
activated by a remote contact closure signal.
- Enable a 2-level demand limit control (between 0 and 100%),
activated by a remote contact closure signal.

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 - Control water pump(s) operation.
- Enable automatic lead-lag of two chillers in a single system.

2. Diagnostics-

a. Display module shall be capable of displaying set points, system status

(including temperatures, pressures, run time and percent loading), and
any alarm or alert conditions.

b. Control Module, in conjunction with the microprocessor, shall be

capable of displaying the output of a full load run test to verify
operation of every switch, sensor, fan and compressor before the
chiller is started, and carrying out a diagnosis and preventive
maintenance (incorrect water loop, oil filter dirty etc.)

3. Safeties-

a. Unit shall be equipped with all necessary components and in

conjunction with the control system shall provide the unit with
protection against the following -

- Loss of refrigerant charge.

- Reverse rotation.
- Low chilled water temperature.
- Low oil pressure (per compressor).
- Current imbalance.
- Thermal overload.
- High pressure.
- Electrical overload.
- Loss of phase.

b. Fan motors shall be individually protected by a circuit breaker.

Control shall provide general alarm remote indication for each
refrigerant circuit. Control system shall have a RS485 serial output port
(option and accessory).

Operating characteristics-

- Unit shall be capable of starting and running at full load at outdoor

ambient temperatures from 0°C to 46°C.
- Unit shall be capable of starting up with 25°C entering fluid
temperature to the evaporator.

Electrical characteristics-

- Unit electrical power supply shall enter the unit at one or two locations.
- Unit shall operate on 3-phase power supply without neutral.

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 - Unit with two compressors shall have a factory-installed, star-delta
starter to limit electrical inrush current.
- Control voltage shall be supplied by a factory-installed transformer.
- Unit shall be supplied with factory-installed electrical disconnect switch
/ circuit breaker.

Finishing-

Electrical cabinet colour – as per manufacturer. Compressor / heat

exchanger colour – as per manufacturer

Low-voltage unit mounted starter

A reducer voltage wye-delta or double / solid-state starter shall be supplied.

The compressor motor starter shall be factory mounted, wired, and tested
prior to shipment by the chiller manufacturer. Customer electrical connection
for compressor motor power shall be limited to main starter power connection
only.

Solid-state starter shall provide stepless compressor motor accelerating and

limit motor in rush current to 150-300% of compressor motor RLA. The starter
shall include 6 Silicon Control Rectifiers (SCR) with integrally mounted bypass
contactors to provide SCR by pass once the motor has achieved full voltage
and speed. The starter shall also include automatic acceleration kick circuitry
which monitors motor current subsides and automatically ramps voltage up at
a faster rate to eliminate the instability that occurs at the break away torque
point.

Starter shall be UL and CSA approved and shall include-

· NEMA 1 enclosure with integral fan cooling and lockable hinged doors.
· Main power disconnect (non-fused type)
· Solid-state 3-phase over load relay with manual reset.
· 2 KVA control / oil heater transformer
· Branch circuit breaker for control power and oil heater
· 5 pilot relays for control of chilled water pump. Condenser water pump, tower
fan, customer remote alarm, shunt trip, and main power disconnect. The shut
trip shall be energized by the SMM during unauthorized operation (such as loss
of communication) between the SSM (Starter Management Module) and
PSIO (Processor Sensor Input / Output Module).

Solid-state starters also include the following standard features-

· Current imbalance detector which monitors 3 phase motor current to provide
the following protection-

- Phase loss
- Phase reversal

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 - Phase imbalance
- Ground fault
- Shorted SCR
- Current flow while stopped protection

· Diagnostic LED’s shall be provided to indicate :

- Starter on
- Run (up to voltage)
- Phase correct
- Over temperature fault
- SCR gates energized
- Ground fault
- Current imbalance fault
- Shorted SCR.

I²T fuses the solid-state circuitry at 200,000 amp interrupting capacity.

Electrical requirements

The contractor shall supply and install main electrical power line, disconnect
switches, circuit breakers, electrical protection devices per local code
requirements and as indicated necessary by the chiller manufacturer.

The contractor shall wire the water flow switches to the chiller control circuit to
ensure that chiller will not operate until flows are established & maintained as
per contractors / consultant’s specifications.

The contractor shall supply and install electrical wiring and devices required
to interface the chiller controls.

Piping requirements – instrumentation and safeties

The contractor shall supply and install pressure gages in readily accessible
locations in piping adjacent to the chiller such that they can be easily read
from a standing position on the floor. Gages shall be very accurate. Scale
range shall be such that design valves shall be indicated at approximately
mid-scale.

Gauges shall be installed in the entering and leaving water lines of the cooler
and condenser.

HVAC contractor shall supply & install flow detection devices in chilled water
and condenser water piping. Switches shall make contact when flow is
established. Flow switches shall be installed in horizontal runs at least 5 pipe
diameters down-stream from any bend or tee.

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1.2 Insulation

1. Chilled water piping and cooler water boxes shall be installed by the HVAC
contractor.

2. Chiller shall be insulated at factory. Final layer of insulation shall be installed at

the job site by the HVAC contractor along with cladding.

3. Chiller insulation shall confirm to UL standard 94, classification 94 HBF and

should be suitable for positive temperature operation.

1.3 Vibration isolation

Chiller manufacturer shall furnish neoprene isolator pads for mounting

equipment on a level concrete surface.

Start-up

1. The manufacturer shall provide a factory trained representative, employed by

the chiller manufacturer, to perform the start-up, operation and maintenance
manual provided by the chiller manufacturer.

2. After the above services have been performed, the same factory trained,
representative shall be available for a period of class room instruction (not to
exceed 4 hours) to instruct the chiller owner’s personnel in the proper
operation and maintenance of the chiller.

3. Manufacturer shall supply the following literature-

a. Start-up, operation and Maintenance Instructions.

b. Installation Instructions
c. Field Wiring Diagrams
d. Maintenance manual showing maintenance based on calendar basis and
hourly basis.

1.4 Quality Assurance

i. Chiller performance shall be rated in accordance with AHRI

Standard 550/590, latest edition.
ii. Equipment and installation shall be in compliance with
ANSI/ASHRAE 15 (latest edition).
iii. Cooler and condenser shall be ASME "U" stamped and nameplate
certifying compliance with ASME Section VIII code for unfired
pressure vessels.
iv. Centrifugal compressor impellers shall be dynamically balanced
and over-speed tested by the manufacturer at a minimum of 120%
design operating speed. Each compressor assembly shall undergo

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 a mechanical run-in test to verify vibration levels, oil pressures, and
temperatures are within acceptable limits.
Each compressor assembly shall be proof tested at a minimum 204
psig (1406 kPa) and leak tested at 185 psig (1276 kPa) with a tracer
gas mixture.
v. Entire chiller assembly shall be proof tested at 204 psig (1406 kPa)
and leak tested at 185 psig (1276 kPa) with a tracer gas mixture on
the refrigerant side. The water side of each heat exchanger shall be
hydrostatically tested at 1.5 times maximum working pressure.
vi. Prior to shipment, the chiller automated controls test shall be
executed to check for proper wiring and ensure correct controls
operation.
vii. Factory testing

A) Capacity& Efficiency:

One Chiller shall be tested for performance at Manufacturer works

at 100% & 25% at AHRI condition and at 75% and 50% at Design
condition (at constant condenser entering temperature) for
verification of IKW/TR & Capacity as per submission of AHRI selection
data sheet. If the inspection is outside India, the contractor shall visit
and witness the test and shall submit photographs/proof to
ascertain his witnessing the testing. The Client (MCGM / consultant)
representative may also witness the test. The cost of their visit shall
be borne by the Client. However, necessary coordination shall be
arranged by the Contractor for their visit.

In case of failure of any equipment during testing, the Contractor

shall be bound to arrange for subsequent inspections. All the
expenses (including travel, boarding etc.) for such inspections shall
be borne entirely by the Contractor.

1.2 FRP COOLING TOWER

Cooling towers operating simultaneously shall be able to reject combined

heat of all units.

(A) CONSTRUCTION

Cooling tower shall be bottle type. Structural components of the tower,

including the cold water basin, structural columns, hot water basin and fan
cylinder shall be fabricated of fiberglass Reinforced Polyester. Mechanical
equipment supports and all other steel components shall be HDG steel. Tower
assembly hardware shall be HDG steel, Tower assembly hardware shall be
HDG steel. Tower manufacturer must supply galvanized steel supporting
grillage. Grillage must be of sufficient strength to support the tower on piers
located near the corners of the tower. Tower price quoted must include