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Refrigerant
Refrigeration depends upon a substance called the
refrigerant, which can readily be converted from liquid
into a vapour (evaporation) and also from a vapour into a
liquid (condensation) within a narrow range of pressures.
Refrigerants are those fluids, which are used as working
fluids, for example in vapour compression refrigeration
systems. These fluids provide refrigeration by
undergoing a phase change process in the evaporator.
A refrigerant gives up heat by condensing at high
temperatures and pressures and absorbs heat by
evaporating at low temperatures and pressures.
REFRIGERANTS
Halocarbon based
Ethane based
CFCs
Non-Halocarbon based
Methane based
HCFCs
HFCs
Primary
Secondary
Pure
Azeotropic
Blended
Near Azeotropic
Zeotropic
Generation of Refrigerants
First Generation 1830-1930s ex: CO2; NH3;
HCs;SO2 etc. usefulness of volatile
compounds
Second Generation: 1931-1990s ex: CFCs;
HCFCs; safety & durability
Third Generation; 1990-2010s ex: HCFCs
and HFCs; Ozone Layer protection
Fourth Generation; 2010 onwards ex: Pure &
Blended HCs; Global warming; high efficiency
Environmental properties
1.
2.
3.
4.
5.
Atmospheric Lifetime
HFC125, the major component of HFC
blend refrigerants, has an atmospheric life
of 29 years, while the atmospheric life of
HFC32 is only five years.
Toxicity
Ideally, refrigerants used in a refrigeration
system should be non-toxic. However, all
fluids other than air can be called as toxic
as they will cause suffocation when their
concentration is large enough. Thus
toxicity is a relative term, which becomes
meaningful only when the degree of
concentration and time of exposure
required to produce harmful effects are
specified.
Toxicity
Some fluids are toxic even in small
concentrations. Some fluids are mildly toxic, i.e.,
they are dangerous only when the concentration
is large and duration of exposure is long. Some
refrigerants such as CFCs and HCFCs are nontoxic when mixed with air in normal condition.
However, when they come in contact with an
open flame or an electrical heating element, they
decompose forming highly toxic elements (e.g.
phosgene-COCl2).
Toxicity
1.
2.
3.
4.
5.
Flammability
The refrigerants should preferably be nonflammable and non-explosive. For
flammable refrigerants special precautions
should be taken to avoid accidents.
Dielectric strength
This is an important property for systems
using hermetic compressors. For these
systems the refrigerants should have as
high a dielectric strength as possible
Economic properties
The refrigerant used should preferably be
inexpensive and easily available.
Halocarbon Refrigerants
Methane (CH4)Based will have a two-digit number ex:R22
First figure shows no. of Hydrogen atoms plus 1 Second
figure shows no. of fluorine Atoms R22=CHClF2
Chlorofluoromethane. The total number of Hydrogen and
replacement atoms should be 4; R11; R12; R13; R23 etc.
Ethane (C2H6) Based will have a three-digit number ex:
R113. First figure shows no. of Carbon atoms minus 1;
Second figure shows no. of Hydrogen atoms plus 1; Third
figure shows no. of fluorine Atoms R113 =CCl2FCClF2
Tricholorofluoroethane; R114; R115 etc.
Chlorofluorocarbons (CFC)
CCl2F2 - Dichlorodifluoromethane (Freon
12 or R12)
CCl3F - Trichlorofluoromethane (Freon 11
or R11)
C2Cl2F4 - Dichlorotetrafluoroethane (Freon
114 or R114)
C2Cl3F3 - Trichlorotrifluoroethane (Freon
113 or R113)
Hydrochlorofluorocarbon (HCFC)
CHClF2 monochlorodifluoromethane
(Freon 22 or R22)
R123 C2HCl2F3
R124 - C2HClF4
Hydrofluorocarbon(HFC)
C2H2F4 - R134a
C2H4F2 - R152a
C2HF5 - R125
CH2F2 - R32
C2H3F3 - R143a
Inorganic refrigerants
These are designated by number 7 followed
by the molecular weight of the refrigerant
(rounded-off).
Mixtures
Azeotropic mixtures (containing two gases
with same boiling point ) are designated
by 500 series, where as zeotropic
(containing two or more gases not having
same boiling point ) refrigerants (e.g. nonazeotropic mixtures) are designated by
400 series.
Effect of UV light
Scientists predict that increased UV light
on earth as a result of ozone depletion
will, amongst other possible
consequences, cause skin cancer,
interfere with immune systems and harm
aquatic systems and crops. Strong
pressure was exerted to phase out CFCs
and HCFCs, resulted in the Montreal
Protocol being adopted in 1987.
Alternate refrigerants
Refrigeration oils
1.
2.
3.
4.
5.
6.
7.
Low viscosity
As the oil particles are carried along with the
refrigerant through out the system, the oil is
subjected to extreme temperatures - low
temperature in the evaporator and high in the
cylinder head. Therefore it should be in a
position to flow freely at both low and high side
temperature. This is the ability of an oil to
maintain good lubrication properties at high
temperatures and good fluidity at low
temperatures, i.e. to provide a good lubricating
film at all times.
Moisture free
Any moisture added with oil may cause
corrosion, and in the case of CFC and
HCFC refrigerants would form as ice in a
choked expansion or regulating valve.
Refrigeration
Refrigeration is a process of cooling by the transfer of
heat. Heat is a form of energy and is indestructible so if
heat is removed from a space or substance to cool it to a
temperature below that of its surroundings, the heat
removed must be discarded to some substance at a
higher temperature where it is of no consequence. Since
heat will not flow freely from a body at a low temperature
to another at a higher temperature, it is necessary to
expend mechanical work, heat, or electrical energy from
an external source to achieve it. Refrigeration thus
depends on thermodynamics, heat transfer and fluid flow
for its practical achievement.
Molliers Chart
Diagrammatic Representation of properties of
Refrigerant. Useful for designing the Refrigeration
system
Gives enthalpy of refrigerant at various pressures
and physical states (liquid, vapour, mixture)
Also called Pressure-Enthalpy Chart.
Enthalpy is the total heat content in a substance
BTUs or KJs
Specific Enthalpy is Enthalpy per unit mass
BTU/lb or KJ/kg
Constant
Entropy
LInes
Constant
Temperature
Lines
Refrigerating effect
The amount of heat absorbed by each unit mass of
refrigerant as it flows through an evaporator is known
as the refrigerating effect, and is equal to the
difference between the enthalpy of the vapour leaving
the evaporator and the enthalpy of the liquid at the
flow control.
Thus, for the system shown in Fig 3, refrigerating
effect,
Refrigerating capacity
The rate at which a system will absorb heat from the
refrigerated space or substance is known as the
refrigerating capacity, and is expressed as,
refrigerating capacity,
Compressor capacity
The capacity of a compressor must be such that it
removes the vapour from the evaporator at the same
rate as that at which it is formed. To maintain a specified
operating condition, a compressor must have a swept
volume equal to the volume of vapour formed in the
evaporator per unit time (m3/h).
To maintain constant operating conditions and produce
the required refrigeration duty would require a
compressor with a swept volume:
V = m x v m3
where v = specific volume of the vapour at the
compressor suction inlet, m3/kg, and v at -25C and
1.32 bar
= 0.18m3/kg.
i.e. V = 0.94 x 0.18 x 3600 = 609 m 3/h.
Heat of compression
The energy input from the compressor motor
to raise the pressure of the vapour to the
required condensing temperature is known as
the heat of compression, and is equal to the
difference between the enthalpy of the vapour
at the compressor outlet and inlet.
Heat of compression,
Condenser duty
The rate of heat transfer from the refrigerant
in the condenser to the cooling medium is
known as the condenser duty, and is
expressed as,
Coefficient of performance
The ratio of refrigerating effect to the heat of
compression is known as the coefficient of
performance (COP).
Thus for the system shown in Fig 3,
R12
R22
R502
- 33.3
23.6
-29.6
-40.6
-45.6
0.2
1.6
3.0
3.5
Absolute condensing
pressure at 30C (Bar)
11.6
0.9
7.4
12.0
13.0
1314
194
159
217
166
Coefficient of performance at
-150C evaporator, 30C
condensing
4.77
5.03
4.71
4.67
4.37
Evaporating temperature at
atmospheric pressure (0C)
Pump-down cycle.
The refrigerated space temperature is monitored
by a thermostat which acts to open and close
the solenoid valve in the liquid line. The routine
starting and stopping of the compressor is
controlled by the low pressure cutout switch in
the compressor suction line. As the space
temperature is reduced to the set point of the
thermostat, the thermostat contacts open, deenergizing the solenoid valve and stopping the
flow of refrigerant to the evaporator. Continued
compressor operation reduces the suction
pressure to the set point of the low pressure
switch, stopping the compressor.
System components
1.
2.
3.
4.
5.
6.
7.
Pressure gauges
Compressors
Oil separators
Condensers
Liquid receiver
Liquid indicator
Evaporators
8. Expansion valves
9. High pressure cut-out
10. Low pressure cutin/cut-out
11. Oil pressure cut-out
12. Room temperature
control
13. Solenoid valves
14. Drier
Pressure gauges
The pressure gauge on
the compressor suction
and discharge shows the
gas pressure and also
has marked on it the
relative condensing
temperature. It helps to
check correct pressuretemperature relationships
for refrigerants. Pressure
gauge in the lub oil line is
normally of differential
type.
Compressors
Refrigeration compressors are usually
reciprocating type for marine refrigeration.
It may be of the rotary screw displacement
type or of the scroll type.
Reciprocating compressors
Reciprocating compressors for systems
cooling domestic store rooms are usually
of the vertical in-line type. The larger
reciprocating compressors have their
cylinders arranged in either V or W
formation with 4,6, 8, 12 or even 16
cylinders. Compressor speeds have been
increased considerably over the years
from 500 rev/min to the high speed of 1500
to 2000 rev/min.
V-belt drive
Compressors are
usually driven by Vbelts. Most are driven
at less speed than the
motor speed. Pulleys
must be in perfect
alignment and the
pulley shafts
(compressor and
motor) must be
parallel to each other.
Lubrication
Oil is supplied to the bearings
and crankshaft seal by means
of a gear pump driven from the
crankshaft. Oil pressure is
about 2 bar above crankcase
pressure and the differential oil
pressure gauge is necessary
to compare oil pressure with
that of the gas in the
crankcase. There is a relief
valve in the oil system set to
about 2.5 bar above crankcase
pressure. Protection against oil
failure is provided by a
differential oil pressure switch.
Crankcase heaters
A certain amount of refrigerant will always be dissolved
in the lubricating oil. However, large amounts of
refrigerant in the oil are undesirable. Excessive dilution
can result in inadequate lubrication. In addition, during
compressor start-up, the lowering of the crankcase
pressure will cause oil foaming due to the vaporization of
the refrigerant. In severe cases, this can disrupt
lubrication and can cause carryover of the liquid
refrigerant and oil into the cylinder. Since marine
systems typically operate on the pump-down cycle, the
low crankcase pressure at shutdown limits refrigerant
absorption by the oil. Crankcase heaters which come on
automatically during the compressor off cycle are used
to keep the oil warm and reduce refrigerant absorption.
Shaft seal
Unloader mechanism
The most common
method of varying the
capacity of multi-cylinder
compressors is to vary
the number of active
cylinders by holding the
suction valves open. The
capacity control system
unloads cylinders (i.e.,
cuts cylinders out of
operation) in response to
decreases in refrigeration
load based on suction
pressure.
Oil separators
Manual Valves
Manual valves are installed
at various locations in the
refrigeration system to
facilitate system operation,
to isolate components for
maintenance and for other
purposes. Most of the valves
used in refrigeration
systems are of the packed
valve type. They are of the
backseating type. When in
the open position, the valve
is backseated to minimize
the possibility of leakage.
Condensers
Most marine refrigeration condensers are of the watercooled, multipass, shell-and-tube type. Seawater is
circulated through the tubes, and the hot gas from the
compressor discharge is admitted to the shell and
condenses on the outer surfaces of the tubes. The
condenser is typically constructed of a steel shell,
copper-nickel tubes and tube plates, and bronze
waterheads. Gas inlet, liquid outlet, purge, and water
regulating valve control connections are provided.
Liquid Receiver
The receiver collects the liquid refrigerant
draining from the condenser. It consists of a
steel shell with steel dished heads welded on
each end. Sight glasses or a liquid level
indicator is installed to permit determination of
the amount of liquid refrigerant in the receiver.
The receiver will typically have sufficient
capacity to hold the entire system refrigerant
charge and will retain a small liquid level during
full load operation. High levels indicate
overcharge and low levels indicate undercharge.
Sometimes bottom part of condenser serves as
the liquid receiver
Refrigerant drier
Shell is filled with a
desiccant such as
activated alumina or silica
gel which absorbs
moisture and also acts as
a filter. Even small
amounts of moisture can
cause problems such as
frozen thermostatic
expansion valves, so it is
important to remove
sufficient moisture to
prevent the release of
water in the low pressure
portions of the system.
Evaporators
Marine evaporators are usually forced
convection evaporators. They are in
common use in ships provision
refrigeration and air conditioning systems.
The units consist of a cooling coil with
finned tubes, a motor-driven fan, and drain
pan, all enclosed in a sheet metal casing.
Units designed for sub-zero temperature
applications are usually fitted with an
electric resistance defrost system.
Expansion device
The basic functions of an expansion device used in
refrigeration systems are to:
1. Reduce pressure from condenser pressure to evaporator
pressure, and
2. Regulate the refrigerant flow from the high-pressure
liquid line into the evaporator at a rate equal to the
evaporation rate in the evaporator
Under ideal conditions, the mass flow rate of refrigerant
in the system should be proportional to the cooling load.
It is desirable that liquid refrigerant should not enter the
compressor. In such a case, the mass flow rate has to be
controlled in such a manner that only superheated
vapour leaves the evaporator.
If the evaporator in
vegetable room is kept at
common pressure of
meat room and fish room,
then ice formation will
take place in this
evaporator also. This ice
will be formed from the
moisture of fruits and
vegetables stored in the
room and they will
become desiccated.
Solenoid valve
The solenoid valve is
thermostat controlled valve
which provides automatic
opening of and closing of
liquid line to the
evaporator. When the coil
(3) is energised, the pilot
orifice (4) is opened and
the diaphragm (1) moves
into open position (vice
versa when coil is deenergised).
Thermostats
Thermostats are temperature-controlled electric
switches. It is used to control the temperature in
a refrigerated space by opening and closing a
solenoid valve in the liquid line.
Three types of element are used to sense and
relay temperature changes to the electrical
contacts.
1. A fluid-filled bulb connected through a capillary
to a bellows.
2. A thermistor
3. A bi-metal element
Reefer Ships
Reefer ships are effectively large refrigerators,
heavily insulated with modern glass fibre or
similarly efficient insulation , shuttered with bright
metal that prevents taint and is easy to clean.
They are ships that tend to be divided into many
more spaces than conventional dry cargo ships,
with several tweendecks spaces, so that different
commodities can be separated and carried, if
required, at different temperatures. Cleanliness
and the maintenance of optimum temperatures
are the pre-requisites.
Showing third pair of headers served by a brine heater and third pump, so
that any battery can be individually defrosted by circulating the warm brine.
Also introduced is a brine "injection cross connection from the delivery of
pump No. 1 to the suction of' pump No. 2. Brine injection is used so that
evaporator No. 1 can assist evaporator No. 2 when No. 1 is set to deliver
brine at a lower temperature than No. 2. A further refinement of this injection
is the by-pass arranged across the inlet and outlet of evaporator No. 2 so
that the cooling, of the brine circulating in No. 2 system can be achieved
entirely by injection if desired.
Refrigerated containers
Porthole container
Refrigeration machinery
Intermodal Refrigerated
Containers
The number of units in operation in 2005 is
approximately 750,000, equivalent to 1,270,000
TEU. TEU Twenty foot Equivalent Unit refers to
a unit of volume corresponding to a twenty foot
ISO container, which used to be the standard
container. But today 40 foot containers of the
HighCube type dominate the market for new
reefer containers. Their size surpasses two TEU
and therefore the increase in container traffic
exceeds the increase in the number of units at
the present time.
Controlled atmosphere
Fruits and vegetables are actually alive,
their cells are metabolising, consuming
oxygen and carbohydrate and producing
water vapour, carbon dioxide and heat.
Also small amounts of ethylene gas (C 2H2)
are produced. Therefore it is not enough
to just refrigerate the cargo, a supply of
fresh air must also be provided.
Controlled atmosphere
If insufficient fresh air is supplied, several things can
happen:
1. Too much carbon dioxide can produce tissue damage, in
apples this condition is known as brown heart
2. Not enough oxygen can result in anaerobic respiration,
in this case the metabolic pathway is incomplete and the
final product becomes alcohol resulting in alcoholic fruit
3. Too much water vapour can encourage the development
of moulds, rots and fungi. However, not enough is just as
bad as it promotes desiccation of fruit and vegetables
4. Ethylene gas is ripening hormone, very small quantities
building up can promote premature ripening in fruit or
degreening in green vegetables
Controlled atmosphere
Rate of breathing or respiration can be lowered
and thus ripening slowed down either by
lowering the temperature or by reducing the
amount of oxygen and increasing the amount of
carbon dioxide in the surrounding atmosphere.
Controlled atmosphere is an inert gas system
used to extend the storage life of seasonal
perishable products and has been used for
many fruits and vegetables; primarily apples and
pears in the past, and now mainly for bananas.
Controlled atmosphere
To successfully store fruit for long periods, the
natural ripening of the produce has to be
delayed without affecting the eating quality. This
is achieved by reducing the temperature of the
fruit to the lowest level possible without causing
damage through freezing or low temperature
breakdown. To further delay ripening, the oxygen
supply in the space is reduced to levels below
that of the natural atmosphere. This level is
below the level required to support human life.
Controlled atmosphere
The precise levels of temperature, oxygen and carbon
dioxide required to maximize storage life and to minimize
storage disorders are extremely variable, depending on
type of produce, growing conditions and maturity.
Optimum storage conditions can vary from farm to farm
and from season to season.
On reefer vessels, oxygen (02) and carbon dioxide (CO2)
levels and relative humidity (RH) in controlled
atmosphere zones (cargo chambers) can be
independently controlled within close tolerances,
irrespective of type, temperature and volume of cargo
carried and the length of the voyage.
Oxygen level
The oxygen level can be decreased by:
a ) injecting pure nitrogen as a gas or
liquid from bottles or storage tanks;
b) burning propane in an open flame
burner, or a burner with a catalyst;
c) generating gas (nitrogen with a low
oxygen level) on board from compressed
dry and clean air, using high pressure
membranes, etc.
Relative humidity
Air motion
Air motion is another factor that can have a marked
effect. Increased air speed over the body and clothing
surfaces can increase convective losses and, when
there is perspiration, the evaporative losses as well.
Thus, under conditions of high temperature and high
humidity, discomfort can often be greatly reduced by
increasing the air flow. It is of more than passing interest
to note that under these conditions even high air speeds
can be pleasant. With cooler conditions, however, even
small localized air circulation may give rise to complaints
of chilliness.
Effective Temperature
It is the
temperature
of still,
saturated air
which would
produce the
same feeling
of warmth.
Air purification
Outside air must be introduced to all living
spaces, although the amount of fresh air
necessary to sustain life is very small
indeed. They are governed by factors
such as body odours and smoking, which
may require a fresh air supply of 12 litre/s
per person or more.
Air conditioning
1.
2.
3.
4.
Dew Point
When a mixture of dry air and water vapour has
a saturation temperature corresponding to the
partial pressure of the water vapour it is said to
be saturated. Any further reduction of
temperature (at constant pressure) will result in
some vapour condensing. This temperature is
called the dew point. Air at dew point contains all
the moisture it can hold at that temperature, as
the amount of water vapour varies in air then the
partial pressure varies, so the dew point varies.
Psychrometric Chart
Psychrometry is the study of the properties of mixtures of
air and water vapour. This subject is important to airconditioning because the systems handle air-water vapor
mixtures, not dry air. Some air-conditioning processes
involve the removal of water from the air-water vapor
mixture (dehumidification) while some involve the
addition of water (humidification). A convenient way to
represent the properties of air-water vapor mixtures is
the psychrometric chart. On the chart, such properties as
dry bulb temperature, wet bulb temperature, dew point,
relative humidity, humidity ratio, specific volume, and
enthalpy are presented in graphical form.
Understanding the
psychrometric chart
Comfort Conditions
Comfort under summer conditions is dependent
on dry and wet bulb readings i.e. relative
humidity as well as air motion. For a given
degree of air turbulence (75 mm/s to 127 mm/s),
relative humidity between 30% and 70%,
average 50%, and thermometer readings 19C
to 250C, average 220C, gives the best degree of
summer comfort. Air at low temperature and
high humidity can be as comfortable as air at
high temperature and low humidity.
6 psychometric zone
classification
Comfort Conditions
Comfort Conditions
Heating
When the temperature of air is increased, so too is its
capacity for carrying water vapour. Air, with a very low
initial dry bulb temperature of -5C and relative humidity
of about 5O%, will, when heated to 21C dry bulb
temperature, have a relative humidity of about 10%. The
temperature rise increases the capacity of the air to carry
moisture in suspension. Air heated to a comfortable
temperature level of 210C but having a relative humidity
of 10% will readily take up moisture whether from
perspiration or from the nasal passages and throat.
People in an atmosphere at 21C but 10% relative
humidity, would experience discomfort from dryness in
their nose and throat and on the skin.
Exercise
Outside air at 35C and
60% relative humidity is to
be conditioned by cooling
and heating so as to bring
the air to within the
"comfort zone". Using the
Psychrometric Chart plot
the required air
conditioning process and
estimate (a) the amount of
moisture removed (b) the
heat removed and (c) the
amount of heat added
Cooling to DBT27
RH100%
Over cooling to
DBT15 RH100%
Heating to DBT25
RH50%
Solution
(a) the amount of
moisture removed [2210=11.5g of H20/kg of
dry air]
(b) the heat removed
[(1)-(2), qcool 88-40=
48kJ/kg-dry-air]
(c) the amount of heat
added [(2)-(3), qheat 5040= 10kJ/kg-dry-air].
SAFETY
1. Mechanical hazards
2. Electrical hazards
3. Chemical hazards
R-717 and R-764 are very irritating to the eyes and lungs.
Avoid exposure to these refrigerants.
R-717 is slightly flammable and mixed with the proper
proportions of air may form an explosive mixture.
Fluorocarbon refrigerants should be treated as toxic gases.
In high concentrations, these vapors have an anesthetic
effect, causing stumbling, shortness of breath, irregular or
missing pulse, tremors, convulsions, and even death.
Ammonia is a respiratory irritant in small concentrations and
is a life threatening hazard at 5,000 parts per million (ppm).
Ammonia is also flammable at a concentration of 150,000270,000 ppm
Mechanical hazards
Personnel should be aware at all times
that refrigeration systems contain liquids
and vapours under pressure. Suitable
precautions must be taken when opening
any part of the system to guard against
the pressure hazard.
Compressors must be operated within
their design parameters.
Mechanical hazards
Mechanical hazards
Opening up part of the system will necessitate
the loss of a certain amount of refrigerant to
atmosphere. It is essential that the amount of
refrigerant which escapes is kept to a minimum
and appropriate steps are taken to prevent
hazardous concentrations of refrigerant
accumulating. Under certain conditions, liquid
refrigerant at low temperature may be present.
Contact with this liquid must be avoided.
Electrical hazards
Before carrying out maintenance or repair
procedures, persons concerned must
ensure that equipment is isolated from the
electrical supply and tests made to verify
that isolation is complete. Whenever
possible, precautions must be taken to
prevent the circuit being inadvertently
energised i.e. withdraw the mains fuses.
Chemical hazards
HCFC and HFC refrigerants can present a
danger to life by excluding air. Inhalation of very
high concentrations of the vapour, even for short
periods, must be avoided since this maybe
dangerous and can produce unconsciousness or
prove suddenly fatal due to oxygen deficiency.
The refrigerant vapour is heavier than air, and in
static or poorly ventilated situations may be slow
to disperse. Anyone suffering from the effects of
inhalation of the vapour should move or be
moved to the open air.
Chemical hazards
Care must be exercised before entering any
area where the presence of high vapour
concentration is suspected. The vapour will
displace air upwards out of cargo chambers,
ships engine rooms, etc., and tend to collect at
deck level and in pits and trenches.
Should accidental escape of the refrigerant
occur indoors, adequate fan assisted ventilation
must be used to disperse the vapour, preferably
by extraction at ground level, before entering the
area. When any doubt exists it is recommended
that breathing apparatus should be worn.
Chemical hazards
HCFC and HFC refrigerants are non-flammable,
but refrigerant vapour coming into contact with
temperatures of 315C and above (burning
cigarettes, gas burners, electrical heating
elements, etc.), will de-compose to form
phosgene, hydrogen fluoride and hydrogen
chloride. These compounds have extremely
harmful physiological effect on human beings.
Naked flame and smoking must be prohibited in
the presence of refrigerant vapour and
refrigerant must be purged from pipes or vessels
before carrying out cutting or welding operations.
Chemical hazards
Approved methods of leak detection only
should be used. If a halide test lamp is
used, remember that the heating or
combustion effect will produce toxic byproducts which could be dangerous if
inhaled.
Chemical hazards
Liquid refrigerant in contact with the eyes
or skin will cause freezing and injuries
similar to a burn. Care must be taken
when opening pipes or vessels which may
contain liquid.
Thus it is essential when loosening a
connection on any part in which refrigerant
is confined, goggles to be worn to protect
the eyes.
Ammonia (R717)
Ammonia is normally considered to be the most
dangerous of the primary refrigerants and has
inherent material and physiological hazards. A
limited range of ammonia/air mixtures (16 27%) ammonia by volume can be ignited by
flame and an explosion may result. Ammonia
must not be allowed to come into contact with
iodine, bromine, chlorine, hypochlorite or
mercury. There is an explosion hazard in each
case.
Ammonia Vapour
Low concentrations may cause only
irritation and discomfort.
High concentrations can destroy body
tissue. The action is more pronounced on
moist tissues: eyes, nose, breathing
passages, and moist areas of the skin
may be burned by high concentrations.
Ammonia Liquid
In this form ammonia can cause severe
burning of the skin and eyes. As the eyes
are particularly delicate organs, even
small amounts of ammonia can be
harmful. The full effects of ammonia on
the eyes may not be apparent for 8-10
days but, ultimately, blindness may result.
Ammonia
Maintenance procedures must not be carried out
unless adequate ventilation has been provided
to avoid risk of explosion and physiological
harm. Naked flames must not be permitted in
the area. The pungency of ammonia will usually
warn personnel against remaining in locations
where dangerously high concentrations of
vapour exist. Personnel must not be permitted to
work without wearing a gas mask, even for short
periods, in a concentration which causes any
discomfort to the eyes or affects breathing.
MAINTENANCE
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Daily maintenance
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Leak detection
Refrigerating plants must be gas-tight to
prevent refrigerant leakage and air
entering the low-pressure side when under
a vacuum. Systems which have been
opened to the atmosphere during repairs,
must be pressure tested for mechanical
strength and leaks before charging with
refrigerant.
Pressure tests
Pressure tests should be done with
nitrogen. Water or other fluids must not be
used as a test medium. The plants
compressors must not be used to
pressurise the plant. The pressure is
gradually increased by pressurising with
nitrogen gas the pressure is equal to 1.5
times the maximum working pressure of
the system. This pressure should be
maintained for about 10 minutes.
Halide lamps
Halide lamp is used to locate leaks of
HCFC refrigerants. This method is based
on the colour of a flame that surrounds a
glowing copper element. The flame turns
blue-green if the air being consumed
contains the refrigerant.
These lamps should only be used in well
ventilated spaces.
Routine inspections
The high pressure side of the system may easily
be tested for leaks with the plant running, but it
may be necessary to stop the compressor, and
allow the pressure in the low pressure side to
rise sufficiently for leak test in the low pressure
side. The amount of refrigerant in the system
should also be strictly monitored as a drop in
level may indicate the presence of a leak. In the
event of a major leak, the initial leak test should
be made using the soap bubble method,
specially in areas where there are signs of an oil
leak.
Drying by evacuation
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This method of removing moisture is based on the fact that the boiling point
of water decreases with falling pressure. In the course of evacuation, any
water or ice in the plant will evaporate, and is carried away by the vacuum
pump.
Connect a vacuum pump to the system using a short length of large bore
pipe, and open all valves in the system (expansion valves, solenoid valves,
etc., may have to be jacked open).
Evacuate the system to a pressure of 6mm Hg or less. If possible, carry out
the evacuation at ambient temperatures above 10C.
Close the line between the system and the vacuum pump. The pressure in
the system may not rise more than 2mm Hg within five minutes. A rise of
more than 2mm Hg indicates the presence of water, and/or a leak. Where
water is present, the system will be colder than its surroundings.
Check for water and/or leaks, carry out any repairs, and repeat the
evacuation procedure until the pressure rise is less than 2mm Hg. When
this is achieved the system is free of moisture and non-condensable gases
and ready for refrigerant charging.
Charging procedures
Refrigerating plants should not be overcharged
with refrigerant, as this may overload or damage
the compressor.
To ensure that the correct amount is added, the
refrigerant should be weighed during charging.
The liquid refrigerant is decanted from the
refrigerant bottle into the system via a charging
valve just after, the liquid receiver.
Charging Procedure
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Condensers
Once a year, the tubes should be cleaned with a
tube brush in order to remove deposits which
would cause a high condensing pressure. The
gaskets must be glued to the condenser end
plate with good contact. If the partition wall
gasket is not properly installed, there is a risk
that it will blow, leading to an excessively high
water velocity and to damage to the tube plate.
If a tube has become defective, it does not have
to be replaced immediately. Up to 10% in each
pass (flow direction) can be plugged.
Corrosion plugs should be renewed if required.
Defrosting
Another task which maybe regarded as
maintenance is to keep frost deposits on
provision and cargo refrigerating plants
under control. Frequent defrosting assures
that the plant will cause few problems.
Investigating trouble
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TROUBLE SHOOTING
When problems are incurred in a refrigerating
plant, these can be attributed in most cases to a
shortage of refrigerant. Bearing this in mind,
always commence trouble-shooting by checking
the refrigerant charge.
For example, in the case of HCFC plants, too
little refrigerant prevents the oil, which always
circulates in the system, from being returned as
the gas velocity is low, and this leads to various
functional troubles.
CONTAMINANTS
If the moisture present in a refrigerating
system exceeds the amount that the
refrigerant can hold in solution it will exist
as free water. At temperatures of 0C or
lower, the free water will freeze into ice in
the expansion valve or evaporator,
restricting the flow of refrigerant. To avoid
freeze-ups, the moisture content in low
temperature HCFC refrigerant systems
must be maintained at a very low level.
Oil
In refrigerating systems some oil is always carried over
from the compressor into the condenser by the
refrigerant gas, from where it is carried by the liquid into
the evaporator. The presence of oil in the circulating
refrigerant reduces the heat transfer capacity of the
various heat exchangers, the problem being greatest in
the evaporator, since oil becomes more viscous and
tends to congeal at low temperature. To prevent oil
related problems, the operation of the oil separator
should be checked regularly to ensure oil is being
returned to the compressor lubrication system. The
amount of oil added to the lubrication system should also
be strictly monitored; an excessive amount indicates that
oil is being trapped in the evaporator or suction line.
Compressor Short-Cycles
Possible Cause
Action
Low refrigerant
charge.
Reduced
evaporator
capacity.
Action
Low refrigerant
charge.
Compressor valves
leaking.
Legionella bacteria