S-6

Section 2
1.

Water Chilling Unit

(Screw)

General :
The contractor shall furnish and install where indicated on plans water chilling units.
Each unit shall be guaranteed by chilling unit manufacturer to produce a capacity of not
less than specified tons of refrigeration at specified water temperature. The construction
and rating of the chillers shall be in accordance with latest ARI standard 590 and shall
comply with ans. B 9.1 safety code, national electrical code and ASME code. Necessary
3 Ph. 50 Hz, 415 Volts, A.C. Power supply shall be made available for all units.

2.

Water Chilling Unit :

Each chilling unit shall be standard cooling model type and comprise :

2.1

Rotary screw compressor along with motor.

2.2

Condenser with accessories and supports.

2.3

Chiller with accessories, supports and insulation.

2.4

Steel structure as required for assembling/mounting the above.

2.5

Microprocessor based control panel with automatic controls and display module.

2.6

Accessories as specified/required.

2.7

Interconnecting refrigerant piping.

2.8

Full charge of R-134a refrigerant and oil.

2.9

Starter for the motor.

3.

Compresssor :

3.1

Rotary Screw
Each unit shall have a rotary screw compressor.
The rotary screw shall be manufactured from forged teel, with profile which are assymmetrical. The profile of screws, shall permit safe operation upto a speed of 3000 rpm for
50 Hz operation.
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The compressor housing shall be of high grade cast iron, machined with precision, to
provide a very close tolerance between the rotors and the housing.
The rotors shall be mounted on antifriction bearings designed to reduce friction and
power input. There shall be multiple cylindrical bearings to handle the radial and axial
loads.
There shall be built in oil resorvoir to ensure full supply of lubricants to all bearings and
a check valve to prevent back spin during shut down.
There shall be oil pump or other means of forced lubrication of all parts during
startup, running and coasting for shut down. An oil header shall be provided in the casing.
The units shall be complete with capacity control mechanism, to permit modulation
or stepped between 20% to 100% of capacity range.
An oil separator shall be included to remove oil from the refrigerent and there shall be
suitable heat exchanger for oil separation, if required.
4.

Compressor Motor :

4.1

The driving motor shall be suitable hermetic type as required, protected against damage by
means of built in protection devices.

5.

Condenser :

5.1

Each unit shall have (1) one horizontal shell and tube, water cooled, multipass condenser, fitted with safety valve, purge valve, and other safety devices.

5.2

The shell shall be of welded steel construction fitted with machined steel tube sheets on
either ends.

5.3

The tubes shall be at least 19 mm O.D. of seamless copper with integral fins. The tubes
shall be supported in the shell to avoid noise and vibrations and the ends shell be properly
expanded in the tube sheets to prevent leakage of refrigerant gas.

5.4

The water heads shall be of fabricated steel, easy to remove, with suitable baffles for
multipass water flow, in and out connections and gasket to prevent water leakage.

5.5

The condenser shall be tested against leaks, with a pressure of 17.5 kg/sq. cm (250 PSIG)
on both the shell side and the water side.

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5.6

The condenser shall be complete in all respects and shall also include :

5.6.1

Support for mounting

5.6.2 Refrigerant in and out connections.

5.6.3

Water in, out and drain connections.

5.6.4

Relief valve and purge valve.

6.

Cooler :

6.1

The cooler shall be direct expansion shell and tube type, with steel shell and seamless
copper tubes. The refrigerant head shall be removable type.The tubes shall be supported
in the shell by adequate stiff supports to eliminate vibrations and noise. The tube ends
shall be fixed firmly into the tube sheets to prevent leakage of refrigerant gas.

6.2

The cooler shall be tested and stamped against leaks in accordance with asme code for
the refrigerant being used and otherwise tested and constructed in accordance with
asme or equivalent approved code requirements.

6.3

The coioler shall have a minimum of 2 independent direct expansion refrigerant circuits.

6.4

The cooler shall be factory insulated with 19 mm thick closed cell polyvinylechloride and
further protected by means of heater cables.

7.

Controls :

7.1

All the controls shall be factory wired and located in a weather proof enclosure. These
shall include fuses, selector switch, oil safety switch, high and low pressure cutouts,
interlocks for crankcase heaters and inherent motor protection devices, fan control
thermostat, recycling pump-down circuit, high discharge temperature cutout indicator
lamps shall be provided for the compressor units.

7.2

Water chilling Machine Control System :

The water chilling unit shall be complete with microprocessor based type control system,
which shall have the following features :-

7.2.1 Electric expansion valve for economic operation of the system.

S-9
7.2.2 Self diagnostic capability to locate faults and give early warning.
7.2.3 Leaving chilled water temperature control and reset capability, with provision to
accept overide commands from a central BMS system.

7.2.4 Automatic sequencing of various functions for starting, running and stopping of the
various components of the unit based on demand.
7.2.5 A programmable microprocessor complete with key pad and led display window to
perform the above fuctions.
7.3

The control package shall also consist of, but not limited to, the following components :

7.3.1 Low control voltage to unit.

7.3.2 Field power and control circuit terminal blocks.
7.3.3 On/off switch.
7.3.4 Replaceable relay board.
7.3.5 Leaving chilled water set point board.
7.3.6 Desiagnostic digital display module.
7.3.7 Microprocessor board.
7.3.8 Temperature reset board.
7.4

The control system shall have an extended module for control and monitoring from a
control location including the reset of chilled water temperature.

7.5

All controls should be of DDC type and fitted with necessary hard wares suitable for
interfacing with building management system and shall be an integral part of the
control panel.

7.6

Power Consumption
The IKW of the chiller shall not be more than 0.8 kw/TR under full load condition,
and under given parameters. The NPLV of the chiller shall be less than 0.6 kw/TR. The
supplier has to confirm that the kw/TR data for chilling unit submitted by him has been
selected at the specified operating parameters and at constant condenser entering water
temperature.
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8.

Refrigerant Circuit :
The refrigerant piping between compressors, chiller and condenser shall be of heavy
gauge copper with brazed joints. The circuit shall include sight glass, moisture
indicator, solenoid valves, electronic expansion valves, filter driers and necessary shut
off valves with charging connections.

9.

Unit Casing :

All the above components shall be housed in an outer

casing fabricated from
galvanised steel, zinc phosphated with multiple coats of baked enamel paint to make
the whole casing wheather proof for outdoor installation. Removable panels shall be
provided for access to all working parts.
10.

Miscellaneous :
Each system shall be provided with the following :-

10.1

Necessary charge of refrigerant gas and lubricating oil.

10.2

Spring vibration isolators below the unit rated by the isolator manufacturers to absorb
90% of unit vibration and as approved by the engineer.

11.

Limitations :
The water velocity in the cooler shall not exceed 10 FPS (3 m/s). The fouling factor for
the cooler shall be 0.0005. (Fps units).

End of Section 2

DMRC2.doc