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YORK CHILLERS

SYSTEM DESCRIPTION (IRI-CH-25)

INDUSTRIAL RESOURCES, INC.

A TRAINING SERVICES COMPANY

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Chillers (IRI-CH-25)

Page 1

PREFACE

The Training System Description (SD) has been designed to assist you in meeting the requirements

of Module (IRI-CH-25) of Power Plant Operations; it contains information about the York Chillers

used in Chiller. This includes the function and details about the York Chiller components and their

operation, the purpose of which is to instruct the employees on the purpose and components of the

York Chillers, and how to operate the system in a safe manner.

You should review each chapter objective. In doing so you will be better prepared to learn the

required information. You should also inspect the equipment, identifying its components and

characteristics. Should you have additional question about the equipment, ask your supervisor.

A separate document, York Chillers Procedure (IRI-CH-25-SOP), covers detailed procedures to be

observed with regard to the York Chillers.


Page 2

YORK CHILLERS

TRAINING DESCRIPTION

TABLE OF CONTENTS

1.0 Introduction ............................................................................................................................ 4

1.1 Function ................................................................................................................................. 4

1.2 Basic System Description ...................................................................................................... 4

2.0 System Major Components .................................................................................................... 6

2.1 Compressor ............................................................................................................................ 7

2.1.1 Compressor Data .................................................................................................................. 15

2.1.2 Compressor Controls ........................................................................................................... 15

2.2 Condenser ............................................................................................................................ 16

2.2.1 Condenser Data .................................................................................................................... 18

2.2.2 Condenser Controls .............................................................................................................. 19

2.3 Intercooler ............................................................................................................................... 19

2.3.1 Intercooler Data ................................................................................................................... 21

2.3.2 Intercooler Control ............................................................................................................... 21

2.4 Evaporator ........................................................................................................................... 21

3.0 System Operation ................................................................................................................. 23

3.1 System Startup .................................................................................................................... 24

3.2 Normal Operation ............................................................................................................... 24

3.3 System Shutdown................................................................................................................. 24


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List of Figures:

Figure 1 – Compressor

Figure 2 – Compressor Lubrication System

Figure 3 – York Compressor Cross Section Diagram

Figure 4 – Control Panel

Figure 5 – Condenser and Intercooler

Figure 6 – Intercooler

Figure 7 – Evaporator

List of Drawings

Drawing 1 – York Chiller Refrigerant Flow Path

Drawing 2 – Chiller Components


Page 4

1.0 Introduction

Chapter Objectives:

Describe the functions of the York Chillers.

1. State from memory the functions of the York Chillers.

2. Describe how the York Chillers operate, and where they are located, used and

maintained.

3. List the normal operating parameters of the York Chillers.

1.1 Function

The York Chillers provide chilled water for campus air conditioning and other cooling purposes.

1.2 Basic System Description

The York OM Titan Chillers are manufactured by Johnson Controls. The four chiller stations are

equipped with a total of 11 chillers ranging from 3,000 to 5,000-ton capacity. Each York Chiller

consists of a compressor, evaporator, condenser, and intercooler. The chillers are powered either

by steam or electricity. The total chiller capacity for the campus is 45,000 tons.

1.2.1 York Chiller Parameters

STATION CHILLER CHARGE (lbs.) CAPACITY

Chiller Station 3 3.1 16,232 5,000

3.2 13,000 3,000

3.3 13,000 3,000

Chiller Station 4 4.1 0 Inoperable

4.2 13,000 3,000

4.3 13,000 3,000


5.2 15,922 4,000

5.3 16,232 5,000


Page 5


6.2 18,237 5,000

6.3 18,237 5,000

1.3 System Flow Path

Drawing 1 illustrates the flow path through a York Chiller. Four systems support the chillers:

cooling towers, condenser, chilled water, and refrigerant gas flows. The Condenser Water Pump

draws condenser water from the cooling tower basin. Discharge from the Condenser Water Pump

goes to the Condenser (tube side). The condenser water absorbs heat from the high-pressure

refrigerant gas (shell side) in the condenser. The heated condenser water is then returned to the

cooling towers.

The Compressor compresses refrigerant gas and pushed the high-pressure gas into the Condenser

(shell side). As the gas condenses, the refrigerant is passed through the Intercooler to the

Evaporator (shell side). The refrigerant exits the top of the Evaporator and is returned to the

Compressor.

Chilled water is pumped by the Chilled Water Pump through the Evaporator (tube side) where

the water is cooled and then pumped to the chilled water distribution headers.

If the water level falls below a set limit in the cooling tower basin, makeup water is added from

the domestic water supply. Chemical injection is also available for the condensate water and

chilled water.


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Drawing 1 – York Chiller Refrigerant Flow Path

2.0 System Major Components

Chapter Objectives:

1. Describe how each York Chiller system component operates.

2. Describe from memory, the operating parameters of the system.

3. State from memory, the names and purposes of the major components of the York

Chiller.

4. Describe the locations of the York Chiller system components.

5. Describe how and from where the York Chiller is controlled.


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The following major components of the York Chiller are described in this chapter:

Compressor

Condenser

Intercooler

Evaporator

Drawing 2 – Chiller Components

2.1 Compressor

The York Compressors in the chiller stations are multistage compressors (Figure 1) with a

capacity of 3,000 to 5,000 tons. Compressors in the chiller stations are driven by Variable

Frequency Drives (VFD) motor, electric drivers, or steam turbines.


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Figure 1 - Compressor

The Compressor has an internal labyrinth seal (Figure 2), balance piston and oil seals, shaft

seals, and pre-rotation vanes, which guide the suction flow path. The Compressor also has a

dedicated lubrication system.

The labyrinth seal prevents gas leakage between the stages. Leakage is kept to a minimum by

means of labyrinths mounted between the diffuser plates and the rotating shaft. The close radial

clearance between the labyrinths and rotator shaft reduces gas leakage along the shaft.

Due to the pressure difference between the suction and discharge of the compressor, the

compressor is equipped with a balance piston. The balance piston is located behind the second

stage impeller to counteract the differential pressure. By subjecting the outboard side of the


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balance piston to low pressure from the inlet side of the compressor, a pressure differential is

created in the opposite direction of the impellers. Any impeller thrust that is not balanced by the

balance piston is absorbed by the thrust bearing. The balance piston seal prevents leakage from

the high stage impeller along the balance piston. Leakage at the balance piston is minimized by

the balance piston seal ring. The balance piston seal ring assembly consists of a floating seal ring

and spring in the balance piston cover. Close clearance between the floating ring and rotating

balance piston reduces gas leakage to a minimum.

Oil leakage from the main bearings into the impellers is prevented by oil seals located on the

rotor shaft inboard from the main bearings. The oil seals permit a slight gas leakage into the

lubricating system that opposes and prevents oil leakage. The front seal is pressurized by a shaft

hole from the second stage inlet while the balance piston pressurizes the rear seal.

The shaft seal prevents gas leakage along the shaft to the atmosphere by means of a spring-

loaded mechanical seal assembly. The shaft seal assembly consists of a rotating cast iron shaft

seal collar with an O-ring and spring-loaded carbon shaft seal ring assembly (12 helical springs

and O-rings). The helical springs in the shaft seal ring assembly keep the carbon seal ring in

contact with the rotating shaft seal collar. The rotating collar is driven by pins and turns with the

shaft. The stationery carbon seal assembly is mounted on the shaft seal cover and is prevented

from rotating by keys. The friction surface between the rotating collar and stationery carbon seal

assembly is lubricated and cooled by oil circulated through the seal cavity.

The compressor Pre-Rotation Vanes (PRVs) are internal guide vanes in the suction flow path to

the first stage impeller wheel. The PRVs throttle the refrigerant flow through the system to

control capacity in response to the temperature of exiting chilled water. The PRVs are

pneumatically operated and automatically open and close in accordance with load requirements.

The compressor lubrication system consists of the main oil pump, auxiliary oil pump, duplex oil

filters, oil cooler, oil reservoir, and all interconnecting oil piping. The centrifugal main pump is


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bolted to and directly driven by the end of the end of the rotator shaft. The following points of

lubrication within the compressor are supplied with forced lubrication by the oil pumps:

Thrust Bearing

Journal Bearing – Suction End

Journal Bearing – Discharge End

Shaft Seal

Figure 2 – Compressor Lubrication System

The centrifugal main oil pump on the end of the rotator shaft is rated to pump 31.2 gpm. The

pump takes suction from the oil reservoir and oil cooler return line, and discharges into a

common header with the auxiliary oil pump. From the common header, the oil passes through a

15-micron filter. From the filter a portion of the oil (21.6 gpm) flows to the discharge end journal

and thrust bearing. The remainder of the oil (9.6 gpm) flows to the suction end of the compressor

to lubricate the journal bearing and shaft seal.


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At the discharge end of the compressor, oil from the filter enters a drilled passage in the side of

the oil sump housing. The oil flows to the space around the shaft at the combination thrust and

discharge end main bearing. From this space a portion of the oil passes through the main bearing

toward the impellers. The remainder of the oil passes to the load surface of the thrust bearing

through the oil pump located between the shaft and thrust bearing. Oil passes through the

discharge end journal bearings toward the impellers and into the space between the oil sump and

the seal ring housing. This oil drains into the oil reservoir. Oil sump pressure is equalized with

the first stage impeller inlet pressure.

The oil that lubricates the thrust surface (inboard surface of the oil pump and outboard surface of

the thrust bearing) flows through the cooler and returns to the centrifugal oil pump suction via

the oil jet pump. As oil flows through the oil jet pump, additional oil from the oil sump is

induced to slow to the compressor oil pump suction.

Oil flowing from the filter to the suction end of the compressor enters the bearing housing and

flows through a drilled passage to a circular space around the suction end journal. The journal

bearing is drilled radially to permit oil to flow to the bearing surfaces. Some of this oil flows

through the journal bearing (toward the impellers) and drains back to the reservoir through the

external oil return line. The remainder of the oil in the suction end main bearing flows into, and

completely floods, the shaft seal. From the shaft seal, the oil returns to the oil reservoir. Any oil

leaking through to the atmospheric side of the shaft seal drains is drained by gravity to the oil

drain tank. The oil drain tank is cast into the underside of the compressor housing.

The discharge end seal is designed to permit some gas from the balance piston to leak into the oil

reservoir.

The auxiliary oil pump is mounted on the side of the compressor and pumps at a rate of 33 gpm.

The auxiliary oil pump is automatically controlled through the auxiliary oil pressure differential


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control (CHOP) which is mounted in the control center. The pump auto starts at 6 psid and stops

when pressure returns to 10 psid.

The primary function of the auxiliary oil pump is to furnish oil to the compressor lubrication

system on startup while the main oil pump is coming up to speed, on shutdown while the rotor is

coming to rest, and at any time the main oil pump fails during operation. The auxiliary oil pump

is fed from the compressor oil sump.

The auxiliary oil pump discharges oil through a check valve to the oil filter, then the oil feeds to

the shaft bearings. The pressure regulating valve is set at 55 psig, relieving pressure from the

discharge line circulating oil back to the compressor sump. During normal compressor operation,

the auxiliary oil pump does not operate.

The oil sump heater is used during periods of shutdown and also during operation. The oil in the

oil sump tends to absorb refrigerant, the amount depending on the temperature of the oil and the

pressure in the oil sump.

To keep the refrigerant concentration at a minimum during normal or short shutdown periods,

two thermostatically controlled heaters are installed in the oil sump housing. These heaters are

factory set at 150°F. Heaters must be turned on during shutdown and off during operation (at the

same time the auxiliary oil pump stops). The heaters are automatically controlled, but should be

checked to assure proper operation.

The oil return system automatically returns oil to the compressor oil reservoir. One hundred

seconds after the unit starts to run, two oil return system solenoid valves are energized to open

and start the oil return system. The high-pressure gas solenoid allows high pressure refrigerant

gas to flow through the jet pump, inducing low pressure oil rich refrigerant liquid to flow from

the cooler to the oil return unit shell. When the oil rich liquid enters the oil return unit the liquid

collects at the bottom of the shell and surrounds the heat exchanger coil. The coil is supplied


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with liquid from the intercooler. High-pressure liquid circulates from the intercooler high-

pressure chamber, through the coil of the oil return unit, and the liquid is returned to the

intercooler intermediate-pressure chamber. High-pressure liquid in the coil has a higher

temperature than the low-pressure oil rich liquid surrounding the coil. The exchange of heat

causes the low-pressure liquid to boil, causing the oil to foam and concentrate on the top of the

refrigerant liquid. The oil and some refrigerant flow through the open oil return solenoid and a

filter-drier to the compressor oil sump. The boiled off refrigerant vapor is returned through a

connection located at the top of the oil return shell to the top of the cooler. The oil return system

operates constantly during unit operation.

The following describes the path of refrigerant gas flow through the compressor (see Figure 3)

and the effect upon the gas as it passes from the inlet to the compressor discharge:


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Figure 3 – York Compressor Cross Section Diagram

Suction gas is drawn from the suction connection through the PRVs (A) and enters the first stage

impeller (B). As the impeller rotates, it imparts kinetic energy to the refrigerant gas in the form

of velocity energy. The refrigerant gas then enters the diffuser (C) where the velocity energy is

transformed into pressure rise. The gas enters the straightening vanes (E) prior to entering the

second stage impeller (D) in order to achieve a uniform and controlled flow pattern.

A second impeller diffuser combination (D and F) discharges refrigerant gas into a collection

space (G), where the gas enters the discharge connection to flow into the condenser. As a result

of the pressure differential between stages, a thrust force is set up at each impeller. The higher


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pressure acts on the back of the impeller, while lower pressure acts on the impeller inlet. The

sum of these forces provides an axial thrust that is compensated for by the balance piston (J),

machined or attached as an integral part of the second stage impeller (D). The piston operates in

a balance piston chamber (K) and is vented to the previous stage.

The high pressure on the front face of the second impeller acts against the lower pressure in the

balance piston chamber behind the impeller to provide a compensating force that almost balances

the thrust of the rotating assembly. The amount of counter thrust is carefully engineered to have

a slight axial thrust in the direction of the coupling, thus preventing any shifting during load

changes.

2.1.1 Compressor Data

Compressor

Manufacturer York International Corporation

Compression Stages Two (2)

Rated 3,000 to 5,000 tons

Driver

The various York Chillers in the chiller stations are driven by VFDs, electric motors, and steam.

Lubrication System

Main Pump Capacity 31.2 gpm

Auxiliary Pump Capacity 33 gpm

2.1.2 Compressor Controls

The York Chillers are monitored and controlled from the control room. The York Chillers are

also controlled from local control panels located at each chiller (Figure 4).


Page 16

Figure 4 – Control Panel

2.2 Condenser

The Condenser (Figure 5) is a shell and tube type heat exchanger. The vessel received hot, high-

pressure vapor refrigerant from the compressor discharge. As the refrigerant vapor flows over the

condenser tubes, heat is removed from the vapor and the vapor condenses into a liquid. Any

residual refrigerant vapor, as well as non-condensable gases, is vented to the Evaporator.


Page 17

Figure 5 – Condenser and Intercooler

The condenser water pump pumps water from the cooling water towers to the condenser through

the condenser’s inlet isolation valve. The condenser water makes two passes through the heat

exchanger, then exits through the condenser’s outlet isolation valve. The isolation valve are air

vane type actuated butterfly valves.

The condenser receives high pressure, high temperature refrigerant gas discharged from the

compressor. In the condenser, heat is transferred from the refrigerant to the cooling water

circulated through the finned tubes. The transfer of heat continues until the temperature

corresponding to the existing pressure is reached. At this point, the refrigerant gives up its latent

heat and condenses to liquid form. The amount of heat removed in the condensation process

equals the amount of heat the refrigerant absorbed in the evaporator, plus the heat (energy) added

by the compressor. Dual liquid outlet connections are provided for effective liquid drainage.


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By running liquid refrigerant over the tubes in the subcooler section in the condenser, the

refrigerant temperature is lowered from saturation temperature to a temperature closer to that of

the entering water. By lowering the refrigerant ahead of the expansion device, the amount of gas

flashing in the intercooler after expansion is reduced. The lower flash gas translates into less gas

flow through the second stage impeller, and therefore lower overall horsepower.

The chiller utilizes a subcooler bundle located in the bottom section of the main condenser. As

liquid refrigerant condenses in the main condenser area, the condensate drains to the bottom of

the vessel. From there the refrigerant is channeled into the subcooler inlet, which is in the return

water box end of the condenser (opposite the water inlet nozzle). Refrigerant liquid enters the

subcooler from the sides and bottom (a plate blocks the top of the subcooler).

The level of refrigerant is adjusted at full load to provide a liquid level an inch or two above the

subcooler at the inlet end to prevent refrigerant gas from entering the subcooler. The refrigerant

liquid then flows axially down the shell length over the subcooler tubes, and exits out the bottom

at the cooling water inlet end.

2.2.1 Condenser Data


Type Shell and tube

Number of passes Two (2)

Refrigerant pressure 180 psig

Condenser water pressure 150 psig

Cooling water flow 9,800 to 15,000 gpm


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2.2.2 Condenser Controls

Condenser water inlet and outlet isolation valves are opened and closed from the screen in the

control room.

As a precaution against tube freezing, and to ensure liquid is not present in the subcooler when

the chiller pump is down or leaks occur, the valve is opened after shutdown to drain the liquid

refrigerant into the evaporator. The valve remains open for five minutes after startup and then

slowly closes until it reaches the position dictated by the liquid level controller. The level of

liquid refrigerant is controlled by a level control valve located between the condenser and

intercooler.

2.3 Intercooler

The purpose of the intercooler (Figure 6) is to increase system efficiency. The intercooler

accomplishes this by allowing a sizeable reduction in temperature of the condensed liquid

refrigerant while the gas is compressed in one stage of the compressor. The intercooler includes a

liquid inlet deflector plate, a York float valve in the high pressure chamber, and mesh inter-stage

gas mist eliminators. The float valve maintains the liquid refrigerant level and controls flow to

the evaporator.


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Figure 6 - Intercooler

The eliminators in the intermediate pressure chamber separate drops of liquid refrigerant from

the flash gas as it flows to the intermediate pressure stage. Baffles are welded to the inside of the

intercooler shall to properly direct the flow of refrigerant through the intercooler. Vented float

guard baffles are mounted over the float balls to minimize the effect of turbulence on the float

balls.

An inter-stage valve connects the intercooler gas space to the compressor inter-stage suction. The

valve controls refrigerant flash gas flow from the intercooler to the second stage compressor

impeller wheel as needed to maintain minimum pressure in the intercooler.


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2.3.1 Intercooler Data

Not available

2.3.2 Intercooler Control

The inter-stage valve remains fully open during compressor operation and closes on shutdown to

reduce compressor backspin. The valve remains closed for 10 minutes after startup to allow the

subcooler level controller to establish a liquid level in the subcooler. When the liquid level is at

the set level, the valve slowly opens until it reaches the position dictated by the capacity controls.

When the intercooler float differential pressure falls below the minimum allowed, the inter-stage

valve is driven closed by the “Intercooler Float Min. Diff. Press. Control” in software. This

maintains a minimum pressure in the intercooler and ensures that the intercooler refrigerant float

valve has sufficient drop to accommodate the design flow of liquid being expanded to the

evaporator.

2.4 Evaporator

The Evaporator (Figure 7) is the largest component in the chiller system. It is a horizontal,

flooded, shell and tube type heat exchanger. A baffle, located under the tube bundle, distributes

the incoming liquid and flash gas. The top portion of the shell provides space for liquid

separation and gas flow. As steel suction baffle, located on top of the shell and extending nearly

the full length of the tubes, minimizes liquid carryover to the compressor.


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Figure 7 – Evaporator

A hot gas bypass inlet connection is located on the side of the shell. A gas impingement

distributor located within the shell provides an even distribution of the hot gas as the gas enters

the cooler. Liquid transfer, pump out, and gauge connections are provided.

Compressors can surge at low loads because suction pressure and volume are so low in

comparison to condenser pressure that partial reversal of refrigerant flow takes place. When low

load conditions exist, the automatic hot gas bypass valve opens because of the pressure setting of

the pneumatic controls and the signal of the low temperature control.

Opening the hot gas bypass valve allows high-pressure hot gas from the top of the condenser

flow to the lower pressure evaporator. High-pressure liquid refrigerant is injected into the hot gas

bypass line desuperheating the hot gas before it enters the evaporator. The desuperheated

refrigerant gas enters the cooler and mixes with the boiled off refrigerant vapor in the top of the


Page 23

cooler. The additional refrigerant vapor provides an increased volume to the compressor suction,

preventing the compressor from surging.

The hot gas bypass valve is also opened at shutdown to equalize condenser pressure with the

evaporator quickly, reducing backflow of high-pressure gas through the compressor to the

evaporator that would spin the compressor backwards.

2.4.1 Evaporator Data


Type Shell and tube

Chilled water flow 7,400 to 13,500 gpm

Design pressure (tube side) 300 psig

Design pressure (shell side) 180 psig

2.4.2 Evaporator Control

Chilled water flow is controlled by a pneumatically operated flow control valve, throttling the

outlet of the cooler.

3.0 System Operation

Chapter Objectives:

Describe the proper operation of the York Chillers during:

System Startup

Normal Operation

System shutdown

Note: This system operation section in included for instructional purposes open, and should not

be used as an operating procedure.


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3.1 System Startup

All system components that have been tagged out for maintenance have tags cleared and

removed. All control and indication instrumentation on which maintenance or calibration has

been performed has been returned to service. The Instrument Air System is in service.

The system should be walked down to verify all pump and motor lubrication is at proper levels.

Verify the system valves have been placed in proper startup positions with all drains closed

except where otherwise noted. Verify all AC and DC electrical power supplies have been racked

in and are ready for service. Check the cooling tower water basin for proper water level and that

the cooling tower fans are ready for operation. Check that the condenser is at its proper level and

the condenser water pump has been filled and vented.

Verify the compressor lubrication and valving are ready for operation. Check the evaporator for

proper refrigerant level. Check the chiller water pump for lubrication, valving, and that the pump

has been filled and vented.

3.2 Normal Operation

All systems should be monitored for pressures, temperatures, flows, and levels. Pump and motor

lubrication are monitored and filled as required. Any abnormal conditions should be reported and

correction action taken.

3.3 System Shutdown

Unload the chiller by raising the chill water temperature controller setpoint. Push the STOP

button on the control panel. The unit will come to a rest within a few minutes. Check the

compressor to be sure lubrication is maintained during coast-down.


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When “Load-Shedding” occurs, all motor-driven equipment at all chiller stations is automatically

tripped to assist the power plant in emergency load management. As many chillers as necessary

will be tripped to keep the electric demand on the city tie below 25 megawatts. There will be no

warning; the units will just shut down, leaving all the auxiliary equipment in service.

If the power plant’s PLC issues a load shed an alarm will be generated displaying which chiller

has been tripped. At the top of all graphics, a message will flash “Load-shed”. From the main

menu of the control panel, select “Load-shed” to display the load shed graphic. Immediately

perform the following to further reduce electrical load and stabilize the system:

1. Take the water off the units that have been tripped and reduce operating pumps.

2. Reduce operating cooling fans.

3. Notify the control room operator.

YORK CHILLERS

OPERATING PROCEDURE (IRI-CH-25)






Page 1

PREFACE

This Training System Operating Procedure (SOP) has been designed to assist you in meeting the

requirements of Module IRI-CH-25-SOP of the Power Plant Training Program. It contains

information about the, Power Plants York Chillers. This includes purpose, precautions, limits and

setpoints, procedures and references for using the York Chillers.

You should identify the components and controls of the York Chillers. Should you have additional

question about the York Chillers, ask your supervisor.


Page 2

YORK CHILLER SYSTEM

TRAINING SYSTEM OPERATING PROCEDURE

TABLE OF CONTENTS

I. Precautions, Limitations and Setpoints .................................................................................... 3

II. Procedure ................................................................................................................................. 3

A. Pre-Start Compressor Check 3

B. York Chiller Startup 4

C. York Chiller Normal Operation 5

D. York Chiller Shutdown 6 III. References .............................................................................................................................. 6

Appendix I York Chiller Valve List .............................................................................................. 7

Appendix II Control Panel Screens................................................................................................ 8


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Purpose

This procedure provides information and guidance for the correct and safe operation of the

York Chillers. Prior to operating the equipment, you must understand the operating

parameters of the York Chillers. Eleven chillers, with capacities from 3,000 to 5,000 tons in

four chiller stations, meet the chilled water needs of all campus facilities.

I. Precautions, Limitations and Setpoints

A. Observe all safety rules and precautions when handling chemicals or performing

any other hazardous tasks.

B. Don the appropriate level of Personnel Protective Equipment (PPE) when

completing tasks involving the York Chillers.

C. All switching and tagging will be performed in accordance with approved

Switching and Tagging Instructions.

D. Verify all maintenance work is completed and all tags are cleared and removed.

E. Verify power is available to supply York Chiller loads.

F. Report any chemical leak, take proper precautions, and secure the leaking

equipment.

G. Use proper cleanup procedures.

II. Procedure

A. Pre-Start Compressor Check

Before starting the chiller, perform the following:


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___1. Check the compressor oil level at the two oil level sight glasses located on

the oil sump end of the compressor.

___2. Add new oil, if necessary.

___3. Completely open all shutoff water valves to the oil cooler. Full flow of

water is required through the oil cooler at all times during startup and

operation to inhibit foaming in the oil.

___4. Check the compressor oil sump temperature. Oil temperature must be a

minimum of 10°F above the condenser saturation temperature (50°F if the

unit has been shut down for less than 30 minutes) before the unit will be

allowed to start.

___5. Open or adjust all shutoff valves necessary for operation of the hot gas

bypass and liquid injection systems and oil return systems.

___6. Verify the compressor pre-rotation vanes are closed to unload the motor

during startup.

B. York Chiller Startup

___1. Set the Pre-Rotation Vanes Control to AUTO.

___2. Set the Hot Gas Control to AUTO.

___3. Set the Interstage Valve Control to AUTO.

___4. Set the Subcooler Level Valve Control to AUTO.


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___5. Select the desired Control Source (LOCAL or ANALOG REMOTE).

___6. Set the Leaving Chilled Liquid Temperature Setpoint.

___7. Set the Current Limit Setpoint to 100% (unless a percentage is desired to

limit maximum current).

___8. Start the chilled water pump and condenser water pump. Verify the

evaporator and condenser flow switches are made.

___9. Reset any existing trips or power failures by moving the panel switch to

the STOP/RESET (O) position and press the CLEAR MESSAGE button

on the display. If all chiller safeties are satisfied the display will indicate

READY TO START.

___10. Move the Panel switch to the START (<) position. The switch is spring-

loaded and returns to the RUN (|) position when released. The start

sequence initiates and the display indicates the operating state of the

chiller as it transitions from startup to run mode.

C. York Chiller Normal Operation

Perform the following hourly:

___1. Record operating readings.

___2. Walk down the chiller area and perform a visual inspection of the chiller

vessels, compressor, and drive. Check for unusual noise or vibration.


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D. York Chiller Shutdown

___1. Move the panel switch to the STOP/RESET (O) position. The chiller will

shut down and the post-lubrication sequence will be initiated. The display

will indicate that the unit is in COASTDOWN mode.

___2. Shut down the chilled water pump and condenser water pump.

___3. Verify the compressor oil sump heaters are energized.

III. References

OM Titan Multi-Stage Chiller Operating Instructions, York, Form 160.72-01 (810)


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Appendix I

York Chiller Valve List

Valve

Number Description Startup Normal Shutdown

Shutoff Water Valves Open Open Open

Hot Gas Bypass Shutoff Valves Open /

Adjusted

Open Open

Liquid Injection System Shutoff Valves Open /

Adjusted

Open Open

Oil Return System Shutoff Valves Open /

Adjusted

Open Open


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Appendix II

Control Panel Screens

Home Screen


Page 9

System Screen


Page 10

Condenser Screen


Page 11

Motor Screen


Page 12

Compressor Screen

YORK CHILLERS

JOB PERFORMANCE MEASURE (IRI-CH-25)






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Power Plant Operators

(IRI-CH-25-JPM)

Performance Measure: York Chillers

Name: __________________________________

All Parts Satisfactorily Completed:

________________________________________ ____________________

(Supervisor’s Signature) (Date)

Supervisor’s Comments: __________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

References:

Training ModuleIRI-CH-25-JPM

Materials Needed:

Pencil and Clipboard.

System Description – York Chillers IRI-CH-25-SD.

System Operating Procedure – York Chillers IRI-CH-25-SOP.

Associated Operator Route Check List.

Associated System P&ID, Logic or E-Drawings, and Equipment Technical Manuals.

Safety/Environmental:

Wear hard hats, safety glasses, safety toe shoe, and ear plugs as required.

Discuss safety and environmental hazards associated with operating the system.

Discuss any unusual operating conditions associated with the system.

Note: Always observe all plant safety rules in accordance with Utility Services Safety and

Health Procedures and all Federal, State and/or local TOSHA Standards.


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Part A: Location of System Components

Conduct a walk-through of the plant, locate, identify and describe the operational function for the

following components.

1. Compressor

2. Evaporator

3. Condenser

4. Control Panel

Satisfactorily Completed ____________________________

Part B: Location of Valves

Conduct a walk-through of the plant, locate, identify and describe the operational function of the

following valves.

1. Shutoff Water Valves

2. Hot Gas Bypass Valves

3. Liquid Injection System Shutoff Valves

4. Oil Return System Shutoff Valves

Satisfactorily Completed _________________________

Part C: Location of Control Panels and Breakers

Conduct a walk-through of the plant, locate, identify and describe the operational function of the

following control panels and breakers.

1. The York Chiller Control Panel

Satisfactorily Completed __________________________


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Part D: Preparation for Operating

Demonstrate or simulate how to prepare for operating the York Chiller. Explain your actions at

each step.

1. Check compressor oil level at the two oil level sight glasses located on the sump end of the

compressor.

2. Add new oil, if necessary.

3. Completely open all shutoff water valves to the oil cooler.

4. Verify the compressor oil sump temperature is within acceptable limits.

5. Open or adjust all shutoff valves necessary for operation of the hot gas bypass and liquid

injection systems and oil returns systems.

6. Verify the compressor pre-rotation vanes are closed to unload the motor during startup.


Part E: System Startup

Demonstrate or simulate a normal startup of the York Chiller. Explain your actions and

observations at each step of the procedure.

1. Set the Pre-Rotation Vanes Control to AUTO.

2. Set the Hot Gas Control to AUTO.

3. Set the Interstage Valve Control to AUTO.

4. Set the Subcooler Level Valve Control to AUTO.

5. Select the desired Control Source (LOCAL or ANALOG REMOTE).

6. Set the Leaving Chilled Liquid Temperature Setpoint.

7. Set the Current Limit Setpoint.

8. Start the chilled water pump and condenser water pump. Verify the evaporator and condenser

flow switches are made.

9. Reset any existing trips or power failures.

10. Move the Panel switch to START.



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Part F: System Operation

Conduct an hourly system inspection of the York Chiller. Explain your actions and observations

as equipment is inspected.

1. Record operational readings.

2. Walk down the chiller area and perform a visual inspection of the chiller vessels, compressor,

and drive. Check for unusual noise or vibration.

Satisfactorily Completed ____________________________

Part G: System Shutdown

Demonstrate or simulate a normal shutdown of the York Chiller. Explain your actions and

observations at each step of the process.

1. Move the panel switch to the STOP/REST position.

2. Shut down the chilled water pump and condenser water pump.

3. Verify the compressor oil sump heaters are energized.

Satisfactorily Completed ___________________________

Part H: Personnel and Equipment Safety

Perform all aspects of the JPM using safe operating practices and following plant safety and

environmental procedures


YORK CHILLERS

FACILITATOR’S GUIDE (IRI-CH-25)






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1.0 Introduction

This Facilitator’s Guide is designed to assist you in coordinating the Training for Module

(IRI-CH-25) of the Safety Training Program. It contains information about conducting

training for the plant.

Each Trainee is required to successfully complete all four (4) elements of the module to be

certified on the Training Progress Monitoring Card (TPMC) as completed. Each of the

following four (4) elements are included in each system training module to ensure the trainee

has knowledge of each system and can perform the required tasks.

Formal System Training provides the trainee with a structured training session that teaches

and tests the knowledge required to understand the operation of the York Chillers used at .

The instructional method can be Facilitator Led Classroom, Video Program, Computer Based

Training, Self-Study, or any combination of acceptable methods that provides quality

instruction that meets the lesson objectives.

System Description (SD) Formal Training provides a formal process for instructing the trainee

on the understanding and proper execution of all Demin Storage

System operations.

On-The-Job Training will be designed to include 1) equipment preventive maintenance, and

2) corrective maintenance. OJT will also include how to properly perform all equipment

checks, the frequency of each check, and any equipment adjustments that are made to bring

the checked parameter within limits.

Equipment Checkout involves formal instruction on how to properly perform all equipment

maintenance and checks. This includes 1) how to perform preventive maintenance, 2) make


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routine equipment adjustments 3) perform corrective maintenance 4) proper use of checklists

while performing routine system inspections and equipment checks.

Both knowledge tests and Job Performance Measures will be used to test trainees on both

knowledge and performance to measure competency.

This training program may utilize the self-study method of training. Training materials and

assistance will be provided to the trainee as needed to complete the module. However, trainee

progress will depend on their willingness to gain the required knowledge and skills.

As the trainees gain the knowledge and skills listed for each module they will be required to

demonstrate actual work proficiency before they can be signed off on that module.

Preparing to complete each module will require preparatory work, such as reading, studying,

observation, or practical experience. The trainee should ask questions if they are unsure about

any items. It is the trainee’s responsibility to take the initiative to request training or help in

learning a knowledge or skill.

The training requirements for each module are listed in the module outline. They have been

designed to include the knowledge and skills needed to satisfactorily perform the job. The

Facilitator is responsible for observing the trainee’s safety habits, work procedures, and

completion time. As the trainee demonstrates skills, the Facilitator will initial and date the

space next to the knowledge or skill demonstrated on the TPMC.

The module requirements as listed in the TPMC do not have to be completed in their order of

appearance except that one (1) level must be completed before the next can be started. The

order in which the trainee performs the demonstration of these skills depends on their

experience and preparation. It also depends on their current work schedule.


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The Facilitator will consider safety habits when judging whether or not to approve a skills

demonstration. An unsafe act may invalidate an otherwise approved performance.

Remember that safety is a crucial part of any Power Plant Operators work and of every task

performed.

You’re Facilitator, or someone designated by the Facilitator, must approve skill

demonstrations. The company-approved safety procedures will be used to determine the

quality of a demonstration. In some cases, the Facilitator may use a team to approve a

demonstration. The Facilitator will date and initial or sign all approvals on the TPMC.

2.0 System Description (SD) Facilitator’s Guide

The System Description Training Module is designed as part of the Safety Training Program.

This module is designed to aid Power Plant Operators in upgrading their knowledge and

understanding of the system.

2.1 Formal Training

The format of the Module formal training materials (System Description Document) is

suited for either formal classroom instruction, self-study or for refresher training.

Unless a waiver is granted, the trainee must have completed the prerequisite basic

knowledge modules (IRI Web Based Training, Videos or CD Rom Programs) and safety

modules before starting training on the next module. If the training is presented as

classroom instruction the following applies.


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2.2 System Description (SD) - Facilitated Training

The following guide is used to formally instruct the trainee in a structured training

environment. If the training is presented as classroom instruction, the following applies:

2.2.1 Suggested training aids and materials:

Overhead Projector

Chalkboard/Whiteboard

Flipchart

PC and Monitor

Pencils

Notebook paper

Highlighters

2.2.2 Facilitator Preparations

Review System Description text.

Prepare copies of System Description for trainee handouts.

Print SD drawings as overhead slides.

Review the Job Performance Measure

Prepare copies of JPM.

Display or Review Reference Materials’ System Description of the York

Chillers, and Charts or Diagrams used in performing the operations.

2.2.3 Classroom Presentation

Describe the module and how the material is to be presented.

Hand out copies of student text.

Present each chapter objective.

Review the contents of each chapter with the students using student text and

drawings.


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Allow for discussion at the end of each chapter. Encourage the students

draw on their past experiences with regard to the lesson.

Summarize each chapter.

Inspect the equipment with the trainee and instruct them to describe the flow

path, identify the equipment components and describe the function of each

component.

At completion of lecture and discussion, administer the written test.

2.2.4 Module System Description (SD) Overall Training Objectives

The objective of this lesson is to present the material relating to the equipment.

Upon completion of the training the Operator should be able to:

Describe the function of the equipment.

List the components that make up the equipment.

Describe the flow path through the equipment.

Describe the function of each component of the equipment.

Identify equipment under the jurisdiction of the Power Plant Operators.

2.2.5 Module System Description Chapter 1.0 - Training Objectives:

This section describes the function of the equipment. It provides a simplified

description of the equipment; introducing the equipment major parts, and flow

path.

Upon completion of this chapter, each student should be able to:

State from memory the function of the equipment.

Draw a simplified diagram of the equipment, including internal parts.

Describe the equipment connections and interaction with other systems.

List the equipment operating parameters.


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2.2.6 Module System Description Chapter 2.0 - Training Objectives:

This segment addresses each Equipment Major Part. The major parts are

described as to their function and type. Upon completion of the chapter, each

student should be able to:

Draw from memory a diagram of the equipment showing major parts.

State from memory the names and functions of major parts.

Describe the location of the major parts.

2.2.7 Module System Description Chapter 3.0 - Training Objectives

This section describes the Equipment Preventive and Corrective Maintenance as

it applies to the power plant Technicians. Upon completion of this section, each

student should be able to describe:

Routine Preventive Maintenance (equipment not taken out of service).

Preventive and Corrective Maintenance (requiring the equipment to be taken

out of service for inspection and repair.)

Reassembly and Testing after Preventive or Corrective Maintenance that

requires the equipment to be taken out of serve.

At the end of the training session a written test will be administered. A score of

75 percent must be obtained to satisfactorily complete this part of the training.

2.3 System Description (SD) - Self-Directed Learning

The following guide is used to provide direction to the trainee to self-study the module

training materials. If a self-directed approach is used, then the following applies:

2.3.1 Trainee Preparation for Self-Study

Provide the trainee with the following tools and training materials:

Pencil

Notebook

Highlighter


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System Description

Plant reference materials such as System Description of the York Chillers,

and Charts or Diagrams used in performing the operations.

Discuss the self-directed learning strategy with the trainee:

Read each chapter of the System Description (SD) and be able to complete

each of the chapter objectives.

Review the System Description on the York Chillers.

Inspect the equipment and refer to the training materials to help you

understand the function of each component, the location of each component,

the flow path and maintenance parameters.

Interact with more experienced Operators and your assigned facilitator.

They are responsible for answering questions, providing you with On-The-

Job Training and conducting oral quizzes to determine your progress and

competency level.

When the facilitator agrees you are ready then you will be given the

written test. A mastery level of 75 percent is required to demonstrate

knowledge.

2.4 System Description (SD)- Facilitated Training

The following guide is used to formally instruct the trainee to understand and perform

all maintenance tasks described in the System Description Procedure.

2.4.1 Suggested Training Aids

Overhead Projector

Chalkboard/Whiteboard

Flipchart

PC and Monitor


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2.4.2 Suggested Student Materials

Pencils

Notebook paper

Highlighters

2.4.3 Classroom Preparation

Review System Description Text.

Prepare copies of System Description Text for employee handouts.

Prepare copies of the written test.

Prepare the SD as overhead slides.

Description of the York Chillers, and Charts or Diagrams used in performing

the operations.

2.4.4 Classroom Presentation

Describe the SD and discuss how the material is to be presented.

Hand out copies of the SD.

Present each section objective.

Review the contents of each section of the SD with the students using

drawings to illustrate locations of components and equipment.

Allow for discussion at the end of each section. Encourage the students to

draw on their past experiences with regard to the lesson.

Summarize each section.

When complete with the classroom instruction, thoroughly inspect the

equipment with the trainee and discuss/demonstrate how to perform all steps

of the equipment maintenance procedure.

At completion of lecture and discussion, administer the written test.


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2.4.5 Module System Description (SD) Objectives

This section describes the maintenance of the equipment. Upon completion of

this training the trainee should be able to:

List the safety requirements associated with the equipment.

Describe any environmental impacts or concerns involved with the

equipment maintenance.

Discuss training and responsibilities required for maintenance of the

equipment.

List the Precautions, Limitations and Setpoints relating to maintenance of the

equipment.

Perform equipment preventive maintenance.

Perform the checks, isolations and tag outs required when performing

corrective maintenance of the equipment.

Perform corrective maintenance.

Test the equipment after completion of corrective maintenance.

Use the Equipment Maintenance Checklist to restore it to service.

2.5 System Description – Self-Directed Learning

To ensure the trainee fully understands all aspects of the Safety Description Procedure, it

is required that he/she is provided with facilitated instruction. However, to minimize

Facilitator time, the trainee can do the following self-study so he/she is better prepared

prior to the formal training session:

2.5.1 Provide the trainee with the following tools and training materials:

Pencil

Notebook

The System Description Procedure.

System Description of the York Chillers, and Charts or Diagrams used in

performing the operations.


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Equipment Maintenance charts and diagrams.

Provide a handout of the Procedure Objectives listed in section 2.4.5

2.5.2 Instruct the trainee to do the following self-study:

Discuss the Procedure Objectives with the trainee and instruct him/her to use

the objectives to direct the outcome of the self-study session.

Read the System Description Procedure.

Inspect the equipment, following each step of the maintenance procedure,

and mentally simulate how to perform the required actions.

Make note of any questions that you may have concerning the procedure so

they can be discussed with your facilitator.


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2.5.3 Once the trainee has completed the self-study, the facilitator will conduct a

facilitated training session that includes the following:

Conduct an oral review to assess the trainee’s understanding and answer the

questions that were noted during the self-study.

Inspect the equipment with the trainee and have them discuss or demonstrate

how to perform each step of the procedure.

Explain and demonstrate any aspects of the procedure that the trainee doesn’t

fully understand.

At the end of the training session administer the written test. A score of 75

percent must be obtained to satisfactorily complete this part of the training.

3.0 On-The-Job Training

The purpose of On-The-Job Training is to demonstrate to the trainee how to perform the

various maintenance procedures associated with the equipment. Trainees are to be given

copies of the JPM. The OJT Training Process is performed as follows:

Step 1 The Facilitator discusses the performance of the JPM

Facilitator gives an overview of the safety procedure associated with York Chillers.

Shows location of the major parts of the equipment.

Describes the preparations needed for maintenance of the equipment.

Step 2 Facilitator describes or performs the JPM

Facilitator describes or performs each step that is needed to isolate the equipment.

Facilitator describes or performs each step that is needed during preventive and corrective

maintenance of the equipment.

Facilitator describes or performs each step that is needed to isolate in readiness to perform

corrective maintenance of the equipment.


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Facilitator describes or performs system corrective maintenance. This includes how to

properly perform the maintenance task, the, any routine adjustments that may be required,

and how to properly use and record information on the maintenance checklist.

4.0 Equipment Checkout

Equipment Checkout involves having the trainee properly perform all system preventive and

corrective maintenance. The trainee will use the JPM, the System Description Procedure, and

Equipment Maintenance Checklist to perform the System Checkout using the following

process:

Step 1 Trainee discusses the System Checkout with the Facilitator

Trainee gives an overview of the procedure or process that is to be performed.

Trainee will show location of Equipment and the major parts.

Step 2 Trainee performs the System Checkout and is evaluated by the Facilitator

Trainee describes or performs the preparations needed for Maintenance of the equipment

using the Safety Description Procedure and associated Checklists as needed.

Trainee describes or performs each step that is needed to perform preventive and

corrective maintenance on the equipment.

Trainee describes or performs each step that is needed during preventive and corrective

maintenance of the equipment.

Trainee describes or performs each step that is needed to test the equipment after

corrective maintenance.

Trainee performs complete equipment inspection and checks after returning the equipment

to service.


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Module Requirements Sign Off

When all the elements of the Equipment Maintenance Training Module have been completed,

the Supervisor or designated Subject Matter Expert will sign off the associated documents in

the trainee’s TPMC.

YORK CHILLLERS

TEST QUESTIONS (IRI-CH-25)






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1. (IRI-CH-25-SQ) How does the compressor raise the pressure and temperature of

refrigerant?

A. Tube in shell heat exchange

B. Steam drum

C. Hotwell

D. Centrifugal force

2. (IRI-CH-25-SQ) Which component of the chiller directly cools water?

A. Compressor

B. Condenser

C. Evaporator

D. Radiator

3. (IRI-CH-25-SQ) What type of heat exchanger is the evaporator?

A. Shell and tube, dry

B. Shell and tube, flooded

C. Hotwell

D. Surface condenser

4. IRI-CH-25-SQ) Which valve allows high pressure refrigerant liquid to expand into the

evaporator?

A. Level control valve

B. Governor valve

C. Subcooler

D. Refrigerant relief valve

5. IRI-CH-25-SQ) Which component of the chiller contains water boxes?

A. Evaporator

B. Compressor

C. Condenser

D. Reservoir


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6. IRI-CH-25-SQ) Which chiller components are controlled by the local control panel?

A. All major chiller components

B. All major chiller components except the electric or steam drive

C. Only the electric or steam drive

D. Evaporator, condenser, and compressor only

7. IRI-CH-25-SQ) Where is the subcooler located?

A. Inside the evaporator

B. Inside the condenser

C. Separate and connected to the condenser

D. Separate and connected to the evaporator

8. IRI-CH-25-SQ) How many chillers operate in the four chiller stations?

A. 8

B. 16

C. 12

D. 11

9. IRI-CH-25-SQ) What is the range in capacity of the campus chillers?

A. 2,000 to 4,500 tons

B. 5,000 to 8,000 tons

C. 1,500 to 3,000 tons

D. 3,000 to 5,000 tons

10. IRI-CH-25-SQ) What controls the level control valve?

A. Refrigerant level sensor in the subcooler

B. Refrigerant level sensor in the evaporator

C. Condensate relief valve in the condenser

D. Refrigerant compression sensor at the outlet of the compressor

11. IRI-CH-25-SQ) Water from the cooling towers flows into the chiller through which

component?

A. Evaporator

B. Condenser

C. Driver

D. Condenser


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12. IRI-CH-25-SQ) Where is the compressor mounted?

A. On top of the evaporator

B. Under the evaporator

C. On the driveline base with the driver

D. Over the condenser

13. IRI-CH-25-SQ) Which is the tube side of the evaporator?

A. Outside the tubes

B. Outside the shell

C. Between the evaporator and subcooler

D. Inside the tubes

14. IRI-CH-25-SQ) How is refrigerant held at the correct saturation temperature?

A. Refrigerant vapor is drawn from the shell side of the evaporator

B. Refrigerant is passed through baffles in the condenser tube sheet

C. Refrigerant is collected in the subcooler until needed

D. Liquid refrigerant is passed through the condenser

15. IRI-CH-25-SQ) What is the model series of the compressor?

A. A

B. OM

C. M

D. Titan

16. IRI-CH-25-SQ) What is “flashing”?

A. High pressure liquid is exposed to centrifugal force

B. High pressure liquid is exposed to a lower pressure causing the refrigerant to boil

C. High pressure liquid is passed through the subcooler

D. High pressure liquid is sent to the cooling towers

17. IRI-CH-25-SQ) As vapor exits the impeller, the velocity of the gas reduces as it passes

through what?

A. Subcooler

B. Evaporator

C. Diffuser

D. Compressor


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18. IRI-CH-25-SQ) What does the condenser do?

A. Refrigerant liquid is superheated and converts to high-pressure gas

B. Refrigerant liquid is combined with water from the cooling towers

C. Steam returned from the campus is converted to water for the cooling towers

D. Latent heat in high-pressure refrigerant gas is removed and the refrigerant is

converted to liquid

19. IRI-CH-25-SQ) What powers the chillers?

A. Steam or electricity

B. Electricity or natural gas

C. Natural gas or diesel

D. Steam or natural gas

20. IRI-CH-25-SQ) What is the total chiller capacity?

A. 10,000 tons

B. 55,000 tons

C. 125,000 tons

D. 45,000 tons

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