GENERAL 1.01 See Criteria Sections 13060 and 15971 for additional information. 1.02 Summary. Product refrigeration includes all display cases, compressors, condensers, heat recovery coils, evaporators (unit coolers for insulated cold storage rooms), refrigerant piping, refrigerant controls, monitoring systems or Refrigeration Monitoring and Control System (RMCS), associated controls, and all wiring including that not indicated on drawings required for a complete, functional and usable system. Refrigeration compressor units with all controls, heat recovery coils, heat reclaim hot water heaters, diverting valves for heat recovery, condensers, unit coolers, display cases and RMCS shall be furnished by a single display case or compressor system manufacturer. The only exception to this is that the selfcontained display cases can be a different manufacturer than the other cases. At pre-design conference, PMP will provide current Guide Specification. Section 15651 1.03 Design, Furnishing and Installation. The Product System Refrigeration System Provider (Provider) shall be either the primary compressor system manufacturer or the primary display case manufacturer. The entire refrigeration system shall be furnished by the Provider who shall be singly responsible for the design, furnishing, installation, testing, and satisfactory operation of the total system, including both high and low side components. The installation shall be supervised by a field engineer employed by the compressor system manufacturer or display case manufacturer, as the case may be. The design shall use the most energy efficient combination and arrangement of compressors for the compressor systems, consistent with operational reliability. Prior to acceptance, the manufacturer shall submit a letter stating that the total refrigeration system has been inspected and approved by the manufacturer and that it meets the manufacturer's installation requirements. Provide registered engineering seal and signature on each drawing. All contractor design and installation not specifically addressed in this RFP shall meet or exceed ASHRAE recommendations/guidelines and recommendations of the equipment manufacturer(s). 1.04 Coordination. The Provider shall coordinate the installation of the total refrigeration systems as delineated, and shall prepare complete shop drawings, submittals, and design analysis of the entire refrigeration system. 1.05 Warranty and Maintenance. Warrant all refrigeration systems and components for a period of one year following completion and acceptance of the building by the Government. During the first 90 days of this warranty period, provide monthly preventative maintenance of the systems to include filter changes, lubrication, and adjustments per systems and component manufacturers' operation and maintenance manuals. Respond to emergency service calls within 2 hours of notification and render system(s) 100% repaired and operational within 24 hours. PRODUCTS 2.01 Mechanical centers: A. Compressor systems shall be installed in mechanical center(s) which shall be installed either at grade or on the roof. Air cooled condensers shall be installed on the roof of the mechanical center when centers are at grade. When centers are on the roof, use horizontal receivers and elevate condensers above roof sufficiently to drain to the receivers by gravity. The centers shall also contain water heaters, electrical equipment and such other equipment as required by Section 15651. The centers shall be located so as to minimize the length of suction and liquid piping to the various cases and coolers as well as the length of hot gas piping to the air handling unit coil. 2.02 Unit Coolers. A. General. Size unit coolers in the preparation areas to meet or exceed the load upon the room at suction temperatures no greater than 11 C (20 F) below room temperatures. Size unit coolers in all other storage rooms to meet or exceed the load upon the room at suction temperatures no greater than 6 C (10 F) below room temperatures. Size unit coolers in frozen food storage rooms to meet or exceed the load upon the room at a suction temperature no greater than 4 C (8 F) below room temperatures. Unit coolers operating in rooms at or below -2 C (28 F) shall have maximum fin spacings of 160 fins per meter (4 fins per inch). Unit coolers operating in rooms above -2 C (28 F) shall have maximum fin spacings of 240-315 fins per meter (6-8 fins per inch). Condensate drain lines in rooms operating at or below 0 C (32 F) shall have 25mm (1") unicellular insulation and heat tape. Run refrigerant piping to compressor units in located in mechanical centers. June 2010 15651 1
B. Suspension. Suspend unit coolers located in insulated cold storage rooms through ceiling via suspension system from roof structural members. Do not use ceiling support columns within the cooler panels. Suspension system shall consist of all members, including fasteners and attachments, required to support unit coolers from underside of roof structural members. Suspension system shall be of steel materials. Design of suspension system shall be in accordance with AISC Specifications for the Design, Fabrication and Erection of Structural Steel for Buildings. C. Provide unit cooler fans with premium efficiency motors. D. Required product temperatures to be maintained in walk in boxes and freezers is: Unit Dairy Storage [Ice Cream Storage] Freezer Vestibule Frozen Food Storage Meat Storage Meat Holding Meat Processing/Wrapping [Deli Storage] Ambient Produce Storage Produce Storage Produce Processing [Fish Storage] Poultry Storage [Frozen Bakery] [Bakery Storage] [Ambient Produce Processing] Pre Pak Meat Storage Temperature Range 1 to 3 C (34 to 37 F) [-12 C (-10 F) or below] 8 to 10 C (46 to 50 F) -21 to -18 C (-6 to 0 F) -2 to 0 C (28 to 32 F) -2 to 0 C (28 to 32 F) 8 to 10 C (46 to 50 F) [1 to 3 C (34 to 37 F)] 16 to 18 C (60 to 65 F) 3 to 6 C (38 to 42 F) 16 to 18 C (60 to 65 F) [-2 to 0 C (28 to 32 F)] -2 to 0 C (28 to 32 F) [-21 to -18 C (-6 to 0 F)] [1 to 3 C (34 to 37 F)] [1 to 3 C (60 to 70 F)] 1 to 3 C (34 to 37 F) E. See Design Standard Plate 15651-10. 2.03 Refrigerated Display Cases. Locate refrigerated display cases in sales area per the [Concept] Floor Plan. A. Commissary Refrigerated Display Case Equipment Descriptions for the types of equipment currently used in DeCA commissaries will be provided in the DeCA Guidespec. B. Required product temperatures, corresponding suction temperatures, coil types and defrost method for all types of display cases shall be as follows: [NOTE TO SPECIFIER: Check against Commissary Equipment List in Appendix A and edit out any inapplicable pieces of equipment:] Case Type Temperature Suction Temp. High Performance Coil Suction Temp Defrost Type E = Electric OC = Off Cycle 1B06 38 42 25 - OC 1BO8 0 - -10-17 - E 1B32 38 42 25 - OC 1D00 36 20 - OC June 2010 15651 2
1D01 33-25 OC 1D02 35 38 27 - OC Case Type Temperature Suction Temp. 1DO3 High Performance Coil Suction Temp Defrost Type OC 1D22 30 34 15 - OC 1D24 30 35-25 OC 1F00 28 32 20 - E 1F01 28 32-25 E 1G00 34 36 20 - OC 1G02 34 38-28 OC 1G06/7-10 -25 E 1G08 0-15 - E 1G09 0-15 - E 1G10 0-7 - E 1G12/13-10 -17 - E 1G14 34 38 +15 - E 1G15/16 Self Contained - - - 1G24 Self Contained - - - 1G27 0-7 - E 1G28-10 -15 - E 1G30 0-7 - E 1G31-10 -15 - E 1M02 28 34 - -25 OC 1M03 0 - -10-16 - E 1M04 C. 30 36-28 OC June 2010 15651 3
1M05 33 38-27 OC 1M06 0-10 - E 1M07 28 34-25 E 1M07F 28 34-25 E 1M08 Self Contained - - - 1M09 28 34 15 - E 1M42 28 32 10 - E 1P02 34 38 30 OC 1P07 35 38 28 OC 1P09 Self Contained - - - D. Display case item descriptions. Refer to Equipment Descriptions for specific requirements E. Refrigerant line and return air duct layout: 1. In the case of island case configurations, -to extent practical, consolidate return air duct risers and refrigerant line risers into shafts at column where they can be run overhead, above the sales area ceiling, to the mechanical center(s) and/or air handling unit.. 2. Where refrigerant piping must be routed above sales area ceiling, where possible, route above shopping aisles, and not above soffitts. This will allow for easier access for maintenance of the piping, electrical and condensate pans. 3. Consider placement of chases to avoid obtrusive views or interference with overall sales area decor and appearance. 4. Condensate pans under refrigerant piping a. For piping routed above Sales Area ceiling: Provide condensate pans under piping operation at O o SST and lower if store is located where 2.5% design wet bulb exceeds 74 o F. b. For piping routed above Walk-in Storage or Processing Rooms and overhead in Warehouse: Provide condensate pans under piping operation at 0 o SST and lower if store is located where 2.5% design wet bulb exceeds 78 o F. c. Slope drain pans to drain fitting. Pipe drain fitting to floor drain. 5. Under floor tunnels shall not be used without express direction from DeCA/END. 6. Conceal ductwork above the ceiling. [See Section 15000 for general guidance if no ceiling is proposed]. 2.04 Product Refrigeration System. A. Comply with requirements of refrigeration system Design Standards Plates. B. The product refrigeration system includes compressors, condensers, recovery systems, evaporators (unit coolers for insulated cold storage rooms), refrigerant piping, refrigerant controls, head pressure controls, defrost systems, and a refrigeration monitoring and control system (RMCS). Provide the product refrigeration with [three] [two] [one] [separate] low temperature system[s] and [three] [two] [one] [separate] medium temperature system[s] [SIZE SPECIFIC: on projects 7430 m 2 (80,000 sf) or less in size, provide with two separate low temperature systems and two separate medium temperature systems and on projects 2790 m 2 (30,000 sf) or less in size, provide with one low temperature system and one medium temperature systems.] Each system shall be a multiplex compressor system. Locate June 2010 15651 4
compressor systems [on the mezzanine] [in mechanical centers] [at grade] [on the roof] with refrigerant lines to cases, coolers, heat reclaim, and remote condensers. Remote condensers shall be air cooled types. Locate remote condensers on the roof [of the mechanical centers] above the compressor systems. Locate compressor racks as close as practical to heat reclaim coils not to exceed 18m (60'- 0") piping run. Summer design ambient temperature shall be the 1% dry bulb design temperature for the area. Condenser capacity shall meet or exceed compressor heat of rejection at a condensing temperature 6 C (10 F) above design entering air temperature for low temperature systems and 8 C (15 F) above the design entering air temperature for medium temperature systems. Use refrigerant R- 404A on all systems. Provide each refrigerated display case with a temperature probe, or as required in the corresponding equipment descriptions, and ensure that the temperature on the refrigeration monitoring and control system is readable. Provide a factory installed temperature probe connected to the RMCS system in each display case. Provide each double-wide frozen food/ice cream case with two such temperature probes (i.e., one on each side of the case). Mount all temperature probes in the discharge air stream not more than 150mm (6") from the discharge air grille and at an easily accessible location. C. Refrigeration Defrost Methods. 1. On display cases with operating SST at greater than -9 C (15 F), the defrost shall be off cycle, or as required in the Equipment Descriptions. 2. On walk-in boxes with operating SST greater than -6 C (22 F), the defrost shall be off cycle. 3. Off cycle defrost shall be time-initiated and time-terminated. 4. All other refrigeration defrost shall be electric. Electric defrost shall be time-initiated and temperature-terminated with time fail safe. 5. Defrost shall be controlled through the RMCS. D. Compressor Systems. Locate multiplex compressor systems [in mezzanine] [or] [in mechanical centers] with refrigerant lines to cases, coolers, heat reclaim, and remote condensers. Install an evaporator pressure regulator at the compressor system for each piping circuit to provide temperature control of fixtures and rooms. For each compressor provide replaceable core suction filter/drier, crankcase heater, high pressure safety switch with manual reset and low pressure cut in/out with automatic reset, braided steel lines to controls, electronic oil pressure safety control, and compressor isolation valves. Compressors shall be high efficiency, semi-hermetic, "Copeland discus" or approved equal. Each compressor system shall have an oil separator, replaceable core liquid line filter drier, and liquid receiver with visual and RMCS level indication. Compressors shall be staged on and off through the RMCS. E. Condensers. Locate on roof[of the mechanical centers]. Condensers shall be air cooled type with copper tubes and aluminum fins.. Maximum fins per meter shall be 400 (10 fins per inch). Fan motors shall be direct drive type. Control shall be through the RMCS and shall provide for staging of each parallel fan set to control condensing pressure. [SITE SPECIFIC: Include following sentence if condensers will be installed within 50km (30 miles) of salt water:] [Provide Copper coil and copper fin condensers.] F. Refrigeration Piping. Type "L" hard drawn copper soldered with a brazing alloy containing minimum 15% silver. Slope refrigeration suction lines minimum of 4mm/m (1" per 20'-0") toward the compressor(s) and provide with a suction trap at the base of each vertical riser. Suction piping shall maintain a minimum refrigerant velocity in horizontal lines of 3.6m/s (700fpm) and 7.6m/s (1500fpm) on vertical risers. Maximum suction line pressure drop shall be 14kPa (2psi) and maximum liquid line pressure drop shall be 35kPa (5psi). Route all refrigeration piping in a manner which provides for easy access for repair of each solder connection without moving display cases, concrete, or cooler panels. In each display case and unit cooler provide "sweat type" brass liquid line ball valves, "sweat type" expansion valves and strainer, "sweat type" schrader valve on the suction line, and a heat exchanger. Use only long radius elbows (45 elbows are not permissible) in the refrigeration piping system. Cover refrigeration suction piping on systems operating below -18 C (0 F) SST with unicellular piping insulation having a minimum thickness of [25mm (1")] [40mm (1 1 / 2")] [SITE SPECIFIC: Use second figure for insulation for suction piping in regions where the 2.5% design wet bulb exceeds 26 C (78 F).]. Cover refrigeration suction piping on systems operating above -18 C (0 F) SST with unicellular piping insulation having a minimum thickness of [20mm ( 3 / 4")] [25mm (1")] [SITE SPECIFIC: Use second figure for insulation for suction piping in regions where the 2.5% design wet bulb exceeds 26 C (78 F).]. June 2010 15651 5
G. Refrigerant Suction Line Insulation. 1. Suction lines operating above 0 degrees F saturated suction temperature (SST) shall be insulated with elastomeric pipe insulation with wall thickness of 20 mm (1"). Where the 2.5% design wet bulb temperature exceeds 26 degrees C (78 degrees F ) insulation wall thickness shall be 25mm (1.) 2. Suction lines operating at a -18 degrees C (0 degrees F) and lower shall be insulated with elastomeric pipe insulation of 25 mm (1") wall thickness. Where the 2.5% design wet bulb temperature exceeds 26 degrees C (78 degrees F ) insulation wall thickness shall be 40mm (1-3/4 ) and may be applied in two layers with only the outer layer being of the factory split self adhesive type. H. Specify aluminum jacket on all exterior insulation. 2.05 Heat Reclaim Water Heaters. Provide to heat domestic water for building with heat rejection of product refrigeration system. 2.06 Prefabricated Walk-in Refrigerators and Freezers. Refer to Section 13060. 2.07 Electrical. A. Provide grounding conductors in all refrigeration electrical conduit runs. B. Provide duplex receptacles in the kick plates 3 feet from the end of each side of each island case lineup. See Design Standard Plate 15651-50. EXECUTION 3.01 Refrigerant Handling. Paragraph of Section 15500 entitled "Refrigerant Handling" applies. 3.02 Display Cases: A. Seal as required to floor, walls and to each other with sheet metal parts and caulking per Design Standards 15500-01 and 15650-16. B. Include details of case sealing on construction drawings. 3.03 Electrical: A. Show on the Refrigeration Drawings: 1. Provide a weatherproof disconnect and enclosure for a permanent plug-in receptacle for power to a temporary refrigeration trailer. The trailer provider will provide a receptacle to match the NEMA configuration of the trailer plug. Provide conductors and circuit breaker for 208V/3Ø/70 ampere load. 2. Provide a duplex outlet at each end and each side of the island case runs. Locate the receptacle in the toe/space of the cases 5 feet ± from each end of each case run except that it shall not be below doors at glass door cases. 3.04 Compressor Systems Locations: A. Mechanical Centers shall be used in lieu of constructing mechanical mezzanines. B. In smaller stores Mechanical Centers may be located on Grade when line lengths exceed practical limits (300 ft.). Locate centers on the roof. C. Locate Roof mounted Mechanical Centers above walk -in coolers to minimize noise in the Sales Area. 3.05 Contract Documents Check List: A. Layout unit cooler drain lines on drawings, such that lines do not cross door openings. B. In add / alter projects insure continuous availability of refrigerated cases and walkins by providing a location for new equipment separated from the old equipment location so that new and existing refrigerated cases and walkins can be operated simultaneously. C. Verify that space and structural support are adequate for replacement equipment. June 2010 15651 6
D. Show location of floor drains for all condensate producing equipment. E. Gas fired equipment located in refrigeration equipment rooms, occupied spaces, or in equipment spaces other than properly ventilated and protected boiler rooms shall be of the separated combustion type with combustion air ducted from out of doors. F. Work with the structural engineer to determine whether seismic restraint or wind restraint is needed for items of mechanical equipment based on ASCE 7-02. G. All unit heaters in machinery rooms and mechanical centers shall be sealed combustion type. H. Show a vapor detector on the drawings in the refrigeration machinery room(s) or mechanical center(s). END OF SECTION June 2010 15651 7