MODEL YST UNITS MANUFACTURED AFTER DECEMBER 2006

Transcription

1 STEAM TURBINE CENTRIFUGAL LIQUID CHILLERS INSTALLATION INSTRUCTIONS Supersedes: N2 (1109) Form N2 (114) MODEL YST UNITS MANUFACTURED AFTER DECEMBER 2006 LD12189 Issue Date: January 10, 2014

2 IMPORTANT! READ BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During installation, operation maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated, as well as severe personal injury or death to themselves and people at the site. This document is intended for use by owner-authorized operating/service personnel. It is expected that these individuals possess independent training that will enable them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced materials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question. SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations: Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken. Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution if proper care is not taken or instructions and are not followed. Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment if proper care is not taken. Highlights additional information useful to the technician in completing the work being performed properly. External wiring, unless specified as an optional connection in the manufacturer s product line, is not to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with Johnson Controls published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of improper control signals. Failure to follow this warning will void the manufacturer s warranty and cause serious damage to property or personal injury. 2 JOHNSON CONTROLS

3 CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement, the information contained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office or accessing the Johnson Controls QuickLIT website at Operating/service personnel maintain responsibility for the applicability of these documents to the equipment. If there is any question regarding the applicability of these documents, the technician should verify whether the equipment has been modified and if current literature is available from the owner of the equipment prior to performing any work on the chiller. CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made. These revisions are to technical information and any other changes in spelling, grammar or formatting are not included. ASSOCIATED LITERATURE MANUAL DESCRIPTION Operation & Maintenance Wiring Diagram - Model YST - Field Control Modifications Wiring Diagram - Model YST - Floor Mounted Steam Condenser Wiring Diagram - Model YST - Top Mounted Steam Condenser Wiring Diagram- Model YST Renewal Parts - Unit Components Renewal Parts - Controls and Instrumentation Engineering Guide FORM NUMBER O PW PW PW PW RP RP EG1 JOHNSON CONTROLS 3

4 Chiller Model Evaporator Code NOMENCLATURE The model number denotes the following characteristics of the unit. YST VF VD J4 - KD C - F S Special (Mandatory) Design Level Steam Condenser Model Condenser Code Compressor Code Turbine Expansion Ratio No. of Turbine Nozzels Steam Turbine Base Model 4 JOHNSON CONTROLS

5 TABLE OF CONTENTS SECTION 1 - INTRODUCTION...9 Field Assembled Units...9 Inspection - Damage - Shortage...9 Shipment...9 Turbine Bearing Disassembly To Remove Mylar Shipping Film...12 Flow Rates...12 Chilled Water...13 Refrigerant Condenser Water Circuit...13 Steam Condenser Package...13 Floor Mounted Steam Condenser (Optional)...13 Steam Turbine Casing Drain Options...13 Remote Steam Turbine Gaugeboard (Optional - Field Installed)...14 Chiller Data Plate...14 Location...14 Clearance...14 Installation Check - Request For Start-Up Service...14 SECTION 2 - RIGGING...15 Chiller Rigging - (Less Surface Condenser)...15 Steam Condenser Package Rigging...17 Rigging Unit To Final Location...17 Locating And Installing Isolator Pads...17 Checking The Isolation Pad Deflection...17 Leveling The Unit...17 SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS...19 Customer Components...19 Steam Inlet Strainer...19 Steam Inlet Moisture Separator...19 Steam Inlet Block Valve...19 Steam Turbine Casing Drain...19 Permanent Strainers...19 Stop Valves...19 Drain and Vent Valves...19 SECTION 4 - CUSTOMER PIPING...21 Customer Piping Requirements...21 Pressure Powered Pump...21 Piping Connections - Water/Drains...21 Piping Connections - Steam/Vents...21 Steam Condenser Vacuum Pump Seal Water...21 Steam Condenser Relief Valve Seal Water...21 Piping Connections - Refrigerant Vents...21 Air (Instrument Quality Air Source - ISA S7.3)...22 Steam And Condensate Piping...22 Steam Piping...22 JOHNSON CONTROLS 5

6 TABLE OF CONTENTS (CONT'D) Governor Valve And Spool Piece (Factory Supplied - Field Installed)...23 Top-Mounted Steam Condenser (Factory Supplied - Field Installed)...23 Expansion Joint Installation (Factory Supplied - Field Installed)...25 Design Data...25 Inlet Steam Temperature Sensor and Inlet Steam Pressure Transducer (Factory Supplied-Field Installed).26 Pipe Strain Testing...28 Steam Piping Recommended Blow-Down Procedure...29 Gland Seal Leak-Off Piping...30 Gland Leak-Off Condenser (Optional)...30 Steam Ring Drain...31 Steam Turbine Casing Drains...31 Pressure Powered Pump...31 Steam Relief...32 Steam Condenser Package Hydrostatic Test...32 Refrigerant Relief Piping...33 SECTION 5 - DRIVELINE ALIGNMENT...37 Alignment...37 Checking For Sag...39 Coupling Spacer Installation...40 SECTION 6 - FIELD INSTALLED WIRING...41 Power Wiring...41 Turbine Instruments...41 KD Turbine...41 KG Turbine...41 Steam Condenser Wiring Kit (Optional Floor Mounted Steam Condenser) JOHNSON CONTROLS

7 LIST OF FIGURES FIGURE 1 - Model YST Chiller...10 FIGURE 2 - Optional Turbine Gaugeboard Connections...14 FIGURE 3 - Rigging...15 FIGURE 4 - Steam Condenser Package Rigging...16 FIGURE 5 - Neoprene Isolators...18 FIGURE 6 - Steam Condenser...24 FIGURE 7 - Turbine Exhaust Expansion Joint Connector...26 FIGURE 8 - KD Turbine Field Installed Components...27 FIGURE 9 - KG Turbine Field Installed Components...27 FIGURE 10 - Pipe Strain...29 FIGURE 11 - Automatic Pressure Powered Pump...32 FIGURE 12 - Typical Refrigerant Vent Piping...33 FIGURE 13 - Typical Piping Arrangement...34 FIGURE 14 - Typical Arrangement For "Face - O.D." Readings To Determine Cold Alignment Of Shafts FIGURE 15 - Measuring "Sag" Of Indicator/Clamp System...39 FIGURE 16 - Typical "Reverse Indicator" To Determine Cold Alignment Of Shafts...39 FIGURE 17 - Coupling Shim Placement...40 FIGURE 18 - Governor Valve And Spool Piece...42 FIGURE 19 - Din Connector Wiring...42 JOHNSON CONTROLS 7

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9 This instruction describes the installation of the YORK Model YST Centrifugal Liquid Chiller Unit. This unit is completely factory-packaged including; the evaporator, refrigerant condenser, compressor, steam turbine, lubrication systems, power panel, control center, and all interconnecting unit piping and wiring. The steam condenser package is shipped separately and suitable for direct mounting onto the chiller or mounting along side the chiller. Refrigerant and oil charges shipped separately unless optional refrigerant condenser isolation valves and Form 1 shipment are ordered. Chillers shipped dismantled MUST be field assembled under the supervision of a Johnson Controls representative, but otherwise installation will be as described in this instruction. FIELD ASSEMBLED UNITS A Johnson Controls representative must be used to check the installation, supervise the initial start-up and operation of all chillers installed within Continental United States. The Johnson Controls Warranty may be voided if the following restrictions are not adhered to: 1. No valves or connections should be opened under any circumstances because such action will result in loss of the factory nitrogen charge. 2. Do not dismantle or open the chiller for any reason except under the supervision of a Johnson Controls representative. 3. When units are shipped dismantled, notify the nearest Johnson Controls office in ample time for Johnson Controls representative to supervise rigging the unit to its operating position and the assembly of components. 4. Do not make final power supply connections to the power panel. 5. Do not charge the compressor with oil. 6. Do not charge the unit with refrigerant. 7. Do not attempt to start the system. 8. Do not run hot water (110 F / 43 C max) or steam through the evaporator or refrigerant condenser at any time. SECTION 1 - INTRODUCTION INSPECTION - DAMAGE - SHORTAGE The unit shipment should be checked on arrival to see that all major pieces, boxes and crates are received. Each unit should be checked on the trailer or rail car when received, before unloading, for any visible signs of damage. Any damage or signs of possible damage must be reported to the transportation company immediately for their inspection. JOHNSON CONTROLS will not be responsible for any damage in shipment or at job site or loss of parts. (Refer to shipping damage claims, form NM) When received at the job site all containers should be opened and contents checked against the packing list. Any material shortage should be reported to YORK immediately. SHIPMENT Units shipped dismantled MUST be reassembled by, or under the supervision of, a Johnson Controls representative. The chiller may be ordered and shipped in any of the following forms: Form 1 - Factory Assembled Unit. (steam condenser package shipped separately) refrigerant and oil are factory charged. 1. The compressor/turbine driveline assembly mounted, with all necessary interconnecting piping assembled. OptiView Control Center is mounted on the unit. Complete unit factory leak tested, evacuated and charged with R-134a. 2. Miscellaneous material - Partial pre-fabricated steam exhaust piping and four (4) neoprene isolation pads. Form 2 - Factory Assembled Unit. (steam condenser package shipped separately.) Refrigerant and oil charges shipped separately. 1 JOHNSON CONTROLS 9

10 SECTION 1 - INTRODUCTION STEAM TURBINE VACUUM BREAKER SOLENOID VALVE STEAM CONDENSER PACKAGE TURBINE OIL COOLING WATER INLET VALVE CONDENSER HOT GAS BYPASS VALVE EVAPORATOR CONTROL CENTER POWER PANEL TURBINE BOX COMPRESSOR OIL COOLING WATER INLET VALVE COMPRESSOR NOTE: KD Turbine shown LD12215 Figure 1 - MODEL YST CHILLER 10 JOHNSON CONTROLS

11 SECTION 1 - INTRODUCTION ATMOSPHERIC RELIEF VALVE STEAM CONDENSER PACKAGE CONDENSATE OVERBOARD VALVE CONDENSATE RECIRCULATION VALVE HOTWELL CONDENSATE PUMP #1 120/460VAC JUNCTION BOX HOTWELL CONDENSATE PUMP #2 (OPTIONAL) VACUUM PUMP #1 HOTWELL CONDENSATE LEVEL VACUUM PUMP #2 INDICATOR / TRANSMITTER VACUUM PUMP #2 SEALING WATER SOLENOID VALVE VACUUM PUMP #2 SEALING WATER FLOW SWITCH LD12216 FIGURE 1 MODEL YST CHILLER (CONT'D) JOHNSON CONTROLS 11

12 SECTION 1 - INTRODUCTION 1. The compressor/turbine driveline assembly mounted, with all necessary interconnecting piping assembled. OptiView Control Center is mounted on the unit. Complete unit factory leak tested, evacuated and charged with holding charge of nitrogen. 2. Miscellaneous material - Partial pre-fabricated steam exhaust piping and four (4) neoprene isolation pads. Form 3 - The compressor/turbine driveline assembly is separate from the shells - Shipped as three major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. The compressor/turbine driveline assembly is removed from the shells and skidded. Evaporator/Refrigerant Condenser is not skidded. The Steam Condenser package is shipped separately. All wiring integral with compressor is left on it, and all conduit is left on shell. Turbine lube system/piping remains on the driveline skid. All openings on compressor, oil separator, and shells are closed and charged with dry nitrogen (2 to 3 PSIG) (14-21kPa). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, etc.; refrigerant charge shipped separately. Partial pre-fabricated steam exhaust piping and neoprene isolation pads are shipped loose. Form 7 - Split Shells - Shipped as four major assemblies. Unit first factory assembled, refrigerant piped, wired and leak tested; then dismantled for shipment. Compressor/turbine driveline assembly removed from shells and skidded. The Steam Condenser package is shipped separately. Evaporator and refrigerant condenser shells are separated at tube sheets and are not skidded. Refrigerant lines between shells are flanged and capped, requiring no welding. All wiring integral with compressor is left on it. All wiring harnesses on shells are removed. Turbine lube system/piping remains on driveline skid. All openings on compressor and shells are closed and charged with dry nitrogen (2 to 3 PSIG) (14-21kPa). Miscellaneous packaging of control center, tubing, water temperature controls, wiring, oil, etc; refrigerant charge shipped separately. Partial pre-fabricated steam exhaust piping and neoprene isolation pads are shipped loose. When more than one chiller is involved, the major parts of each unit will be marked to prevent mixing of assemblies. Both shells and driveline for a specific unit will be marked with the sales order and alphabetic letter for identification. For example; order number A, both shells and driveline will be painted with the identification A. The next set of shells and driveline will have the sales order with letter B, such as B. TURBINE BEARING DISASSEMBLY TO REMOVE MYLAR SHIPPING FILM Mylar shipping film must be removed from bearings before any attempts are made to rotate turbine shaft. The Murray turbine will be shipped with a Mylar shipping film between the top bearing assembly and the turbine shaft on both ends of the turbine. This Mylar film should be removed from both capsules before any attempts are made to rotate the turbine shaft. The bearing housing and bearing top cap will have to be removed in order to remove the Mylar film. Care must be taken during the removal of the mylar film to protect the vibration probes (if supplied), temperature sensors, and other electrical connections that are present on the bearing housings. When re-assembling the bearing housing components, a sealant equal to Tite Seal joint sealing compound or Permatex Hylomar HPF product will properly seal the split line of the bearing capsule. FLOW RATES For normal water chilling duty, evaporator and refrigerant condenser flow rates are permitted at water velocity levels in the heat exchangers tubes between 3 ft/ sec and 12 ft/sec (0.9 m/s and 3.7 m/s). Variable flow applications are possible, however, chiller selections must be made using a water velocity within the range noted above. Variable flow in the refrigerant condenser is not recommended, as it generally raises the energy consumption of the system by keeping the refrigerant condenser pressure high in the chiller. Additionally, the rate of fouling in the refrigerant and steam condensers will increase at lower water velocities associated with variable flow, raising system maintenance costs. Cooling towers typically have narrow ranges of operation with respect to flow rates and will be more effective with full design flow. 12 JOHNSON CONTROLS

13 SECTION 1 - INTRODUCTION CHILLED WATER Foreign objects which could lodge in, or block flow through the evaporator and refrigerant condenser tubes must be kept out of the water circuit. All water piping must be cleaned or flushed before being connected to the chiller, or other equipment. Thermal type water flow switches are factory mounted in the chilled and condensed water nozzles and are factory wired to the OptiView control panel. These solid-state flow sensors have a small internal heating element and use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established. REFRIGERANT CONDENSER WATER CIRCUIT The chiller is engineered for maximum efficiency at both design and part load operation by taking advantage of the colder cooling tower water temperatures which naturally occur during the winter months. Appreciable power savings are realized from these reduced heads. The minimum entering refrigerant condenser water temperature for other full and part load conditions is provided by the following equation: Min. ECWT = LCHWT - C RANGE + 17 F Min. ECWT = LCHWT - C RANGE C where: ECWT = Entering refrigerant Condensing Water Temperature. LCHWT = Leaving Chilled Water Temperature CONTROL RANGE = refrigerant condensing water temperature range at the given load condition. At initial startup, entering condensing water temperature may be as much as 25 F (14 C) colder than the standby chilled water temperature as long as it is above the minimum ECWT allowed. STEAM CONDENSER PACKAGE The Steam Condenser package is shipped separately as a packaged assembly. The Steam Condenser package consists of a skid mounted surface condenser with pre-piped accessories for the condensate and vacuum systems. The atmospheric relief valve is shipped loose for field assembly. The Steam Condenser package shipment should be checked on arrival to see that all major pieces, boxes and crates are received. Each Steam Condenser package should be checked on the trailer or rail car when received, before unloading, for any visible signs of damage. Any damage or signs of possible damage must be reported to the transportation company immediately for their inspection. When the optional factory piping kit is ordered for the steam exhaust trunk, lifting lugs are provided loose with the piping to be located and welded at the job site, in a suitable location to enable the rigging of the major piping assemblies. The optional piping kit is provided as partial pre-fabricated to be final trimmed/fitted and welded at the site. Welding back-up rings are provided with the piping kit. FLOOR MOUNTED STEAM CONDENSER (Optional) As an alternative to the standard YST arrangement, the steam condenser package can be ordered for floor mounting adjacent to the chiller package. Prefabricated piping kits for the steam trunk, and water piping between chiller package and steam condenser are not included with a floor mounted arrangement. These interconnecting components must be designed, supplied and installed by others. An optional piping kit may be ordered from the factory when the original equipment is placed. External piping loads to the steam inlet and water box connections should be minimized. Allowable nozzle loads are available upon request if any concerns develop. STEAM TURBINE CASING DRAIN OPTIONS The steam turbine casing must be provided with a means of draining during operation (while under vacuum). Factory available options are: Automatic pressure powered pump (standard option) Manual condensate drain tank (by special quote) Automatic condensate drain tank (by special quote) When the factory casing drain option is supplied, the equipment is shipped loose for installation at the jobsite. 1 JOHNSON CONTROLS 13

14 SECTION 1 - INTRODUCTION REMOTE STEAM TURBINE GAUGEBOARD (Optional - Field Installed) A remote steam turbine gaugeboard can be purchased. When required, the remote turbine gaugeboard will be mounted on a freestanding station. The gaugeboard is provided with three pressure gauges (steam inlet, nozzle ring, and exhaust) and a tachometer. The remote gaugeboard is shipped loose for installation at the job site. All the piping between the instrumentation on the gaugeboard and turbine shall be provided and installed by others. Stainless steel is recommended (see Figure 2 on page 14). The inlet steam pressure gauge connection is located in the pipe tee of the inlet steam pressure transmitter. The transmitter is shipped loose for installation at the job site in the customer supplied inlet steam line upstream of the governor valve (see Figure 17 on page 40). The tachometer is shipped in a separate kit and must be installed on the gaugeboard and wired to the chiller control panel. Refer to Form PW2. Chiller Data Plate A unit data plate is mounted on the control center assembly of each unit, showing unit model number, design working pressure, water passes, refrigerant charge, and serial numbers. Location YORK Chillers are furnished with neoprene vibration isolator mounts for basement or ground level installations (see Figure 5 on page 18). Units may be located on upper floor levels providing the floor is capable of supporting the total unit operating weight. Clearance Sufficient clearance to permit normal service and maintenance work should be provided all around and above the unit. Additional space should be provided at one end of the unit to permit tube removal, cleaning of evaporator, refrigerant condenser and steam condenser tubes, as required. A doorway or other properly located opening may be used Figure 2 - OPTIONAL TURBINE GAUGEBOARD CONNECTIONS INSTALLATION CHECK - REQUEST FOR START-UP SERVICE LD12217 To avoid possible equipment damage and to ensure warranty coverage, a Johnson Controls representative must verify the installation and supervise the initial startup and operation on all chillers installed within the Continental United States. After the unit is installed, piped and wired as described in this Instruction, but before any attempt is made to start the unit, the Johnson Controls District Office should be advised so that the start-up service can be scheduled. If necessary, the condenser and accessory items may be separated from the skid base. Disconnect bolting, piping and wiring as required. 14 JOHNSON CONTROLS

15 SECTION 2 - RIGGING 2 Refer to Engineering Guide EG1 for dimensions and Base Unit weights. Figure 3 - RIGGING LD09288a To prevent equipment damage, a Johnson Controls representative must verify the installation prior to the unit being started, and supervise the initial startup and operation on the chiller. The chiller package and Steam Condenser package must be rigged separately. Never attempt to rig the entire YST package with the Steam Condenser chiller installed. The Steam Condenser package must be mounted on the chiller after the chiller package has been installed in its final location. Units shipped dismantled should be assembled under the supervision of a Johnson Controls representative. CHILLER RIGGING - (LESS SURFACE CONDENSER) The complete standard chiller is shipped without skids. When optional skids are used it may be necessary to remove the skids so riggers skates can be used under the unit end sheets to reduce overall height. Each unit has four (4) lifting holes (two in each end) in the end sheets which should be used to lift the unit. Care should be taken at all times during rigging and handling of the chiller to avoid damage to the unit and its external connections. Lift the unit only using spreader bars and the holes in the endsheets as shown in Figure 3. The rigging and operating weights and dimensions are provided in the enginering guide Form EG1. Add 6 (15 cm) to overall height for optional skidded unit. Do NOT lift the unit with slings around compressor or by means of eye bolts in the tapped holes of the compressor. Do NOT turn a unit on its side for rigging. Do NOT rig vertically without factory supplied vertical rigging option. JOHNSON CONTROLS 15

16 SECTION 2 - RIGGING Figure 4 - STEAM CONDENSER PACKAGE RIGGING LD JOHNSON CONTROLS

17 SECTION 2 - RIGGING STEAM CONDENSER PACKAGE RIGGING Lifting lugs are provided at the four corners of the structural steel skid, and lifting eyes are provided on the condenser shell. Use chains or equalizing cables and spreader bars, as necessary, to prevent contact with the piped accessories. See Figure 4 on page 16 for Steam Condenser package rigging recommendations. All lifting should be performed slowly with frequent inspection from level. All lifting should be performed slowly with frequent inspection of cables or chains which may apply pressure on piping or accessories. The condenser skid can be lifted or moved with forklift trucks. Keep load bearing surfaces isolated on the structural steel only. The chiller package and Steam Condenser package must be rigged separately. Never attempt to rig the entire YST package with the Steam Condenser chiller installed. The Steam Condenser package must be mounted on the chiller after the chiller package has been installed in its final location. RIGGING UNIT TO FINAL LOCATION Rig the chiller package to its final location on the floor or mounting pad, lift the unit (or shell assembly) by means of an over head lift and lower the unit to its mounting position. If optional shipping skids are used, remove them before lowering the chiller to its mounting position. LOCATING AND INSTALLING ISOLATOR PADS The isolator pad mounts are to be located as shown in Figure 5 on page 18. After the isolator pads have been placed into position on the floor, lower the chiller onto the pads. When the unit is in place, remove the rigging equipment and check that the unit is level. The unit should be level within 1/4 (6 mm) from one end to the other end and from front to the rear. If the chiller is not level within the amount specified, lift it and place shims between the isolation pad and the chiller tube sheets. Shims are included with the isolator kit. Lower unit again and recheck to see that it is level. CHECKING THE ISOLATION PAD DEFLECTION All isolation pads should be checked for the proper deflection while checking to see if the unit is level. Each pad should be deflected approximately 0.10 inches (2.5 mm) to 0.20 inches (5 mm). If an isolation pad is un der deflected, shims should be placed between the unit tube sheet and the top of the pad to equally deflect all pads. LEVELING THE UNIT The longitudinal alignment of the unit should be checked by placing a level on the top center of the evaporator shell under the compressor assembly. Transverse alignment should be checked by placing a level on top of the shell tube sheets. After the Steam Condenser package has been installed in place, care should be taken in leveling the condenser package, shimming at the skid/tubesheet, if necessary. 2 JOHNSON CONTROLS 17

18 SECTION 2 - RIGGING LD12218 LD12219 UNIT WEIGHT 28,836 to 53,530 LBS. (13,108 to 24,332 Kgs.) UNIT WEIGHT 53,531 to 100,464 LBS. (24,333 to 45,666 Kgs.) UNIT WEIGHT 100,465 to 130,000 LBS. 45,667 to 58,967 LD12220 See YORK standard arrangement drawings for floor layout of Neoprene Isolators by model. Figure 5 - NEOPRENE ISOLATORS 18 JOHNSON CONTROLS

19 SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS CUSTOMER COMPONENTS Steam Inlet Strainer Full flow strainer with fine [3/64 (1.2 mm) perforations], stainless steel mesh, suitable for steam service. Steam Inlet Moisture Separator Steam supply to turbine must be dry & saturated for optimum efficiency, and to help prevent damage to turbine and/or governor valve. Steam Inlet Block Valve Manual globe valve for inlet steam isolation. Steam Turbine Casing Drain The steam turbine casing must be provided with a means of draining during operation (while under vacuum). Available factory options for this function are an automatic pressure powered pump, a manual condensate drain tank or an automatic condensate drain tank. A connection is provided on the steam condenser hotwell for customer connection of the casing drain equipment outlet, i.e. condensate outlet of automatic pressure powered pump, or drain tank may be piped to the steam condenser hotwell (piping by others). Never pipe turbine casing drain directly to the steam condenser hotwell. Turbine casing drains by gravity only and must be pumped to steam condenser hotwell by means of condensate handling equipment. An automatic pressure powered pump is factory supplied when the system autostart option is ordered. Permanent Strainers Permanent strainers are recommended in both the evaporator and refrigerant condenser water circuits to protect the chiller as well as the pumps, tower spray nozzles, chilled water coils and controls, etc. The strainer must be installed in the entering chilled water line, directly up stream of the chiller. Water piping circuits should be arranged so that the pumps discharge through the chiller, and should be controlled as necessary to maintain essentially constant chilled and refrigerant condenser water flows through the unit at all load conditions. If pumps discharge through the chiller, the strainer may be located upstream from pumps to protect both pump and chiller. (Piping between strainer, pump and chiller must be very carefully cleaned before start-up.) If pumps are remotely installed from chiller, strainers should be located directly upstream of the chiller. Stop Valves Stop valves may be installed in the evaporator and refrigerant condenser water piping adjacent to the unit to facilitate maintenance. Thermometer wells and pressure taps should be provided in the piping as close to the unit as possible to facilitate operational check. Drain and Vent Valves Drain and vent valves should be installed in the connections provided in the evaporator and refrigerant condenser water boxes. These connections may be piped to drain if desired. 3 JOHNSON CONTROLS 19

20 SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS THIS PAGE INTENTIONALLY LEFT BLANK 20 JOHNSON CONTROLS

21 SECTION 4 - CUSTOMER PIPING CUSTOMER PIPING REQUIREMENTS After the unit is leveled the piping connections may be made. The piping should be arranged with offsets for flexibility, and adequately supported and braced in dependently of the unit to avoid strain on the unit and vibration transmission. Hangers must allow for alignment of pipe. Isolators (by others) in the piping and hangers are highly desirable, and may be required by specifications, in order to effectively utilize the vibration isolation characteristics of the vibration isolation mounts of the unit. PRESSURE POWERED PUMP Referance Figure 11 on page 32 Inlet Motive Pressure Vent to Turbine Exhast Piping Turbine Casing Drain Hotwell Connection or Drain PIPING CONNECTIONS - WATER/DRAINS Reference Figure 12 on page 33 for typical piping arrangement Refrigerant condenser inlet/outlet** Evaporator inlet/outlet Turbine/Compressor cooling water manifold inlet/ outlet and piping drains Steam condenser inlet**/outlet Steam condenser vacuum pump seal water: 3.5gpm (0.2 approx. 60 F (15.6 C) Steam condenser vacuum pump seal water discharge separator drain Steam condenser relief valve seal water: trickle flow Steam condenser relief valve seal water drain Steam turbine casing drain Steam turbine gland leak off drain. Steam turbine steam ring drain Steam condenser condensate overboard valve Approximately 20 psig (138kPa) discharge pre sure available at outlet of overboard valve. If down stream pressure requirements exceed this, a custom condensate pump selection is required. Steam condenser hotwell level system drain Water box drains - evaporator, refrigerant condenser and steam condenser. PIPING CONNECTIONS - STEAM/VENTS Steam turbine steam inlet Steam turbine steam exhaust** Steam condenser steam inlet** Steam condenser relief valve vent Steam Condenser Vacuum Pump Seal Water The vacuum pump discharge separator drain can either be piped to sewer or be piped to a holding tank for use as tower make-up water. The approximate flow rate will be 3.5 gpm from the vacuum pump seal water supply. Steam Condenser Relief Valve Seal Water The steam condenser relief valve seal water drain can either be piped to sewer or piped to a holding tank for use as tower make-up water. The approximate flow rate is a freshwater trickle flow that is adjusted by a manual valve to seal the relief valve. Piping Connections - Refrigerant Vents Refrigerant condenser relief valves(s) Evaporator relief valve(s) ** YORK provided pre-fabricated piping for these connections. **York provided pre-fabricated piping for these connections. 4 JOHNSON CONTROLS 21

22 SECTION 4 - CUSTOMER PIPING Air (Instrument Quality Air Source - ISA S7.3) Bearing seal air purge and governor valve positioner: psig ( kPa), approx. 13 SCFM (22 sm3/h). Steam condenser level control system: psig ( kPa), approx. 0.5 SCFM (0.9 sm3/h). Trip and steam control: psig ( kPa), approx. 0.4 SCFM (0.7 sm3/h). STEAM AND CONDENSATE PIPING A suitable piping arrangement with flexible type joints and piping supports/ hangers, as required, must be provided for the steam inlet line to the turbine. It is recommended that a piping analysis be performed by a qualified engineer to verify the design adequately protects the steam turbine from excessive strains due to system/thermal loads. Maximum allowable loads on steam connections are governed by NEMA SM23 Steam Turbines for Mechanical Drive Services. STEAM PIPING Inlet and exhaust piping for the steam turbine should be designed and installed by knowledgeable persons experienced in turbine work. The size of steam inlet line is based upon velocities in the piping generally accepted as being good practice for runs of straight pipe up to 200 feet, or the equivalent in valves and fittings. The piping contractor must ensure that the steam supply is available at the turbine flange at the temperature and pressure required to achieve the design capacity of the chiller. Johnson Controls assumes no responsibility in regard to pressure or temperature drops. The performance of the turbine specified is based upon the inlet pressure and temperature as measured at the turbine steam inlet flange. Steam inlet piping for the standard YST condensing turbines should include a full-size block valve in the main steam inlet line. Exhaust piping is available as an optional kit for field installation. A relief valve to protect the turbine exhaust casing and surface condenser is provided on the steam condenser package for standard YST chillers. Piping for special back pressure turbines should include a throttle valve in the steam inlet line and a stop valve in the exhaust line. A suitable relief valve to protect the turbine exhaust casing must be provided between the turbine exhaust flange and the exhaust stop valve. The exhaust relief valve or the rupture disc should correspond in size to those indicated for steam and exhaust lines found in APPENDIX-A of NEMA SM 23-8, Steam Piping Systems manual. These relief valves serve to protect the turbine casing against over-pressurization in case the turbine is started with the exhaust valve closed or the backpressure rises for any reason during operation. The relief valve should be of sufficient capacity to relieve the rated steam flow of the turbine at the maximum operating pressure specified when all hand valves are Contact YORK Factory Service for specifications on sizing the valve, relieving capacity, and over-pressurization limits. Steam inlet and exhaust piping (if not supplied by YORK) must be properly designed and supported so that its weight and thermal expansion will not produce excessive strains on the turbine inlet or exhaust flanges, either when cold or when at normal operating temperature. The piping must be designed so that it does not have to be sprung into position for bolting to the turbine flanges when cold. Likewise, the piping must not be spring out of position when everything is at running temperature. Force due to thermal expansion must be accounted for, which can cause misalignment. Refer to NEMA SM 23, Part 8 (Steam Piping Systems) for additional information. 22 JOHNSON CONTROLS

23 SECTION 4 - CUSTOMER PIPING Factory supplied STANDARD steam exhaust piping does NOT require additional support or pipe hangers. Moisture in the inlet steam not only increases the steam consumption but causes rapid wear of the valve seats, nozzles and turbine blades. A moisture separator and steam trap must be installed at the low point of the inlet piping to ensure that the turbine receives dry steam. Where exhaust piping bends upward after leaving the turbine, steam traps must be provided to keep the exhaust line drained to prevent water from building up in the exhaust pipe and turbine casing. Failure to keep the exhaust line drained may result in a restriction in the exhaust line, causing a loss of power and damage to the turbine rotor. Connecting the steam line should always begin at the header or other source, the turbine connection being made last. If an expansion joint is used in either line it must be securely anchored to prevent axial strain on the turbine. Be sure to blowout and clean all steam lines before connecting to the turbine. Failure to do so may result in damage to the steam strainer screen and other internal parts. Johnson Controls accepts no responsibility for damage resulting from the entrance of foreign materials (refer to the procedure covered in this manual). Steam inlet connection must be loosened during the pipe strain testing procedure described in this section GOVERNOR VALVE AND SPOOL PIECE (Factory Supplied - Field Installed) The factory supplied field installed spool piece and governor valve must be supported along with the rest of the steam supply piping. It is the installer's/installing contractor's responsibility to ensure the steam supply pip opened. ing, field installed governor valve, and field installed spool piece are fully supported so that there are no forces acting on the turbine steam supply connection point (refer to NEMA SM 23, part 8) when the steam supply piping is installed, or operated at design temperature. The governor valve and spool piece must not be suported from the turbine base. The governor valve and spool piece must NOT be supported from the turbine base. Any external force or moment exerted on the turbine may lead to drive line misalignment and subsequent turbine and/ or compressor failure. TOP-MOUNTED STEAM CONDENSER (Factory Supplied - Field Installed) To locate the steam condenser package, the steam condenser water inlet must be aligned with the refrigerant condenser water outlet, before attaching the mounting brackets. Refer to the Steam Condenser Field Kit Drawing and associated Field Notes included in the job manual for detailed installation instructions. See Figure 6 on page Complete the water line between the (2) connections before bolting the angles to the steam condenser base, and welding the angles to the refrigerant condenser tube sheet. See Figure 6 on page Condenser water outlet to steam condenser may be at either end of unit. When required, victaulic couplings are not YORK factory supplied. 3. Partial prefabricated pipe caps or covers are factory supplied to provide reasonable protection of internally blasted surfaces. Note: brush off blasting may be required prior to field assembly. 4. Proper handling and storage of prefab piping at the job site is essential in providing proper protection for the internally blasted surfaces. Piping should be unloaded by overhead lifting devices. Note: Do not drag or damage to caps may occur. 5. Prefabricated piping should not be stored outdoors. If stored outside. The piping must be covered with a waterproof tarp, and not directly exposed to the weather. Pipe must not be stood on end, any and all damage to caps or closures must be repaired immediately. 4 JOHNSON CONTROLS 23

24 SECTION 4 - CUSTOMER PIPING 6. The installing contractor must inspect the steam exhaust expansion joint (YORK supplied) prior to installation to verify that the tie rod nuts are set to allow zero compression in the axial direction. 7. All finish painting. Touching up or special painting to be done in field 8. All applicable state, county, city and local laws, rules and regulations pertaining to construction, installation and inspection of steam and water piping shall beconformed to. 9. Installing contractor is responsible for fit and form of turbine steam and condenser water piping shown. Unnecessary strain on turbine and condenser nozzles must be avoided. Figure 6 - STEAM CONDENSER 24 JOHNSON CONTROLS

25 SECTION 4 - CUSTOMER PIPING EXPANSION JOINT INSTALLATION (Factory Supplied - Field Installed) 1. The as-shipped expansion joint, with the tackwelded shipping brackets attached, defines the zero-referance point for as-installed tolerances. Therefore, the shipping brackets should be left on the expansion joint during installation, and only removed after the mating piping is fully assembled and meets the as-installed tolerances. 2. As-installed tolerances: Radial alignment: During installation, the flange must not be forced more than 1/16" radially to line up with the mating piping flange. Axial Length, Flange face to flange face: Nominal Axial length +0.25"/-0.50" Parallelism: The flange faces shall be no greater than +/- 1/8" out of parallel, I.E., Two overall length measurements taken 180 apart from each other at the outside diameter of the overall length measurements take 180 apart from each other at the outside diameter of the flanges shall not differ by more than 0.25" 3. Provided the as-installed tolerances noted above are met, the tie rods nuts can be adjusted to ensure there are no residual stresses on the steam trunk piping when the chiller unit is fully assembled. DO NOT Over-tighten Nuts. Tie rods should be able to be rotated. Note that no gap exists between washers and flange Axial compressor and expansion of the flange is ZERO. 4. Nuts are tack-welded once connector is correctly field-installed per instructions. Design Data Axial Compression: NONE Axial Extension: NONE Lateral Deflection: 1/8" Angular Rotation: NONE Installation Tolerances: Radial: + 1/16" Axial: +1/4", -1/2" Parallelism: + 1/8" Refer to the installation drawing included with the factory supplied expansion joint (top-mounted surface condensers) for detailed installation notes and installation tolerances. Shipping brackets should be left on the expansion joint during installation, and ONLY removed after the mating piping is fully assembled and meets the as-installed tolerances. Nuts are to be tack welded once installation is within tolerance and no piping strain exists. 4 JOHNSON CONTROLS 25

26 SECTION 4 - CUSTOMER PIPING ITEM DESCRIPTION QTY. 5 Tie Rod: 3/4" - 10UNC x 15 1/2" Long 3 6 Tie Rod Nut: 3/4" - 10 UNC (HVY. HEX.) 12 7 Spherical Washers: 3/4" Size 12 Figure 7 - TURBINE EXHAUST EXPANSION JOINT CONNECTOR Exhaust piping connections must loosened during the Pipe Strain Testing Procedure listed in this section. INLET STEAM TEMPERATURE SENSOR AND INLET STEAM PRESSURE TRANSDUCER (Factory Supplied-Field Installed) The inlet steam temp and pressure sensor must be field installed ahead of the governor valve. See Figure 8 on page 27 and Figure 13 on page 34. Piping Alignment - Upon completion of piping, a connection in each line as close to the unit as possible should be opened, by removing the flange bolts or coupling and checked for piping alignment. If any of the bolts are bound in their holes, or if the connection springs out of alignment, the misalignment must be corrected by properly supporting the piping or by applying heat to anneal the pipe. If the piping is annealed to relieve stress, the inside of the pipe must be cleaned of scale before it is finally bolted in place. 26 JOHNSON CONTROLS

27 * = Supplied in separate kit for Field Installation VACUUM BREAKER SOLENOID SENTINAL WARNING VALVE FIRST STAGE PRESSURE TRANSMITTER * SECTION 4 - CUSTOMER PIPING TURBINE TRIP VALVE LIMIT SWITCH TURBINE TRIP SOLENOID VALVE TURBINE NOZZLE VALVE AIR DUMP SOLENOID VALVE 4 TURBINE AUXILIARY OIL PUMP MOTOR OIL RESERVOIR OIL COOLER INLET THERMOMETER * OIL COOLER OUTLET THERMOMETER * OIL FILTER OIL COOLER Figure 8 - KD TURBINE FIELD INSTALLED COMPONENTS HAND TRIP KNOB SHAFT OIL PUMP GLAND LEAK-OFF CONNECTION INLET STEAM TEMPERATURE AND PRESSURE TRANSMITTER * (see FIG. 13) STEAM RING DRAIN SOLENOID LD09427a * = Supplied in separate kit for Field Installation VACUUM BREAKER SOLENOID SENTINAL WARNING VALVE FIRST STAGE PRESSURE TRANSMITTER * GOVERNOR END BEARING OIL THERMOMETER * BREATHER FILTER ASSEMBLY CONTSANT LEVEL OILER TURBINE NOZZLE VALVE AIR DUMP SOLENOID VALVE TURBINE TRIP VALVE LIMIT SWITCH TURBINE TRIP SOLENOID VALVE HAND TRIP KNOB Figure 9 - KG TURBINE FIELD INSTALLED COMPONENTS GLAND LEAK-OFF CONNECTION LEVEL GAUGE INLET STEAM TEMPERATURE AND PRESSURE TRANSMITTER * (see FIG. 13) STEAM RING DRAIN SOLENOID LD09608a JOHNSON CONTROLS 27

28 SECTION 4 - CUSTOMER PIPING PIPE STRAIN TESTING In order to assure that no inherent piping stain is present the following procedures should be employed on the inlet steam line and the exhaust trunk piping. It is better to perform these tests as the piping is being installed but the following procedure is based on all piping being installed and completed. Note: The exhaust bellows shipping brackets should still be in place. 1. Remove the center section of the main drive coupling. 2. Mount 2 dial indicators from the compressor shaft coupling hub at a 12 o'clock and a 9 o'clock position. 3. Loosen the inlet steam piping connection of the turbine and the exhaust trunk piping connection at the exhaust bellows. 4. Make sure that all flanges at both connections are parallel and square to their respective mating flange. 5. Make sure that there is a visual gap between the flanges to assure no forces are present. This may require lifting devices to lift the exhaust trunk piping. 6. Make sure that all bolts of both flanges are free and loose. 7. Reset each dial indicator to a zero position. 8. Tighten the inlet steam piping utilizing standard mechanical cross tightening procedures to the proper bolt torques recommended by the turbine manufacturer. 9. The dial indicators should indicate less than a.002" movement in either plain. If the indicators move the turbine more than.002" in either plain excessive piping forces are present and the piping will have to be modified to correct the inherent piping strain. 10. Lower the exhaust trunk into position and tighten the exhaust trunk flange to the exhaust bellows flange utilizing standard mechanical cross tightening procedures to the proper bolt torques recommended by the turbine manufacturer. 11. The dial indicators should indicate less than a.002" movement in either plain. If the dial indicators move the turbine more than.002" in either plain excessive piping forces are present and the piping will have to be modified to correc the inherent piping strain. 12. After all piping is installed and exhibits less than the maximum.002" piping strain the exhaust bellows shipping brackets can be removed. The dial indicators should be observed during the removal of the brackets. After the shipping brackets are removed the exhaust bellows stay bolts should be free to rotate and exhibit a slight free axial movement. If the stay bolts are tight or either of the indicators exibit movement greater than.002" then piping strain is still present. 28 JOHNSON CONTROLS

29 SECTION 4 - CUSTOMER PIPING When installing relief piping an ANSI flange or a piping union must be used to make a servicable piping connection. 4 Horizontal Mis-aligned Vertical Offset Compressed When installing relief piping there must NOT be any piping strain. Relief piping must be properly aligned and supported to eliminate any possible piping strain. LD16677 Figure 10 - PIPE STRAIN STEAM PIPING RECOMMENDED BLOW- DOWN PROCEDURE Removal of foreign material from the piping is the responsibility of the party installing the piping. The turbine warranty does not cover damage due to the entrance of foreign material. Newly constructed steam piping must be blown-down to remove scale, weld beads and any other foreign material. Such material can cause severe damage if it enters the steam turbine. The blow-down connection should be as close to the turbine as possible. The diameter of the blow-down connection should be a minimum of one-half the diameter of the line being blown-down to ensure that steam velocity in the piping is high enough to break loose and carry away any foreign material stuck to the inside of the piping. Blow-down should be done before the piping is insulated. Steam at full temperature and pressure should be bled through the piping. After the piping has been warmed up, the valve in the blow-down connection should be opened wide for about 15 seconds to allow live steam to blow out any loose material in the piping. Piping should then be allowed to cool down to room temperature, about 6-8 hours. Thermal expansion and contraction which occurs during warming up and cooling down, helps break loose the foreign material inside the piping. Hammering around any welded joints in the piping will also help to break loose foreign material The above procedures of warm-up, blow-down, and cool off should be repeated as many times as necessary to clean all foreign materials out of the piping. To check for clean piping, a target should be placed about two feet away from the blow-down opening so that the steam will hit the target, and any solids in the steam will become embedded in the target. Aluminum and polished stainless steel are commonly used target materials. Piping can be considered clean when no embedded particles and indentations are found in the target after a 15 second blow-down. JOHNSON CONTROLS 29