15600-1 Anytown, USA - 11110000 11/03/13

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15600
-
1


Anytown, USA
-

11110000




11/03/13

UniSpec II

111910

SECTION 15600
(23 6000)


REFRIGERATION EQUIPMENT


PART 1
-


GENERAL

SUMMARY

A.

Section Includes:

O
wner and Wal
-
Mart

furnished, Contractor installed r
efrigeration
equipment.

Contractor furnished and installed
refrigeration equipment related items
.

B.

Related
Requirements
:

Section 01454
-

Architect
-
Engineer Quality Assurance

Section 01640
-

Owner Furnished Products.

Section 01600
-

Product Requirements: De
livery, Storage and Handling
.

Section 01
77
0
-

Contract Closeout
.

Section 16100
-

Wiring Methods: Wiring for refrigeration equipment.

1.2

REFERENCES

A.

The publications listed belo
w form a part of this specification to the extent referenced
. P
ublications are re
ferenced

within the text by the basic designation only.

B.

ASTM International

(
ASTM
):

ASTM A

536

-

Ductile Iron Castings

ASTM B

75
-

Seamless Copper Tube

ASTM B

88
-

Seamless
Copper Water Tube

ASTM B

584
-

Copper Alloy Sand Castings for General Applications

ASTM D

2000
-

Standard Classification System for Rubber Products in Automotive Applications

C.

American National Standards (ANSI):

ANSI
B

16.18

-

Cast Copper Alloy Solder Joint

Pressure Fittings

CLOSEOUT
SUBMITTAL
S

D.

Refrigeration Start
-
Up Report:
Submit

completed report Wal
-
Mart Stores, Inc., 2001 SE 10
th

Street, Bentonville,
AR 72712
-
0550, Attention:

Mechanical Services Department Construction Manager, for verification of
completion.

E.

As
-
Built Drawings
:
Provide

as built piping drawings

in 18
-

by 24
-
inch
plexi
-
glass frame. Install on
interior side of
compressor room

door or on interior side of door panel
.

F.

Record Letter of Conformance: Submit Contractor’s Record Letter of Con
formance in accordance with Section
01770 and on the forms attached at the end of this Section.

1.3

DELIVERY, STORAGE AND HANDLING

A.

Section 01600


Product Requirements: Transport, handle, store and protect products.

B.

Coordinate delivery of Owner f
ur
nished ref
rigeration equipment and refrigerant with Wal
-
Mart Mechanical
Services Construction Manager.

C.

Receive and unload Owner furnished refrigeration equipment using the services of the refrigeration subcontractor.

D.

Handle and store in manufacturer's original packa
ging, following manufacturer's recommendations.


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E.

Store in a dry area and in a manner to prevent damage.

F.

Equipment shall remain
boxed

until ready for installation.

G.

Notify Owner of equipment received from carrier in damaged conditions and shortages.
Obtain
verification of
damage from carrier’s truck driver.

RESPONSIBILITIES

H.

Contractor Responsibilities:

Provide refrigerant piping
, drain piping
,

and

condenser water piping including t
ubing, fittings, insulation for
refrigerant lines,
Unistrut
, fasteners,
bolts, hangers
, and other accessories required for installation
.

Receive and unload Owner furnished refrigeration equipment through refrigeration subcontractor.

Install
ation

of Owner furnished equipment
.

Make final e
lectrical connections to Owner

furnished

equipment.

Attach rooftop refrigeration equipment to structural support frame as shown on Drawings.

Provide sheet metal refrigeration piping and conduit enclosure as shown on Drawings.

E
lectrical wiring except terminatio
ns and slave wires
as specified in

Section 16100.

Structural support for refrigeration equipment

as specified in Section

07721.

Charging and lubricating of systems.

Furnish refrigerant as needed for charge of system.

Adjustment of controls.

Identification
of systems.

System testing.

Providing qualified labor for assisting EOR in refrigeration functional performance tests as specified in
Specification 01454.

System
s
tart
-
u
p

Operation and
c
heckout of all installed equipment and piping.

I.

Owner

Responsibilities:


Furnish r
efrigeration equipment scheduled or shown on Drawings

and identified
.

WARRANTY

J.

P
rovide warranty and service on equipment and materials installed regardless of whether equipment or materials
were furnished by Contractor.
Provide

supplemental warr
anty service
to
include failures during installation and for
90 days beyond store Grand Opening date. The supplemental warranty shall include labor, parts, and refrigerant
for repairs to
installed refrigeration
equipment
and piping. Owner’s

equipment
manuf
acturer (OEM) supplier will

furnish replacement parts for failures of OEM parts during installation period and for one year beyond store Grand
Opening date. Contractor shall obtain replacement parts from equipment manufacturer. Owner will not pay
additiona
l costs associated with repair or replacement of materials and parts during the warranty period. Additional
costs attributed to equipment failures shall be handled directly with the manufacturer.

In the event the Contractor fails to respond to emergency ca
lls or fails to perform required maintenance or repairs
during warranty

period, the Owner will have the right to have the repair or maintenance performed

by
another contractor. In this case, the Contractor agrees to pay the Owner the invoiced amount of the

services
performed plus 15 percent.
R
esponse time to emergency calls
shall be within

two hours.

If the

Contractor subcontracts the warranty

work, the 90 day warranty

responsibility remains with
the
Contractor
.
The

Contractor shall resolve all payments between the two parties. The Owner will
not involve

itself in
resolving payment issues. If the service contractor discontinues or drops their service level because the

Contractor has failed to make payment on completed

warranty work, Wal
-
Mart will remove that Contractor
from New Stores Bid List until such time when

all disputes or claims are settled.

K.

Perform inspection of installation 90 days after store Grand Opening date. Make necessary corrections and
adjustments. Co
mplete refrigeration
punch list
. Send completed
punch list

to Wal
-
Mart Stores, Inc., 2001 S.E. 10
th

St., Bentonville, AR 72716
-
0550, Attention: Mechanical Services Department, for verification of completion.
Notify Wal
-
Mart Mechanical Services Constructi
on Manager

(MSCM)

prior to inspection.


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At

90

day inspection, include necessary lubrication, leak tests of all joints, flare nuts, and tightening of strapping
as may be necessary. Perform leak test on small leak setting of
refrigerant

leak detector.

At 90 d
ay inspection, change

suction, liquid, and oil filters. Leave oil filters and dryers in motor room for
inspection by Wal
-
Mart Mechanical Services Construction Manager. Place in a
sealable

plastic bag to
prevent setting off any leak detection system.

L.

At the

end of warranty period, certify in a letter to the Owner
that equipment

and m
aterials installed or connected

are functioning properly.

Include certification

that systems are free of leaks and are maintaining satisfactory
temperatures at normal control adj
ustments.

PART 2
-

PRODUCTS

OWNER FURNISHED PRODUCTS

A.

Wal
-
Mart (or Owner if noted)

will furnish
refrigeration

equipment as follows under provisions of Section 01640

for installation by the Contractor
.

R
e
f
rigeration Equipment scheduled or shown on drawings to be furn
ished by Owner.

Refrigeration alarm systems.

Condensers/
Evaporators.

Compressor houses.

(Owner furnished)


Weatherpacs
.

Hybrid Houses.

Refrigerated cases.

Self
-
contained
refrigerated
cases (where indicated).

Ice flakers (where indicated)

Produce misting system. (where indicated)

PRODUCTS
FURNISHED AND INSTALLED BY WAL
-
MART (EQUIPMENT SUPPLIER)

B.

Wal
-
Mart

will furnis
h
and install Walk
-
in Freezers and Coolers.

MATERIALS (OWNER FURNISHED/CONTRACTOR INSTALLED)

C.

Refrigeration equipment shall be as shown on the drawings.


MATERIAL
S

(CONTRACTOR FURNISHED AND INSTALLED)

D.

Refrigeration Piping:

Provide refrigeration piping of Type L hard drawn copper tubing. In portions of installation where it is necessary
to use soft drawn copper tubing and such use i
s approved in writing by Wal
-
Mart Mechanical Services
Construction Manager, provide Type L. All tubing shall be factory sealed ACR tubing.

For medium temperature glycol systems, provide Georg Fischer Cool Fit ABS pi
ping or Type L hard drawn
copper tubing. Use water
-
soluble flux (Aqua
-
brite flux) on glycol copper. In portions of installation where
it is necessary to use soft drawn copper tubing and such use is approved in writing by Wal
-
Mart
Mechanical Services Cons
truction Manager, provide Type L.

Provide refrigeration piping of Type L hard drawing copper tubing for low temperature Secondary CO
2

system
pipes less than or equal to 1
-
3/8”, and provide Type K hard drawing copper tu
bing for low temperature
Secondary CO
2

system pipes larger than or equal to 1
-
5/8”. All tubing shall be factory sealed ACR tubing.

Refrigeration Piping Elbows: Wrought copper, 90
-
degree long radius type. 45
-
degree elbows will not be
permitted.

Run 3/4 i
nch copper condensate line from evaporator directly to outside of walk
-
in walls, and adapt to individual
PVC trap and stub into common 2 inch diameter Schedule 40 white PVC condensate header. Clean
markings off of PVC with solvent. Insulate and apply heat
tape to condensate drains inside walk
-
ins below
32º with 1
-
inch AP Armaflex,

Halstead, Aerof
lex,

K
-
Flex,

or R
ubatex.

Do not insulate PVC piping.

Provide drain line heater for walk
-
ins below 32º

F
. Provide self
-
regulating type heater (no thermostat) such
as
Frostex
-
RSI, Raychem, or equal. Ensure drain line and drain line heater are operating properly. Insulate
freezer drain lines with 1
-
inch pipe insulation.


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Support overhead copper refrigeration lines at 10 feet maximum intervals on Unistrut hung on
galvanized all
-
thread rod. Attach hangers to top of bar joist only. Support supply and return lines at each hanger with 10
inch length of Schedule 40

PVC pipe with an I.D. equal to insulation O.D. surrounding pipe insulation, and
secure to Unistrut with Pa
nduit strap (or equal), 120 lbs. tensile strength

(see support detail on Drawings).

Support overhead Georg Fischer Cool Fit ABS refrigeration piping per “Georg Fischer Piping Systems Product
Range and Price List” rec
ommendations, page 12, Distance Between Pipe Brackets.

Secure vertical refrigerant piping installed outside building walls to Unistrut fastening system with #022

Cush
-
a
-
Clamps. Fasten clamps directly to copper pipe, not to outside of insulation. Butt insu
lation tightly against
clamp and insulate uncovered areas to prevent sweating. Cover exterior refrigerant pipe insulation
(including heat reclaim lines) and interior prep room lines with .020 inch thickness PV jacketing and fitting
covers, Proto or Zeston.

Jacketing shall be vapor and weather sealed.

Provide 1
-
inch wall thickness AP Armaflex, Halstead, Aerofl
ex,
K
-
Flex,
or R
ubatex on less than or equal to 1
-
1/2

inch diameter low temperature and medium temperature suction lin
es. Provide 1
-
1/2 inch wall thickness AP
Armaflex, Halstead, Aero
flex,
K
-
Flex,
or Ru
batex on lines greater than 1
-
1/2

inch diameter low
temperature and medium temperature suction lines. Provide 1/2 inch thickness on produce and seafood case
drain lines. In
sulate liquid lines with 1/2 inch AP Armaflex, Halstead, Ae
roflex,

K
-
Flex,

or

Rubatex. If
local code calls for thicker insulation, comply with local code. Slip insulation over pipe before making
joints. Split type insulation is acceptable on
fittings only.

Provide mitered corners for insulation.
Install
insulation in conformance with manufacturer's recommendations, including glued joints.

If receiver is
mounted outside, provide UV protection for pipe insulation on the liquid line from the receiver to the
refrigeration rack by application of a covering or coating specifically for the purpose of UV protection and
as recommended by the manufacturer.

For medium temperature Secondary Glycol supply and return lines (coppe
r or Georg Fischer Cool Fit ABS pipe),
provide 1
-
inch wall thickness AP A
rmaflex,

K
-
Flex,

Rubatex, or Trymer on medium temperature return
and supply lines for pipe diameters smaller than or equal to 1
-
1/4 inch
; provide

1
-
1/2 inch wall thickness
AP Armaflex,
K
-
Flex,
Rubatex, or Trymer for pipe

diameters greater than or equal to 1
-
1/2 inch. Provide
1/2 inch thickness on produce and seafood case drain lines.

If local code calls for thicker insulation,
comply with local c
ode. Slip insulation over pipe before making joints. Split type insulation is acceptable
on
fittings only.
Provide mitered corners for insulation.
Install insulation in conformance
with
manufacturer's recommendations, including glued joints.

Provide 1
-
1/2 inch wall thickness AP Armaflex,
K
-
Flex,
Aeroflex, or Trymer on all low temperature secondary
CO
2

lines. If local code calls for thicker insulation, comply with local code. Slip insulation over pipe
before making j
oints. Split type insulation is acceptable on
fittings only.
Provide mitered corners for
insulation.
Install insulation in conformance with manufacture
r's recommendations, including glued joints.

Liquid supply line tees shall be bull headed inside cases.

Install 1/4 inch king valve on top of inverted trap on inlet side of condensers on rack houses. Install valve at
highest point in the discharge line. Provide king valves with brass or steel caps.

Return lines that are
teed

into a common return line shall
be
teed

into the top.

Install heat reclaim lines with 1 inch thickness
CertainTeed

one
-
piece fiberglass covering with fire resistant jacket
with self
-
sealing lap, or Owens
-
Corning or Armstrong. Cover fittings with Zeston, Knauf, or equal
premolded insulati
ng fittings. Install insulation in professional, neat appearing manner. Poor workmanship
shall be corrected at the Contractor's expense.

Provide branch supply and return line ball valves for isolation purposes as indicated on refrigeration piping

plans.
Co
ordinate location with Wal
-
Mart Mechanical Services Construction Manager. Install valves at fully
accessible location. Do not conceal by walls, fixtures, or other equipment. Install as
-
built piping plan,
indicating final location and identification of fiel
d installed isolation valves (one for each system) in glass
frame in an appropriate location close to the system indicated.

Insulate isolation valves in accordance with
refrigeration line insulation requirements.
Provide ball valves as manufactured by He
nry Valve Co., or
Mueller Brass, of welded body construction. Bolted body valves will not be approved.

E.

Condenser Water Piping

Type "L" hard drawn, s
eamless copper water tube, ASTM B88.

Jointing: Join with wrought copper pressure fittings, ANSI B16.22. Make joints using "lead free" solder and a
non
-
corrosive, paste
-
type flux. Core solder is not permitted. Solder shall be solid string or wire type. Whe
re
soldered copper piping is connected to threaded brass piping, use cast brass adaptor.

At Contractor’s option, in lieu of a soldered copper piping system as specified above, any of the
following copper

pipe assembly systems may be used.


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CTS Copper Groove
d Piping System: Copper tubing systems from
1
-
1/2”
-

3”

shall be installed using
mechanical pipe couplings of a bolted type, with pressure
-
responsive gaskets and grooved end
copper or bronze fittings.

Copper Tube: Type "L" hard drawn, seamless copper wat
er tube, ASTM B88.

Mechanical Coupling: Style 606 rigid couplings
1
-
1/2”
-
3”

for copper consisting of ductile iron cast
housing

and

synthetic
rubber gasket of pressure
-
responsive design with plated nuts and bolts to secure unit
together.

Coupling Housing:
Ductile iron conforming to ASTM A536, Grade 65
-
45
-
12, with a copper color alkyd
enamel paint coating.

Gaskets: Molded of Grade “E” EPDM synthetic rubber, conforming to ASTM D2000, designation
2CA615A25B24F17Z, and recommended for potable water service wit
hin the specified temperature
range of

30 to +230 degrees F. Gaskets shall conform to the copper tube size (CTS) outside
diameter and coupling housing inside diameter.

Flange Adapters: Style 641 adapters
1
-
1/2”
-
3”,

ductile iron ASTM A536, Grade 65
-
45
-
12
, engaging
directly into roll grooved copper tube and fittings and bolting directly to ANSI Class 125 cast iron
and Class 150 steel flanged components; installer shall provide standard flange bolts.

Fittings:

Full flow copper fittings with grooves
designed to accept Victaulic grooved end couplings. Fittings
shall be copper per ASTM B75 alloy C12200; or bronze sand castings per ASTM B584
copper alloy CDA 844 (81
-
3
-
7
-
9) per ANSI B16.18.

Use Style 47 dielectric waterways when connecting dissimilar meta
ls in liquid systems.

Assembly and Quality Assurance:

Contractor shall be a certified installer of Victaulic piping systems.

The piping system manufacturer shall certify that the piping system is installed in accordance with
its recommendations.

Provide 1
-
inch wall thickness AP Armaflex
, Arma
-
Check Armaflex, or K
-
Flex

on condenser water piping.
Slip insulation over pipe before making joints. Split type insulation is acceptable on fittings only.
Install insulation in conformance with manufacturer’s recommend
ations including glued joints.
Provide WB Armaflex finish on insulation. Apply finish in accordance with manufacturer’s
recommendations.

FABRICATION

F.

Size refrigeration piping in accordance with Refrigeration
Piping
Schedule indicated on Drawings and as
sp
ecified.

G.

Perform cutting of tubing with wheel
-
type cutter where possible, and reamed to original bore. Where necessary to
saw cut
, drag tubing clean after reaming. Before using, drag clean tubing left open on job after cutting and
sanding.

H.

For Georg Fischer Cool Fit ABS pipe, chamfer pipe per instruction from Georg Fischer.

I.

For medium temperature Secondary Glycol copper piping, make joints with use of soft solder. Use Staybrite or
Silva
-
Brite. AquaBrite Flux shall be
used in soft soldered joints. Clean joints thoroughly before brazing and have
dry nitrogen at 1/2 psi pressure flowing through tubing while joints are being brazed to avoid internal scale. Refer
to Georg Fischer installation recommendations for ABS piping
.

J.

Make joints with use of brazing alloy containing minimum of 15 percent silver. Clean joints thoroughly before

brazing and have dry nitrogen at 1/2 psi pressure flowing through tubing while joints are being brazed to avoid
internal scale. If brazing allo
y of less than 15 percent silver is found on job, Wal
-
Mart Mechanical Services
Construction Manager will require

all fittings be cut out and replaced with new fittings using 15 percent alloy.

K.

Install replacement parts (i.e. expansion valves, heat exchanger
s, sight glasses) using Harris Stay Brite #8,
excluding parts in hot gas lines. Use heat dams in all instances.

PART 3
-

EXECUTION


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INSTALLATION

A.

Install equipment in accordance with manufacturer’s
instructions

B.

Installation shall be by Contractor or by refrigeration

contractor or other installer as shown on the drawings
through services obtained by the Contractor.

C.

Suspend refrigeration piping by Unistrut hangers or equal, space to prevent sagging. Fasten securely. Install
exposed piping to provide easy access in case

of leaks.

D.

Under no condition shall copper pipes touch each other when necessary to cross pipes. Offset or insulate

to insure
no copper
-
to
-
copper contact. Refrigerant piping shall not come in contact with electrical conduit or other
dissimilar grounded met
als.

E.

Install oil traps before vertical risers and as recommended by Refrigeration EOR. On risers above 16 feet, double
oil traps spaced as shown on refrigeration drawings.

F.

Seal penetrations into
building or
walk
-
ins
(refrigerant pipe, condensate drains) with urethane foam and seal over
with silicone caulk.

G.

Mount
electronic suction pressure regulator valves,
TXV valves, pump down solenoids, thermostats, and h
eat
exchangers. Allow enough pipe at evaporator outlet to mount TXV feeler bulb insuring 100% contact.

H.

Mount TXV

valves, pump down solenoids, thermostats, and heat exchangers. Allow enough pipe at evaporator
outlet to mount TXV feeler bulb insuring 100% contact.

I.

Trap evaporators at coil outlet and vertical suction line risers. Traps shall be one piece type at botto
m of risers.
Size P traps to match horizontal pipe or coil outlet pipe. Do not reduce to riser size. Take vertical risers as high as
possible (just below structure). Due to the special nature of the loop piping system utilized on some projects,
coordinate
between Wal
-
Mart Mechanical Services Construction Manager and the refrigeration
EOR

to ensure that
piping system is installed as designed.

J.

Pitch horizontal suction lines minimum of one inch per twenty feet of run

in direction of refrigerant flow.

Insure
no

oil traps are formed in piping.

K.

Install trapeze hangers no farther than two feet on each side of 90 degree turns.

L.

Install unions on condensate drains in walk
-
ins close to drain
pan;

allow clearance for pans to hinge open. Provide
heat tape on condensate
lines inside walk
-
ins with temperature 32 degrees or less and insulate. Install common
condensate line outside the walk
-
in. Paint non
-
insulated copper drain lines to match walk
-
in box.

M.

Maintain slope of one inch per ten feet of horizontal run for condensat
e lines. Provide traps in condensate lines
outside of walk
-
ins just before entering common condensate line.

N.

Do not deviate pipe routing, case, condenser, and compressor rack location from Drawings without approval from
Wal
-
Mart Mechanical Services Construc
tion Manage
r and refrigeration EOR
.

O.

Seal and pressure test each individual refrigerant circuit before connecting to condensing unit or refrigeration
compressor rack. Line shall hold pressure without drop for 24 hour period. Testing shall be verified by Wal
-
Mart
Mechanical Services Construction Manager. Repair leaks and repeat test until line is totally leak
-
free.

P.

Provide Schrader valve access on each suction line leaving evaporators and on highest point of the invert in
condenser supply.

Q.

Make final electric
al connections, including slave wiring, to refrigerated cases, evaporators, power defrost heaters,
cooler and freezer box door lights and anti
-
sweat heaters, and compressor houses.
Make connections per wiring

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diagrams and instructions from equipment suppli
er.
Electrical work shall conform to Section 16100

and applicable
electrical codes
.


IDENTIFICATION

R.

Provide engraved plastic identification 2 inch by 3 inch tags, attached with screws or pop rivets.

S.

Provide job notebook with model and serial numbers, refr
igerant charge per rack, warranty expiration date,
emergency service telephone numbers in plastic envelope. Work performed after start
-
up, warranty or non
-
warranty, shall be logged in job notebook and referred to by designation number. Locate job notebook
in
mechanical refrigeration house. Refrigerant charge per rack shall be written in black indelible marker on each
system compressor breaker panel.

T.

Identify refrigeration equipment with matching numbers

as shown on the
Drawings:

Tag circuits connecting to t
hese condensing units or racks with corresponding number and circuit.

Identify refrigeration equipment, including compressor houses, racks, walk
-
ins, sensor or thermostat locations,
chiller tanks, heat reclaim coils, and hot water tanks.

Tag cases with an
approximate location of field installed control valves.

CASE SETTING

U.

Set cases level and in line with transit. Shim
each
vertical support or at maximum 4 foot intervals with galvanized
plates where floor condition requires
at
front and rear of case.

V.

Apply
Butyl caulking compound at case joints.

Manufacturer's seal is not sufficient.
Reseal joints if seal is broken
by shifting or movement of equipment.

W.

Do not cut bottom case rails without Wal
-
Mart Mechanical Services Construction Manager approval.

X.

Hang case shelving and place pans in refrigeration cases including door shelving in
d
airy cooler.

TESTING, EVACUATION, AND CHARGING

Y.

Notify Wal
-
Mart Mechanical Services Construction Manager 72 hours in advance of tests so that Owner's
representative may be
present for test if desired.

Z.

When refrigeration connections have been completed, test system at minimum of 150 psig, but not to exceed 200
psig, with compressor suction and discharge valves closed, and all other valves in s
ystem open, with exception of
transducers which must be kept closed during pressure testing and evacuation procedures. Comply with
requirements of local codes if higher test pressures are required. Refrigeration piping
shall be

gas tight. If leaks are
foun
d, isolate leaks, discharge gas and repair leaks, and then repeat test. When testing has been completed, release
pressure.

AA.

When refrigeration connections have been completed,
leak
test

medium temperature Secondary Glycol system at a
minimum of 75 psig, but not to exceed 100 psig.

Tests to be completed

with
all valves in system
s

open, with
exception of transducers which must be kept closed during pressure testing and evacuation procedur
es. Comply
with requirements of local codes if higher test pressures are required. Refrigeration piping will not be acceptable
unless it is gas tight. If leaks are found, isolate leaks, discharge gas and repair leaks, and then repeat test. When
testing

has been completed, release pressure using safe procedure.

Refer to Georg Fischer installation/testing
recommendations for ABS piping.

BB.

When refrigeration connections have been completed,

leak test low temperature Sec
ondary
CO2 system at
minimum of 150 psig, but not to exceed 200 psig
. Tests to be completed

with
all valves in system
s

open, with
exception of transducers which must be kept closed during pressure testing and evacuation procedures. Comply
with requirement
s of local codes if higher test pressures are required. Refrigeration piping will not be acceptable
unless it is gas tight. If leaks are found, isolate leaks, discharge gas and repair leaks, and then repeat test. When
testing has been completed, release

pressure using safe procedure.


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CC.

Evacuate system with vacuum pump specifically manufactured for vacuum duty, having capability of pulling
vacuum of 50 microns or less. Do not evacuate system by use of refrigeration compressor. Connect pump to both
low and
high side evacuation valves with copper tube. Compressor service valves shall remain open. Attach high
vacuum gage, capable of registering pressure in microns, to system for pressure readings. Do not operate hermetic
or semi
-
hermetic motor compressors duri
ng evacuation because of reduced electric strength of atmosphere within
motor chamber. To check system pressure, provide hand valve between pressure gage and vacuum pump which
can be closed to isolate system and check pressure.

DD.

Evacuate each rack to an abs
olute pressure not exceeding 1,500 microns. Break vacuum to 2 psig with dry
nitrogen. Repeat evacuation process, again breaking vacuum with dry nitrogen. Install drier of required size in
liquid line. Evacuate to absolute pressure not exceeding 500 microns
. Leave vacuum running for not less than two
hours without interruption, valve off, and remove vacuum pump. System shall hold 500 microns for twenty
-
four
hours. Contact Wal
-
Mart Mechanical Services Construction Manager for verification of system performanc
e.
Raise system pressure to 2 psig with refrigerant, and remove vacuum. Do not pull

high pressures and low vacuums
on transducers.

EE.

Use only refrigerant in equipment for which that equipment was designed by manufacturer. Use only one type of
refrigerant in
system.

FF.

Only use refrigerant in the equipment for which the manufacturer designed the equipment and the EOR has
specified in refrigeration drawings. Both the refrigeration drawings and the equipment manufacturer’s labeling
shall be cross referenced prior

to charging of refrigeration system. Any contradictions shall be brought to the
refrigeration EOR’s attention before system charging.

GG.

Charge refrigerant directly from original drums. Charge system by means of charging fitting in liquid line.

HH.

Top off all o
il charges.

SYSTEM
START
-
UP

II.

Final payment will not be made until start
-
up reports are received and job notebook is turned over to store
management
.

JJ.

Complete system balance and start
-
up by the end of the fifth day

after commencement
.

KK.

Fill out start
-
up repor
ts and send to manufacturer (if applicable) indicated on condensing units.

LL.

After compressor is started, continue charging until system has sufficient refrigerant for proper operation. Do not
overcharge. During start
-
up, do not leave compressor operating un
attended and unmatched until system is properly
charged with refrigerant and oil. Charge receivers to 50 percent or more with unit in heat reclaim in 100 percent
condenser and all condenser fan controls set properly. Maintain these levels throughout warran
ty period. If at end
of warranty period, receiver level has dropped, completely re
-
check system for leaks
.

Repair leaks and bring
system back to specified charge level at no cost to Owner.

MM.

Do not add refrigeration oil while system is short of refrigerant u
nless oil level is dangerously low. If oil has been
added during charging, carefully check compressor crank case sight glass after reaching normal operating
condition

to assure
system does not contain excessive amount of oil which can cause slugging or los
s of
refrigeration capacity.

NN.

Start
-
up
shall consist

of the following:

Adjusting of E.P.R. valves at rack, TXV valves at fixtures, liquid hold
-
back valves, compressor high and low
pressure switches.

Adjusting of TXV valves at fixtures, liquid hold
-
back valves, compressor high and low pressure switches.
]

Adjusting of balance valves at fixtures, balance valves at rack,
liquid hold
-
back valves, compressor high and low
pressure switches.

Tightening electrical connections.

Checking electrical load balances.


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Complet
ing

refrigerant and oil charge.

Adjusting oil float levels

and replacing

liquid, suction
,

and oil line filter dryers, etc.

Verifying p
ressure and temperature gages
are

accurate.

3.2

OPERATION AND CHECK
-
OUT

A.

Set expansion valve superheat at 6 to 12 degrees on medium and low temperature DX systems. This setting will b
e
at the bottom of valve swing. Balance multi
-
plex systems to within 2 degrees of cut out and with not more than 2
degrees variation in discharge air temperature between cases. Verify after fixtures have been loaded with product
and store temperature and
humidity design levels have been reached.

B.

Adjust balance valves to balance multi
-
plex systems to within 2 degrees of cut out and with not more than 2
degrees variation in discharge air temperatu
re between cases.

C.

Verify and reset superheat after cases and walk
-
ins have been loaded with product, and temperature and humidity
levels have been reached.

D.

Change liquid line filter dryers, oil system dryers, and suction line filter dryers after 24 hours
of run time. Filters
shall

be rated for wax removal.

FIELD QUALITY CONTROL

E.

Field Quality Control shall be performed by the Contractor unless otherwise specified.

F.

Functional Performance Testing (FPT): FPT will be conducted by Wal
-
Mart Engineer of Record at

no cost to the
Contractor in accordance with Section 01454. FPT will be performed after Wal
-
Mart possession date.
Deficiencies noted and related to the Contractor’s installation responsibilities shall be corrected prior to Grand
Opening.

JOINT INSPECTIO
N

G.

If directed by the
Wal
-
Mart Mechanical Services Construction Manager
,
cut out five randomly selected joints

to
verify use of dry nitrogen during brazing operations. Joints
shall

be inspected
in the presence of the MSCM
for
oxidation. For each joint which

shows evidence of oxidation and non
-
compliance,

cut out

an
additional

joint
. If
four fittings are found oxidized,
rework all joints includ
ing

those removed for inspection
.

END OF SECTION




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11/03/13


Refrigeration Installation

Handover Document / Sign Off Sheet


All sections of this document must be completed before the installation will be accepted.

Store No.






Town





St












Store Type







(Supercenter, Sams Cl ub, Nei ghborhood Market)










GO Date








(Date of proj ect GO
-

for
warranty purposes)










Project Type







(New Store / Cl ub, Rel ocati on, Remodel, Capex)










Installing Contractor






(Contractor's name and branch l ocati on i f appl i cabl e)










Equipment Supplier






(Hi l l Phoeni x, Kysor Warren,
Zero Zone, Hussmann)










Refrigerant







(R 407A, R 410, etc)










System Type







(DX / CO2 / Gl ycol Secondary Loop)










Heat Reclaim







(Domesti c Water, N/A)










EMS System







(Novar, Danfoss, CPC)










Verisae Data Submitted






(Date submi tted or N/A)



















Comments:
















































































Approval

















The work carried out during this project is complete and the

standard achieved is acceptable.


























Wal mart Mech. Serv.

Constructi on Manager (name)


Signature


Date










Noti ce to WM MSCM:








By signing this form, you are confirming that the work detailed above is complete and that
all systems are operating as
intended.

All handover documentation has been completed and you are satisfied with their contents.


All issues are either resolved or you are satisfied with the plan for resolution.






15600
-
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-

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Refrigeration Installation

Handover

Document / Glossary of Terms











GO Date


Grand Opening Date
-

the date a store officially opens (new
store) or reopens (remodels / Capex)

Capex


Capital Expenditure project
-

this type of project will be
specified as Capex at the time of
bidding

DX


Direct Expansion
-

a type of refrigeration system where the
primary refrigerant delivers cooling directly to the cases /
walk
-
ins

Weatherpac

A type of machine room smaller than a rack house, located
on the roof.

Hybrid House

A type of
machine room, smaller than a traditional rack
house, but larger that a Weatherpac, typically located on
the roof.

HP


Hill Phoenix
-

a manufacturer of refrigeration equipment
and cases

KW


Kysor Warren
-

a manufacturer of refrigeration equipment
and
cases

ZZ


Zero Zone
-

a manufact urer of refri gerat i on
equi pment and cases


O and M


Operat i on and
Mai nt enance





Paral l el reci p

A t ype of refri gerat i on syst em
-

usi ng reci procat i ng
compressors and di st ri but ed syst ems, bot h pi ped i n a
paral l el confi gurat i on.



Typi cal l y i nst al l ed out si de t he bui l di ng i n a purposel y
manufact ured machi ne room.

RIB


Rack In a Box
-

a t ype of
refri gerat i on syst em
-

t he
equi pment i s housed i n a smal l encl osure.



Thi s t ype of syst em i s t ypi cal l y mount ed i nsi de t he
bui l di ng.




NOTE: RIB i s al so an abbreviation f or "RELAY IN A BOX" However,
f or t he pur poses of t hi s document, i t i s assumed t hat



t he abbr eviation wi l l r efer t o Rack i n a
Box.




PF modul e

Phase Fai l ure modul e
-

a devi ce whi ch det ect s anomal i es
i n t he el ect ri cal

suppl y t o t he refri gerat i on syst em.

EMS


Energy Management Syst em
-

Manages t he cont rol for t he
refri gerat i on and HVAC syst ems i n t he bui l di ng

EPR


Evaporat or Pressure Regul at or
-

a val ve l ocat ed i n t he
suct i on l i ne of t he refri gerat i on syst em used t o
cont rol
pressure / t emperat ure.

T'stat


Thermost at
-

t emperat ure cont rol
devi ce




EEPR


El ect roni c Evaporat or Pressure Regul at or
-

an el ect roni cal y
cont rol l ed EPR

OPR


Out l et Pressure Regul at or
-

a val ve used t o cont rol t he
out l et pressure of t he
l i qui d refri gerant l eavi ng t he
subcool er

VFD


Vari abl e Frequency Dri ve
-

a devi ce used t o cont rol t he
speed of t he condenser fan mot ors





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-
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Refrigeration Installation

Handover Document / Sign Off Sheet


Machine Rooms

All sections of this document
must be completed before the installation will be accepted.

Store No.






Town





St












Technician











Date






Name of technician carrying out checks and completing this
form.


















Circle as
Required

Type of machine
room
-

(Rack / hybrid houses or weatherpacs)



Machine room supplier
-

(HP, KW, ZZ etc)





Are weatherpacks bolted to steel?




y / n

Are all penetrations properly
sealed?




y / n

Do all power sockets / lights operate correctly?



y / n

Do all
exhaust fans operate
correctly?




y / n

Are all (weatherpac) doors hung properly and operating correctly?

y / n

Is there any damage to the room which needs attention / repair?

y / n

Are all shields / hoods installed correctly?



y / n

O and M manuals
left on site?





y / n

Drawings mounted on walls of machine rooms?



y / n

Confirm liquid line filter dryers, oil system dryers, and suction


line filter driers have been changed after 24 hours of run time

y / n

Is leak detection installed?





y /
n

If so, has it been tested and certified functional?



y / n

Electrical drawings mounted inside electrical panels?


y / n

Are all electrical distribution panels labeled correctly?


y / n

Are all trunking lids and junction box covers in place?


y / n

Have all relevant labels been fixed to major items of equipment?

y / n

Is the machine room clean and free from rubbish?


y / n










Capex / Remodel Projects







Have all existing, redundant materials (conduit, pipework, etc)



been stripped
out and / or made
safe?




y / n










Comments:




















































































15600
-
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11110000




11/03/13


Refrigeration Mechanical Installation

Handover Document / Sign Off Sheet


Refrigeration Vacuum Test

All
sections of this document must be completed before the installation will be accepted.

Store #







Location






Date Submitted






WM Construction
Manager







Installing Contractor



Address







Telephone



Email Address



Person Attesting

to Vacuum



Telephone










Gauge Used for Testing






Mfg.

Type

Model #

Range in Microns



























A

B

C

D

E

F

First













Second













Final













Date of Final




















Pressure at
Check
-
In



























Signature:



Date:










Comments:






















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Refrigeration Mechanical Installation

Handover Document / Sign Off Sheet






Rack A





All sections of this document must be completed before
the installation will be accepted.

Store No.






Town





St












Technician











Date






Name of technician carrying out checks and completing
this form.











Rack Type (Parallel Recip / RIB /
Modular)



















Rack
Manufacturer












Rack Model No.












Rack Serial No.












Refrigerant type





Record system refrigerant charge



Does the refrigerant type match what is called for on the legend? y/n










~~~~

~~~~ ~~~~










Verify the main power voltage


L 1 > GD



L1>L2

















L 2 > GD



L1>L3

















L 3 > GD



L2>L3












Verify the control voltage
















Delay


Voltage

Confirm
operation of PF module and record settings















Verifiy all electrical connections are tight


y/n










~~~~ ~~~~ ~~~~










Compressor manufacturer?















Record model number of each compressor. (Ensure model numbers
match legend)










Comp 1




Comp 2












Comp 3




Comp 4












Comp 5




Comp 6












Record running amps for each compressor










Comp 1




Comp 2




LOADED

L1

L2

L3


LOADED

L1

L2

L3











UNLOADED

L1

L2

L3



UNLOADED

L1

L2

L3










Comp 3




Comp 4




LOADED

L1

L2

L3


LOADED

L1

L2

L3











UNLOADED

L1

L2

L3



UNLOADED

L1

L2

L3










Comp 5




Comp 6




LOADED

L1

L2

L3


LOADED

L1

L2

L3











UNLOADED

L1

L2

L3



UNLOADED

L1

L2

L3










Allow the oil pressure switch to trip (on each compressor) to insure proper operation.

After oil pressure switch trips, wait two (2) minutes, and check crankcase heater operation.

Record amp draw of each crank case heater.












C1




C2
















C3




C4
















C5




C6














Check and record compressor's

net
oil pressure.


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11/03/13












C1




C2
















C3




C4
















C5




C6














Adjust and record compressor's start delay timer setting












C1




C2
















C3




C4
















C5




C6














Adjust and record compressor's HP cut out switch setting












C1




C2
















C3




C4
















C5




C6














~~~~ ~~~~ ~~~~










Confirm calibration of EMS suction transducer


y / n












Record the
(EMS) rack suction pressure settings.

Cut In



Cut Out












Check and record the rack suction pressure.

EMS



Guage












Check and record the suction temperature.

EMS



Meter












What is the rack superheat?















Have all

EPR's been set correctly?


y / n



(Note: Individual EPR settings to be recorded on case start
-
up documents)










~~~~ ~~~~ ~~~~










Check and record the ambient temperature.

EMS



Meter












Confirm calibration of EMS discharge
transducer


y / n












Check and record the discharge pressure.

EMS



Guage












Check and record the discharge temperature

EMS



Meter












Check and record the drop leg temperature.

EMS



Meter












Does this rack have hot

water/heat reclaim?



y / n












Record heat reclaim control settings Reclaim t'
stat



Electric heater
t'stat



Note: Reclaim t'stat set should be set to 140 F / Electric back
-
up t'stats should be set to 130
F.










Check and record
correct heater element voltage.















Record the (rack) high pressure (EMS) lock out setting














~~~~ ~~~~ ~~~~










Does this rack have ambient subcooling? (surge)


y / n












Check and record the EMS (surge)
setpoints.

Cut In



Cut Out












Check for correct operation. System operating okay?

y / n












Does this rack have subcooling?



y / n












Record liquid (subcooling) temp (EMS) set point.















Record actual liquid temp.

















Record EPR / EEPR setting (as applicable).















Record OPR setting (If applicable).
















Record bypass valve setting (If applicable).















Confirm correct operation.




y / n












~~~~ ~~~~
~~~~











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11/03/13

Condenser Manufacturer












Condenser Model No.












Confirm that condenser is clean and free from debris

y / n












Confirm correct rotation of condenser fan motors


y / n












Does store location require
condenser fins to be coated?

y / n












Does this condenser have a VFD controlling the fan motors?

y / n












Confirm correct settings / operation of VFD


y / n












If no VFD's, confirm correct condenser control by EMS.

y / n












Confirm correct settings / operation of condenser split

y / n












Confirm correct operation of condenser drain down system

y / n












Confirm the installation of an inverted trap on the inlet side

y / n



of condenser pipe work.
















Confirm the installation of a test valve on inlet side


y / n



of condenser pipe work.
















Record setting of liquid hold back
valve
















~~~~ ~~~~ ~~~~










Confirm operation of receiver level alarm
device


y / n












Record level of refrigerant in tank
(%age)
















~~~~ ~~~~ ~~~~










Caps for all valves on and tightened at end of startup

y / n












Record setting of (rack) high pressure cut out
switch















Confirm that sufficient oil is in the oil reservoir


y / n












Confirm that the oil level in each compressor is correct.

y / n












Verify oil is clear in color and free of oxidation after minimum 24 runtime

y/n










Comments:




















































































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11/03/13


Refrigerated Case Installation

Handover Document / Sign Off Sheet






Rack
A





All sections of this document must be completed before the installation will be
accepted.

Store No.






Town





St












Technician











Date






Name of technician carrying out checks and completing this form.











All system identification labels installed




y/n


All expansion valve strainers cleaned. Check

three strainers per rack.

y/n


List circuit number of strainer checked







Verify condensate drains operating correctly:



y/n


All glass doors adjusted properly




y/n


Cases shimmed every 4'





y/n


Case to case joints siliconed





y/n


Bottom

penatrations in cases foam shaved flat and siliconed


y/n





























System #




Make





Case #





Model









Length (ft)



















Float


EPR
Setting


EMS Setting


Superheat
Setting


Circuit


(psi)


(Cut In 'F)

(Cut
Out
'F)


('F)


y/n























Lighting
Amps


Fan
Amps


Defrost
Amps


Trim Heater
Amps
























Confirm that the breakers to the following circuits are labelled correctly:










Lighting



Fans



Defrost



Trim Heaters















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-

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11/03/13










System #




Make





Case #





Model









Length (ft)












EPR
Setting


EMS Setting


Superheat
Setting




(psi)


(Cut In 'F)

(Cut Out
'F)


('F)

























Lighting
Amps


Fan
Amps


Defrost
Amps


Trim Heater
Amps
























Confirm that the breakers to the following circuits are labelled correctly:










Lighting



Fans



Defrost



Trim Heaters






























System #




Make





Case #





Model









Length (ft)












EPR
Setting


EMS Setting


Superheat
Setting




(psi)


(Cut In 'F)

(Cut Out
'F)


('F)

























Lighting
Amps


Fan
Amps


Defrost
Amps


Trim
Heater
Amps
























Confirm that the breakers to the following circuits are labelled correctly:










Lighting



Fans



Defrost



Trim Heaters






























System #




Make





Case #





Model









Length (ft)












EPR
Setting


EMS Setting


Superheat
Setting




(psi)


(Cut In 'F)

(Cut Out
'F)


('F)

























Lighting
Amps


Fan
Amps


Defrost
Amps


Trim
Heater
Amps
























Confirm that the breakers to the following circuits are labelled correctly:










Lighting



Fans



Defrost



Trim Heaters













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-
20


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11/03/13

RACK DATA COLLECTION FOR VERISAE

PAGE



OF





























































This form is to be filled out completely by installing contractor, then e
-
mailed to MSCM.







MSCM to forward (via e mail) to Deb
Menning, Sharon Hajdasz and Stephanie Pitts.















































Date



STORE #







CITY







STATE







































































PROJECT TYPE (circle one) NEW STORE RELOCATION EXPANSION





































































RACK LETTER











































































































A





B





C





D





E





F





G





REMOTE CONDENSOR
1































































REMOTE CONDENSOR 2





REMOTE CONDENSOR 3





REMOTE CONDENSOR 4









































































REMOTE CONDENSOR 5





REMOTE CONDENSOR 6





REMOTE CONDENSOR 7









































































REFRIGERANT TYPE









































































































R22





R404A





R422D





R422A





R134A





R407A





OTHER





























































FULL CHARGE













































































































LBS.





OZS.































































































CHARGE METHOD









































































































ACTUAL





RECEIVER CACULATION





ON SITE MEASUREMENT











































































TEMPERATURE











































































































LOW TEMP.





MEDIUM TEMP.































































































MANUFACTURER NAME







































































































HILL PHOENIX





KYSOR





TYLER





SYSTEMATIC





ZERO ZONE



































































OTHER





































































































MODEL #







































































SERIAL #































































































































































































RACK LETTER











































































































A





B





C





D





E





F





G





REMOTE CONDENSOR
1































































REMOTE CONDENSOR 2





REMOTE CONDENSOR 3





REMOTE CONDENSOR 4









































































REMOTE CONDENSOR 5





REMOTE CONDENSOR 6





REMOTE CONDENSOR 7









































































REFRIGERANT TYPE









































































































R22





R404A





R422D





R422A





R134A





R407A





OTHER





























































FULL CHARGE


















































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LBS.





OZS.































































































CHARGE METHOD









































































































ACTUAL





RECEIVER CACULATION





ON SITE MEASUREMENT











































































TEMPERATURE











































































































LOW TEMP.





MEDIUM TEMP.































































































MANUFACTURER NAME







































































































HILL PHOENIX





KYSOR





TYLER





SYSTEMATIC





ZERO ZONE



































































OTHER





































































































MODEL #







































































SERIAL #














































































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CONTRACTOR'S RECORD LETTER OF CONFORMANCE

SECTION 15600


REFRIGERATION SYSTEMS

Project Location:



Date:



(City & State)













Project Number:




Store Number:





Statement of Conformance:

This Record Letter of Conformance is provided as a Record Document in accordance with Section 01770


Contract
Closeout.
The undersigned hereby declares that the Refrigeration Systems

(hereafter referred to as the “Systems”) is installed
and is in general conformance with the Contract Documents, applicable Codes, and shop drawings. The “Systems” have been
provided and placed

in operational condition in accordance with the manufacturer's published instructions and the Contract
Documents. To

be accepted, all signatures must be original ink signatures (copies are not allowed).


____________


(Contractor Signature)


____________


Phone Number: ( )


(Contractor name and address)


Recommendation of Acceptance:

This Recommendation of Acceptance is provided as a Record Document in accordance with Section 01770


Contract
Closeout.
We recommend Wal
-
Mart accept the installation
of
the “Systems” (as referenced above)
. The “Systems” are found
to be in
general conformance with the Contract Documents, and Approved Drawings
.
This recommendation is based on MEP
Site Observation and Functional Performance Test witnessed on _____________
_____
_ (
Report Date),
and follow

up
verification of identified issues conducted on ___________________ (Trip Date, Report Date).


While this review is an integral part of this project, it does not relieve the Contractor of their responsibility to comply
with
the applicable provisions of the Contract Documents along with the mandated codes and standards. These examinations shall
not be construed as a check of every item nor does it prevent authorities from hereafter requiring corrections of errors in p
lans

or installation.

WAL
-
MART’S MECHANICAL CONSULTANT:




(Wal
-
Mart’s Mechanical Consultant
Signature)




Phone Number: ( )


(Wal
-
Mart’s Mechanical Consultant name and address)



Subscribed and sworn before me this


day of


, 20

.



Notary Public:




My Commission Expires:




[SEAL] (Render Seal visible for copying)