160 67-N2 PDF

STEAM TURBINE
CENTRIFUGAL LIQUID CHILLERS
INSTALLATION INSTRUCTIONS Supersedes: 160.67-N2 (1109) Form 160.67-N2 (114)
MODEL YST
UNITS MANUFACTURED AFTER DECEMBER 2006
LD12189
Issue Date:
January 10, 2014
FORM 160.67-N2
ISSUE DATE: 1/10/2014
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. which it is situated, as well as severe personal injury or
During installation, operation maintenance or service, death to themselves and people at the site.
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants, This document is intended for use by owner-authorized
materials under pressure, rotating components, and operating/service personnel. It is expected that these
both high and low voltage. Each of these items has the individuals possess independent training that will en-
potential, if misused or handled improperly, to cause able them to perform their assigned tasks properly and
bodily injury or death. It is the obligation and respon- safely. It is essential that, prior to performing any task
sibility of operating/service personnel to identify and on this equipment, this individual shall have read and
recognize these inherent hazards, protect themselves, understood this document and any referenced mate-
and proceed safely in completing their tasks. Failure rials. This individual shall also be familiar with and
to comply with any of these requirements could result comply with all applicable governmental standards and
in serious damage to the equipment and the property in regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation Identifies a hazard which could lead to

which will result in death or serious injury damage to the machine, damage to other
if proper care is not taken. equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Indicates a potentially hazardous situa- Highlights additional information useful

tion which will result in possible injuries to the technician in completing the work
or damage to equipment if proper care is being performed properly.
not taken.
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.
2 JOHNSON CONTROLS
FORM 160.67-N2
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin- these documents, the technician should verify whether
uous product improvement, the information contained the equipment has been modified and if current litera-
in this document is subject to change without notice. ture is available from the owner of the equipment prior
Johnson Controls makes no commitment to update or to performing any work on the chiller.
provide current information automatically to the man-
ual owner. Updated manuals, if applicable, can be ob- CHANGE BARS
tained by contacting the nearest Johnson Controls Ser- Revisions made to this document are indicated with a
vice office or accessing the Johnson Controls QuickLIT line along the left or right hand column in the area the
website at http://cgproducts.johnsoncontrols.com. revision was made. These revisions are to technical in-
Operating/service personnel maintain responsibility for formation and any other changes in spelling, grammar
the applicability of these documents to the equipment. or formatting are not included.
If there is any question regarding the applicability of
ASSOCIATED LITERATURE
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
JOHNSON CONTROLS 3
FORM 160.67-N2
NOMENCLATURE
The model number denotes the following characteristics of the unit.
YST VF VD J4 - KD71750090 - 14 - 0.6 - 33192C - F S

Chiller Special (Mandatory)
Model
Design Level
Evaporator Code
Steam Condenser Model
Turbine Expansion Ratio

Condenser Code
No. of Turbine Nozzels
Compressor Code Steam Turbine Base Model
4 JOHNSON CONTROLS
FORM 160.67-N2
TABLE OF CONTENTS
SECTION 1 - INTRODUCTION..................................................................................................................................9
Field Assembled Units ...................................................................................................................................... 9
Inspection - Damage - Shortage....................................................................................................................... 9
Shipment........................................................................................................................................................... 9
Turbine Bearing Disassembly To Remove Mylar Shipping Film...................................................................... 12
Flow Rates...................................................................................................................................................... 12
Chilled Water................................................................................................................................................... 13
Refrigerant Condenser Water Circuit.............................................................................................................. 13
Steam Condenser Package............................................................................................................................ 13
Floor Mounted Steam Condenser (Optional).................................................................................................. 13
Steam Turbine Casing Drain Options.............................................................................................................. 13
Remote Steam Turbine Gaugeboard (Optional - Field Installed).................................................................... 14
Chiller Data Plate...................................................................................................................................14
Location..................................................................................................................................................14
Clearance...............................................................................................................................................14
Installation Check - Request For Start-Up Service..........................................................................................14
SECTION 2 - RIGGING............................................................................................................................................15
Chiller Rigging - (Less Surface Condenser).................................................................................................... 15
Steam Condenser Package Rigging............................................................................................................... 17
Rigging Unit To Final Location......................................................................................................................... 17
Locating And Installing Isolator Pads.............................................................................................................. 17
Checking The Isolation Pad Deflection........................................................................................................... 17
Leveling The Unit............................................................................................................................................ 17
SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS................................................................ 19

Customer Components................................................................................................................................... 19
Steam Inlet Strainer................................................................................................................................19
Steam Inlet Moisture Separator.............................................................................................................. 19
Steam Inlet Block Valve..........................................................................................................................19
Steam Turbine Casing Drain..................................................................................................................19
Permanent Strainers..............................................................................................................................19
Stop Valves............................................................................................................................................19
Drain and Vent Valves............................................................................................................................19
SECTION 4 - CUSTOMER PIPING..........................................................................................................................21

Customer Piping Requirements...................................................................................................................... 21
Pressure Powered Pump................................................................................................................................ 21
Piping Connections - Water/Drains................................................................................................................. 21
Piping Connections - Steam/Vents.................................................................................................................. 21
Steam Condenser Vacuum Pump Seal Water....................................................................................... 21
Steam Condenser Relief Valve Seal Water............................................................................................ 21
Piping Connections - Refrigerant Vents................................................................................................. 21
Air (Instrument Quality Air Source - ISA S7.3) ....................................................................................... 22
Steam And Condensate Piping....................................................................................................................... 22
Steam Piping................................................................................................................................................... 22
JOHNSON CONTROLS 5
FORM 160.67-N2
TABLE OF CONTENTS (CONT'D)
Governor Valve And Spool Piece (Factory Supplied - Field Installed)............................................................ 23

Top-Mounted Steam Condenser (Factory Supplied - Field Installed).............................................................. 23
Expansion Joint Installation (Factory Supplied - Field Installed)..................................................................... 25
Design Data............................................................................................................................................25
Inlet Steam Temperature Sensor and Inlet Steam Pressure Transducer (Factory Supplied-Field Installed) .26
Pipe Strain Testing.......................................................................................................................................... 28
Steam Piping Recommended Blow-Down Procedure .................................................................................... 29
Gland Seal Leak-Off Piping ............................................................................................................................ 30
Gland Leak-Off Condenser (Optional)............................................................................................................. 30
Steam Ring Drain............................................................................................................................................ 31
Steam Turbine Casing Drains......................................................................................................................... 31
Pressure Powered Pump................................................................................................................................ 31
Steam Relief.................................................................................................................................................... 32
Steam Condenser Package Hydrostatic Test.................................................................................................. 32
Refrigerant Relief Piping................................................................................................................................. 33
SECTION 5 - DRIVELINE ALIGNMENT..................................................................................................................37

Alignment........................................................................................................................................................ 37
Checking For Sag............................................................................................................................................ 39
Coupling Spacer Installation............................................................................................................................ 40
SECTION 6 - FIELD INSTALLED WIRING..............................................................................................................41

Power Wiring................................................................................................................................................... 41
Turbine Instruments ........................................................................................................................................ 41
KD Turbine.............................................................................................................................................41
KG Turbine.............................................................................................................................................41
Steam Condenser Wiring Kit (Optional Floor Mounted Steam Condenser).................................................... 41
6 JOHNSON CONTROLS
FORM 160.67-N2
LIST OF FIGURES
FIGURE 1 - Model YST Chiller��10

FIGURE 2 - Optional Turbine Gaugeboard Connections ��14
FIGURE 3 - Rigging��15
FIGURE 4 - Steam Condenser Package Rigging��16
FIGURE 5 - Neoprene Isolators��18
FIGURE 6 - Steam Condenser��24
FIGURE 7 - Turbine Exhaust Expansion Joint Connector��26
FIGURE 8 - KD Turbine Field Installed Components��27
FIGURE 9 - KG Turbine Field Installed Components��27
FIGURE 10 - Pipe Strain��29
FIGURE 11 - A
utomatic Pressure Powered Pump��32
FIGURE 12 - Typical Refrigerant Vent Piping��33
FIGURE 13 - Typical Piping Arrangement��34
FIGURE 14 - Typical Arrangement For "Face - O.D." Readings To Determine Cold Alignment Of Shafts�� 38
FIGURE 15 - M
easuring "Sag" Of Indicator/Clamp System��39
FIGURE 16 - Typical "Reverse Indicator" To Determine Cold Alignment Of Shafts�� 39
FIGURE 17 - Coupling Shim Placement��40
FIGURE 18 - Governor Valve And Spool Piece��42
FIGURE 19 - Din Connector Wiring��42
JOHNSON CONTROLS 7
FORM 160.67-N2
THIS PAGE INTENTIONALLY LEFT BLANK
8 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 1 - INTRODUCTION 1
This instruction describes the installation of the YORK INSPECTION - DAMAGE - SHORTAGE
Model YST Centrifugal Liquid Chiller Unit. This unit
The unit shipment should be checked on arrival to see
is completely factory-packaged including; the evapo-
that all major pieces, boxes and crates are received.
rator, refrigerant condenser, compressor, steam turbine,
Each unit should be checked on the trailer or rail car
lubrication systems, power panel, control center, and
when received, before unloading, for any visible signs
all interconnecting unit piping and wiring.
of damage. Any damage or signs of possible damage
The steam condenser package is shipped separately and must be reported to the transportation company imme-
suitable for direct mounting onto the chiller or mount- diately for their inspection.
ing along side the chiller. Refrigerant and oil charges JOHNSON CONTROLS will not be re-
shipped separately unless optional refrigerant condens- sponsible for any damage in shipment
er isolation valves and Form 1 shipment are ordered. or at job site or loss of parts. (Refer to
Chillers shipped dismantled MUST be field assembled shipping damage claims, form 50.15-NM)
under the supervision of a Johnson Controls represen-
tative, but otherwise installation will be as described in
this instruction. When received at the job site all containers should be
opened and contents checked against the packing list.
FIELD ASSEMBLED UNITS Any material shortage should be reported to YORK
A Johnson Controls representative must be used to immediately.
check the installation, supervise the initial start-up and
operation of all chillers installed within Continental SHIPMENT
United States. Units shipped dismantled MUST be re-
The Johnson Controls Warranty may be assembled by, or under the supervision
voided if the following restrictions are not of, a Johnson Controls representative.
adhered to:
1. No valves or connections should be
opened under any circumstances because The chiller may be ordered and shipped in any of the
such action will result in loss of the factory following forms:
nitrogen charge.
Form 1 - Factory Assembled Unit. (steam condenser
2. Do not dismantle or open the chiller for
package shipped separately) refrigerant and oil are fac-
any reason except under the supervision
tory charged.
of a Johnson Controls representative.
3. When units are shipped dismantled, 1. The compressor/turbine driveline assembly
notify the nearest Johnson Controls of- mounted, with all necessary interconnecting pip-
fice in ample time for Johnson Controls ing assembled. OptiView ™ Control Center is
representative to supervise rigging the unit mounted on the unit. Complete unit factory leak
to its operating position and the assembly tested, evacuated and charged with R-134a.
of components. 2. Miscellaneous material - Partial pre-fabricated
4. Do not make final power supply con- steam exhaust piping and four (4) neoprene isola-
nections to the power panel. tion pads.
5. Do not charge the compressor with oil. Form 2 - Factory Assembled Unit. (steam condenser
6. Do not charge the unit with refrigerant. package shipped separately.) Refrigerant and oil charg-
es shipped separately.
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.
JOHNSON CONTROLS 9
FORM 160.67-N2
SECTION 1 - INTRODUCTION
STEAM TURBINE
VACUUM BREAKER
SOLENOID VALVE
STEAM CONDENSER
PACKAGE
TURBINE OIL
COOLING WATER
INLET VALVE
COMPRESSOR OIL COOLING

WATER INLET VALVE
TURBINE
BOX
CONTROL COMPRESSOR
CENTER
POWER
PANEL
CONDENSER
HOT GAS BYPASS EVAPORATOR
VALVE
NOTE: KD Turbine shown
LD12215
Figure 1 - MODEL YST CHILLER
10 JOHNSON CONTROLS
FORM 160.67-N2
ATMOSPHERIC RELIEF
VALVE
STEAM CONDENSER
PACKAGE
CONDENSATE
OVERBOARD
VALVE
CONDENSATE
RECIRCULATION
VALVE
HOTWELL
CONDENSATE
PUMP #1
120/460VAC
JUNCTION BOX
HOTWELL
CONDENSATE PUMP #2
(OPTIONAL) VACUUM PUMP #1
HOTWELL
CONDENSATE LEVEL VACUUM PUMP #2
INDICATOR / TRANSMITTER
VACUUM PUMP #2
SEALING WATER
SOLENOID VALVE
VACUUM PUMP #2
SEALING WATER
FLOW SWITCH
LD12216
FIGURE 1 – MODEL YST CHILLER (CONT'D)
JOHNSON CONTROLS 11
FORM 160.67-N2
1. The compressor/turbine driveline assembly When more than one chiller is involved, the major
mounted, with all necessary interconnecting pip- parts of each unit will be marked to prevent mixing of
ing assembled. OptiView ™ Control Center is assemblies. Both shells and driveline for a specific unit
mounted on the unit. Complete unit factory leak will be marked with the sales order and alphabetic let-
tested, evacuated and charged with holding charge ter for identification.
of nitrogen.
For example; order number 06-123456-01A, both
2. Miscellaneous material - Partial pre-fabricated shells and driveline will be painted with the identi-
steam exhaust piping and four (4) neoprene isola- fication 06-123456-01A. The next set of shells and
tion pads. driveline will have the sales order with letter B, such as
06-123456-01B.
Form 3 - The compressor/turbine driveline assembly
is separate from the shells - Shipped as three major TURBINE BEARING DISASSEMBLY TO
assemblies. Unit first factory assembled, refrigerant REMOVE MYLAR SHIPPING FILM
piped, wired and leak tested; then dismantled for ship-
Mylar shipping film must be removed
ment. The compressor/turbine driveline assembly is re-
from bearings before any attempts are
moved from the shells and skidded. Evaporator/Refrig-
made to rotate turbine shaft.
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 The Murray turbine will be shipped with a Mylar ship-
remains on the driveline skid. All openings on com- ping film between the top bearing assembly and the
pressor, oil separator, and shells are closed and charged turbine shaft on both ends of the turbine. This Mylar
with dry nitrogen (2 to 3 PSIG) (14-21kPa). film should be removed from both capsules before any
attempts are made to rotate the turbine shaft. The bear-
Miscellaneous packaging of control center, tubing, wa-
ing housing and bearing top cap will have to be re-
ter temperature controls, wiring, oil, etc.; refrigerant
moved in order to remove the Mylar film. Care must be
charge shipped separately. Partial pre-fabricated steam
taken during the removal of the mylar film to protect
exhaust piping and neoprene isolation pads are shipped
the vibration probes (if supplied), temperature sensors,
loose.
and other electrical connections that are present on the
Form 7 - Split Shells - Shipped as four major assem- bearing housings. When re-assembling the bearing
blies. Unit first factory assembled, refrigerant piped, housing components, a sealant equal to Tite Seal joint
wired and leak tested; then dismantled for shipment. sealing compound or Permatex Hylomar HPF product
Compressor/turbine driveline assembly removed from will properly seal the split line of the bearing capsule.
shells and skidded. The Steam Condenser package is
shipped separately. FLOW RATES
For normal water chilling duty, evaporator and refrig-
Evaporator and refrigerant condenser shells are sepa-
erant condenser flow rates are permitted at water ve-
rated at tube sheets and are not skidded. Refrigerant
locity levels in the heat exchangers tubes between 3 ft/
lines between shells are flanged and capped, requiring
sec and 12 ft/sec (0.9 m/s and 3.7 m/s). Variable flow
no welding. All wiring integral with compressor is left
applications are possible, however, chiller selections
on it.
must be made using a water velocity within the range
All wiring harnesses on shells are removed. Turbine noted above.
lube system/piping remains on driveline skid. All open- Variable flow in the refrigerant condenser is not recom-
ings on compressor and shells are closed and charged mended, as it generally raises the energy consumption of
with dry nitrogen (2 to 3 PSIG) (14-21kPa). the system by keeping the refrigerant condenser pressure
Miscellaneous packaging of control center, tubing, high in the chiller. Additionally, the rate of fouling in the
water temperature controls, wiring, oil, etc; refrigerant refrigerant and steam condensers will increase at lower
charge shipped separately. Partial pre-fabricated steam water velocities associated with variable flow, raising
exhaust piping and neoprene isolation pads are shipped system maintenance costs. Cooling towers typically
loose. have narrow ranges of operation with respect to flow
rates and will be more effective with full design flow.
12 JOHNSON CONTROLS
FORM 160.67-N2
CHILLED WATER and crates are received. Each Steam Condenser pack-
age should be checked on the trailer or rail car when 1
Foreign objects which could lodge in, or block flow
received, before unloading, for any visible signs of
through the evaporator and refrigerant condenser tubes
damage. Any damage or signs of possible damage must
must be kept out of the water circuit. All water piping
be reported to the transportation company immediately
must be cleaned or flushed before being connected to
for their inspection.
the chiller, or other equipment.
When the optional factory piping kit is ordered for the
Thermal type water flow switches are factory mounted steam exhaust trunk, lifting lugs are provided loose
in the chilled and condensed water nozzles and are fac- with the piping to be located and welded at the job site,
tory wired to the OptiView ™ control panel. These sol- in a suitable location to enable the rigging of the major
id-state flow sensors have a small internal heating ele- piping assemblies. The optional piping kit is provided
ment and use the cooling effect of the flowing fluid to as partial pre-fabricated to be final trimmed/fitted and
sense when an adequate flow rate has been established. welded at the site. Welding back-up rings are provided
with the piping kit.
REFRIGERANT CONDENSER WATER
CIRCUIT FLOOR MOUNTED STEAM CONDENSER
The chiller is engineered for maximum efficiency at (Optional)
both design and part load operation by taking advantage As an alternative to the standard YST arrangement,
of the colder cooling tower water temperatures which the steam condenser package can be ordered for floor
naturally occur during the winter months. Appreciable mounting adjacent to the chiller package. Prefabricat-
power savings are realized from these reduced heads. ed piping kits for the steam trunk, and water piping
The minimum entering refrigerant condenser water between chiller package and steam condenser are not
temperature for other full and part load conditions is included with a floor mounted arrangement. These in-
provided by the following equation: terconnecting components must be designed, supplied
and installed by others.
Min. ECWT = LCHWT - C RANGE + 17°F
An optional piping kit may be ordered
Min. ECWT = LCHWT - C RANGE + 9.4°C from the factory when the original
equipment is placed.
where:
ECWT = Entering refrigerant Condensing Water Tem-
perature. External piping loads to the steam inlet
LCHWT = Leaving Chilled Water Temperature and water box connections should be
minimized. Allowable nozzle loads are
CONTROL RANGE = refrigerant condensing water available upon request if any concerns
temperature range at the given load condition. develop.
At initial startup, entering condensing water tempera-
ture may be as much as 25°F (14°C) colder than the STEAM TURBINE CASING DRAIN OPTIONS
standby chilled water temperature as long as it is above The steam turbine casing must be provided with a
the minimum ECWT allowed. means of draining during operation (while under vacu-
um). Factory available options are:
STEAM CONDENSER PACKAGE
• Automatic pressure powered pump (standard op-
The Steam Condenser package is shipped separately
tion)
as a packaged assembly. The Steam Condenser pack-
age consists of a skid mounted surface condenser with • Manual condensate drain tank (by special quote)
pre-piped accessories for the condensate and vacuum • Automatic condensate drain tank (by special
systems. The atmospheric relief valve is shipped loose quote)
for field assembly.
When the factory casing drain option is supplied,
The Steam Condenser package shipment should be the equipment is shipped loose for installation at the
checked on arrival to see that all major pieces, boxes jobsite.
JOHNSON CONTROLS 13
FORM 160.67-N2
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.
LD12217
Chiller Data Plate
Figure 2 - OPTIONAL TURBINE GAUGEBOARD
A unit data plate is mounted on the control center as- CONNECTIONS
sembly of each unit, showing unit model number, de-
sign working pressure, water passes, refrigerant charge,
INSTALLATION CHECK -
and serial numbers.
REQUEST FOR START-UP SERVICE
Location To avoid possible equipment damage and to ensure
YORK Chillers are furnished with neoprene vibration warranty coverage, a Johnson Controls representative
isolator mounts for basement or ground level installa- must verify the installation and supervise the initial
tions (see Figure 5 on page 18). Units may be locat- startup and operation on all chillers installed within the
ed on upper floor levels providing the floor is capable Continental United States. After the unit is installed,
of supporting the total unit operating weight. piped and wired as described in this Instruction, but be-
fore any attempt is made to start the unit, the Johnson
Clearance Controls District Office should be advised so that the
Sufficient clearance to permit normal service and start-up service can be scheduled.
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.
14 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 2 - RIGGING
Refer to Engineering Guide 160.67-EG1

for dimensions and Base Unit weights.
LD09288a
Figure 3 - RIGGING
To prevent equipment damage, a Johnson

CHILLER RIGGING - (LESS SURFACE
Controls representative must verify the
CONDENSER)
installation prior to the unit being started,
and supervise the initial startup and op- The complete standard chiller is shipped without skids.
eration on the chiller. When optional skids are used it may be necessary to
remove the skids so riggers skates can be used under
The chiller package and Steam Con- the unit end sheets to reduce overall height.
denser package must be rigged separately.
Each unit has four (4) lifting holes (two in each end)
Never attempt to rig the entire YST pack-
in the end sheets which should be used to lift the unit.
age with the Steam Condenser chiller
installed. The Steam Condenser package Care should be taken at all times dur-
must be mounted on the chiller after the ing rigging and handling of the chiller
chiller package has been installed in its to avoid damage to the unit and its
final location. external connections. Lift the unit only
using spreader bars and the holes in
Units shipped dismantled should be the endsheets as shown in Figure 3.
assembled under the supervision of a
Johnson Controls representative. 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 CONTROLS 15
FORM 160.67-N2
SECTION 2 - RIGGING
LD09388
Figure 4 - STEAM CONDENSER PACKAGE RIGGING
16 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 2 - RIGGING
STEAM CONDENSER PACKAGE RIGGING LOCATING AND INSTALLING ISOLATOR

PADS
Lifting lugs are provided at the four corners of the
structural steel skid, and lifting eyes are provided on The isolator pad mounts are to be located as shown in
the condenser shell. Use chains or equalizing cables Figure 5 on page 18. After the isolator pads have 2
and spreader bars, as necessary, to prevent contact with been placed into position on the floor, lower the chiller
the piped accessories. See Figure 4 on page 16 for onto the pads. When the unit is in place, remove the
Steam Condenser package rigging recommendations. rigging equipment and check that the unit is level. The
unit should be level within 1/4” (6 mm) from one end
All lifting should be performed slowly with frequent to the other end and from front to the rear. If the chiller
inspection from level. All lifting should be performed is not level within the amount specified, lift it and place
slowly with frequent inspection of cables or chains shims between the isolation pad and the chiller tube
which may apply pressure on piping or accessories. sheets. Shims are included with the isolator kit. Lower
The condenser skid can be lifted or moved with fork- unit again and recheck to see that it is level.
lift trucks. Keep load bearing surfaces isolated on the
structural steel only. CHECKING THE ISOLATION PAD DEFLECTION
The chiller package and Steam Con- All isolation pads should be checked for the proper de-
denser package must be rigged sepa- flection while checking to see if the unit is level. Each
rately. Never attempt to rig the entire pad should be deflected approximately 0.10 inches (2.5
YST package with the Steam Con- mm) to 0.20 inches (5 mm). If an isolation pad is un
denser chiller installed. The Steam der deflected, shims should be placed between the unit
Condenser package must be mounted tube sheet and the top of the pad to equally deflect all
on the chiller after the chiller package pads.
has been installed in its final location.
LEVELING THE UNIT
The longitudinal alignment of the unit should be
RIGGING UNIT TO FINAL LOCATION
checked by placing a level on the top center of the
Rig the chiller package to its final location on the floor evaporator shell under the compressor assembly. Trans-
or mounting pad, lift the unit (or shell assembly) by verse alignment should be checked by placing a level
means of an over head lift and lower the unit to its on top of the shell tube sheets. After the Steam Con-
mounting position. If optional shipping skids are used, denser package has been installed in place, care should
remove them before lowering the chiller to its mount- be taken in leveling the condenser package, shimming
ing position. at the skid/tubesheet, if necessary.
JOHNSON CONTROLS 17
FORM 160.67-N2
SECTION 2 - RIGGING
LD12218 LD12219
UNIT WEIGHT 28,836 to 53,530 LBS. UNIT WEIGHT 53,531 to 100,464 LBS.
(13,108 to 24,332 Kgs.) (24,333 to 45,666 Kgs.)
LD12220
UNIT WEIGHT 100,465 to 130,000 LBS.
45,667 to 58,967
See YORK standard arrangement

drawings for floor layout of Neoprene
Isolators by model.
Figure 5 - NEOPRENE ISOLATORS
18 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS
CUSTOMER COMPONENTS Permanent Strainers

Steam Inlet Strainer Permanent strainers are recommended in both the
evaporator and refrigerant condenser water circuits to
Full flow strainer with fine [3/64” (1.2 mm) perfora-
tions], stainless steel mesh, suitable for steam service.
protect the chiller as well as the pumps, tower spray 3
nozzles, chilled water coils and controls, etc. The
Steam Inlet Moisture Separator strainer must be installed in the entering chilled water
line, directly up stream of the chiller. Water piping cir-
Steam supply to turbine must be dry & saturated for cuits should be arranged so that the pumps discharge
optimum efficiency, and to help prevent damage to tur- through the chiller, and should be controlled as neces-
bine and/or governor valve. sary to maintain essentially constant chilled and refrig-
erant condenser water flows through the unit at all load
Steam Inlet Block Valve
conditions.
Manual globe valve for inlet steam isolation.
If pumps discharge through the chiller, the strainer
Steam Turbine Casing Drain may be located upstream from pumps to protect both
pump and chiller. (Piping between strainer, pump and
The steam turbine casing must be provided with a
chiller must be very carefully cleaned before start-up.)
means of draining during operation (while under vac-
If pumps are remotely installed from chiller, strainers
uum). Available factory options for this function are
should be located directly upstream of the chiller.
an automatic pressure powered pump, a manual con-
densate drain tank or an automatic condensate drain
Stop Valves
tank. A connection is provided on the steam condenser
hotwell for customer connection of the casing drain Stop valves may be installed in the evaporator and re-
equipment outlet, i.e. condensate outlet of automatic frigerant condenser water piping adjacent to the unit
pressure powered pump, or drain tank may be piped to to facilitate maintenance. Thermometer wells and pres-
the steam condenser hotwell (piping by others). sure taps should be provided in the piping as close to
the unit as possible to facilitate operational check.
Never pipe turbine casing drain directly
to the steam condenser hotwell. Tur- Drain and Vent Valves
bine casing drains by gravity only and
Drain and vent valves should be installed in the con-
must be pumped to steam condenser
nections provided in the evaporator and refrigerant
hotwell by means of condensate handling
condenser water boxes. These connections may be
equipment.
piped to drain if desired.
An automatic pressure powered pump is
factory supplied when the system auto-
start option is ordered.
JOHNSON CONTROLS 19
FORM 160.67-N2
SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS
20 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 4 - CUSTOMER PIPING
CUSTOMER PIPING REQUIREMENTS Approximately 20 psig (138kPa) dis-

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

• Steam turbine gland leak off drain.
• Steam turbine steam ring drain
• Steam condenser condensate overboard valve
JOHNSON CONTROLS 21
FORM 160.67-N2
Air (Instrument Quality Air Source - ISA S7.3) Steam inlet piping for the standard YST condensing
• Bearing seal air purge and governor valve posi- turbines should include a full-size block valve in the
tioner: 80-150 psig (552 - 1030kPa), approx. 13 main steam inlet line.
SCFM (22 sm3/h). Exhaust piping is available as an optional kit for field
• Steam condenser level control system: 80-150 installation. A relief valve to protect the turbine ex-
psig (138 - 1030kPa), approx. 0.5 SCFM (0.9 haust casing and surface condenser is provided on
sm3/h). the steam condenser package for standard YST chill-
ers. Piping for special back pressure turbines should
• Trip and steam control: 80-150 psig include a throttle valve in the steam inlet line and a
(552 - 1030kPa), approx. 0.4 SCFM (0.7 sm3/h). stop valve in the exhaust line. A suitable relief valve
to protect the turbine exhaust casing must be provided
STEAM AND CONDENSATE PIPING between the turbine exhaust flange and the exhaust
A suitable piping arrangement with stop valve. The exhaust relief valve or the rupture disc
flexible type joints and piping supports/ should correspond in size to those indicated for steam
hangers, as required, must be provided and exhaust lines found in APPENDIX-A of NEMA
for the steam inlet line to the turbine. It SM 23-8, Steam Piping Systems manual.
is recommended that a piping analysis
These relief valves serve to protect the turbine casing
be performed by a qualified engineer to
against over-pressurization in case the turbine is started
verify the design adequately protects the
with the exhaust valve closed or the backpressure rises
steam turbine from excessive strains due
for any reason during operation. The relief valve should
to system/thermal loads. Maximum al-
be of sufficient capacity to relieve the rated steam flow
lowable loads on steam connections are
of the turbine at the maximum operating pressure spec-
governed by NEMA SM23 Steam Turbines
ified when all hand valves are Contact YORK Factory
for Mechanical Drive Services.
Service for specifications on sizing the valve, relieving
capacity, and over-pressurization limits.
STEAM PIPING
Steam inlet and exhaust piping (if not supplied by
Inlet and exhaust piping for the steam turbine should
YORK) must be properly designed and supported so
be designed and installed by knowledgeable persons
that its weight and thermal expansion will not produce
experienced in turbine work. The size of steam inlet
excessive strains on the turbine inlet or exhaust flang-
line is based upon velocities in the piping generally ac-
es, either when cold or when at normal operating tem-
cepted as being good practice for runs of straight pipe
perature. The piping must be designed so that it does
up to 200 feet, or the equivalent in valves and fittings.
not have to be sprung into position for bolting to the
The piping contractor must ensure that the steam sup-
turbine flanges when cold. Likewise, the piping must
ply is available at the turbine flange at the temperature
not be spring out of position when everything is at run-
and pressure required to achieve the design capacity of
ning temperature.
the chiller.
Force due to thermal expansion must
Johnson Controls assumes no responsi-
be accounted for, which can cause mis-
bility in regard to pressure or temperature
alignment. Refer to NEMA SM 23, Part
drops. The performance of the turbine
8 (Steam Piping Systems) for additional
specified is based upon the inlet pressure
information.
and temperature as measured at the tur-
bine steam inlet flange.
22 JOHNSON CONTROLS
FORM 160.67-N2
Factory supplied STANDARD steam ex- there are no forces acting on the turbine steam supply
haust piping does NOT require additional connection point (refer to NEMA SM 23, part 8) when
support or pipe hangers. 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
Moisture in the inlet steam not only increases the steam NOT be supported from the turbine base.
consumption but causes rapid wear of the valve seats, Any external force or moment exerted on
nozzles and turbine blades. A moisture separator and the turbine may lead to drive line mis- 4
steam trap must be installed at the low point of the inlet alignment and subsequent turbine and/
piping to ensure that the turbine receives dry steam. or compressor failure.
Where exhaust piping bends upward after leaving the
turbine, steam traps must be provided to keep the ex- TOP-MOUNTED STEAM CONDENSER
haust line drained to prevent water from building up in (Factory Supplied - Field Installed)
the exhaust pipe and turbine casing. To locate the steam condenser package, the steam con-
Failure to keep the exhaust line drained denser water inlet must be aligned with the refrigerant
may result in a restriction in the exhaust condenser water outlet, before attaching the mount-
line, causing a loss of power and damage ing brackets. Refer to the Steam Condenser Field Kit
to the turbine rotor. Connecting the steam Drawing and associated Field Notes included in the job
line should always begin at the header or manual for detailed installation instructions.
other source, the turbine connection being
See Figure 6 on page 24
made last. If an expansion joint is used in
either line it must be securely anchored to 1. Complete the water line between the (2) connec-
prevent axial strain on the turbine. tions before bolting the angles to the steam con-
denser base, and welding the angles to the refrig-
Be sure to blowout and clean all steam erant condenser tube sheet. See Figure 6 on page
lines before connecting to the turbine. 24.
Failure to do so may result in damage to
the steam strainer screen and other inter- 2. Condenser water outlet to steam condenser may
nal parts. Johnson Controls accepts no be at either end of unit. When required, victaulic
responsibility for damage resulting from couplings are not YORK factory supplied.
the entrance of foreign materials (refer 3. Partial prefabricated pipe caps or covers are fac-
to the procedure covered in this manual). tory supplied to provide reasonable protection of
internally blasted surfaces. Note: brush off blast-
Steam inlet connection must be loosened ing may be required prior to field assembly.
during the pipe strain testing procedure
described in this section 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.
GOVERNOR VALVE AND SPOOL PIECE
(Factory Supplied - Field Installed) 5. Prefabricated piping should not be stored out-
doors. If stored outside. The piping must be cov-
The factory supplied field installed spool piece and ered with a waterproof tarp, and not directly ex-
governor valve must be supported along with the rest posed to the weather. Pipe must not be stood on
of the steam supply piping. It is the installer's/install- end, any and all damage to caps or closures must
ing contractor's responsibility to ensure the steam sup- be repaired immediately.
ply pip opened. ing, field installed governor valve, and
field installed spool piece are fully supported so that
JOHNSON CONTROLS 23
FORM 160.67-N2
6. The installing contractor must inspect the steam 8. All applicable state, county, city and local laws,
exhaust expansion joint (YORK supplied) prior to rules and regulations pertaining to construction,
installation to verify that the tie rod nuts are set to installation and inspection of steam and water pip-
allow zero compression in the axial direction. ing shall beconformed to.
7. All finish painting. Touching up or special paint- 9. Installing contractor is responsible for fit and
ing to be done in field form of turbine steam and condenser water piping
shown. Unnecessary strain on turbine and con-
denser nozzles must be avoided.
6WHDP
&RQGHQVHU
%DVH
5HIULJHUDQW
&RQGHQVHU
7XEHVKHHW
7<3

'(7$,/³$´
6HH'HWDLO³$´
$WPRVSKHULF
(YDSRUDWRU &RQGHQVHU 5HOLHI9DOYH
6WHDP([KDXVW
:DWHU3LSH
:LWK)ODQJHV :DWHU3LSH
6WHDP&RQGHQVHU
3DFNDJH
([SDQVLRQ-RLQW
&RPSUHVVRU
6WHDP
7XUELQH
&RQGHQVHU 3DFNDJH
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Figure 6 - STEAM CONDENSER
24 JOHNSON CONTROLS
FORM 160.67-N2
EXPANSION JOINT INSTALLATION 4. Nuts are tack-welded once connector is correctly

(Factory Supplied - Field Installed) field-installed per instructions.
1. The as-shipped expansion joint, with the tack- Design Data
welded shipping brackets attached, defines the
zero-referance point for as-installed tolerances. Axial Compression: NONE
Therefore, the shipping brackets should be left Axial Extension: NONE
on the expansion joint during installation, and
only removed after the mating piping is fully Lateral Deflection: 1/8"
assembled and meets the as-installed toleranc- 4
Angular Rotation: NONE
es.
Installation Tolerances:
2. As-installed tolerances: Radial: + 1/16"
Radial alignment: During installation, the flange Axial: +1/4", -1/2"
must not be forced more than 1/16" radially to line Parallelism: + 1/8"
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 Refer to the installation drawing included with the fac-
be no greater than +/- 1/8" out of parallel, I.E., tory supplied expansion joint (top-mounted surface
Two overall length measurements taken 180° condensers) for detailed installation notes and instal-
apart from each other at the outside diameter of lation tolerances.
the overall length measurements take 180° apart
Shipping brackets should be left on the
from each other at the outside diameter of the
expansion joint during installation, and
flanges shall not differ by more than 0.25"
ONLY removed after the mating piping is
3. Provided the as-installed tolerances noted above fully assembled and meets the as-installed
are met, the tie rods nuts can be adjusted to ensure tolerances. Nuts are to be tack welded
there are no residual stresses on the steam trunk once installation is within tolerance and
piping when the chiller unit is fully assembled. no piping strain exists.
DO NOT Over-tighten Nuts. Tie rods should be
able to be rotated. Note that no gap exists be-
tween washers and flange – Axial compressor and
expansion of the flange is ZERO.
JOHNSON CONTROLS 25
FORM 160.67-N2
:36 7DFN:HOG
7<3
1XWV6KDOO%H
7DFN:HOGHG,Q)LHOG

´
7<3
)/2:
/'
ITEM DESCRIPTION QTY.

5 Tie Rod: 3/4" - 10UNC x 15 1/2" Long 3
6 Tie Rod Nut: 3/4" - 10 UNC (HVY. HEX.) 12
7 Spherical Washers: 3/4" Size 12
Figure 7 - TURBINE EXHAUST EXPANSION JOINT CONNECTOR
Exhaust piping connections must loos- Piping Alignment - Upon completion of piping, a
ened during the Pipe Strain Testing Pro- connection in each line as close to the unit as possi-
cedure listed in this section. 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
INLET STEAM TEMPERATURE SENSOR AND corrected by properly supporting the piping or by ap-
INLET STEAM PRESSURE TRANSDUCER plying heat to anneal the pipe.
(Factory Supplied-Field Installed)
If the piping is annealed to relieve stress,
The inlet steam temp and pressure sensor must be field the inside of the pipe must be cleaned of
installed ahead of the governor valve. See Figure 8 on scale before it is finally bolted in place.
page 27 and Figure 13 on page 34.
26 JOHNSON CONTROLS
FORM 160.67-N2
SENTINAL WARNING VALVE
* = Supplied in separate kit for Field Installation FIRST STAGE PRESSURE
TRANSMITTER *
VACUUM BREAKER TURBINE TRIP VALVE LIMIT

SOLENOID SWITCH
TURBINE TRIP SOLENOID

VALVE
TURBINE NOZZLE
VALVE AIR DUMP
SOLENOID VALVE
4
TURBINE
AUXILIARY
OIL PUMP
MOTOR
OIL
RESERVOIR
STEAM RING DRAIN

SOLENOID
OIL COOLER
INLET SHAFT OIL PUMP
THERMOMETER *
OIL COOLER GLAND LEAK-OFF
OUTLET THERMOMETER * CONNECTION
OIL FILTER HAND TRIP KNOB

INLET STEAM TEMPERATURE
OIL COOLER
AND PRESSURE TRANSMITTER *
(see FIG. 13) LD09427a
Figure 8 - KD TURBINE FIELD INSTALLED COMPONENTS
* = Supplied in separate kit for Field Installation

SENTINAL WARNING VALVE
FIRST STAGE PRESSURE

TRANSMITTER *
VACUUM BREAKER GOVERNOR END
SOLENOID BEARING OIL THERMOMETER *
BREATHER FILTER ASSEMBLY

CONTSANT LEVEL
OILER
TURBINE NOZZLE
VALVE AIR DUMP
SOLENOID VALVE
STEAM RING DRAIN

TURBINE TRIP SOLENOID
VALVE LIMIT
SWITCH GLAND LEAK-OFF
CONNECTION
TURBINE TRIP LEVEL GAUGE
SOLENOID VALVE
INLET STEAM TEMPERATURE AND
HAND TRIP KNOB
PRESSURE TRANSMITTER * LD09608a
(see FIG. 13)
Figure 9 - KG TURBINE FIELD INSTALLED COMPONENTS
JOHNSON CONTROLS 27
FORM 160.67-N2
PIPE STRAIN TESTING

In order to assure that no inherent piping stain is pres- 9. The dial indicators should indicate less than a
ent the following procedures should be employed on .002" movement in either plain. If the indicators
the inlet steam line and the exhaust trunk piping. It is move the turbine more than .002" in either plain
better to perform these tests as the piping is being in- excessive piping forces are present and the piping
stalled but the following procedure is based on all pip- will have to be modified to correct the inherent
ing being installed and completed. Note: The exhaust piping strain.
bellows shipping brackets should still be in place.
10. Lower the exhaust trunk into position and tighten
1. Remove the center section of the main drive cou- the exhaust trunk flange to the exhaust bellows
pling. flange utilizing standard mechanical cross tight-
ening procedures to the proper bolt torques rec-
2. Mount 2 dial indicators from the compressor shaft ommended by the turbine manufacturer.
coupling hub at a 12 o'clock and a 9 o'clock posi-
tion. 11. The dial indicators should indicate less than a
.002" movement in either plain. If the dial indica-
3. Loosen the inlet steam piping connection of the tors move the turbine more than .002" in either
turbine and the exhaust trunk piping connection at plain excessive piping forces are present and the
the exhaust bellows. piping will have to be modified to correc the in-
4. Make sure that all flanges at both connections herent piping strain.
are parallel and square to their respective mating 12. After all piping is installed and exhibits less than
flange. the maximum .002" piping strain the exhaust bel-
5. Make sure that there is a visual gap between the lows shipping brackets can be removed. The dial
flanges to assure no forces are present. This may indicators should be observed during the removal
require lifting devices to lift the exhaust trunk pip- of the brackets. After the shipping brackets are re-
ing. moved the exhaust bellows stay bolts should be
free to rotate and exhibit a slight free axial move-
6. Make sure that all bolts of both flanges are free ment. If the stay bolts are tight or either of the in-
and loose. dicators exibit movement greater than .002" then
7. Reset each dial indicator to a zero position. piping strain is still present.
8. Tighten the inlet steam piping utilizing standard
mechanical cross tightening procedures to the
proper bolt torques recommended by the turbine
manufacturer.
28 JOHNSON CONTROLS
FORM 160.67-N2
When installing relief piping an

ANSI flange or a piping union
must be used to make a
servicable piping connection.
Horizontal Vertical Compressed

Mis-aligned Offset
When installing relief piping there
must NOT be any piping strain.
Relief piping must be properly
aligned and supported to eliminate
any possible piping strain.
LD16677
Figure 10 - PIPE STRAIN
STEAM PIPING RECOMMENDED BLOW-

DOWN PROCEDURE
Removal of foreign material from the After the piping has been warmed up, the valve in the
piping is the responsibility of the party blow-down connection should be opened wide for
installing the piping. The turbine war- about 15 seconds to allow live steam to blow out any
ranty does not cover damage due to the loose material in the piping. Piping should then be al-
lowed to cool down to room temperature, about 6-8
entrance of foreign material.
hours.
Thermal expansion and contraction which occurs dur-
Newly constructed steam piping must be blown-down
ing warming up and cooling down, helps break loose
to remove scale, weld beads and any other foreign ma-
the foreign material inside the piping. Hammering
terial. Such material can cause severe damage if it en-
around any welded joints in the piping will also help to
ters the steam turbine.
break loose foreign material
The blow-down connection should be as close to the
The above procedures of warm-up, blow-down, and
turbine as possible. The diameter of the blow-down
cool off should be repeated as many times as neces-
connection should be a minimum of one-half the diam-
sary to clean all foreign materials out of the piping.
eter of the line being blown-down to ensure that steam
To check for clean piping, a target should be placed
velocity in the piping is high enough to break loose and
about two feet away from the blow-down opening so
carry away any foreign material stuck to the inside of
that the steam will hit the target, and any solids in the
the piping.
steam will become embedded in the target. Aluminum
Blow-down should be done before the piping is insu- and polished stainless steel are commonly used target
lated. Steam at full temperature and pressure should be materials. Piping can be considered clean when no em-
bled through the piping. bedded particles and indentations are found in the tar-
get after a 15 second blow-down.
JOHNSON CONTROLS 29
FORM 160.67-N2
Turbine supply steam and condensate piping connec- If it is necessary to run the pipe for a long distance the
tions to the chiller are to be supplied and installed by size should be increased so that back pressure does not
the site piping contractor. build up on the packing gland. This pipe must slope
A suitable piping arrangement with down from the connection point to avoid forming a
flexible type joints and piping supports/ water trap and must not contain a shut-off valve. On
hangers, as required, must be provided non-condensing turbines, a small amount of steam will
for the steam inlet line to the turbine. It pass through this line at all times. The amount of steam
is recommended that a piping analysis passing through the line will depend upon the amount
be performed by a qualified engineer to of back pressure.
verify the design adequately protects the The leak-off steam is commonly piped to a sewer or
steam turbine from excessive strains due open header. If this line becomes partially clogged,
to system/thermal loads. Maximum al- or the back pressure builds up for any reason, steam
lowable loads on steam connections are will blow out the shaft at the packing gland. Some ma-
governed by NEMA SM23-1991 Steam chines may be equipped with an optional gland con-
Turbines for Mechanical Drive Services. denser which condenses the gland leakage as well as
steam leaking from other leak-off connections. The
The turbine exhaust piping to the steam condenser shall
condensate from this gland condenser can be returned
be installed by the piping contractor, however, the de-
to the feed water system.
sign and supply of the exhaust piping and components
may be supplied by YORK depending on the options GLAND LEAK-OFF CONDENSER
chosen. Piping should be adequately supported and (Optional)
braced independently of the chillers. Hangers must al-
low for piping alignment at the operating temperature. This equipment may be specified for use on high back-
pressure applications, those turbines operating with a
Factory supplied, STANDARD steam ex-
high pressure differential across the glands, and which
haust piping does NOT require additional
must operate for long periods of time between shut-
support or pipe hangers.
downs (some low pressure turbines may also use this
equipment).
The condenser is piped to the outer leak-off connec-
The piping contractor is responsible for the form and fit tions of the glands. It creates a slight vacuum on the
of turbine steam piping. The piping must be installed outer leak-off areas, assuring that leakage will leave
with the flanges and bolt holes properly aligned. The through leak-off piping and not past inactive seals. The
bolts should be able to be inserted without any diffi- most common configuration is the gland condenser
culty and no force should be applied to allow the bolts and ejector. The gland condenser is a shell-and-tube
to be inserted or flanges aligned. When the flange bolts type heat exchanger in which cooling water is used to
are tightened, they must not impose any force or mo- condense steam leakage from the glands.
ment on the turbine flanges. The ejector is a steam nozzle which creates a low pres-
All steam piping must be arranged so that strains will sure area to remove any air which has leaked into the
not be imposed on the turbine. The total resultant force system and thus maintains the vacuum in the leak-off
and total resultant moment at any connection should areas. This equipment is available for all types of leak-
not exceed the limits defined by NEMA SM23-1991 off flows. The condensed leakage steam and cooling
for steam turbine systems. water can be recovered and returned to the boiler. Note
that the condenser tubes and ejector both require peri-
GLAND SEAL LEAK-OFF PIPING odic cleaning.
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.
30 JOHNSON CONTROLS
FORM 160.67-N2
STEAM RING DRAIN

All YST chillers are provided with a tapped drain open- On standard YST chillers with up-discharge turbine
ing in the turbine steam ring for getting rid of excess exhaust, an exhaust casing drain connection is sup-
moisture that accumulates in the steam ring when the plied. The turbine must be supplied with a means of
turbine casing is cold at startup. The drain line is fitted draining the casing during operation (While under
with a check valve and solenoid valve. The line must vacuum). The standard Factory supplied option is an
be piped to a sewer or any other low point that permits automatic pressure powered pump. Also available by
the waste to drain off by gravity. The location of this special quotation is a condensate drain tank (manual
opening is shown in Figure 8 on page 27 and Figure or automatic). When either option is supplied, it is
4
12 on page 33. shipped loose for installation at the job site.
The steam ring drain solenoid valve remains energized On any application where the exhaust piping bends
(open) during the initial startup. The check valve in the upward after leaving the turbine, steam traps must be
steam ring drain line prevents air from being drawn provided to keep the exhaust line drained to prevent
into the turbine when the turbine steam ring drops be- water from building up in the exhaust pipe and turbine
bylow atmospheric pressure during the initial evacu- casing.
ation and while the turbine is slow rolling. When the
Failure to keep the exhaust line
inlet steam valves open to begin slow roll and during
the ramp up to minimum speed, the steam ring will rise
drained may result in a restriction
above atmospheric pressure and any condensate will in the exhaust line, causing a loss of
be blown out of the turbine. power and damage to the turbine rotor.
STEAM TURBINE CASING DRAINS

The steam turbine casing must be provided with a PRESSURE POWERED PUMP
means of draining during operation (while under vac- See Figure 11 on page 32
uum). Available factory options for this function are
an automatic pressure powered pump, a manual con- A Factory supplied automatic pressure powered pump
densate drain tank or an automatic condensate drain is provided for draining condensate from the steam
tank. A connection is provided on the steam condenser turbine casing during operation. The pressure powered
hotwell for customer connection of the casing drain pump is shipped loose and all piping and installation is
equipment outlet, i.e. condensate outlet of automatic provided by others.
pressure powered pump, or drain tank may be piped to
A strainer and condenser trap are included with the
the steam condenser hotwell (piping by others).
pressure powered pump for field installation. See Fig-
Never pipe turbine casing drain directly ure 11 on page 32.
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.
JOHNSON CONTROLS 31
FORM 160.67-N2
Motive Never pipe turbine casing drain directly

Pressure
to the steam condenser hotwell. Turbine
casing drains gravity only and must be
To Turbine
Exhaust Piping
Factory Supplied / Field pumped to steam condenser hotwell by
Installed Strainer *
means of condensate handling equipment.
CONDENSATE DRAIN TANK - (Optional)

From Turbine
Casing Insulation of the type specified for the job, or mini
Drain Drip mum thickness to prevent sweating of 30°F (-1°C) sur-
Trap With
Steam Only * faces should be furnished (by others) and applied to the
To Hotwell evaporator shell, end sheets, liquid feed line to flow
Connection or Drain
(Atmosphere) chamber, compressor suction connection, evaporator
waterboxes, and connections. The waterbox flange
insulation must be removable, to allow waterbox re
Automatic Pressure
Powered Pump*
LD14441
moval for the tube maintenance.
NOTES:
* Factory Supplied - Field Installed STEAM RELIEF
Figure 11 - A
UTOMATIC PRESSURE POWERED Each steam condenser is equipped with an atmospheric
PUMP relief valve, sized to relieve all the steam which can
be exhausted from a turbine under maximum possible
Liquid enters the pump body through the inlet check full throttle conditions. The atmospheric relief valve is
valve causing the float to rise. As the chamber fills designed/selected per HEI (Heat Exchange Institute)
the valve changeover linkage is engaged opening the standards for steam condensers and provides protec-
motive supply valve and closing the equalizing valve. tion for the steam turbine exhaust and exhaust trunk,
As motive pressure is above the total back pressure, as well as the steam condenser shell. The discharge of
condensate is forced out through the outlet check valve the atmospheric relief valve should be piped to direct
into the return system. a large volumetric flow of hot steam to a safe area out-
Motive pressure for automatic pressure side, away from all personnel.
powered pumps cannot exceed a maxi-
STEAM CONDENSER PACKAGE
mum of 200 PSIG (steam or air may be
HYDROSTATIC TEST
used). Application with higher pressure
motive supply must use custom selected After the installation is complete , the entire condens-
condensate drain equipment suitable for ing system and piping on the exhaust steam side should
higher pressures. be tested to prove the tightness of all connections. This
can be completed by filling the condensing package
As the liquid level falls within the pump, the float re- with water to the top of the steam inlet flange. If pos-
engages the valve changeover linkage causing the mo- sible, put the Condensing Package under 15 PSIG of
tive supply valve to close and the equalizing valve to pressure. Inspect all connections, valves, gauges, fit-
open allowing condensate to re-enter through the inlet tings, pumps and other accessories for leaks.
check valve and the cycle is repeated. Refer to YORK Evaporator And Refrigerant Condenser Water
standard flow diagram for typical pressure pump pip- Piping
ing installation.
All the piping associated with the instal- The evaporator and refrigerant condenser water boxes
lation of the Automatic Pressure Powered have nozzles which are grooved, suitable for welding
Pump is field provided and installed. 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
32 JOHNSON CONTROLS
FORM 160.67-N2
for 150 PSIG DWP on the water side. If job require- REFRIGERANT RELIEF PIPING
ments are for greater than 150 PSIG DWP, check the
Each unit is equipped with pressure relief valves locat-
unit data plate before applying pressure to evapora-
ed on the refrigerant condenser and on the evaporator
tor or refrigerant condenser to determine if the chiller
for purpose of quickly relieving excess pressure of the
has provisions for the required DWP. Inlet and outlet
refrigerant charge to the atmosphere as a safety precau-
connections are identified by labels placed adjacent to
tion in case of an emergency, such as fire. Refrigerant
each nozzle.
relief vent piping (by others), from the relief valves to
CHECKING PIPING CIRCUITS AND VENTING the outside of the building, is required by code in most
AIR areas and should be installed on all chillers. 4
After the water piping is completed, but before any
water box insulation is applied, torque the waterbox Vent to Atmosphere
flange nuts to 30 and 60 ft. lbs. (41 and 81 Nm). Gasket Flanged Joint
shrinkage and handling during transit cause waterbox to Permit Piping Support Vent Piping to Avoid
Disassembly Strain on Relief Piping
flange nuts to loosen. If water pressure is applied be-
fore tightening is done, the gaskets may be damaged Flexible Connector
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. Condensation
Trap
Refrigerant Condenser
Before the initial operation of the pumps
Relief
both water circuits should be thoroughly Valves
vented of all air at the high points. Failure (See Note)
Evaporator
to do so will result in pass baffle damage.
NOTE: Shells may be furnished with

one or two relief valves,
Fill both the chilled and condenser water circuits, and depending on shell size. LD09387
vent any air from the chiller water boxes. Operate the
pumps manually and carefully check the evaporator, Figure 12 - TYPICAL REFRIGERANT VENT PIPING
refrigerant and steam condenser waterboxes and pip-
ing for leaks. Repair leaks as necessary. The vent line should be sized in accordance with the
ANSI/ASHRAE-15, or local code. The vent line must
INSULATION include a dirt trap in the vertical leg to intercept and
Do NOT field insulate until the unit has permit clean out and trap any vent stack condensation.
been leak tested under the supervision of The piping MUST be arranged to avoid strain on the
the Johnson Controls representative. 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.
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.
JOHNSON CONTROLS 33
34
Condenser Water* Oil Cooling
Symbols
Vent to Safe Outlet W7 Water Return
Area Outside
Y Type Strainer
Gate Casing Drain (to Pres-
Vent to Safe
From W6 sured Powered Pump or
Check Area Outside
Condensate Tank)
Butterfly Atmospheric Temp
Ball or Plug Relief S4 Indicator Steam Ring
Drain
Drain
Steam
* - Exact orientation of Inlet Gland Leak-Off S9
Chilled or Condenser Water S3 1-1/2” = NPT to
Nozzels depends on
Sewer w/out
selected configurations.
Evaporator Positive Head
Exhaust
Relief S6 S2 Moisture
Inlet Steam
Separator
Figure 13 - TYPICAL PIPING ARRANGEMENT

Temp Sensor
Governor
Valve
Condenser Steam
Water Inlet Trap
W4 * Main
Air Steam S1 Inlet Steam
W8
Oil Cooling Supply Pressure Sensor
Water Supply S8
To W5 W3 Oil Cooling
Water Outlet
W6
Oil Cooling
Temp Water Inlet
Indicator W5
Inlet
Water Reference all drawings and installation
W2* Water* instructions supplied by Johnson Controls
Outlet for additional detail on connection desig-
W1
nations and piping requirements.
JOHNSON CONTROLS
LD09346a
FORM 160.67-N2
Equalizing Line to Pressure Reference all drawings and installation
Powered Pump or Condensate Tank instructions supplied by Johnson Controls
(1 inch Coupling Located in Appropriate
Location to be Supplied By Installer)
for additional detail on connection desig-
nations and piping requirements.
FORM 160.67-N2
Refrigerant Condenser
Relief, Vent to Safe Area
Outside
JOHNSON CONTROLS
Note 1
S7 Discharge Separator,
Relief Valve Vent to Atmosphere
Seal Water
W10
Air Supply
S10 Inlet NOTE 1: Automatic Pressure Powered
Turbine S3 Pump provides pump only. All piping
Relief Valve associated with installation is by the
Casing Drain
Drain field. Location of the Automatic Pres-
sure Powered Pump and piping is for
reference only. Location to be floor-
mounte by the installer.
Condensate
Overboard
FIGURE 12 – TYPICAL PIPING ARRANGEMENT (CONT'D)

(Return to Boiler)
W9
Equalizing
Line Hotwell
Drain Victaulic Couplings Supplied
by installer. Flanges Available
W8 as Factory Supplied Option
Strainer*
W3
Motive
Supply Vacuum Pump
Vacuum Seal Water
Pumping Separator
Drain Note 1
Trap* Sealing
) Water
and Hotwell Fill
Connection
(Potable Water)
Automatic
Pressure Pipe to Steam W11 NOTE:
Powered Condenser Hotwell * Factory supplied and field installed
Pump
35
LD09347d
4
FORM 160.67-N2
36 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 5 - DRIVELINE ALIGNMENT
ALIGNMENT knowledge that the preparations have been done prop-

erly, it is best to verify these items. Some areas that
Alignment refers to the proper relationship between warrant specific attention would be:
the centerlines and distance between the turbine shaft
and compressor. Factory assembled packages are • Assure that the piping is installed in accordance
aligned prior to shipment and must be re-checked prior with design criteria, that it is complete, and that
to startup. it is in its functional state. Look for proper place-
ment and adjustment of guides, anchors, and sup-
Turbine to Compressor Cold Misalignment ports; proper adjustment of tie-bolts on expansion
The typical Murray turbine utilized on the YST sys- joints; correct positioning of spring hangers; com- 5
tem has a minor cold alignment offset. In hotcheck plete make-up of flanges with gaskets in place and
alignment procedures employed on other similiar 5 to bolts tightened; absence of slip-blinds which may
7 stage Murray turbines utilized on the YST syatems, have been installed for pressure testing of pipe-
the turbine shaft should be .003"/.004" above the com- lines; and proper orientation of check valves and
pressor shaft at the compressor coupling, and the face other control devices.
of the coupling open on the top by .002"/.003" at cold • Check the grouting to assure it is complete and
start-up conditions. The most accurate form of align- supports the structure of the unit.
ment procedure to utilize on the YST system is the
double reverse indicator method. Other forms of align- • Check all foundation bolts to assure tightness.
ment. ie. Face and Rim, Laser etc. are viable methods • Check all shim packs for rust, improperly cut
but are subject to errors due to the possible axial move- shims, folds and wrinkles, burrs, hammer marks,
ment of the turbine and the compressor shafts. and dirt etc. Shims are a vital link between the
Inaccurate alignment can result in de- machine and the foundation and are essential to
structive vibration, loosening of grout, the maintenance of alignment over long periods.
failure of bearings, coupling failure, bent Good practice dictates that as few shims as possi-
shaft, and other conditions that could lead ble be used if changes are required, replace many
to catastrophic equipment damage. thin shims with fewer shims of greater thickness.
Shims of stainless steel should be used wherever
Alignment Data possible. Also it is important to make sure the
equipment supports and soleplate/baseplate are
The following instructions and suggestions are made clean and in good condition.
for guidance in alignment of newly installed equipment
• Check for misalignment of machine supports rela-
and under the presumption that:
tive to the soleplate, this is sometimes referred to
• The persons reading this are familiar with high as a “soft foot” condition. Mounting a dial indica-
speed turbomachinery and that they are aware of tor on the machine support with the indicator stem
the basic principles of alignment. resting on the soleplate can make a simple test for
this condition. Watch the indicator as the hold-
• It is understood that the various procedures sug-
down bolts are loosened. If the movement of the
gested for checking completed portions of the sys-
indicator is more than .002”, it is an indication of
tem are in no way a substitution for proper design,
a problem which must be rectified. It is also ap-
engineering, and construction. Additionally, the
propriate to remove the shim pack and check with
suggestions made represent only one of several
feeler gauges to assure that the machine support is
acceptable alternatives.
parallel with the soleplate.
In the case of turbomachinery, many of the items vi- The goal of proper alignment is to provide
tal to a good alignment have been done well ahead of the most accurate collinear alignment
the actual “cold alignment” of the equipment. Unless during the majority of operating condi-
the person responsible for the alignment has first-hand tions.
JOHNSON CONTROLS 37
FORM 160.67-N2
• Check for piping strain - Reference Section 4 Pipe Dial indicators which are anti-magnetic
Strain Testing are strongly recommended.
Piping strain can cause problems with Make sure the indicator stem is near the
alignment and must be corrected before center of travel before taking readings
operating the unit. 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.
• Verify that the Mylar shipping film has been re-
moved from the turbine shaft bearing prior to ro- DIAL INDICATORS
tating the turbine shaft.

• Make sure that the bearings have been properly COUPLING HUB
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 ALIGNMENT BRACKET
LD09290
between the two shafts, with the machines in a non-
Figure 14 - TYPICAL ARRANGEMENT FOR "FACE
operating temperature stabilized or “cold” condition.
- O.D." READINGS TO DETERMINE
The term implies both offset and angularity. The im- COLD ALIGNMENT OF SHAFTS
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 To eliminate inaccuracies in geometry of the coupling
during operation. It is the fundamental benchmark and hub, turning of both shafts simultaneously such that the
must be accurately done and properly recorded. indicator readings are taken always at the same place
on the hub will give more precision. This precaution
There are various methods which can be utilized to
can be difficult on larger equipment and may not be
perform the alignment. The method described in this
possible. Face measurements taken by this method
manual will be that of using dial indicators. While the
must have the axial float of the two shafts accounted
method of employing dial indicators is an old and well-
for.
established technique, these are precautions which the
technician should already be aware of. Axial movement must be taken into account when
turning the shafts on equipment with hydrodynamic
The most widely used of the traditional alignment
thrust bearings or no thrust bearings. Small machin-
methods is commonly referred to as the “Face-O.D.”
ery utilizing ball bearings may not encounter any axial
method as illustrated in Figure 14 on page 38. As
float. The shafts must have axial positions rechecked
shown in the figure, a bracket is attached to one shaft
each time a reading is taken. One additional element
and extends to the proximity of the coupling hub on the
that must be accounted for is the difference between
adjacent shaft. Dial indicators are affixed to this bracket
the exhaust end shaft rise and the steam end shaft rise.
with the stem of one indicator resting on the face of the
Typically, the steam end will rise more than the ex-
coupling hub and the stem of the other indicator resting
haust end due to higher temperatures. This will result
on the outside diameter of the same hub. The "parallel"
in cold misalignment offsets that have the coupling
offset of the shafts is determined by the “O.D.” read-
face “open” at the top.
ings, while angularity of the shafts is determined by the
“face” readings. It is required that the proper distance Care must also be taken in the brackets that are used
between the shafts be established before any alignment to hold the dial indicators. “Universal” or makeshift
method is used. This spacing dimension can be found brackets contrived on the spur of the moment can give
on the outline drawing and/or the coupling drawing for inaccurate readings, which can lead to improper align-
the specific application.
38 JOHNSON CONTROLS
FORM 160.67-N2
ments. Refer to the "Checking for Sag" section in this DIAL INDICATORS
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 SAG

Clamp the indicator system onto a piece of pipe (1-1/2
- 2 inch diameter).
ALIGNMENT BRACKET
Make sure the indicator/clamp system LD09291a
measures the same distance as the cou- Figure 16 - TYPICAL "REVERSE INDICATOR" TO
pling span. DETERMINE COLD ALIGNMENT OF
5
SHAFTS
This method employs indicator readings taken on the

Zero the indicator while on top. Rotate to the bottom outside diameter of the coupling hubs or shaft only.
and record any change in reading on the indicator. This The figure indicates two brackets used simultaneously,
is the amount of "Sag" due to gravity. If Sag measures which is normally the preferred method. One bracket
more than 0.003 inches the brackets should be rein- could be utilized by switching back and forth for each
forced or modified (see Figure 15 on page 39). set of readings but this is far less convenient and may
DIAL INDICATOR
affect accuracy.
0
Use of the “Reverse Indicator” method eliminates the

0.000
INDICATOR CLAMP
requirement for removing the coupling spacer in a ma-
PIPE PIPE
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.
INDICATOR CLAMP 0.0??
LD09699a One precaution that carries over to the “Reverse Indi-

cator” method which was present in the “Face O.D.”
Figure 15 - M
EASURING "SAG" OF INDICATOR/ method is that of deflection or Sag in the alignment
CLAMP SYSTEM bracket. This problem can be minimized by building
the bracket with substantial material to prevent SAG or
An alternative method is sometimes preferred because by determining the deflection in the alignment fixture
of the elimination of some of the problems mentioned and making the appropriate corrections in the align-
above with the “Face O. D.” method would be to uti- ment data (see the checking for Sag section previously
lize the “Reverse Indicator” method as illustrated in discussed in this section).
Figure 16 on page 39. 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 CONTROLS 39
FORM 160.67-N2
In recent years people have questioned the value of YORK DBL. TAPER
the traditional “Hot Check Alignment”. Not only is "D" DIMENSION
COUPLING P/N
it costly and time-consuming to bring a machine up to 029-20899-001 4.75
temperature, stop it, break couplings, and attempt to
determine alignment before it cools off, but the results
SHIM QTY. AT LOCATION
are highly questionable. VARIANCE
1 2 3 4
It is normally not possible to make the check quickly 0-0.014 0 0 0 0
enough to accurately determine the thermal growth of 0.015-0.029 1 0 0 0
the equipment. Also any hydraulic forces and torque 0.030-0.044 2 0 0 0
reactions, which can be significant, are never revealed
0.045-0.059 2 1 0 0
by the traditional check methods because the forces
0.060-0.074 2 2 0 0
disappear immediately upon stopping the machine.
0.075-0.089 2 2 1 0
One alternative is to use the cold position of the shafts 0.090-0.104 2 2 2 0
as a benchmark, and deduce the hot alignment by mon- 0.105-0.119 2 2 2 1
itoring the movement of the machine casings, shafts, 0.12 2 2 2 2
or bearing centerlines from the cold position to the
hot position. There are several methods used for this 2. If the measurement is greater than the "D" dimen-
monitoring. A variety of techniques can be applied to sion listed in the table above add the appropriate
the actual determination of casing or shaft movement, shims to the proper shim points as indicated in
which includes optical or electronic (laser) techniques. Figure 17 on page 40. Shims are sent with each
In any event, a "Hot Alignment" check of the driveline coupling and will allow up to an additional .120"
alignment at operating temperatures is required. of face-to-face coupling installation (min. 4.75" to
max. 4.870"). The shims should be installed per
COUPLING SPACER INSTALLATION
table above at the locations stated in Figure 17 on
1. After the unit has operated in it's initial slow roll page 40.
for 30 minutes and the turbine has achieved oper- Some couplings use shims that are cir-
ating temperature, obtain an accurate face-to-face cular and span the entire diameter of the
measurment with the turbine and compressor on coupling reference (see Figure 17).
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.
LD12213
Figure 17 - COUPLING SHIM PLACEMENT
40 JOHNSON CONTROLS
FORM 160.67-N2
SECTION 6 - FIELD INSTALLED WIRING
POWER WIRING TURBINE INSTRUMENTS

The chiller must be supplied with a single 3-phase Standard YST turbines are shipped with some instru-
power supply rated at 29 KVA. Do NOT make final ments packaged as a separate kit to avoid damage in
power connections to the Power Panel until approved transit. Included are the following instruments:
by a YORK/Johnson Controls representative.
KD Turbine
When the steam condenser package is
located remotely all power and control *Oil Cooler Oil Inlet Thermometer
wiring between the condenser and chiller *Oil Cooler Oil Outlet Thermometer
is supplied by York and installed by the Tachometer (Must be Field installed on Optional Re-
installing contractor. The size and type mote Steam Turbine Gaugeboard when purchased)
of conduit used must be determined by the *Inlet Steam Pressure Transmitter (including Pipe 6
electrical installation contractor. Tee, Pipe Nipple, Siphon, and Valve)
See Figure 1 on page 10 and applicable form 160.67- KG Turbine

PW6. *First Stage Pressure Transmitter
*Shaft End Bearing Oil Thermometer
After the governor valve is installed all units require
*Governor End Bearing Oil Thermometer
the final connection to the valve positioner (4-20 ma
Tachometer (Must be Field installed on Optional Re-
dc).
mote Steam Turbine Gaugeboard when purchased)
After the steam condenser unit is installed, all units Inlet Steam Pressure Transmitter (including Pipe Tee,
require the final connections to the steam condenser Pipe Nipple, Siphon, and Valve)
junction box (120/460Vac wiring), the hotwell level
*These instruments must be installed on the turbine as
control I/P transducer (4-20 ma dc), and the hotwell
shown in Figure 8 on page 27.
level transmitter (4-20 ma dc).
The Inlet Steam Pressure Transmitter and
The connecting cables are supplied with
associated hardware must be installed in
the appropriate din connectors and coiled
the inlet steam piping upstream of the
on the chiller for shipment.
governor valve as shown in Figure 18.
The connecting cable is supplied with the
appropriate connector and coiled on the
chiller for shipment.
On units shipped disassembled, control wiring must be
completed between unit components, control center, STEAM CONDENSER WIRING KIT
power panel, and turbine box, using wiring harnesses (Optional Floor Mounted Steam Condenser)
furnished.
Wires are provided for the motor power and 120 VAC
Field wiring connections for commonly encountered control wiring between terminal boxes located on the
control modifications (by others) if required, are shown refrigerant condenser and the steam condenser. Low
on Form 160.67-PW2. voltage shielded cables are provided for the hotwell
No deviations in unit wiring from that level transmitter and I/P transducer (4-20 mA) wiring
shown on drawings furnished shall be to be connected between a terminal box located on the
made with out prior approval of a YORK/ refrigerant condenser and the devices on the steam con-
Johnson Controls representative. 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 CONTROLS 41
FORM 160.67-N2
SECTION 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. LD12288
Figure 19 - DIN CONNECTOR WIRING
Inlet Steam
Temp Sensor
LD12499
Figure 18 - GOVERNOR VALVE AND SPOOL PIECE
42 JOHNSON CONTROLS
FORM 160.67-N2
NOTES
JOHNSON CONTROLS 43
P.O. Box 1592, York, Pennsylvania USA 17405-1592 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2014 www.johnsoncontrols.com ALL RIGHTS RESERVED
Form 160.67-N2 (114)
Issue Date: January 10, 2014
Supersedes: 160.67-N2 (1109)

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STEAM TURBINE

CENTRIFUGAL LIQUID CHILLERS

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

Indicates a possible hazardous situation Identifies a hazard which could lead to

Indicates a potentially hazardous situa- Highlights additional information useful

CHANGEABILITY OF THIS DOCUMENT

YST VF VD J4 - KD71750090 - 14 - 0.6 - 33192C - F S

Turbine Expansion Ratio

Compressor Code Steam Turbine Base Model

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

SECTION 4 - CUSTOMER PIPING..........................................................................................................................21

TABLE OF CONTENTS (CONT'D)

Governor Valve And Spool Piece (Factory Supplied - Field Installed)............................................................ 23

SECTION 5 - DRIVELINE ALIGNMENT..................................................................................................................37

SECTION 6 - FIELD INSTALLED WIRING..............................................................................................................41

THIS PAGE INTENTIONALLY LEFT BLANK

COMPRESSOR OIL COOLING

NOTE: KD Turbine shown

Figure 1 - MODEL YST CHILLER

FIGURE 1 – MODEL YST CHILLER (CONT'D)

REMOTE STEAM TURBINE GAUGEBOARD

Refer to Engineering Guide 160.67-EG1

To prevent equipment damage, a Johnson

STEAM CONDENSER PACKAGE RIGGING LOCATING AND INSTALLING ISOLATOR

See YORK standard arrangement

Figure 5 - NEOPRENE ISOLATORS

SECTION 3 - CUSTOMER SUPPLIED & INSTALLED COMPONENTS

CUSTOMER COMPONENTS Permanent Strainers

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION 4 - CUSTOMER PIPING

CUSTOMER PIPING REQUIREMENTS Approximately 20 psig (138kPa) dis-

• Steam turbine casing drain

Figure 6 - STEAM CONDENSER

EXPANSION JOINT INSTALLATION 4. Nuts are tack-welded once connector is correctly

ITEM DESCRIPTION QTY.

Figure 7 - TURBINE EXHAUST EXPANSION JOINT CONNECTOR

VACUUM BREAKER TURBINE TRIP VALVE LIMIT

TURBINE TRIP SOLENOID

STEAM RING DRAIN

OIL FILTER HAND TRIP KNOB

* = Supplied in separate kit for Field Installation

FIRST STAGE PRESSURE

BREATHER FILTER ASSEMBLY

STEAM RING DRAIN

PIPE STRAIN TESTING

When installing relief piping an

Horizontal Vertical Compressed

Figure 10 - PIPE STRAIN

STEAM PIPING RECOMMENDED BLOW-

Where the rotor shaft passes through the turbine cas-

STEAM RING DRAIN

STEAM TURBINE CASING DRAINS

An automatic pressure powered pump is

Motive Never pipe turbine casing drain directly

CONDENSATE DRAIN TANK - (Optional)

NOTE: Shells may be furnished with

Figure 13 - TYPICAL PIPING ARRANGEMENT

FIGURE 12 – TYPICAL PIPING ARRANGEMENT (CONT'D)

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Figure 19 - DIN CONNECTOR WIRING