DARTMOUTH COLLEGE DESIGN November 15, 2007

& CONSTRUCTION GUIDELINES

SECTION 15744

CENTRIFUGAL CHILLERS

PART 1 DESIGN DIRECTIVE

1.1 QUALITY ASSURANCE

A. Firms regularly engaged in manufacture of centrifugal chillers, of types and capacities

required, whose products have been in satisfactory use in similar service for not less than
5 years.

B. Comply with ASHRAE 15 for chiller leak monitoring, testing, and installation.

C. Fabricate centrifugal chillers to comply with UL 465 "Central Cooling Air Conditioners".

D. Chiller shall comply with ASME Boiler and Pressure Vessel Code, Section VIII, Division
1 and be stamped accordingly.

E. Chiller performance shall be rated in accordance with Air Conditioning & Refrigeration
Institute (ARI) standard 550.

F. Prior to shipment the chiller automated-controls test shall be executed to check for proper
wiring and ensure correct controls operation.

G. Comply with NFPA 70.

1.2 DELIVERY, STORAGE, AND HANDLING

A. Store chillers to prevent damage and protect from weather, dirt, fumes, water, and debris
in a clean dry place.

B. Handle chillers in accordance to manufacturer’s written rigging and installation

instructions for transportation, unloading, and setting in final location.

C. Unit shall be shipped with firmly attached metal plates that indicate name of
manufacturer, chiller model number, chiller serial number, and refrigerant used.

1.3 DESIGN CRITERIA

A. All chillers shall use refrigerant 134a.

B. Provide a Coefficient of Performance (COP) for centrifugal chillers not less than 10.0.

C. Part load conditions shall be accommodated via a variable frequency drive.

D. Chillers shall be equipped with open communications protocol such as Lon Works,
Modbus, or BACnet.

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PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Subject to compliance with requirements, provide centrifugal chillers from one of the
following:
1. Carrier A/C Group; Carrier Corp.
2. McQuay Group, Snyder-General
3. Trane Co.,
4. York International.

2.2 UNIT DESCRIPTION

A. Packaged, factory-assembled, centrifugal type chillers consisting of centrifugal

compressor, compressor motor(s), motor starters, variable speed drive, evaporator,
condenser, controls and panels including gages and indicating lights, auxiliary
components, and accessories.

2.3 COMPONENTS

A. Compressor:

1. The rotor assembly shall consist of a heat treated alloy steel drive shaft and
impeller shaft with a lightweight, high strength, cast aluminum impeller.

2. Casing shall be fine grain cast iron with gasket sealed casing joints.

3. Open drive type compressors preferable. The journal and thrust bearings shall
be fabricated of aluminum alloy, precision bored, and axially grooved. For an
open drive the seal shall consist of a spring loaded ring assembly using O-rings
and carbon rings with stress relieved collars. The seal shall be oil flooded at all
times and pressure operated during compressor operation.

4. The gears shall be shall be helical with crowned teeth designed so that more than
one tooth is in contact at all times. Gears shall be integrally assembled in the
compressor rotor support and shall be film lubricated. Each gear shall be
individually in its own jurnal and thrust bearings to isolate it from impeller and
motor forces. Provide inspection openings for the gears and bearings without
needing to disassemble or remove any major components.

5. Lubrication system shall be force fed to all bearings by an oil pump that operates
prior to startup, continuously during operation and coast-down. A reservoir
mounted high shall provide lubrication during coast down in case of power
failure. A thermostatically operated heater shall be provided that can maintain
the oil at appropriate temperature for the condition to prevent refrigerant from
mixing with the oil. The oil shall be filtered through an externally mounted,
easily replaceable, 1/2 micron filter. The oil shall be cooled using a refrigerant
cooled oil cooler. Both the refrigerant and oil piping to the cooler shall be
provided with isolation valves for service. An automatic oil return system shall
recover any oil that has migrated to the evaporator. All oil piping shall be
factory installed.

6. Motor shall be open or hermetically sealed, variable speed, controlled by

variable frequency AC power from the control system as a part of the capacity
reduction controls. The motor shall comply with DC Standard, ‘ELECTRICAL
REQUIREMENTS FOR MECHANICAL EQUIPMENT’. The VFD shall be 12-pulse and

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an IEEE 519-1992 harmonic analysis shall be done as part of the submittal

package with a follow-up weeklong measured harmonic analysis to verify
performance.

7. If no VFD, provide separate motor starters for field mounting and wiring.
Starters shall be a wye-delta closed transition type, of sizes, ratings, and
electrical characteristics scheduled; with a NEMA 1 enclosure. Provide starters
with an electronic protection system to monitor and protect against three-phase
overload, overload during starting, phase unbalance, and over and under voltage.

B. Evaporator and Condenser:

1. Shell and water boxes shall be fabricated from rolled carbon steel plates with
welded seams. Provide 150 psig maximum working pressure water boxes and
nozzle connections. The refrigerant side shall be rated and tested for suitable
pressure for the refrigerant. Provide vents and drains in water boxes to permit
tube cleaning. Fabricate steel water heads with integral water connections
bolted to shell of vessel. Provide water piping stub-outs, flanged connections,
150 psig raised face flanges.

2. Tube sheets shall be fabricated of thick carbon steel sheets welded to the shell
and drilled for tubes.

3. Tubes shall be high efficiency, externally and internally enhanced, individually

replaceable, finned, seamless copper tubes. Tubes shall be removable from
either end of the heat exchanger without affecting strength and durability of the
tube sheets and without causing leakage in adjacent tubes. Provide suitable
baffles or distributing plates in condenser tubes to evenly distribute refrigerant
discharge gas on heat transfer tubes.

C. Pressure Limiting and Pressure Relief Devices: Manufacturer's standard complying with
ASHRAE 15 and ASME Code for Unfired Pressure Vessels.

D. Provide refrigerant charging transfer connections, pressure relief device on the evaporator
to prevent excessive pressure in refrigerant side, and means to sense refrigerant pressure
or temperature.

2.4 ACCESSORIES

A. Purge system shall be designed to evacuate non-condensable gases and water vapor form
the system and for condensing, separating, and returning refrigerant to the system.
Provide all necessary devices to automatically isolate purge system from chiller.

B. Pump-out system shall include compressor and drive, oil separator, filter drier, water
cooled condenser, piping, wiring, motor starter, and an external refrigerant storage vessel
large enough to hold the entire refrigerant charge of the largest chiller in the plant. The
unit shall come with necessary valves and hoses to replace and destill refrigerant.

C. Electric chillers shall include a receiver tank sized for full charge.

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2.5 CONTROLS AND SAFETIES

A. Refrigerant flow shall be controlled by a variable orifice. The variable orifice shall
automatically adjust to maintain proper refrigerant levels in the condenser and
evaporator. This shall be controlled by monitoring refrigerant liquid level in the
condenser assuring optimal subcooler performance.

B. Capacity control shall be designed and fabricated to regulate evaporator leaving water
temperature. Design for capacity modulation, from full load to scheduled minimum load
capacity. Modulating hot gas bypass shall be provided and programmed to be used in
very low load conditions and sudden load changes. The hot gas bypass shall be
programmed to not operate in normal conditions, hurting efficiency.

C. Provide variable guide vanes to provide stable operation without surge, cavitation, or
vibration from 100 to 10 percent of full load capacity, without hot-gas bypass.

D. Variable speed drive that meets the specifications in section 16.

E. Design safety controls cutouts to operate independently and factory wire to control panel.
Design controls to stop compressor motor in event of any condition that will jeopardize
the chiller.

F. Provide operational controls to ensure that compressor will start only under unloaded
condition. Provide sequencing controls to ensure lubrication of compressor motor
bearings and seals (if any).

G. Provide a diagnostic module capable of indicating all lockout conditions specified above,
plus recording the elapsed time (pre-alarm to alarm), the operating conditions for the
compressor motor (amperes), refrigerant temperatures and pressures, and chilled and
condenser water temperatures (entering and leaving) at the time of lockout.

H. Each unit shall be provided with a factory-mounted and wired control panel. The control
center shall use easy to understand English language with numeric data in English units.
The panel shall provide digital programming of essential set points. These set points
shall be, but not limited to, percent current limit, pull down demand limiting, seven day
time clock fro starting and stopping, pumps, tower, and remote reset.

I. Provide pilot lights or visual flag switches for indicated operations and cutouts including
the following:
1. Oil pump operation
2. Low chilled water temperature cutout
3. Low water flow cutout
4. Oil separator heater operation
5. Low evaporator refrigerant pressure or temperature cutout
6. High condenser pressure cutout
7. High motor winding temperature cutout
8. Low oil pressure cutout
9. Motor overload cutout

J. Provide elapsed hourly time meter designed to automatically record total chiller operating
time.

K. Provide electrical interlock to prevent chiller operation when condenser water or chilled
water pumps are not operating.

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2.6 VIBRATION CONTROL

A. Refer to DC Standard, ‘SEISMIC RESTRAINT AND VIBRATION CONTROL’ for requirements.

2.7 INSULATION

A. Insulate evaporators and other cold surfaces with elastomeric insulation, to prevent
condensation, with ambient humidity of 75 percent and dry-bulb temperature of 90°F no
air movement.

2.8 SOURCE QUALITY CONTROL

A. Test and inspect centrifugal chillers in accordance with ASME Boiler and Pressure
Vessel Code, Section VIII, Division 1.

PART 3 EXECUTION

3.1 FACTORY FIELD SERVICES

A. Provide the services, to include a written report, of a factory authorized service

representative to supervise the field assembly of the components, installation, and piping
and electrical connections.

B. Provide the services of a factory authorized service representative to provide start-up

service and to demonstrate and train the Owner's maintenance personnel as specified
below.

C. Evacuate, dehydrate, vacuum pump and charge with specified refrigerant. Leak test in
accordance with manufacturer's instructions. Test and adjust controls and safeties.
Replace damaged or malfunctioning controls and equipment.

D. Perform lubrication service, including filling of reservoirs with manufacturer approved

lubricant

E. Do not place chillers in sustained operation prior to initial balancing of mechanical

systems for interface with chillers.

F. Schedule training with Owner through the Engineer with at least 7 days prior notice.
Train the Owner's maintenance personnel on start-up and shut-down procedures,
troubleshooting and servicing procedures, and preventative maintenance schedules and
procedures. Review with the Owner's personnel the data contained in the Operating and
Maintenance Manuals.

END OF SECTION 15744

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