documents

LD12189

Issue Date: January 10, 2014

MODEL YST UNITS MANUFACTURED AFTER DECEMBER 2006

STEAM TURBINE CENTRIFUGAL LIQUID CHILLERS

INSTALLATION INSTRUCTIONS Supersedes: 160.67-N2 (1109) Form 160.67-N2 (114)

JOHNSON CONTROLS2

FORM 160.67-N2 ISSUE DATE: 1/10/2014

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 respon-sibility 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

IMPORTANT!READ BEFORE PROCEEDING!

GENERAL SAFETY GUIDELINES

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 en-able 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 mate-rials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.

SAFETY SYMBOLSThe 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.

Indicates a potentially hazardous situa-tion which will result in possible injuries or damage to equipment if proper care is not taken.

Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollu-tion if proper care is not taken or instruc-tions and are not followed.

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 accor-dance 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 warn-ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3

FORM 160.67-N2 ISSUE DATE: 1/10/2014

MANUAL DESCRIPTION FORM NUMBER

Operation & Maintenance 160.67-O2

Wiring Diagram - Model YST - Field Control Modifications 160.67-PW2

Wiring Diagram - Model YST - Floor Mounted Steam Condenser 160.67-PW4

Wiring Diagram - Model YST - Top Mounted Steam Condenser 160.67-PW5

Wiring Diagram- Model YST 160.67-PW6

Renewal Parts - Unit Components 160.67-RP1

Renewal Parts - Controls and Instrumentation 160.67-RP2

Engineering Guide 160.67-EG1

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin-uous 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 man-ual owner. Updated manuals, if applicable, can be ob-tained by contacting the nearest Johnson Controls Ser-vice office or accessing the Johnson Controls QuickLIT website at http://cgproducts.johnsoncontrols.com.

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 litera-ture is available from the owner of the equipment prior to performing any work on the chiller.

CHANGE BARSRevisions 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 in-formation and any other changes in spelling, grammar or formatting are not included.

ASSOCIATED LITERATURE

JOHNSON CONTROLS4

FORM 160.67-N2 ISSUE DATE: 1/10/2014

NOMENCLATUREThe model number denotes the following characteristics of the unit.

YST VF VD J4 - KD71750090 - 14 - 0.6 - 33192C - F SChiller Model

Evaporator Code

Condenser Code

Compressor Code

Special (Mandatory)

Design Level

Steam Condenser Model

Turbine Expansion Ratio

No. of Turbine Nozzels

Steam Turbine Base Model

JOHNSON CONTROLS 5

FORM 160.67-N2 ISSUE DATE: 1/10/2014

TABLE OF CONTENTS

SECTION 1 - INTRODUCTION .................................................................................................................................9Field Assembled Units .....................................................................................................................................9Inspection - Damage - Shortage ......................................................................................................................9Shipment ..........................................................................................................................................................9Turbine Bearing Disassembly To Remove Mylar Shipping Film .....................................................................12Flow Rates .....................................................................................................................................................12Chilled Water ..................................................................................................................................................13Refrigerant Condenser Water Circuit .............................................................................................................13Steam Condenser Package ...........................................................................................................................13Floor Mounted Steam Condenser (Optional) .................................................................................................13Steam Turbine Casing Drain Options .............................................................................................................13Remote Steam Turbine Gaugeboard (Optional - Field Installed) ...................................................................14

Chiller Data Plate ..................................................................................................................................14Location .................................................................................................................................................14Clearance ..............................................................................................................................................14

Installation Check - Request For Start-Up Service .........................................................................................14

SECTION 2 - RIGGING ...........................................................................................................................................15Chiller Rigging - (Less Surface Condenser) ...................................................................................................15Steam Condenser Package Rigging ..............................................................................................................17Rigging Unit To Final Location ........................................................................................................................17Locating And Installing Isolator Pads .............................................................................................................17Checking The Isolation Pad Deflection...........................................................................................................17Leveling The Unit............................................................................................................................................17

SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS ...............................................................19Customer Components ..................................................................................................................................19

Steam Inlet Strainer ...............................................................................................................................19Steam Inlet Moisture Separator .............................................................................................................19Steam Inlet Block Valve .........................................................................................................................19Steam Turbine Casing Drain .................................................................................................................19Permanent Strainers .............................................................................................................................19Stop Valves ...........................................................................................................................................19Drain and Vent Valves ...........................................................................................................................19

SECTION 4 - CUSTOMER PIPING .........................................................................................................................21Customer Piping Requirements .....................................................................................................................21Pressure Powered Pump ...............................................................................................................................21Piping Connections - Water/Drains ................................................................................................................21Piping Connections - Steam/Vents .................................................................................................................21

Steam Condenser Vacuum Pump Seal Water ......................................................................................21Steam Condenser Relief Valve Seal Water ...........................................................................................21Piping Connections - Refrigerant Vents ................................................................................................21Air (Instrument Quality Air Source - ISA S7.3) ......................................................................................22

Steam And Condensate Piping ......................................................................................................................22Steam Piping ..................................................................................................................................................22

JOHNSON CONTROLS6

FORM 160.67-N2 ISSUE DATE: 1/10/2014

Governor Valve And Spool Piece (Factory Supplied - Field Installed) ...........................................................23Top-Mounted Steam Condenser (Factory Supplied - Field Installed) .............................................................23Expansion Joint Installation (Factory Supplied - Field Installed) ....................................................................25

Design Data ...........................................................................................................................................25Inlet Steam Temperature Sensor and Inlet Steam Pressure Transducer (Factory Supplied-Field Installed) 26Pipe Strain Testing..........................................................................................................................................28Steam Piping Recommended Blow-Down Procedure ...................................................................................29Gland Seal Leak-Off Piping ...........................................................................................................................30Gland Leak-Off Condenser (Optional) ............................................................................................................30Steam Ring Drain ...........................................................................................................................................31Steam Turbine Casing Drains ........................................................................................................................31Pressure Powered Pump ...............................................................................................................................31Steam Relief ...................................................................................................................................................32Steam Condenser Package Hydrostatic Test .................................................................................................32Refrigerant Relief Piping ................................................................................................................................33

SECTION 5 - DRIVELINE ALIGNMENT .................................................................................................................37Alignment .......................................................................................................................................................37Checking For Sag ...........................................................................................................................................39Coupling Spacer Installation ...........................................................................................................................40

SECTION 6 - FIELD INSTALLED WIRING .............................................................................................................41Power Wiring ..................................................................................................................................................41Turbine Instruments .......................................................................................................................................41

KD Turbine ............................................................................................................................................41KG Turbine ............................................................................................................................................41

Steam Condenser Wiring Kit (Optional Floor Mounted Steam Condenser) ...................................................41

TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS 7

FORM 160.67-N2 ISSUE DATE: 1/10/2014

LIST OF FIGURES

FIGURE 1 - Model YST Chiller ................................................................................................................................10FIGURE 2 - Optional Turbine Gaugeboard Connections .......................................................................................14FIGURE 3 - Rigging.................................................................................................................................................15FIGURE 4 - Steam Condenser Package Rigging....................................................................................................16FIGURE 5 - Neoprene Isolators ..............................................................................................................................18FIGURE 6 - Steam Condenser ................................................................................................................................24FIGURE 7 - Turbine Exhaust Expansion Joint Connector .......................................................................................26FIGURE 8 - KD Turbine Field Installed Components ..............................................................................................27FIGURE 9 - KG Turbine Field Installed Components ..............................................................................................27FIGURE 10 - Pipe Strain .........................................................................................................................................29FIGURE 11 - Automatic Pressure Powered Pump ....................................................................................................32FIGURE 12 - Typical Refrigerant Vent Piping ..........................................................................................................33FIGURE 13 - Typical Piping Arrangement ...............................................................................................................34FIGURE 14 - Typical Arrangement For "Face - O.D." Readings To Determine Cold Alignment Of Shafts .............38FIGURE 15 - Measuring "Sag" Of Indicator/Clamp System ....................................................................................39FIGURE 16 - Typical "Reverse Indicator" To Determine Cold Alignment Of Shafts ...............................................39FIGURE 17 - Coupling Shim Placement .................................................................................................................40FIGURE 18 - Governor Valve And Spool Piece .......................................................................................................42FIGURE 19 - Din Connector Wiring.........................................................................................................................42

JOHNSON CONTROLS8

FORM 160.67-N2 ISSUE DATE: 1/10/2014

THIS PAGE INTENTIONALLY LEFT BLANK

JOHNSON CONTROLS 9

FORM 160.67-N2 ISSUE DATE: 1/10/2014

1SECTION 1 - INTRODUCTION

This instruction describes the installation of the YORK Model YST Centrifugal Liquid Chiller Unit. This unit is completely factory-packaged including; the evapo-rator, 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 mount-ing along side the chiller. Refrigerant and oil charges shipped separately unless optional refrigerant condens-er isolation valves and Form 1 shipment are ordered.

Chillers shipped dismantled MUST be field assembled under the supervision of a Johnson Controls represen-tative, 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 of-fice 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 con-nections 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.

INSPECTION - DAMAGE - SHORTAGEThe 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 imme-diately for their inspection.

JOHNSON CONTROLS will not be re-sponsible for any damage in shipment or at job site or loss of parts. (Refer to shipping damage claims, form 50.15-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.

SHIPMENTUnits shipped dismantled MUST be re-assembled 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 fac-tory charged.

1. The compressor/turbine driveline assembly mounted, with all necessary interconnecting pip-ing 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 isola-tion pads.

Form 2 - Factory Assembled Unit. (steam condenser package shipped separately.) Refrigerant and oil charg-es shipped separately.

JOHNSON CONTROLS10

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 1 - INTRODUCTION

EVAPORATOR

CONDENSER

COMPRESSOR

STEAM TURBINE

CONTROL CENTER

STEAM CONDENSER PACKAGE

HOT GAS BYPASS VALVE

VACUUM BREAKERSOLENOID VALVE

COMPRESSOR OIL COOLING WATER INLET VALVE

POWERPANEL

LD12215

TURBINEBOX

FIGURE 1 - MODEL YST CHILLER

TURBINE OILCOOLING WATER

INLET VALVE

NOTE: KD Turbine shown

JOHNSON CONTROLS 11

SECTION 1 - INTRODUCTIONFORM 160.67-N2 ISSUE DATE: 1/10/2014

ATMOSPHERIC RELIEF VALVE

CONDENSATE OVERBOARD

VALVE

CONDENSATE RECIRCULATION

VALVE

HOTWELL CONDENSATE PUMP #2

(OPTIONAL)

HOTWELL CONDENSATE

PUMP #1

HOTWELL CONDENSATE LEVEL

INDICATOR / TRANSMITTER

VACUUM PUMP #1

VACUUM PUMP #2

VACUUM PUMP #2 SEALING WATER SOLENOID VALVE

VACUUM PUMP #2 SEALING WATER FLOW SWITCH

120/460VAC JUNCTION BOX

FIGURE 1 – MODEL YST CHILLER (CONT'D)

STEAM CONDENSER PACKAGE

LD12216

JOHNSON CONTROLS12


1. The compressor/turbine driveline assembly mounted, with all necessary interconnecting pip-ing 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 isola-tion 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 ship-ment. The compressor/turbine driveline assembly is re-moved from the shells and skidded. Evaporator/Refrig-erant 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 com-pressor, oil separator, and shells are closed and charged with dry nitrogen (2 to 3 PSIG) (14-21kPa).

Miscellaneous packaging of control center, tubing, wa-ter 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 assem-blies. 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 sepa-rated 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 open-ings 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 let-ter for identification.

For example; order number 06-123456-01A, both shells and driveline will be painted with the identi-fication 06-123456-01A. The next set of shells and driveline will have the sales order with letter B, such as 06-123456-01B.

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 ship-ping 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 bear-ing housing and bearing top cap will have to be re-moved 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 RATESFor normal water chilling duty, evaporator and refrig-erant condenser flow rates are permitted at water ve-locity 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 recom-mended, 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.

JOHNSON CONTROLS 13

SECTION 1 - INTRODUCTIONFORM 160.67-N2 ISSUE DATE: 1/10/2014

1CHILLED WATERForeign 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 fac-tory wired to the OptiView ™ control panel. These sol-id-state flow sensors have a small internal heating ele-ment and use the cooling effect of the flowing fluid to sense when an adequate flow rate has been established.

REFRIGERANT CONDENSER WATER CIRCUITThe 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 + 9.4°C

where:

ECWT = Entering refrigerant Condensing Water Tem-perature.

LCHWT = Leaving Chilled Water Temperature

CONTROL RANGE = refrigerant condensing water temperature range at the given load condition.

At initial startup, entering condensing water tempera-ture 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 PACKAGEThe Steam Condenser package is shipped separately as a packaged assembly. The Steam Condenser pack-age 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 pack-age 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. Prefabricat-ed piping kits for the steam trunk, and water piping between chiller package and steam condenser are not included with a floor mounted arrangement. These in-terconnecting 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 OPTIONSThe steam turbine casing must be provided with a means of draining during operation (while under vacu-um). Factory available options are:

• Automatic pressure powered pump (standard op-tion)

• 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.

JOHNSON CONTROLS14


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 tachom-eter. The remote gaugeboard is shipped loose for in-stallation 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 160.67-PW2.

Chiller Data PlateA unit data plate is mounted on the control center as-sembly of each unit, showing unit model number, de-sign working pressure, water passes, refrigerant charge, and serial numbers.

LocationYORK Chillers are furnished with neoprene vibration isolator mounts for basement or ground level installa-tions (see Figure 5 on page 18). Units may be locat-ed on upper floor levels providing the floor is capable of supporting the total unit operating weight.

ClearanceSufficient 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 lo-cated opening may be used

If necessary, the condenser and accessory items may be separated from the skid base. Disconnect bolting, piping and wiring as required.

FIGURE 2 - OPTIONAL TURBINE GAUGEBOARD CONNECTIONS

LD12217

INSTALLATION CHECK - REQUEST FOR START-UP SERVICETo 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 be-fore 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.

JOHNSON CONTROLS 15

FORM 160.67-N2 ISSUE DATE: 1/10/2014

2

SECTION 2 - RIGGING

LD09288aFIGURE 3 - RIGGING

Refer to Engineering Guide 160.67-EG1 for dimensions and Base Unit weights.

To prevent equipment damage, a Johnson Controls representative must verify the installation prior to the unit being started, and supervise the initial startup and op-eration on the chiller.

The chiller package and Steam Con-denser package must be rigged separately. Never attempt to rig the entire YST pack-age 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 dur-ing 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 160.67-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 CONTROLS16

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 2 - RIGGING

FIG

UR

E 4

- STE

AM

CO

ND

EN

SE

R P

AC

KA

GE

RIG

GIN

GLD

0938

8

JOHNSON CONTROLS 17

SECTION 2 - RIGGINGFORM 160.67-N2 ISSUE DATE: 1/10/2014

2

STEAM CONDENSER PACKAGE RIGGINGLifting 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 fork-lift trucks. Keep load bearing surfaces isolated on the structural steel only.

The chiller package and Steam Con-denser package must be rigged sepa-rately. Never attempt to rig the entire YST package with the Steam Con-denser 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 LOCATIONRig 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 mount-ing position.

LOCATING AND INSTALLING ISOLATOR PADSThe 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 DEFLECTIONAll isolation pads should be checked for the proper de-flection 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 UNITThe longitudinal alignment of the unit should be checked by placing a level on the top center of the evaporator shell under the compressor assembly. Trans-verse alignment should be checked by placing a level on top of the shell tube sheets. After the Steam Con-denser package has been installed in place, care should be taken in leveling the condenser package, shimming at the skid/tubesheet, if necessary.

JOHNSON CONTROLS18

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 2 - RIGGING

UNIT WEIGHT 53,531 to 100,464 LBS. (24,333 to 45,666 Kgs.)

UNIT WEIGHT 28,836 to 53,530 LBS.(13,108 to 24,332 Kgs.)

UNIT WEIGHT 100,465 to 130,000 LBS. 45,667 to 58,967

LD12220

FIGURE 5 - NEOPRENE ISOLATORS

LD12218 LD12219

See YORK standard arrangement drawings for floor layout of Neoprene Isolators by model.

JOHNSON CONTROLS 19

FORM 160.67-N2 ISSUE DATE: 1/10/2014

3

CUSTOMER COMPONENTS

Steam Inlet StrainerFull flow strainer with fine [3/64” (1.2 mm) perfora-tions], stainless steel mesh, suitable for steam service.

Steam Inlet Moisture SeparatorSteam supply to turbine must be dry & saturated for optimum efficiency, and to help prevent damage to tur-bine and/or governor valve.

Steam Inlet Block ValveManual globe valve for inlet steam isolation.

Steam Turbine Casing DrainThe steam turbine casing must be provided with a means of draining during operation (while under vac-uum). Available factory options for this function are an automatic pressure powered pump, a manual con-densate 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. Tur-bine 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 auto-start option is ordered.

SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS

Permanent StrainersPermanent 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 cir-cuits should be arranged so that the pumps discharge through the chiller, and should be controlled as neces-sary to maintain essentially constant chilled and refrig-erant 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 ValvesStop valves may be installed in the evaporator and re-frigerant condenser water piping adjacent to the unit to facilitate maintenance. Thermometer wells and pres-sure taps should be provided in the piping as close to the unit as possible to facilitate operational check.

Drain and Vent ValvesDrain and vent valves should be installed in the con-nections provided in the evaporator and refrigerant condenser water boxes. These connections may be piped to drain if desired.

JOHNSON CONTROLS20

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS


JOHNSON CONTROLS 21

FORM 160.67-N2 ISSUE DATE: 1/10/2014

4

CUSTOMER PIPING REQUIREMENTSAfter 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 desir-able, 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 PUMPReferance Figure 11 on page 32

• Inlet Motive Pressure

• Vent to Turbine Exhast Piping

• Turbine Casing Drain

• Hotwell Connection or Drain

PIPING CONNECTIONS - WATER/DRAINSReference Figure 12 on page 33 for typical piping arrangement

• Refrigerant condenser inlet/outlet**

• Evaporator inlet/outlet

• Turbine/Compressor cooling water manifold in-let/ outlet and piping drains

• Steam condenser inlet**/outlet

• Steam condenser vacuum pump seal water: 3.5gpm (0.2 L/s) @ approx. 60°F (15.6 °C)

• Steam condenser vacuum pump seal water dis-charge 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

SECTION 4 - CUSTOMER PIPING

Approximately 20 psig (138kPa) dis-charge pre sure available at outlet of overboard valve. If down stream pressure requirements exceed this, a custom con-densate pump selection is required.

• Steam condenser hotwell level system drain

• Water box drains - evaporator, refrigerant con-denser 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 WaterThe vacuum pump discharge separator drain can ei-ther 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 WaterThe 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 con-nections.

JOHNSON CONTROLS22

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 4 - CUSTOMER PIPING

Air (Instrument Quality Air Source - ISA S7.3) • Bearing seal air purge and governor valve posi-

tioner: 80-150 psig (552 - 1030kPa), approx. 13 SCFM (22 sm3/h).

• Steam condenser level control system: 80-150 psig (138 - 1030kPa), approx. 0.5 SCFM (0.9 sm3/h).

• Trip and steam control: 80-150 psig

(552 - 1030kPa), approx. 0.4 SCFM (0.7 sm3/h).

STEAM AND CONDENSATE PIPINGA 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 al-lowable loads on steam connections are governed by NEMA SM23 Steam Turbines for Mechanical Drive Services.

STEAM PIPINGInlet 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 ac-cepted 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 sup-ply is available at the turbine flange at the temperature and pressure required to achieve the design capacity of the chiller.

Johnson Controls assumes no responsi-bility 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 tur-bine 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 ex-haust casing and surface condenser is provided on the steam condenser package for standard YST chill-ers. 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 spec-ified 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 flang-es, either when cold or when at normal operating tem-perature. 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 run-ning temperature.

Force due to thermal expansion must be accounted for, which can cause mis-alignment. Refer to NEMA SM 23, Part 8 (Steam Piping Systems) for additional information.

JOHNSON CONTROLS 23

SECTION 4 - CUSTOMER PIPINGFORM 160.67-N2 ISSUE DATE: 1/10/2014

4

Factory supplied STANDARD steam ex-haust 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 ex-haust 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 inter-nal 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/install-ing contractor's responsibility to ensure the steam sup-ply 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 de-sign 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 mis-alignment and subsequent turbine and/or compressor failure.

TOP-MOUNTED STEAM CONDENSER (Factory Supplied - Field Installed)To locate the steam condenser package, the steam con-denser water inlet must be aligned with the refrigerant condenser water outlet, before attaching the mount-ing 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 24

1. Complete the water line between the (2) connec-tions before bolting the angles to the steam con-denser base, and welding the angles to the refrig-erant condenser tube sheet. See Figure 6 on page 24.

2. 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 fac-tory supplied to provide reasonable protection of internally blasted surfaces. Note: brush off blast-ingmayberequiredpriortofieldassembly.

4. Proper handling and storage of prefab piping at the job site is essential in providing proper pro-tection 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 out-doors. If stored outside. The piping must be cov-ered with a waterproof tarp, and not directly ex-posed to the weather. Pipe must not be stood on end, any and all damage to caps or closures must be repaired immediately.

JOHNSON CONTROLS24


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. Allfinishpainting.Touchinguporspecialpaint-ingtobedoneinfield

8. All applicable state, county, city and local laws, rules and regulations pertaining to construction, installation and inspection of steam and water pip-ing shall beconformed to.

9. Installing contractor is responsible for fit andform of turbine steam and condenser water piping shown. Unnecessary strain on turbine and con-denser nozzles must be avoided.

FIGURE 6 - STEAM CONDENSER

JOHNSON CONTROLS 25


4

EXPANSION JOINT INSTALLATION (Factory Supplied - Field Installed)

1. The as-shipped expansion joint, with the tack-welded shipping brackets attached, defines thezero-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 toleranc-es.

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 be-tweenwashersandflange–AxialcompressorandexpansionoftheflangeisZERO.

4. Nuts are tack-welded once connector is correctly field-installedperinstructions.

Design DataAxial Compression: NONE

Axial Extension: NONE

Lateral Deflection: 1/8"

Angular Rotation: NONEInstallation Tolerances: Radial: + 1/16" Axial: +1/4", -1/2" Parallelism: + 1/8"

Refer to the installation drawing included with the fac-tory supplied expansion joint (top-mounted surface condensers) for detailed installation notes and instal-lation 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.

JOHNSON CONTROLS26


ITEM DESCRIPTION QTY.5 Tie Rod: 3/4" - 10UNC x 15 1/2" Long 36 Tie Rod Nut: 3/4" - 10 UNC (HVY. HEX.) 127 Spherical Washers: 3/4" Size 12

FIGURE 7 - TURBINE EXHAUST EXPANSION JOINT CONNECTOR

Exhaust piping connections must loos-ened during the Pipe Strain Testing Pro-cedure 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 possi-ble 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 ap-plying 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.

JOHNSON CONTROLS 27


4

FIGURE 8 - KD TURBINE FIELD INSTALLED COMPONENTSLD09427a

SENTINAL WARNING VALVE

VACUUM BREAKERSOLENOID

TURBINE AUXILIARYOIL PUMP

MOTOR

OIL RESERVOIR

OIL FILTER HAND TRIP KNOB

OIL COOLEROUTLET THERMOMETER *

OIL COOLERINLET

THERMOMETER *GLAND LEAK-OFFCONNECTION

FIRST STAGE PRESSURETRANSMITTER *

TURBINE TRIP VALVE LIMIT SWITCH

TURBINE TRIP SOLENOID VALVE

SHAFT OIL PUMP

STEAM RING DRAINSOLENOID

TURBINE NOZZLE VALVE AIR DUMPSOLENOID VALVE

* = Supplied in separate kit for Field Installation

INLET STEAM TEMPERATURE AND PRESSURE TRANSMITTER *

(see FIG. 13)

OIL COOLER

FIGURE 9 - KG TURBINE FIELD INSTALLED COMPONENTSLD09608aHAND TRIP KNOB

LEVEL GAUGE

GLAND LEAK-OFFCONNECTION

FIRST STAGE PRESSURETRANSMITTER *

SENTINAL WARNING VALVE

VACUUM BREAKERSOLENOID

CONTSANT LEVELOILER

TURBINE TRIP VALVE LIMIT

SWITCH

TURBINE TRIPSOLENOID VALVE

GOVERNOR ENDBEARING OIL THERMOMETER *

BREATHER FILTER ASSEMBLY

STEAM RING DRAINSOLENOID

TURBINE NOZZLE VALVE AIR DUMPSOLENOID VALVE

* = Supplied in separate kit for Field Installation

INLET STEAM TEMPERATURE AND PRESSURE TRANSMITTER *

(see FIG. 13)

JOHNSON CONTROLS28


PIPE STRAIN TESTINGIn order to assure that no inherent piping stain is pres-ent 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 in-stalled but the following procedure is based on all pip-ing being installed and completed. Note: The exhaust bellows shipping brackets should still be in place.

1. Remove the center section of the main drive cou-pling.

2. Mount 2 dial indicators from the compressor shaft coupling hub at a 12 o'clock and a 9 o'clock posi-tion.

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 connectionsare parallel and square to their respective mating flange.

5. Make sure that there is a visual gap between the flangestoassurenoforcesarepresent.Thismayrequire lifting devices to lift the exhaust trunk pip-ing.

6. Makesure thatallboltsofbothflangesare freeand 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 bemodified to correct the inherentpiping strain.

10. Lower the exhaust trunk into position and tighten the exhaust trunk flange to the exhaust bellowsflange utilizing standardmechanical cross tight-ening procedures to the proper bolt torques rec-ommended by the turbine manufacturer.

11. The dial indicators should indicate less than a .002" movement in either plain. If the dial indica-tors move the turbine more than .002" in either plain excessive piping forces are present and the pipingwillhavetobemodifiedtocorrecthein-herent piping strain.

12. After all piping is installed and exhibits less than the maximum .002" piping strain the exhaust bel-lows shipping brackets can be removed. The dial indicators should be observed during the removal of the brackets. After the shipping brackets are re-moved the exhaust bellows stay bolts should be free to rotate and exhibit a slight free axial move-ment. If the stay bolts are tight or either of the in-dicators exibit movement greater than .002" then piping strain is still present.

JOHNSON CONTROLS 29


4

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.

When installing relief piping an ANSI flange or a piping union must be used to make a servicable piping connection.

HorizontalMis-aligned

VerticalOffset

Compressed

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 war-ranty 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 ma-terial. Such material can cause severe damage if it en-ters 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 diam-eter 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 insu-lated. 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 al-lowed to cool down to room temperature, about 6-8 hours.

Thermal expansion and contraction which occurs dur-ing 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 neces-sary 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 em-bedded particles and indentations are found in the tar-get after a 15 second blow-down.

JOHNSON CONTROLS30


Turbine supply steam and condensate piping connec-tions to the chiller are to be supplied and installed by the site piping contractor.

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 al-lowable loads on steam connections are governed by NEMA SM23-1991 Steam Turbines for Mechanical Drive Services.

The turbine exhaust piping to the steam condenser shall be installed by the piping contractor, however, the de-sign and supply of the exhaust piping and components may be supplied by YORK depending on the options chosen. Piping should be adequately supported and braced independently of the chillers. Hangers must al-low for piping alignment at the operating temperature.

Factory supplied, STANDARD steam ex-haust piping does NOT require additional support or pipe hangers.

The piping contractor is responsible for the form and fit of turbine steam piping. The piping must be installed with the flanges and bolt holes properly aligned. The bolts should be able to be inserted without any diffi-culty and no force should be applied to allow the bolts to be inserted or flanges aligned. When the flange bolts are tightened, they must not impose any force or mo-ment on the turbine flanges.

All steam piping must be arranged so that strains will not be imposed on the turbine. The total resultant force and total resultant moment at any connection should not exceed the limits defined by NEMA SM23-1991 for steam turbine systems.

GLAND SEAL LEAK-OFF PIPING Where the rotor shaft passes through the turbine cas-ing, packing glands of the segmented carbon ring or labyrinth type are provided. These have leak-off con-nections piped to a common point shown in Figure 8 on page 27 From this point, the customer must pro-vide suitably sized piping.

If it is necessary to run the pipe for a long distance the size should be increased so that back pressure does not build up on the packing gland. This pipe must slope down from the connection point to avoid forming a water trap and must not contain a shut-off valve. On non-condensing turbines, a small amount of steam will pass through this line at all times. The amount of steam passing through the line will depend upon the amount of back pressure.

The leak-off steam is commonly piped to a sewer or open header. If this line becomes partially clogged, or the back pressure builds up for any reason, steam will blow out the shaft at the packing gland. Some ma-chines may be equipped with an optional gland con-denser which condenses the gland leakage as well as steam leaking from other leak-off connections. The condensate from this gland condenser can be returned to the feed water system.

GLAND LEAK-OFF CONDENSER (Optional)This equipment may be specified for use on high back-pressure applications, those turbines operating with a high pressure differential across the glands, and which must operate for long periods of time between shut-downs (some low pressure turbines may also use this equipment).

The condenser is piped to the outer leak-off connec-tions of the glands. It creates a slight vacuum on the outer leak-off areas, assuring that leakage will leave through leak-off piping and not past inactive seals. The most common configuration is the gland condenser and ejector. The gland condenser is a shell-and-tube type heat exchanger in which cooling water is used to condense steam leakage from the glands.

The ejector is a steam nozzle which creates a low pres-sure area to remove any air which has leaked into the system and thus maintains the vacuum in the leak-off areas. This equipment is available for all types of leak-off flows. The condensed leakage steam and cooling water can be recovered and returned to the boiler. Note that the condenser tubes and ejector both require peri-odic cleaning.

JOHNSON CONTROLS 31


4

STEAM RING DRAINAll YST chillers are provided with a tapped drain open-ing in the turbine steam ring for getting rid of excess moisture that accumulates in the steam ring when the turbine casing is cold at startup. The drain line is fitted with a check valve and solenoid valve. The line must be piped to a sewer or any other low point that permits the waste to drain off by gravity. The location of this opening is shown in Figure 8 on page 27 and Figure 12 on page 33.

The steam ring drain solenoid valve remains energized (open) during the initial startup. The check valve in the steam ring drain line prevents air from being drawn into the turbine when the turbine steam ring drops be-bylow atmospheric pressure during the initial evacu-ation and while the turbine is slow rolling. When the inlet steam valves open to begin slow roll and during the ramp up to minimum speed, the steam ring will rise above atmospheric pressure and any condensate will be blown out of the turbine.

STEAM TURBINE CASING DRAINSThe steam turbine casing must be provided with a means of draining during operation (while under vac-uum). Available factory options for this function are an automatic pressure powered pump, a manual con-densate 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. Tur-bine 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 York supplied when the system auto-start option is ordered.

On standard YST chillers with up-discharge turbine exhaust, an exhaust casing drain connection is sup-plied. The turbine must be supplied with a means of draining the casing during operation (While under vacuum). The standard Factory supplied option is an automatic pressure powered pump. Also available by special quotation is a condensate drain tank (manual or automatic). When either option is supplied, it is shipped loose for installation at the job site.

On any application where the 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.

PRESSURE POWERED PUMPSee Figure 11 on page 32

A Factory supplied automatic pressure powered pump is provided for draining condensate from the steam turbine casing during operation. The pressure powered pump is shipped loose and all piping and installation is provided by others.

A strainer and condenser trap are included with the pressure powered pump for field installation. See Fig-ure 11 on page 32.

JOHNSON CONTROLS32


Automatic Pressure Powered Pump

To HotwellConnection or Drain

(Atmosphere)

To TurbineExhaust Piping

From TurbineCasing Drain

Motive Pressure

Drip Trap With

Steam Only

Factory Supplied / FieldInstalled Strainer

FIGURE 11 - AUTOMATIC PRESSURE POWERED PUMP

LD14441NOTES:* Factory Supplied - Field Installed

*

*

*

Liquid enters the pump body through the inlet check valve causing the float to rise. As the chamber fills the valve changeover linkage is engaged opening the motive supply valve and closing the equalizing valve. As motive pressure is above the total back pressure, condensate is forced out through the outlet check valve into the return system.

Motive pressure for automatic pressure powered pumps cannot exceed a maxi-mum of 200 PSIG (steam or air may be used). Application with higher pressure motive supply must use custom selected condensate drain equipment suitable for higher pressures.

As the liquid level falls within the pump, the float re-engages the valve changeover linkage causing the mo-tive supply valve to close and the equalizing valve to open allowing condensate to re-enter through the inlet check valve and the cycle is repeated. Refer to YORK standard flow diagram for typical pressure pump pip-ing installation.

All the piping associated with the instal-lation of the Automatic Pressure Powered Pump is field provided and installed.

Never pipe turbine casing drain directly to the steam condenser hotwell. Turbine casing drains gravity only and must be pumped to steam condenser hotwell by means of condensate handling equipment.

CONDENSATE DRAIN TANK - (Optional)

Insulation of the type specified for the job, or mini mum thickness to prevent sweating of 30°F (-1°C) sur-faces should be furnished (by others) and applied to the evaporator shell, end sheets, liquid feed line to flow chamber, compressor suction connection, evaporator waterboxes, and connections. The waterbox flange insulation must be removable, to allow waterbox re moval for the tube maintenance.

STEAM RELIEFEach steam condenser is equipped with an atmospheric relief valve, sized to relieve all the steam which can be exhausted from a turbine under maximum possible full throttle conditions. The atmospheric relief valve is designed/selected per HEI (Heat Exchange Institute) standards for steam condensers and provides protec-tion for the steam turbine exhaust and exhaust trunk, as well as the steam condenser shell. The discharge of the atmospheric relief valve should be piped to direct a large volumetric flow of hot steam to a safe area out-side, away from all personnel.

STEAM CONDENSER PACKAGE HYDROSTATIC TESTAfter the installation is complete , the entire condens-ing system and piping on the exhaust steam side should be tested to prove the tightness of all connections. This can be completed by filling the condensing package with water to the top of the steam inlet flange. If pos-sible, put the Condensing Package under 15 PSIG of pressure. Inspect all connections, valves, gauges, fit-tings, pumps and other accessories for leaks.

Evaporator And Refrigerant Condenser Water Piping

The evaporator and refrigerant condenser water boxes have nozzles which are grooved, suitable for welding 150 PSIG DWP flanges or the use of Victaulic cou-plings. Factory mounted flanges are optional. The nozzles and water pass arrangements are furnished in accordance with the job requirements (see Engineer-ing Guide 160.67-EG1). Standard units are designed

JOHNSON CONTROLS 33


4

for 150 PSIG DWP on the water side. If job require-ments are for greater than 150 PSIG DWP, check the unit data plate before applying pressure to evapora-tor or refrigerant condenser to determine if the chiller has provisions for the required DWP. Inlet and outlet connections are identified by labels placed adjacent to each nozzle.

CHECKING PIPING CIRCUITS AND VENTING AIR

After the water piping is completed, but before any water box insulation is applied, torque the waterbox flange nuts to 30 and 60 ft. lbs. (41 and 81 Nm). Gasket shrinkage and handling during transit cause waterbox flange nuts to loosen. If water pressure is applied be-fore tightening is done, the gaskets may be damaged and need to be replaced. Check the steam condenser piping connection for leaks. Pipe unions and flanges may loosen during shipment and installation. Re-tight-en, if necessary.

Before the initial operation of the pumps both water circuits should be thoroughly vented of all air at the high points. Failure to do so will result in pass baffle damage.

Fill both the chilled and condenser water circuits, and vent any air from the chiller water boxes. Operate the pumps manually and carefully check the evaporator, refrigerant and steam condenser waterboxes and pip-ing for leaks. Repair leaks as necessary.

INSULATIONDo NOT field insulate until the unit has been leak tested under the supervision of the Johnson Controls representative.

Insulation of the type specified for the job, or mini-mum thickness to prevent sweating of 30°F (-1°C) surfaces should be furnished (by others) and applied to the evaporator shell, end sheets, liquid feed line to flow chamber, compressor suction connection, evap-orator waterboxes, and connections. The waterbox flange insulation must be removable, to allow water-box removal for the tube maintenance.

REFRIGERANT RELIEF PIPINGEach unit is equipped with pressure relief valves locat-ed on the refrigerant condenser and on the evaporator for purpose of quickly relieving excess pressure of the refrigerant charge to the atmosphere as a safety precau-tion in case of an emergency, such as fire. Refrigerant relief vent piping (by others), from the relief valves to the outside of the building, is required by code in most areas and should be installed on all chillers.

Flanged Jointto Permit Piping

Disassembly

CondensationTrap

ReliefValves

(See Note)

Vent to Atmosphere

Support Vent Piping to AvoidStrain on Relief Piping

Flexible Connector

Refrigerant Condenser

Evaporator

NOTE: Shells may be furnished with one or two relief valves, depending on shell size.

FIGURE 12 - TYPICAL REFRIGERANT VENT PIPING

LD09387

The vent line should be sized in accordance with the ANSI/ASHRAE-15, or local code. The vent line must include a dirt trap in the vertical leg to intercept and permit clean out and trap any vent stack condensation. The piping MUST be arranged to avoid strain on the relief valves, using a flexible connection, if necessary. See Figure 13 on page 34 for a typical piping ar-rangement. Also refer to 160.73-AD1 for additional details.

JOHNSON CONTROLS34


FIGURE 13 - TYPICAL PIPING ARRANGEMENT

Con

dens

er

Wat

er In

let

W4

*

* - E

xact

orie

ntat

ion

of

Chi

lled

or C

onde

nser

Wat

er

Noz

zels

dep

ends

on

sele

cted

con

figur

atio

ns.

Eva

pora

tor

Rel

ief S

6

Vent

to S

afe

Are

a O

utsi

de

Vent

to S

afe

Are

a O

utsi

de

Atm

osph

eric

R

elie

f S4

Con

dens

er W

ater

* O

utle

t W7

Oil

Coo

ling

Wat

er R

etur

n

From

W6

Tem

p In

dica

tor

Cas

ing

Dra

in (t

o P

res-

sure

d P

ower

ed P

ump

or

Con

dens

ate

Tank

)

Ste

am R

ing

Dra

in

Gla

nd L

eak-

Off

S9

1-1/

2” =

NP

T to

S

ewer

w/o

ut

Pos

itive

Hea

d

Gov

erno

r Va

lve

Moi

stur

e S

epar

ator

Ste

am

Trap

Oil

Coo

ling

Wat

er O

utle

t W

6

Mai

n S

team

S1

Air

Sup

ply

S8

Oil

Coo

ling

Wat

er In

let

W5

Wat

er*

Out

let

W1

Inle

t W

ater

W

2*Tem

p In

dica

tor

Oil

Coo

ling

Wat

er S

uppl

y

To W

5

W8

W3

Ste

am

Inle

t S

3

Exh

aust

S

2

Y Ty

pe S

train

erG

ate

Che

ckB

utte

rfly

Bal

l or P

lug

Dra

in

Sym

bols

Inle

t Ste

am

Tem

p S

enso

r

Inle

t Ste

am

Pre

ssur

e S

enso

r

LD09346a

Ref

eren

ce a

ll dr

awin

gs a

nd in

stal

latio

n in

struc

tions

supp

lied

by J

ohns

on C

ontro

ls fo

r add

ition

al d

etai

l on

conn

ectio

n de

sig-

natio

ns a

nd p

ipin

g re

quire

men

ts.

JOHNSON CONTROLS 35


4

FIGURE 12 – TYPICAL PIPING ARRANGEMENT (CONT'D)

Mot

ive

Sup

ply

Stra

iner

*

NO

TE:

* Fa

ctor

y su

pplie

d an

d fie

ld in

stal

led

Equ

aliz

ing

Line

)

Hot

wel

lD

rain

Turb

ine

Cas

ing

Dra

in

Air

Sup

ply

S10Rel

ief V

alve

S

eal W

ater

W

10

Rel

ief V

alve

D

rain

Ref

riger

ant C

onde

nser

R

elie

f, Ve

nt to

Saf

e A

rea

Out

side

S7

Inle

t S

3

Vacu

um P

ump

Sea

l Wat

er

Sep

arat

or

Dra

in

Dis

char

ge S

epar

ator

, Ve

nt to

Atm

osph

ere

Not

e 1

Equ

aliz

ing

Line

to P

ress

ure

Pow

ered

Pum

p or

Con

dens

ate

Tank

(1 in

ch C

oupl

ing

Loca

ted

in A

ppro

pria

te

Loca

tion

to b

e S

uppl

ied

By

Inst

alle

r)

NO

TE 1

: Aut

omat

ic P

ress

ure

Pow

ered

P

ump

prov

ides

pum

p on

ly. A

ll pi

ping

as

soci

ated

with

inst

alla

tion

is b

y th

e fie

ld. L

ocat

ion

of th

e A

utom

atic

Pre

s-su

re P

ower

ed P

ump

and

pipi

ng is

for

refe

renc

e on

ly. L

ocat

ion

to b

e flo

or-

mou

nte

by th

e in

stal

ler.

Vict

aulic

Cou

plin

gs S

uppl

ied

by in

stal

ler.

Flan

ges

Avai

labl

e as

Fac

tory

Sup

plie

d O

ptio

nW

8

W3

Not

e 1

Vacu

um

Pum

ping

S

ealin

g W

ater

an

d H

otw

ell F

ill

Con

nect

ion

(Pot

able

Wat

er)

W11

Pip

e to

Ste

am

Con

dens

er H

otw

ell

Aut

omat

ic

Pre

ssur

e P

ower

ed

Pum

p

Trap

*

Con

dens

ate

Ove

rboa

rd

(Ret

urn

to B

oile

r)

W9

LD09347d

Ref

eren

ce a

ll dr

awin

gs a

nd in

stal

latio

n in

struc

tions

supp

lied

by J

ohns

on C

ontro

ls fo

r add

ition

al d

etai

l on

conn

ectio

n de

sig-

natio

ns a

nd p

ipin

g re

quire

men

ts.

JOHNSON CONTROLS36



JOHNSON CONTROLS 37

FORM 160.67-N2 ISSUE DATE: 1/10/2014

5

ALIGNMENTAlignment refers to the proper relationship between the centerlines and distance between the turbine shaft and compressor. Factory assembled packages are aligned prior to shipment and must be re-checked prior to startup.

Turbine to Compressor Cold Misalignment

The typical Murray turbine utilized on the YST sys-tem has a minor cold alignment offset. In hotcheck alignment procedures employed on other similiar 5 to 7 stage Murray turbines utilized on the YST syatems, the turbine shaft should be .003"/.004" above the com-pressor shaft at the compressor coupling, and the face of the coupling open on the top by .002"/.003" at cold start-up conditions. The most accurate form of align-ment procedure to utilize on the YST system is the double reverse indicator method. Other forms of align-ment. ie. Face and Rim, Laser etc. are viable methods but are subject to errors due to the possible axial move-ment of the turbine and the compressor shafts.

Inaccurate alignment can result in de-structive vibration, loosening of grout, failure of bearings, coupling failure, bent shaft, and other conditions that could lead to catastrophic equipment damage.

Alignment Data

The following instructions and suggestions are made for guidance in alignment of newly installed equipment and under the presumption that:

• The persons reading this are familiar with high speed turbomachinery and that they are aware of the basic principles of alignment.

• It is understood that the various procedures sug-gested for checking completed portions of the sys-tem are in no way a substitution for proper design, engineering, and construction. Additionally, the suggestions made represent only one of several acceptable alternatives.

In the case of turbomachinery, many of the items vi-tal to a good alignment have been done well ahead of the actual “cold alignment” of the equipment. Unless the person responsible for the alignment has first-hand

SECTION 5 - DRIVELINE ALIGNMENT

knowledge that the preparations have been done prop-erly, it is best to verify these items. Some areas that warrant specific attention would be:

• Assure that the piping is installed in accordance with design criteria, that it is complete, and that it is in its functional state. Look for proper place-ment and adjustment of guides, anchors, and sup-ports; proper adjustment of tie-bolts on expansion joints; correct positioning of spring hangers; com-pletemake-upofflangeswithgasketsinplaceandbolts tightened; absence of slip-blinds which may have been installed for pressure testing of pipe-lines; and proper orientation of check valves and other control devices.

• Check the grouting to assure it is complete and supports the structure of the unit.

• Check all foundation bolts to assure tightness.

• Check all shim packs for rust, improperly cut shims, folds and wrinkles, burrs, hammer marks, and dirt etc. Shims are a vital link between the machine and the foundation and are essential to the maintenance of alignment over long periods. Good practice dictates that as few shims as possi-ble be used if changes are required, replace many thin shims with fewer shims of greater thickness. Shims of stainless steel should be used wherever possible. Also it is important to make sure the equipment supports and soleplate/baseplate are clean and in good condition.

• Check for misalignment of machine supports rela-tive to the soleplate, this is sometimes referred to as a “soft foot” condition. Mounting a dial indica-tor on the machine support with the indicator stem resting on the soleplate can make a simple test for this condition. Watch the indicator as the hold-down bolts are loosened. If the movement of the indicator is more than .002”, it is an indication of aproblemwhichmustberectified.Itisalsoap-propriate to remove the shim pack and check with feeler gauges to assure that the machine support is parallel with the soleplate.

The goal of proper alignment is to provide the most accurate collinear alignment during the majority of operating condi-tions.

JOHNSON CONTROLS38

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 5 - DRIVELINE ALIGNMENT

• Check for piping strain - Reference Section 4 Pipe Strain Testing

Piping strain can cause problems with alignment and must be corrected before operating the unit.

• Verify that theMylarshippingfilmhasbeenre-moved from the turbine shaft bearing prior to ro-tating the turbine shaft.

• Make sure that the bearings have been properly installed in the machines, are lubricated, and bear-ing covers are properly tightened.

The term “Cold Alignment” refers to the position of the centerline of the shaft of one piece of equipment rela-tive to the centerline of the shaft of an adjoining ma-chine to which it is connected, as well as the distance between the two shafts, with the machines in a non-operating temperature stabilized or “cold” condition. The term implies both offset and angularity. The im-portance of this cold alignment is that it is usually the only check made to ascertain directly the relative posi-tion of the two shafts. The result of this check is the basis for determining shaft alignment of the equipment during operation. It is the fundamental benchmark and must be accurately done and properly recorded.

There are various methods which can be utilized to perform the alignment. The method described in this manual will be that of using dial indicators. While the method of employing dial indicators is an old and well-established technique, these are precautions which the technician should already be aware of.

The most widely used of the traditional alignment methods is commonly referred to as the “Face-O.D.” method as illustrated in Figure 14 on page 38. As shown in the figure, a bracket is attached to one shaft and extends to the proximity of the coupling hub on the adjacent shaft. Dial indicators are affixed to this bracket with the stem of one indicator resting on the face of the coupling hub and the stem of the other indicator resting on the outside diameter of the same hub. The "parallel" offset of the shafts is determined by the “O.D.” read-ings, while angularity of the shafts is determined by the “face” readings. It is required that the proper distance between the shafts be established before any alignment method is used. This spacing dimension can be found on the outline drawing and/or the coupling drawing for the specific application.

Dial indicators which are anti-magnetic are strongly recommended.

Make sure the indicator stem is near the center of travel before taking readings and will remain in contact with the flange surface. Rotate the shaft to insure the in-dicators will not be impacted or obstructed when rotated.

FIGURE 14 - TYPICAL ARRANGEMENT FOR "FACE - O.D." READINGS TO DETERMINE COLD ALIGNMENT OF SHAFTS

ALIGNMENT BRACKET

DIAL INDICATORS

COUPLING HUB

LD09290

To eliminate inaccuracies in geometry of the coupling hub, turning of both shafts simultaneously such that the indicator readings are taken always at the same place on the hub will give more precision. This precaution can be difficult on larger equipment and may not be possible. Face measurements taken by this method must have the axial float of the two shafts accounted for.

Axial movement must be taken into account when turning the shafts on equipment with hydrodynamic thrust bearings or no thrust bearings. Small machin-ery utilizing ball bearings may not encounter any axial float. The shafts must have axial positions rechecked each time a reading is taken. One additional element that must be accounted for is the difference between the exhaust end shaft rise and the steam end shaft rise. Typically, the steam end will rise more than the ex-haust end due to higher temperatures. This will result in cold misalignment offsets that have the coupling face “open” at the top.

Care must also be taken in the brackets that are used to hold the dial indicators. “Universal” or makeshift brackets contrived on the spur of the moment can give inaccurate readings, which can lead to improper align-

JOHNSON CONTROLS 39

SECTION 5 - DRIVELINE ALIGNMENTFORM 160.67-N2 ISSUE DATE: 1/10/2014

5

ments. Refer to the "Checking for Sag" section in this manual. Especially when the spans between the shafts are quite long, care must be taken to assure that the bracket being utilized is stiff enough that it will not deflect under its own weight.

CHECKING FOR SAGClamp the indicator system onto a piece of pipe (1-1/2 - 2 inch diameter).

Make sure the indicator/clamp system measures the same distance as the cou-pling span.

Zerotheindicatorwhileontop.Rotatetothebottomand record any change in reading on the indicator. This is the amount of "Sag" due to gravity. If Sag measures more than 0.003 inches the brackets should be rein-forced or modified (see Figure 15 on page 39).

FIGURE 15 - MEASURING "SAG" OF INDICATOR/CLAMP SYSTEM

0.000

DIAL INDICATOR

PIPE

INDICATOR CLAMP

0

0.0??

PIPE

INDICATOR CLAMP

LD09699a

An alternative method is sometimes preferred because of the elimination of some of the problems mentioned above with the “Face O. D.” method would be to uti-lize the “Reverse Indicator” method as illustrated in Figure 16 on page 39.

FIGURE 16 - TYPICAL "REVERSE INDICATOR" TO DETERMINE COLD ALIGNMENT OF SHAFTS

ALIGNMENT BRACKET

DIAL INDICATORS

LD09291a

This method employs indicator readings taken on the outside diameter of the coupling hubs or shaft only. The figure indicates two brackets used simultaneously, which is normally the preferred method. One bracket could be utilized by switching back and forth for each set of readings but this is far less convenient and may affect accuracy.

Use of the “Reverse Indicator” method eliminates the requirement for removing the coupling spacer in a ma-jority of cases. This reduces the wear and tear on the coupling. The error caused by coupling hub run-out is entirely eliminated since both shafts turn as a unit (with spacer installed), and angular misalignment is greatly magnified as the hub separation is increased and more precisely diagnosed. Since face readings are eliminat-ed, there is limited concern about axial float.

One precaution that carries over to the “Reverse Indi-cator” method which was present in the “Face O.D.” method is that of deflection or Sag in the alignment bracket. This problem can be minimized by building the bracket with substantial material to prevent SAG or by determining the deflection in the alignment fixture and making the appropriate corrections in the align-ment data (see the checking for Sag section previously discussed in this section).

Dial indicator readings will be 2X the actual shaft centerline measurement.

Make sure the indicator stem is perpen-dicular and near the center of its travel before taking any readings.

JOHNSON CONTROLS40

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 5 - DRIVELINE ALIGNMENT

YORK DBL. TAPERCOUPLING P/N

"D" DIMENSION

029-20899-001 4.75

VARIANCESHIM QTY. AT LOCATION

1 2 3 40-0.014 0 0 0 0

0.015-0.029 1 0 0 00.030-0.044 2 0 0 00.045-0.059 2 1 0 00.060-0.074 2 2 0 00.075-0.089 2 2 1 00.090-0.104 2 2 2 00.105-0.119 2 2 2 1

0.12 2 2 2 2

2. If the measurement is greater than the "D" dimen-sion listed in the table above add the appropriate shims to the proper shim points as indicated in Figure 17 on page 40. Shims are sent with each coupling and will allow up to an additional .120" of face-to-face coupling installation (min. 4.75" to max. 4.870"). The shims should be installed per table above at the locations stated in Figure 17 on page 40.

Some couplings use shims that are cir-cular and span the entire diameter of the coupling reference (see Figure 17).

FIGURE 17 - COUPLING SHIM PLACEMENT

LD12213

In recent years people have questioned the value of the traditional “Hot Check Alignment”. Not only is it costly and time-consuming to bring a machine up to temperature, stop it, break couplings, and attempt to determine alignment before it cools off, but the results are highly questionable.

It is normally not possible to make the check quickly enough to accurately determine the thermal growth of the equipment. Also any hydraulic forces and torque reactions, which can be significant, are never revealed by the traditional check methods because the forces disappear immediately upon stopping the machine.

One alternative is to use the cold position of the shafts as a benchmark, and deduce the hot alignment by mon-itoring the movement of the machine casings, shafts, or bearing centerlines from the cold position to the hot position. There are several methods used for this monitoring. A variety of techniques can be applied to the actual determination of casing or shaft movement, which includes optical or electronic (laser) techniques. In any event, a "Hot Alignment" check of the driveline alignment at operating temperatures is required.

COUPLING SPACER INSTALLATION1. After the unit has operated in it's initial slow roll

for 30 minutes and the turbine has achieved oper-ating temperature, obtain an accurate face-to-face measurment with the turbine and compressor on their normal operating position.

Verify the turbine has stopped rotating and all power / steam supply sources are properly locked out and tagged out before the measurement is obtained.

JOHNSON CONTROLS 41

FORM 160.67-N2 ISSUE DATE: 1/10/2014

6

SECTION 6 - FIELD INSTALLED WIRING

POWER WIRINGThe chiller must be supplied with a single 3-phase power supply rated at 29 KVA. Do NOT make final power connections to the Power Panel until approved by a YORK/Johnson Controls representative.

When the steam condenser package is located remotely all power and control wiring between the condenser and chiller is supplied by York and installed by the installing contractor. The size and type of conduit used must be determined by the electrical installation contractor.

See Figure 1 on page 10 and applicable form 160.67-PW6.

After the governor valve is installed all units require the final connection to the valve positioner (4-20 ma dc).

After the steam condenser unit is installed, all units require the final connections to the steam condenser junction box (120/460Vac wiring), the hotwell level control I/P transducer (4-20 ma dc), and the hotwell level transmitter (4-20 ma dc).

The connecting cables are supplied with the appropriate din connectors and coiled on the chiller for shipment.

On units shipped disassembled, control wiring must be completed between unit components, control center, power panel, and turbine box, using wiring harnesses furnished.

Field wiring connections for commonly encountered control modifications (by others) if required, are shown on Form 160.67-PW2.

No deviations in unit wiring from that shown on drawings furnished shall be made with out prior approval of a YORK/Johnson Controls representative.

TURBINE INSTRUMENTS Standard YST turbines are shipped with some instru-ments packaged as a separate kit to avoid damage in transit. Included are the following instruments:

KD Turbine*Oil Cooler Oil Inlet Thermometer *Oil Cooler Oil Outlet Thermometer Tachometer (Must be Field installed on Optional Re-mote Steam Turbine Gaugeboard when purchased) *Inlet Steam Pressure Transmitter (including Pipe Tee, Pipe Nipple, Siphon, and Valve)

KG Turbine*First Stage Pressure Transmitter *Shaft End Bearing Oil Thermometer *Governor End Bearing Oil Thermometer Tachometer (Must be Field installed on Optional Re-mote Steam Turbine Gaugeboard when purchased) Inlet Steam Pressure Transmitter (including Pipe Tee, Pipe Nipple, Siphon, and Valve)

*These instruments must be installed on the turbine as shown in Figure 8 on page 27.

The Inlet Steam Pressure Transmitter and associated hardware must be installed in the inlet steam piping upstream of the governor valve as shown in Figure 18. The connecting cable is supplied with the appropriate connector and coiled on the chiller for shipment.

STEAM CONDENSER WIRING KIT (Optional Floor Mounted Steam Condenser)Wires are provided for the motor power and 120 VAC control wiring between terminal boxes located on the refrigerant condenser and the steam condenser. Low voltage shielded cables are provided for the hotwell level transmitter and I/P transducer (4-20 mA) wiring to be connected between a terminal box located on the refrigerant condenser and the devices on the steam con-denser. The length of these harnesses (50/75/100 feet) must be specified on the factory order. These harnesses must be installed in appropriate conduit as determined by the electrical installation contractor.

JOHNSON CONTROLS42

FORM 160.67-N2 ISSUE DATE: 1/10/2014SECTION 6 - FIELD INSTALLED WIRING

The din connector for making the final connections to the transmitter and I/P transducer are shipped inside the ter-minal box on the refrigerant condenser and must be installed at final assembly per Figure 19.

Refer to the Field Wiring Diagram Form 160.67-PW4 for the wiring connections required. All loose wires and shielded cables are permanently stamped with the appropriate wire/cable numbers along their entire length and may be trimmed to the required length to suit the final routing of the conduit.

Inlet Steam Temp Sensor

FIGURE 18 - GOVERNOR VALVE AND SPOOL PIECELD12499

FIGURE 19 - DIN CONNECTOR WIRINGLD12288

JOHNSON CONTROLS 43

FORM 160.67-N2 ISSUE DATE: 1/10/2014

6

NOTES

P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2014 www.johnsoncontrols.com ALL RIGHTS RESERVEDForm 160.67-N2 (114)Issue Date: January 10, 2014 Supersedes: 160.67-N2 (1109)

documents | chillers | johnson ... - product documentation