Shawano Medical Center

		Shawano Medical Center was in the middle of an expansion when their TRANE CVAA 130 Air Cooled R-12 chiller experienced a mechanical failure. The system was losing oil pressure under load and would fail on the oil pressure lockout. The cooling season was coming to an end but, being a hospital, they would require additional cooling capacity for the remaining fall months. SAMSA, Inc. was contracted to supply auxiliary cooling capacity to sustain the hospital, analyze existing air conditioning loads with consideration given to the new addition under construction, and estimate potential capacity for future expansion.

The Trane RTHB 215 Water Cooled Chiller supplied 220 tons at 147 kW/ using 460 volts, 60 cycles, 3 phase. Cooler flow rate is 529 GPM of 55 deg. F entering water and 45 deg. F leaving water. Condenser flow rate is 629 GPM of 85 deg. F entering water and 95 deg. F leaving water. The existing building chilled water piping was the limiting factor for chiller selection. We were tying into an existing system with future expansion considerations and an existing expansion in progress. The air cooled direct expansion air conditioning system on order was cancelled and a chilled water air handling unit was substituted.

SAMSA, Inc. located the new chiller in the existing boiler room Northwest corner of the building. The chiller would fit in through the receiving doorway and roll down a hallway to the boiler room. The boiler room had a double door and the chiller would fit through it. A ramp was constructed and the chiller was rolled to the boiler room floor level where the chiller would be slid into an open area South side of the boiler room. Access to the piping for chilled and condenser water was difficult due to limited space constraints.

The new chilled water pump is a Bell & Gossett 1510 - 5BC pump with 15 hp 460 volts, 60 cycles, 3 phase 1750 RPM motor with a B&G HG-3 suction diffuser, inlet strainer and a B&G 3D5-55 triple duty valve. Pump performance - 530 GPM @ 50 Ft Hd.

Operating pump curve

Published pump curve

The cooling tower is a Baltimore Air Coil model VT1-N220-O forced draft, counterflow cooling tower with G-235 galvanized steel construction. The Energy Mizer Fan System has a 30 hp high speed motor and a 7.5 hp low speed motor and is powered by 460 volt, 60 cycle, 3 phase. The Baltibond Corrosion Protection System and electric pan heaters were a must for a thirty year system and low ambient operation.

Locating the cooling tower on the boiler room roof in the Northwest corner of the building was the logical placement and most convenient for the piping scheme and maintenance issues. Shawano Medical Center confirmed placement and verified structural support.

All water treatment chemical and equipment (blow down solenoid, pump, timer) was supplied by Shawano Medical Center

SAMSA, Inc. furnished and installed all necessary condenser and chilled water piping, valves, drain valves, chemical treatment access valves,(i.e. tower blow down), pot feeders, expansion tanks, airtrol, makeup water (both condenser and chilled water), pressure gauges and thermometers for a completely operational system.

All main condenser water piping was 8 inch.

All main chilled water piping was 8 inch inside new chiller room to provide for future expansion. All chilled water piping heading towards existing chilled water pipes would be 6 inch and because of the location of the new chilled water pump the supply and return lines for the old existing coils needed to be reversed. Both the condenser and chilled water pumps were stubbed out for future standby pump installation .

The chilled water pipes were routed through a side wall of the chiller room and followed existing steam lines in a pipe chase through a new electrical room. The new chilled water pipes exited Northeast wall of electrical room where new chilled water pipes met old existing chilled water piping.

Condenser water pipe was routed through the chiller room roof and connected to the tower sump from the suction side of condenser pump.

Chiller, chilled water and condenser water pumps were secured to the chiller room floor. Cooling tower was secured to a secured base flashing.

Insulation: All chilled water piping was insulated with 3/4 inch armaflex insulation to include: valves flanges, pumps airtrol and any equipment that could sweat. Insulation exposed to outdoor elements was painted. The chiller was factory insulated.

Salvage: Removal of old Trane CVAA 130 located on roof was excluded from project. Shawano Medical Center personel dismanteled old unit and scrapped it out. All Refrigerant 12 and oil was recovered and disposed of in accordance with all State and Federal regulations. Refrigerant was recovered into DOT approved recovery cylinders and shipped to a reclamation facility. System oil was withdrawn from the defective chillers' oil sump and oil filter was removed and disposed of as a hazardous waste. The defective system was dehydrated to 28 mm. hg. prior to salvage.

Start up service and warranty: SAMSA, Inc. provided start up and warranty service on all new equipment. All manufacturers supplied one year parts warranty on their equipment. SAMSA, Inc. de-rated the new Trane chiller to supply 150 tons of refrigeration at 45 deg. F. leaving chilled water or 68% of full load.

Project Management:.SAMSA, Inc. managed all facets of this project with respect to the installation of the new chiller. SAMSA, Inc. also directed all subcontractors to ensure a sound installation. SAMSA, Inc. supplied subcontractors with all necessary diagrams and information required for the installation of equipment.

SAMSA, Inc. is the contractor for your next retrofit. When the heat is on and the system fails no other performs like SAMSA, Inc.