LIQUID CHILLING PACKAGES

1.0 SCOPE

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at manufacturer's works, delivery at site,
handling at site, installation, testing, commissioning and carrying out performance test at
site of Screw / Centrifugal Liquid Chilling Packages for Ozone Generator Cooling.

2.0 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance of

screw liquid chilling packages shall comply with all currently applicable statutes,
regulations, codes and standards in the locality where the equipment is to be installed.
Nothing in this specification shall be construed to relieve the CONTRACTOR of this
responsibility. In particular, the screw liquid chilling packages shall conform to the latest
edition of following standards:

ASHRAE 15 Safety Code for Mechanical Refrigeration

ASHRAE 23 Methods of Testing for Rating Positive Displacement Refrigerant
Compressors and Condensing Units
ASHRAE 30 Methods of Testing Liquid Chilling Packages
ASHRAE 2016 HVAC System and Equipment
ASHRAE 2017 Fundamentals
ASHRAE 2018 Refrigeration
ASHRAE 2015 Applications
ASME SEC. VIII Boiler and Pressure Vessel Code
DIV. 1
ANSI B 31.5 Code for Refrigeration Piping
ARI 550/590 Water Chilling Packages using the Vapour Compression Cycle
ARI 575 Standard for Method of Measuring Machinery Sound within an
Equipment Space
TEMA Standards of the Tubular Exchanger Manufacturers Association

AHRI 210 Unitary Air Conditioning Equipment

AHRI 270 Standard for Sound Rating of Outdoor Unitary Equipment
Commercial and Industrial Unitary Air Conditioning
AHRI 360
Equipment
AHRI 410 Forced Circulation Air-Cooling and Air- Heating Coils

3.0 GENERAL REQUIREMENTS

3.1 Each chilling package shall be complete assembly of all components viz. electric motor
driven open or semi-hermetic or hermetic screw / centrifugal compressor as specified in
the data sheet, chiller, condenser, expansion device, refrigerant piping, oil cooler and
protective devices etc. mounted on a common structural frame.

3.2 All rotating parts shall be statically and dynamically balanced.

3.3 In addition to the features specified, if the chilling package requires any additional
features for safe and efficient operation, the same shall be included in the scope of
supply and shall be clearly indicated and described.
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3.4 The initial charge of refrigerant, oil and consumables shall be provided till the screw liquid
chilling package complete in all respects is taken over by the PURCHASER.

3.5 The chilling package shall be despatched to site in an assembled or disassembled

condition with or without the refrigerant and oil charge. In case the chilling package or its
components viz. compressor, condenser, chiller, receiver etc. are despatched without the
refrigerant and oil charge, these shall be despatched duly filled with dry nitrogen, under a
minimum pressure of 0.2 kg/cm2(g).

4.0 Air Cooled Water Chillers

4.1 General

Provide factory-assembled and tested air-cooled liquid chillers, suitable for outdoor
installation. Chillers shall include twin screw compressors /centrifugal compressors (as
applicable), evaporator, condensers, electronic expansion valves and control panels.
Provide capacity and electrical characteristics as indicated on the Chiller Data Sheet at
the end of this specification.

All refrigerants shall be a HFC or HFC blend of refrigerant, and must be suitably selected
for use in the ambient temperatures specified

The unit shall be able to operate as standard with outside air temperature from – 10ºC to
55ºC.

4.2 Fluids

Provide full operating charge of refrigerant, oil and all other fluids as required for proper
operation. Refrigerant shall not contain chlorine. Environment friendly refrigerant shall be
used in chillers. CONTRACTOR shall evaluate the available environmentally friendly
refrigerant.

4.3 Housing

Provide manufacturer’s equipment housing, constructed for outdoor installation with

corrosion protection coating and exterior finish. Provide removable panels and/or access
doors for inspection and access to internal parts and components. Evaporator Provide
shell and tube (flooded type) design with seamless copper tubes roller expanded into
tube sheets.

Design, test, and stamp for refrigerant side working pressure of 1550 kPa minimum and
water side working pressure of 1034 kPa minimum in accordance with ASME Pressure
Vessel Code or equivalent European Codes. Provide one water pass with series of
internal baffles. Provide 1034 kPa flanged water connections. Insulate with 19 mm
minimum flexible unicellular insulation. Provide water drain connection and bulb wells for
temperature controller and low temperature cut-out. The evaporator shall be mounted on
support feet with thermal bridge rupture. Provide independent multiple refrigerant circuits’
gasketed evaporator heads. The evaporator shell insulation shall be protected by factory
fitted aluminium cladding.

4.4 Condenser

Construct copper coils with copper headers and configured aluminium fins mechanically
bonded to seamless copper tubing. Provide integral sub-cooling circuit with liquid
accumulators. Leak test coils over exposed coil faces at 2930 KPA air pressure. Provide
protective guard over exposed coil faces. Coil shall be guaranteed for a period of three
years. Condensers coils shall be coated with heresite or by – gold to prevent corrosion in
the plant environment. Coating shall be guaranteed for a period of five years from the
date of provision acceptance certificate.
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Condenser fans: Provide propeller fans, direct driven, draw-through vertical discharge
design, statically and dynamically balanced. Motors shall be 3 phase with permanently
lubricated ball bearings, built – in current and thermal over – load protection. Motors shall
be rated for outdoor use. Provide protective grille over air discharge. The three – phase
electric motor shall have class F insulation, IP 55 protection with a minimum efficiency of
80%. They shall have individual overload protection via a circuit breaker.

OR

The coils with integrated sub cooling will be entirely of aluminium to limit galvanic
corrosion and will offer a resistance to corrosion compatible with environments. Coil shall
be mounted in a painted frame to reduce corrosion risk and shall be isolated from the
Chiller frame by rubber insulating mount.

The coil shall pressure test at 4400 KPA. Coils should have a thickness of 1 inch to
generate low air pressure drop and offer reduce sensitivity to clogging. The fins shall be
0.1 mm thickness and shall in rows protected by the coil rows from top and bottom. Fins
shall be brazed to the coil from top and bottom in an automatic process in an oven to
create sturdy coil/fins body. Manual brazing in not accepted. Coil shall be guaranteed for
a period of five years.

4.5 Compressors

The hermetic or semi-hermetic twin screw compressors shall be the twin rotor-type with
direct drive, refrigerant gas-cooled motors. Each compressor shall have a lubrication
system including an oil filter, an oil sump heater, an oil level sensor, and an oil pressure
sensor. All main components shall be fully accessible. Compressors shall be mounted on
sliding rail and equipped with discharge gas shut – off valve for ease service. Compressor
speed shall not exceed 3000 RPM. Each compressor shall be mounted on vibration
isolators within the chiller housing. Vibration isolators shall have an isolation efficiency of
no less than 95 percent.

Screw compressor shall conform to relevant API standards and Design General
Specifications. Compressor and oil separator shall have an acoustic enclosure with large
access doors. Compressor shall be guaranteed for a period of five years.

In case of Centrifugal compressor, the compressor shall be single stage centrifugal type
powered by an open drive electrical motor. The housing shall be fully accessible with
vertical circular joints, with the complete operating assembly removable from the
compressor and scroll housing. Compressor casting shall be designed for the highest
working pressure and hydrostatically tested in accordance with the design standard. The
rotor assembly shall consist of a heat-treated alloy steel driveshaft and impeller shaft with
cast aluminium, fully shrouded impeller. The impeller shall be designed for balance thrust,
dynamically balanced and over speed tested for smooth, vibration-free operation. Insert –
type journal and thrust bearing shall be fabricated of aluminium alloy, precision bored and
axially grooved.

Internal single helical gears with crowned teeth shall be designed so that more than one
tooth is in contact all the times to provide even distribution of compressor load and quiet
operation. Each gear shall be individually mounted in its own journal and thrust bearings
to isolate it from impeller and motor forces. The shaft seal shall be spring loaded carbon
ring with precision lapped collar cooled by oil during operation. A gravity- fed oil reservoir
shall be built into the top of the compressor to provide lubrication during coast down in the
event of a power failure.

4.6 Capacity Modulation

For screw chillers, provide capacity control by means of a hydraulically activated slide
valve capable to adjust the chiller capacity to 10% of load which is located below the
rotating screw rotors. Capacity control shall be based on leaving water temperature. The
LIQUID CHILLING PACKAGES

leaving water temperature sensor shall be factory furnished and installed.

Centrifugal compressor capacity control shall be achieved by use of pre-rotation vanes to

provide fully-modulating control from full load to minimum load. Pre-rotation vane position
shall be automatically controlled by an external electric actuator to maintain constant
leaving chilled water temperature.

4.7 Refrigerant Circuit

Chiller shall have independent circuit for each compressor to provide redundancy.

Provide the following for each refrigerant circuit:

 Liquid line solenoid valve

 Filter dryer

 Liquid line sight glass

 Electronic expansion valve

 Insulated suction line with aluminium cladding.

 Suction and discharge manual shutoff valves

 High side pressure relief device

 Suction and discharge gauge (pressure and temperature)

The refrigerant piping connecting the evaporator and the condenser of large units shall be
hard drawn copper tubing and shall include all valves, fittings and accessories including
but not limited to thermostatic expansion device valve, distributor, liquid strainer, and
dehydrator. The refrigerant piping connecting the evaporator and the condenser of
unitary equipment shall be L type class and shall include all valves and fitting.

4.8 Equipment and pipework shall be fully charged with refrigerant and oil.
LIQUID CHILLING PACKAGES

5.0 MICRO-PROCESSOR / MICRO-COMPUTER CONTROL PANEL

5.1 The chilling package shall be equipped with micro-processor or micro-computer control
panel in a locked enclosure, factory mounted, wired and tested as specified in data sheet
A. The control panel shall include a alpha-numeric back-lit Liquid Crystal Display (LCD) or
Light Emitting Diode (LED) display showing all system parameters in the English
language with numeric data in MKS units.

5.2 Digital programming of essential set points through a colour coded, tactile-feel keypad
shall include:

(a) Chilled water or brine outlet temperature

(b) Percent current limit
(c) Pull-down demand limiting
(d) Seven-day time clock for starting and stopping chilling package, pumps and
cooling tower or condenser fan complete with local holiday schedule
(e) Remote re-set temperature range

5.3 All safety and cycle shut-downs shall be annunciated through the alpha-numeric display
and consist of day, time, cause of shut-down and type of re-start required.

5.4 Safety shut-downs shall include:

(a) High oil pressure

(b) High compressor discharge pressure
(c) Low evaporator pressure
(d) Motor fault
(e) Sensor malfunction

5.5 Cycling shut-downs shall include:

(a) Low chilled water or brine outlet temperature

(b) Low oil temperature
(c) Chilled water or brine low flow or interruption or chilled water or brine pump
failure
(d) Condenser water low flow or interruption or condenser water pump failure or
condenser fan failure
(e) Power fault
(f) Internal time clock
(g) Anti-recycle

5.6 System operating information shall include:

(a) Chilled water or brine inlet and outlet temperatures

(b) Condenser water inlet and outlet temperatures
(c) Evaporator and condenser refrigerant pressure
(d) Oil pressure and oil filter differential pressure
(e) Oil temperature and oil level
(f) Suction and discharge temperatures
(g) Slide valve position
(h) Chilling package status
- Start-up sequence status
- Shut-down and operational status
(i) Number of compressor starts
(j) Total hours of operation
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(k) Hours since last start

(l) Time of last start and time of last stop
(m) Compressor motor current
(n) Fault history

5.7 Security access shall be provided to prevent unauthorized change of set points to allow
local or remote control of the chilling package.

5.8 Control panel shall be interfaced with Building Automation System, if called for in data
sheet A. Control panel shall be provided with ports compatible with the Building
Automation System offered, to output all system operating data, safety and cycling shut-
down messages and a record of the last at least four safety shut-downs to a remote
printer.

5.9 Control panel shall be able to interface with Building Automation System to provide the
following:

(a) Remote chilling package start/stop

(b) Chilled water or brine temperature re-set
(c) Current limit re-set
(d) Status
- Chilling package is ready to start
- Chilling package is operating
- Chilling package is shut down on a safety requiring re-set
- Chilling package is shut down on a recycling safety

5.10 Field instruments, sensors and control wiring from field instruments and sensors to
control panel shall be in CONTRACTOR'S scope.

5.11 Control panel shall be suitable for ambient temperature 50°C.

6.0 NOISE AND VIBRATIONS

5.1 Noise level produced by any equipment individually or collectively shall not exceed 80
dB(A) measured at a distance of 1.5 metres from the source in any direction.

5.2 The overall vibration level shall be as per zones A and B of ISO 10816-1. Vibration
isolators shall be provided.
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DATASHEET FOR CHILLER PLANT

Sr.
Items Description
No.
1.0 General
a Designation Water Cooled Screw/Centrifugal Chiller
b Nos. *
c Tag Nos. *
d Location Indoor
e Duty ContinuouseContinuous (working +standby ?)
Actual Capacity Required at a
f Specified Design Conditions per *
Chilling Package (TR)
R134a / R410a / any other environment
g Refrigerant
friendly
h Maximum IKW/TR at specified 0.70
Neoprene Rubber Pads with Sole Plates, The
i Vibration Isolators Overall Vibration Level shall be As Per Zones
A and B of ISO 10816-1
j Painting As Per Manufactures Standards
k Shipping Weight, Kg *
l Operating weight, Kg *
Maximum weight of Single Component,
m *
Kg
2.0 Compressor
a Type (Open/Semi-hermatic/Hermatic) Semi-Hermatic/Hermatic
b Capacity Control Automatic 10% to 100% Capacity
3.0 Chiller
a Type Shell and Tube
b No. of Passes Even
c Chilled Water Quality Filter Water
d Chilled Water Inlet Temp. (OC) 3113
e Chilled Water Outlet Temp. (OC) 2618
Chilled Water Flow Per Chilling
f 75 (not checked)
Package (m3/hr)
g Fouling Factor (ft2hr°F/Btu) 0.0005
Maximum Chilled Water Pressure at
h *
Inlet (Kg/ cm2-g)
Maximum Chilled Water Pressure Drop
i 6
(MLC)
j Material Of Construction
Shell, End Cover and Tube Sheets Carbon Steel
Tubes Seamless Copper
k Chiller and Suction Line Insulation As Per Manufactures Standards
l Water Flow Switch *
4.0 Condenser
a Type Water Cooled , Shell and Tube
b Condenser Cooling Water Quality Filter Water
LIQUID CHILLING PACKAGES

Cooling Water Inlet/Outlet

c *
Temperatures (0C)
Maximum Cooling Water Flow Per
d 130 (not checked)
Chilling Package (m3/hr)
Maximum Cooling Water Pressure at
e *
Inlet (kg/cm2)
Maximum Cooling Water Pressure
f 4.50
Drop (MLC)
g Material of Construction
Shell, End Covers and Tubes Sheets Carbon Steel
Tubes Seamless Copper
h Fouling Factor (ft2.hrOF/Btu) 0.001
i Water Flow Switch Bidder to Provide
5.0 Motor Data
a Motor *
b Soft Starter *
c Cabling from Starter to Motor *
d Earthing from Motor to Earthing Grid *
6.0 Control Panel
a Type Micro-processor with LED/LCD Display
Control Panel to be interfaced with
b Yes
Building Automation System
Control Panel shall be suitable for
c 50 °C
temperature limit

* Bidder to furnish

Site Conditions:
Plant Site:-Wajirabad, Delhi, India
Atmospheric Temperature (Design) = 48.4 °C
Site Elevation= varied from 215.00 m to 210.00 m

Data regarding DBT (Dry Bulb Temperature), WBT (Wet Bulb Temperature), Relative Humidity
be obtained from ASHRAE Handbook.