03 0 Industrial Refrigeration PDF

3
Energy Efficiency
Best Practice Guide
Industrial Refrigeration
Best Practice Guide
Contents
1 Introduction 4
2 The business benefits of efficient refrigeration 5
3 What is your opportunity? 6
4 Solution 1 – Improve the efficiency of your existing system 7

4.1 Step 1: Review refrigeration demand 8
4.2 Step 2: Review insulation 11
4.3 Step 3: Review the coolant distribution system 11
4.4 Step 4: Review refrigeration plant, controls, set points and heat rejection 13
4.5 Step 5: Optimise maintenance 15
4.6 Step 6: Measure the improvement 17
5 Solution 2 – Design a new system 18

5.1 Step 1: Design with a whole-system approach
19
5.2 Step 2: Design for year-round efficiency 19
5.3 Step 3: Select a compressor 19
5.4 Step 4: Select evaporators and condensers 20
5.5 Step 5: Select the refrigerant 21
5.6 Step 6: Select the transfer fluids 22
5.7 Step 7: Consider heat recovery 22
5.8 Summary of savings 22
6 Summary of design considerations for refrigeration systems 23
7 Selecting a service provider 25
Appendix A Industrial refrigeration system overview 26
Appendix B Life cycle assessment 30
Appendix C General maintenance checklist 31
Appendix D Glossary 32
Appendix E Further reading/references 34
Table of Contents i
Best Practice Guide
List of Figures
Figure 1: Cooling energy balance. 8

Figure 2: Typical energy consumption curve for a reciprocating compressor – inverse of COP 19
Figure 3: Typical energy consumption curve for centrifugal compressor – inverse of COP. 20
Figure 4: Typical energy consumption curve for screw compressor – inverse of COP 20
Figure 5: A typical vapour compression refrigeration cycle. 26
Figure 6: Common refrigeration pressure-enthalpy diagram. 27
List of Tables
Table 1: Typical refrigeration-related electricity use. 5

Table 2: Cooling load issues. 10
Table 3: Cooling load issues. 10
Table 4: Savings due to installation of variable speed drives. 12
Table 5: Control systems issues. 14
Table 6: Condensor maintenance. 16
Table 7: Typical compressor efficiency values 19
Table 8: Characteristics of refrigerant groups. 21
Table 9: Potential energy savings. 22
Table 10: Design considerations for efficient refrigeration systems. 23
Table 11: Condensor types. 28
Table of Contents 3
Best Practice Guide
1 Introduction
This document is a step-by-step guide to improving The guide has been developed to lead decision makers
energy efficiency in medium to large-scale industrial and service providers through system changes; it is not
refrigeration systems for industry. It provides best intended to be a thorough technical guide. References
practice information on system operation and outlines for more detailed technical information are provided.
opportunities for improving system performance and
efficiency, which will lead to benefits for your business.
By following this guide, you will be able to determine

what changes can be made in order to improve
the performance of equipment, reduce operating
costs and improve environmental outcomes. Using
refrigeration loads to minimise peak demand energy
costs is not covered in this document.
Introduction 4
Best Practice Guide
2 The business benefits of efficient refrigeration
Refrigeration systems consume large amounts of electricity Energy efficiency can deliver a range of savings,
and thereby contribute greatly to the running costs of such as:
businesses with considerable cooling requirements. In • reduced energy costs
industry, refrigeration can be responsible for up to 85% • reduced operation and maintenance costs
of total energy consumption, depending on the industry • improved system reliability
sector, as shown in Table 1. Improvements to technical • improved safety
elements of modern refrigeration systems have the • increased productivity
potential to reduce energy consumption by 15%–40%. • better matching of refrigeration load
Improving simple operational practices with minimal and equipment capacity
expense can often reduce energy costs by 15% or • a better working environment
more. This will become more important as a price is • reduced resource consumption and greenhouse
placed on greenhouse gas emission in future years and gas emissions1.
as energy prices rise. Its importance also relates to an
increased focus on reducing fugitive emissions from Money saved on power bills improves the bottom line,
industrial systems such as refrigerant gas1. meaning it can be of greater value than increased sales.
For example, if a company had a gross margin of 10%,
Table 1: Typical refrigeration-related electricity use.2 then saving $1 in operational costs is like achieving $10
Industry Sector Electricity Used for Refrigeration in additional sales revenue.
Liquid milk processing 25%
Breweries 35%
Confectionery 40%
Chilled ready meals 50%
Frozen food 60%
Cold storage 85%
The business benefits of efficient refrigeration 5

Best Practice Guide
3 What is your opportunity?
Delivering the best outcome for your business requires • Solution 1: Improve the efficiency of
a whole-systems approach to the design, installation, your existing system
operation and maintenance of your refrigeration system. Do you have a refrigeration system that could be
Energy efficient operation of each individual component running more efficiently? If a complete upgrade
can achieve gains in overall system efficiency. However, cannot be achieved, incremental improvements can
the operation of each individual component can be limited often be made by making small alterations and
by or impact the operation of other components. For conducting simple maintenance practices.
this reason, the greatest system efficiencies can generally
be achieved by taking a system approach,whether an • Solution 2: Design a new system
existing system is being improved upon, a new system Are you planning a brand new refrigeration system?
is being designed, or a service provider is involved. The costs of a new refrigeration system can
Appendix A provides an overview of components used sometimes quickly be recovered in energy savings
in industrial refrigeration systems. over an old system. Life cycle costing analysis of
existing systems should be undertaken to determine
Defining the limitations of your current refrigeration when it is viable to replace it. (Refer to Appendix B for
system is the key to finding the best solution to how to conduct a life cycle analysis).
achieving energy efficiency for your business:
Are you expanding your premises and need to ensure
• Can I make my system more efficient? that your refrigeration system will work effectively?
• Do I need a new refrigeration plant or This will involve elements of both solutions. Firstly,
system components? ensure your existing system is running efficiently
• How do I expand my existing system? (Solution 1) and secondly, if your system needs to
• What do I need to know to install a new system? be expanded, design the new components (Solution
2). Following this process will ensure that you are not
This guide offers step-by-step solutions to help you wasting money purchasing more than you actually
identify opportunities to implement best practice to need. Additionally, information gained from reviewing
achieve energy efficiency of your refrigeration system. efficiency may guide the selection and design of the
new components of the system.
What is your opportunity? 6

Best Practice Guide
4 Solution 1 – Improve the efficiency

of your existing system
Often, a refrigeration system runs inefficiently because

the current system requirements differ from the original
design conditions. Challenges to improving system
efficiency are:
• Large-scale improvements can require replacement

of a fully integrated system and require significant
capital expenditure.
• Some industries require 24-hour refrigeration,
so that any alterations to improve the efficiency
of the system requiring disrupted shutdowns are
extensively avoided.
However, even if a complete upgrade cannot be

achieved, incremental improvements can often be
made through a greater understanding of refrigeration
systems, conducting simple maintenance practices
and making small alterations.
A suggested process to follow when designing a new

refrigeration system is as follows:
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6

Review Review Review coolant Review plant, Optimise Measure the
controls, set points
refrigeration insulation distribution and heat rejection
maintenance improvement
demand system
Solution 1 – Improve the efficiency of your existing system 7

Best Practice Guide
4.1 Step 1: It is often difficult to estimate how much heat is being

gained from the environment; an energy ‘balance’
Review refrigeration demand may assist you:
4.1.1 Assess the cooling load 1. Calculate/estimate all theoretical cooling loads at
Making a comprehensive list of products and cooling the heat exchanger, cool store or process where
processes, and their specific cooling requirements, the refrigeration load is occurring.
helps you to understand: 2. Calculate/estimate the refrigeration energy provided
by the centralised system.
• what your theoretical refrigeration load should be 3. The difference between these two numbers would
• which processes dominate your cooling be ‘unaccounted for heat gain’.
energy consumption
• which refrigeration load temperature needs can Figure 1 represents a typical energy balance for a cool
be grouped together, with potential benefits to store and two other refrigeration processes in which the
your central system operation. system is providing 30% more refrigeration energy than
the load demands.
A typical refrigeration load is made up of process
cooling requirements (that is, cooling the product Figure 1: Cooling energy balance.
or space itself) and unwanted other heat gains as
listed below:
• poorly situated and uninsulated pipework Unaccounted for

heat gain 30% Cool store
• heat exchangers 30%
• poorly sited refrigeration equipment
• walls, floors and ceiling of a cool room
• air infiltration through doorways
• internal fan motors and pumps
• lights and other electrical devices
• people and handling equipment
(such as forklifts).
Process 2 Process 1
20% 20%

Best Practice Guide
Creating a high-level energy balance for the

refrigeration system
4.1.2 Reduce heat gain
1. Identify all major process-cooling loads through Potential solutions for reducing heat gains into
looking at equipment manuals, process specifications a system are given below. As each product and
and theoretical energy consumption for your process. process is different, consideration needs to be
This may not be perfect, but it will help you target given to specific process temperature or other
your investigation. requirements before implementing these solutions,
2. Investigate the major cooling loads in more particularly in the food industry.
detail through measuring the volumetric flow rate
of secondary coolant (if used), temperature rise The potential solutions are:
of the coolant, and its specific heat capacity. • Allow ambient cooling of product before refrigeration.
3. As an alternative to step 2, measure the heat flows • Increase insulation on pipework and avoid hot areas.
from your product (for example, by using the mass • Ensure process equipment is operating
flow rate, specific heat capacity and temperature correctly and look for unexpected heat gains
changes of your product instead of the coolant). (for example, pasteurisers).
4. Ideally, use data-loggers for flow rates and • Ensure product or spaces are not overheated
temperature rises, but this can be time consuming to begin with.
and expensive and needs to be balanced against • Reassess whether cooling is required at all,
the savings possible. Continue these steps until or raise the temperature of the coolant if possible.
you have collected data on all the major cooling • Reduce solar gain (provide shading).
loads (greater than 70% of all loads). • Place cooling equipment as far as possible from
heat sources such as radiators and air-conditioning
Your refrigeration supplier can assist you in doing this equipment.
process, as they often need to estimate cooling loads. • Minimise air infiltration into a cooled space.
• Install more efficient (especially internal) fan motors.
• Install more efficient pumps and turn off when
not required.
• Reduce time personnel spend in (or passing through)
cool areas – improve layout if possible.
4.1.3 Reduce the cooling load

Some common cooling load issues are summarised
in Table 2. By addressing these, you will also be
improving the efficiency of your refrigeration system.

Best Practice Guide
Table 2: Cooling load issues.2

Symptom Problem Measure
Temperature of the product Fouled process heat exchanger Check upstream process and
reaching the refrigeration plant is temperature control settings
higher than expected. If product
is pre-cooled before reaching the
refrigeration system, there is an
‘upstream’ problem
Table 3: Cooling load issues.2

Product being cooled Product temperature Check temperature control system
below required temperature too low
If possible, raise the coolant
temperature
Heat load in a cold store Excessive heat and moisture Improve door closing ‘discipline’
higher than expected; ingress through cool store doors Check door seals, airlock,
ice build higher than expected strip curtains
Evaporator fans or pumps run Excessive auxiliary Ensure control systems maximise
when product has reached power possibilities to switch auxiliaries
target temperature off or reduce their speed
Cool store temperature Incorrect control Adjust thermostat

too low
Cool store temperature Inadequate cooling Check that load is not too high (for
too high example, doors left open, excessive
warm product load) Ensure
evaporators are defrosted. Check
refrigeration plant performance
(for example, control system
problem, fouled heat exchangers)

Best Practice Guide
4.2 Step 2: Review insulation 4.3.2 Adjustable and variable-speed

drives on pumps
Uninsulated or poorly insulated coolant pipes can When applied to pumps in the coolant distribution
absorb heat from their surroundings. This has many system, more efficient flow control can be achieved
negative effects and can seriously affect performance by using adjustable-speed drives (ASDs) and variable-
of the refrigeration system. For example: speed drives (VSDs) or installing multiple pumps.
• System heat gain means that the suction ASDs and VSDs are the preferred option when pumps
temperature of the evaporator is higher than operate for at least 2000 hours per year and process
necessary (increased energy consumption in flow rate requirements vary by 30% or more over time.3
the compressor).
• It could lead to process conditions not being In pumping systems with variable flow rate requirements,
reached (product quality failures). ASDs and VSDs are an efficient alternative to throttling
• It could lead to higher brine/coolant flows or bypass pumping control methods.
(higher pumping energy).
ASDs and VSDs save energy by varying the pump’s
Insulation should also be regularly inspected for rotational speed.Reducing the pump speed means less
moisture ingress, as this can form ice on the pipework, energy is imparted to the fluid and less energy needs to
further damaging any insulation. be throttled or bypassed. However, it should be noted
that they do not save energy in applications that operate
close to fully loaded most of the time, due the lower
4.3 Step 3: Review the coolant efficiencies. Table 4 shows the potential savings from
the installation of a VSD for a 5.5 kW and an 8.5 kW
distribution system motor operating for 8000 hours per year. In these
cases, payback can be less than three years.
4.3.1 Distribution system
The energy involved in pumping transfer fluids around
a system can be a big energy waster.
This means you should:
• Check if you are using the most appropriate
secondary cooling fluid for your requirements (that is,
pump the least amount of fluid practical; consider
using fluids with a high heat capacity).
• Check that your pump system flexibly responds
to variable refrigeration loads, rather than using
the same amount of energy irrespective of the
refrigeration requirement.
• Check that your insulation is in good order.
• Check that you have large-diameter pipes to
minimise pumping pressure.
The mechanical efficiency of the pump drives is
also highly important, and energy-efficient motors
or variable-speed drives could be used.

Best Practice Guide
Energy Energy Energy Energy

Consumption Consumption Consumption Consumption
5.5 kW motor 5.5 kW motor 18.5 kW motor 18.5 kW motor
with no VSD with VSD with no VSD with VSD
Annual Energy 44000 35200 148000 118400

Use (kWh)
Annual Energy $4,400 $3,520 $14,800 $11,840

Cost
Annual Energy $880 $2,960

Saving
VSD Cost $1295 $3,460
Payback 1.5 years 1.2 years
Table 4: Savings due to installation of variable speed drives.4

Assumptions: 8000 operating hours per year; 20% reduction in energy
consumption due to VSD; electricity cost 10 cents/kWh.

Best Practice Guide
4.4 Step 4: Review refrigeration 4.4.3 Common compressor suction

and discharge piping
plant, controls, set points Heat transfer is a function of area (amongst other things).
and heat rejection So the greater the area, the more effective the heat
transfer. In many systems, condensers are coupled
directly to one compressor. It is more efficient to
4.4.1 Improve condensers and reduce make the entire evaporative condenser capacity, or
head pressure heat transfer area, available to the refrigeration plant
Evaporative condensers require water flow over at all times. This approach will minimise the head
tubes containing the hot refrigerant, and fans to move pressure on the compressor, improving the overall
air through and help evaporate the water. Sometimes, efficiency of the system.
fans on evaporative condensers run at a fixed speed
and are scheduled to turn on and off based on a 4.4.4 Improve part-load performance
fixed condenser pressure setting. Compressor efficiency reduces considerably when run
at partial loading. For a large cooling load, it is generally
The most efficient manner to run an evaporative more efficient to split up the load between smaller
condenser is to optimise it in conjunction with the compressors and run them in a way that minimises
compressor head pressure. Under this scenario, part-load operation for any individual compressor.
variable-speed fans may be installed on the condenser An alternative is to implement a VSD on compatible
and they would be controlled in such a way to minimise compressors.
head pressure on the condenser whilst not expending
more energy than is saved in the process. The lower 4.4.5 Add controls to operate compressors
head pressure reduces energy consumption in at highest efficiency point
the compressor, and the VSD fans enable variable Using automatic computer controls enables automatic
airflows through the condenser whilst reducing the sequencing of compressors so that they can run at
specific energy of providing that airflow. optimum efficiency and be switched off when not
required. This not only increases compressor and
4.4.2 Variable speed drives for evaporator motor drive efficiency, but also increases operating life.
and condenser fans It can also be assisted through larger evaporator or
When VSDs are applied to condenser fans, typical coolant storage systems.
operating cost savings are in the order of 2–3% of
total refrigeration costs.5 Variable-speed fans on
air-based evaporators can also have a good return
depending on operating conditions. Two-speed control
is another good, although slightly less efficient, option.
In both circumstances, the fan speed control should be
linked to the compressor head pressure management
system and ambient conditions.

Best Practice Guide
4.4.6 Compressor sequencing and control

Refrigeration systems can be operated automatically,
semiautomatically, manually or by a combination of
these. Of these, automatically computer monitored
and controlled systems have the potential to operate
the system at the greatest efficiency.
Some control issues are listed in Table 5 below.
Table 5: Control systems issues.2

Product temperature Incorrect temperature Check setting of main
low. Plant running controller temperature controller
even though target
temperature achieved Check calibration and
location of temperature
sensor
In cool weather, Incorrect head pressure Check head pressure

discharge pressure control setting control settings and
is higher than ensure they are set at
expected lowest practical level
4.4.7 Variable-speed compressors 4.4.8 Raise suction pressure

VSDs may be applied to screw compressors, although Refrigeration systems are most efficient when run
energy savings may only be realised if changes are at the highest possible suction pressure. Where
also made to the control of the internal slide valve, evaporator pressure regulators are used on all loads,
load sharing between the fixed and variable-speed the suction pressure can be raised and can potentially
compressors. The role of the variable-speed improve compressor capacity by 2.5% for each degree
compressor would be to ‘load-follow’, with other of saturated suction temperature.5 Efficiency increases
fixed‑speed compressors sharing the base load depend on the starting point of your suction pressure
capacity. Your compressor manufacturer should be increase, but improvements in the range of 2% for
consulted before any retrofits, which may or may not each degree increase in saturated suction temperature
be possible. are possible.5
New types of compressors are also now on the market; 4.4.9 Reduce temperature lift
one is an oil free, magnetic bearing, variable-speed, Temperature lift is the difference between the
centrifugal compressor that was originally designed in evaporating and condensing temperatures.
Australia. Its full load coefficient of system performance The importance of minimising lift requirements is
(COP – refer to cycle and system efficiency in Appendix essential, as a 1°C reduction in temperature lift can
A for more information on COPs) of approximately 5.5 improve plant efficiency by 3–4%.6 Temperature lift
increases towards a COP of 12 at part load. It is most reduces if the condensing temperature is lowered
suited to water-cooled applications and can be retrofitted. and/or the evaporating temperature is raised. The
Its higher efficiency is due in part to its very high rotational COP of refrigeration systems is greater at lower
speed and use of magnetic bearings. temperature lifts.

Best Practice Guide
4.4.10 Reduce suction line pressure drop

If a direct expansion system is used (that is, refrigerant
4.5 Step 5: Optimise maintenance
is sent out into your plant for direct use in vessels and 4.5.1 Overview
heat exchangers), then it is important to minimise the If the refrigeration system is older than 10 years,
pressure drop in the return line. This is because, from it should be considered for replacement, since this
the perspective of the compressor, a large pressure may increase efficiency by up to 30% to 40%.7
drop will mean the effective suction temperature is A life cycle cost analysis (refer to Appendix B) should
lower than necessary, impacting on system efficiency. be undertaken to assess this.
Consider larger refrigerant return pipes or a secondary
cooling fluid. To avoid poor heat transfer and efficiency issues on
an existing system, the refrigeration operator should
4.4.11 Floating head pressure control have procedures in place for the regular monitoring
It is possible to adjust head pressure in order to and testing of overall performance, as well as
maintain an optimum heat-rejection temperature with servicing of all components as recommended by
regard to the ambient or wet-bulb temperature. This is the manufacturers. This should be done routinely,
a more efficient practise than fixing the head pressure as it can help identify problems early and has a large
at the maximum required to provide refrigeration on impact on energy consumption.
the hottest days.
Monitoring gauges and switches on filters and
4.4.12 Reduce parasitic loads valves can be installed to alert workers when
Eliminate heat gains to your system. Visual inspection system pressure drops or other malfunctions occur.
and thermal imaging can help identify ‘hot spots’. A general maintenance checklist is available in
Efficient fan and pump motors also save electricity. Appendix C and more specific component symptoms
This is often a very cost-effective measure of improving and efficiency maintenance measures are available in
your refrigeration efficiency and is a key example of Section 6. Changes and repairs should be undertaken
a system-level approach. by qualified personnel.
4.4.13 Convert from liquid injecting oil cooling 4.5.2 Improve evaporator maintenance
to external cooling and defrosting
Screw compressors often require oil cooling and Evaporators assist the transfer of heat from a
it is quite common for them to use liquid injection cooled space into the refrigerant so that heat can
oil cooling. Converting from high pressure, liquid- be released externally. A defrost cycle is often used
injection, oil cooling screw compressors to external to free evaporator coils from ice, to ensure maximum
(thermosiphon or fluid-cooled) oil coolers heat transfer and energy efficiency. Different defrost
can give savings of over 3%.5 cycle control strategies have widely varying impacts
on energy efficiency, bearing in mind that the heat
4.4.14 Heat recovery at oil coolers used to achieve the defrost should be minimised since
It is possible to recover a small amount of waste it enters the refrigerated space. Defrost should ideally
heat from the compressor oil coolers for activities such be initiated when detectable loss of performance is
as domestic hot water, boiler feed water pre‑heating evident. Airflow sensors and thermocouples can stop
and so on. Where there are suitable loads, and heat the defrost system as soon as the ice has melted
recovery does not lower system efficiency, heat to ensure maximum energy efficiency is achieved.
recovery represents industry best practice. A control system with evaporator ‘defrost on demand’
is the best system and defrosting should stop as soon
as the evaporator fins are clear of ice.

Best Practice Guide
Excessive ice might indicate that a drain is blocked or 4.5.4 Improve maintenance on expansion valves
that the unit is too close to the thermostat. Evaporator Expansion valve problems are generally caused by
fans should be cycled by the control system such that the valve being open or closed when it shouldn’t be,
they are only used when needed. Most evaporator increasing compressor head pressure. Electronic
faults create a heat transfer problem that in turn causes valves with direct expansion evaporators can reduce
evaporator inefficiencies, which results in low compressor compressor head pressure, and can have a good
suction pressure. payback – up to 20% in some situations.
4.5.3 Improve condenser maintenance 4.5.5 Improve compressor maintenance

Maintaining an optimum condenser temperature is Compressor faults can be difficult to identify but
important for energy-efficient operation. Condenser are generally caused by either a mechanical issue
temperature depends on the condenser size and or internal blockages. Checking for oil levels,
condition as well as airflow, ambient temperature listening for worn bearings and checking for
and non-condensable gas in the refrigerant. leaks should be undertaken.
Condenser faults include blockages and heat transfer

problems. Air and other non-condensables in the
refrigerant will increase the condensing temperature
and lower the efficiency. High discharge pressures
are caused by inefficient condensing, which further
reduces system efficiency down the line. Table
6 presents maintenance measures that assist in
condenser performance.
Table 6: Condensor maintenance.

Air-cooled Water-cooled and
Evaporative
Keep coils clean De-scale tubes
Ensure fans Maintain water quality
running correctly
Shade condenser Ensure fill (membranes) are
clean and achieving an even
distribution
Ensure all control Maintain pumps and fans

working systems Ensure all control systems
working

Best Practice Guide
4.6 Step 6: Measure the Power input includes the total consumption of all the
components associated with the refrigeration system;
improvement that includes compressors, pumps and fans. A good
way to assess refrigeration plant performance is to
Throughout the improvement process, you can assess ask the plant supplier or maintenance contractor
changes in performance quickly by comparing baseline to prepare a table of estimated COP for different
performance to actual performance after individual operating conditions (ambient temperature and part-
system modifications have been completed. There loading) and then assess this against the actual
are two ways of measuring plant performance and chiller and system COP over time. Tracking specific
improvement. The first is to take an ‘instantaneous’ refrigeration consumption and cooling energy under a
snapshot of the system. Measurements that should range of conditions before and after the improvements
be taken and compared to design parameters are: are made gives a good indication of the savings that
have been made. Some examples of COPs for different
• condensing temperature at the inlet and outlet compressor types are presented in Section 5.3.
• evaporator temperature at the inlet and outlet
• compressor pressure and temperature at the inlet
and outlet
• power to the compressor
• ambient temperature
• brine temperature.
The second method is to do an energy consumption

assessment. In this method, the current system
baseline operating performance characteristics are
logged for energy usage versus ambient temperature
and load. This can then be used to compare to
the design parameters, track changes to the plant
operation as a whole, or parts of the system, and
measure improvements. The total energy consumption
is calculated, which is made up of:
• compressors
• auxiliary equipment (pumps and fans).
The overall energy efficiency of a refrigeration system

can be difficult to measure, can vary dependent on
the temperature lift required and can be difficult to
conceptualise, as it is usually greater than one.
The system COP is calculated by dividing the cooling
duty (the amount of cooling being carried out) by the
power input:
COP = cooling duty (kW) / power input (kW)

Best Practice Guide
5 Solution 2 – Design a
new system
The costs of a new refrigeration system can sometimes

quickly be recovered in energy savings over an old
system. Life cycle costing analysis (refer to Appendix B)
of existing systems should be undertaken to determine
when it is viable to replace it.
When designing a new system:
• Review current and estimated future cooling

requirements.
• Detail refrigeration requirements over the year and
provide this information to potential suppliers.
• Ensure designs minimise heat gain (for example,
through efficient equipment, good pipe insulation)
as described in 4.1.2 of Solution 1.
A suggested process to follow when designing a new

refrigeration system is as follows
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7

Design with a Design for Select a Select Select the Select the Consider heat
whole-systems year-round compressor evaporators & refrigerant transfer fluids recovery
approach efficiency condensers
Solution 2 – Design a new system 18

Best Practice Guide
5.1 Step 1: Design with a 5.3 Step 3: Select a compressor

whole-system approach As the compressor is usually the greatest consumer
in the refrigeration system, it is important to choose the
Taking a whole-system approach is critical when most efficient compressor for the purpose and the load.
designing a new system, as this presents the Compressors have different properties – reciprocating
greatest opportunity to incorporate energy efficiency compressors are generally used for small to medium-
throughout the whole process, unhindered by the sized chillers whilst larger capacity chillers incorporate
constraints that may be posed by existing equipment. centrifugal or screw compressors. As a guide, the
Taking a whole-system approach entails considering following are considered to be typical efficiency
the system operation as a whole rather than just values at full-load operation:
focusing on individual components, as each component
has flow-on effects that impact on other components, Table 7: Typical compressor efficiency values
and therefore the efficiency of the system as a whole. Reciprocating: 0.27–0.29 kWe/kWr (COP ~ 3.5)
Centrifugal (without VSD): 0.18–0.22 kWe/kWr (COP ~ 5)

Many of the considerations for whole-system design
and selection of individual components that were Screw: 0.18–0.22 kWe/
introduced in Solution 1 also apply when designing Centrifugal (high speed with 0.09–0.17 kWe/kWr (COP~ 5.5–10)
a new system. Critically, a whole-system approach integrated VSD):
also continually evaluates how well the system design
provides the necessary cooling function throughout
the year and as the system is maintained over the
course of its lifetime. Opportunities for enhanced 5.3.1 Reciprocating compressors
heat recovery may also be identified when taking Reciprocating compressors are limited in size, generally to
a whole-system approach during system design. between 350 kWr and 1000 kWr, for economic reasons.
A water chiller that incorporates multiple compressors
can provide good staging in reduction of capacity.
5.2 Step 2: Design for year Figure 2 illustrates a typical energy consumption curve
round efficiency for a 3-stage reciprocating compressor.
0.3
Quite often, refrigeration systems are designed for
the peak cooling demand (which occurs for less than
5% of the year8 ). That means the systems run for 0.25
considerable periods at part load, which can be highly
kWe/kWr
inefficient if incorrectly designed. A new system should

be designed for efficiency at part-load performance 0.2
over the entire year and still meet peak demand.
Using a systemic approach, any designs should also
consider minimising the thermal loads on the system 0.15
10 20 30 40 50 60 70 80 90 100
in the first place.
% load
A good way to assess the operating envelope is to
develop a table of the existing or predicted cooling Figure 2: Typical energy consumption curve for a
loads versus ambient temperature and the amount reciprocating compressor – inverse of COP9
of time this occurs per year. Tenderers can then use
this information to predict the energy consumption
over the year.

Best Practice Guide
5.3.2 Centrifugal compressors 0.70

A centrifugal compressor is similar to a centrifugal pump 0.60
and compresses refrigerant by spinning at high speeds.
kWe/kWr
0.50
The capacity of a centrifugal compressor can be varied 0.40
by a set of vanes at the compressor inlet to 0.30
vary the refrigerant flow through the compressor. 0.20
Capacity of centrifugal chilled water units would usually
0.10
start at about 800–1000 kWr up to 4000 kWr or more. 10 20 30 40 50 60 70 80 90 100
Figure 3 illustrates a typical energy consumption curve % load
for a centrifugal compressor.
Figure 4: Typical energy consumption curve for
0.40 screw compressor – inverse of COP9
0.35
0.30 5.4 Step 4: Select evaporators
kWe/kWr
0.25
0.20 and condensers
0.15
0.10
0.05
Condenser and evaporators should be sized to maintain
0.00 the lowest practical condensing temperature and
10 20 30 40 50 60 70 80 90 100
the highest effective evaporating temperature – key
% load
considerations in any whole-system design approach.
The use of common evaporator suction pipes and
Figure 3: Typical energy consumption curve for
condenser pipework should be considered.
centrifugal compressor – inverse of COP.9
5.4.1 Evaporators
A new high-speed compressor is an oil-free, magnetic
The cooling effect of the evaporator is determined by
bearing, variable speed centrifugal compressor that
the size and design of the evaporator and the difference
was originally designed in Australia.
in temperature between the process/product being
Its full load COP of approximately 5.5 improves
cooled and the evaporating refrigerant. The wider the
remarkably at part load to over 10. It is most suited
temperature differences between the process/product
to water cooled applications, and can be retrofitted.
and refrigerant, the greater the rate of transfer of heat.
5.3.3 Screw compressors
A larger evaporator will generally be able to achieve
A screw compressor tends to be more compact than
higher evaporator efficiencies. The design of the
an equivalent centrifugal compressor and operates
evaporator should be chosen for the specific
with less vibration. Capacity is varied by a slide valve.
application. There are a number of types including:
Similar to centrifugal compressors, the screw
compressor water chiller units commence at between
• direct expansion coolers
800 kWr and 1000 kWr capacity. Whilst screw
• pumped liquid air coolers
compressors have traditionally operated more
• shell and tube liquid coolers
efficiently than centrifugal and reciprocating
• plate heat exchanger liquid coolers
compressors, their part-load performance without
• baudelot liquid coolers.
a variable-speed drive is far worse. Figure 4
illustrates a typical energy consumption curve.
To avoid inefficient use of the evaporator, superheating
in the evaporator should be limited to 5ºC above the
evaporating temperature. When defrosting the evaporators,
a defrost operation should be done using the most
efficient method possible, only initiated when necessary
to prevent a loss of performance, and stopped as soon
as the fins are clear of ice. The best way to initiate defrosting
is using sensors, an approach which is always more
efficient than timers.

Best Practice Guide
5.4.2 Condensers
The more surface area a condenser has, the closer
5.5 Step 5: Select the refrigerant
the condensing temperature is to the temperature Refrigerant selection is important, as the type of
of the cooling medium, whether air or water. Lower refrigerant can affect the efficiency of a system by
condensing temperature results in lower energy up to 10%.10 With the phasing out of fluorocarbon
consumption. Best practice design takes a balanced chemicals (CFC, HCFC), due to their detrimental
approach toward the consumption of water and effects on the environment, ammonia is still currently
energy, particularly taking into account the atmospheric the dominant refrigerant for industrial refrigeration in
temperature and humidity. Condensing pressure should Australia.11 It is the least expensive of the common
be enabled to ‘float’ with ambient temperature to take refrigerants, has good heat transfer properties in both
advantage of cooler temperatures. When this floating liquid and vapour states – it is thermodynamically
is allowed to occur, more advanced expansion valves 3–10% more efficient than HCFC-22 and HCFC134a12
should be used (such as electronic).
Table 8: Characteristics of refrigerant groups.13

Type Examples Uses Issues
CFC R12, R502, Widely used up until 1990 Phased out due to
R11 ozone depletion issues
HCFC R22, R409A, Widely used but not To be phased out by 2015
R411B recommended after 1999 Stringently regulated
NH3 R717 Widely used since Toxic in high
(Ammonia) the birth of refrigeration concentration and
flammable, also reacts
with copper
HFC R134a, R404, R407C, Started to be used in Different compressor
R410C, R507 place of CFCs from 1990 oil required
Some performance
and reliability issues
HC R600a, R290, Care 30, R290 still used in some Flammable
(propane,iso-butane etc) Care 50, R1270 industrial systems Care 30
and 50 used commercially
CO2 Used widely before the High operating pressures
1950s and is now being require special materials
‘rediscovered’ and construction
Toxic in high concentrations

Best Practice Guide
A study into the most appropriate type of refrigerant

for your needs should be undertaken, particularly given
5.7 Step 7: Consider heat recovery
that refrigerant leakage can be highly toxic, have a
large global warming and/or ozone-depletion effect, Some heat recovery is possible from oil coolers on the
and leakage varies significantly by refrigerant type compressor, superheat from the compressor or the
and application (for example, from <1% up to 40% per system condenser. Many industrial processes require
annum depending on the size and age of the system14 heat at a much higher temperature than the reject
). Refrigerant choice also affects the energy efficiency stream of the compressor, but if your process requires
of chiller operation, and some refrigerants are to be heat at less than 80°C, then heat recovery should be
phased out over the coming years (such as HCFC). considered.
Chillers with greater than 100 kg of refrigerant will need
to be registered under the new Australian National
Greenhouse and Energy Reporting Systems Policy.
5.8 Summary of savings
Carbon dioxide (CO2) has recently been rediscovered Throughout the document, potential savings of energy
as a good primary and secondary refrigerant. It has been have been noted and are summarised in Table 9.
successfully used in a number of large-scale storage Whilst savings are not necessarily cumulative,
and processing refrigeration plants around the world, this demonstrates the importance of whole-system
including a new system in western Victoria, which is approaches, which includes design, installation,
estimated to be saving 29% of its refrigeration costs operation, maintenance and periodic review.
compared to ammonia. Propane can also be used as
a refrigerant, with similar efficiency to that of ammonia. Table 9: Potential energy savings.
Method Potential Saving
5.6 Step 6: Select the (Energy, unless otherwise noted)
transfer fluids Use of electronic

expansion valves
20%
Transfer fluids must be compatible with the materials VSD on motors 20%
in the distribution system. They should also be safe
VSD on evaporator and 2–3% of total refrigeration costs
and economical to use. When subjected to the condenser vans
lowest temperatures in the system, the fluid should
allow satisfactory heat transfer and reasonable Evaporator pressure 2.5% greater compressor capacity
pressure drop. The advantages of using a transfer regulators for each degree of saturated suction
temperature
fluid distribution system include:
• Using a secondary fluid separates potentially Evaporator pressure 2% for each degree increase in
dangerous chemicals from food processing plant regulators saturated suction temperature
and working areas.
• The primary refrigerant is used in the refrigeration- Reduced temperature lift 3–4% improvement for 1°C reduction
plant room area only, which means leak detection
Conversion from liquid injection Over 3%
and repairs are more easily undertaken. Less primary oil cooling to external oil coolers
pipework also means that pressure drops are reduced.
Refrigeration system replacement if Up to 30–40%
The disadvantage of this type of system is that a higher older than 10 years
temperature lift is required, due to loss in the heat
Refrigerant selection 3–10%
exchange transfer with the secondary fluid.

Best Practice Guide
6 Summary of design considerations

for refrigeration systems
Table 10 summarises design considerations for

components of industrial refrigeration systems.
Table 10: Design considerations for efficient refrigeration systems.

–Ensure a whole-system approach is used
System considerations
–Design for year-round efficiency
–Avoid heat gain in the system by using ambient cooling,
insulation, shading, minimising air infiltration and so on
–Design for part-load performance using
–VSDs on compressors or efficient staged compressor control
–Use automatically controlled (on-demand) defrost

Evaporators
–Install drains for removing non-condensables from
the evaporator
–Use electronic expansion valves on smaller units
–Raise evaporator pressure as far as possible and allow
to ‘float’ higher when the refrigeration demand is low
–Allow for easy cleaning
–Consider VSDs for evaporator fans
Compressors –Ensure you enquire about compressor efficiency (COP)

over the range of expected loads
–Use common compressor suction and discharge piping
–Use VSDs where appropriate
–Consider high-speed, magnetic bearing, variable-speed
centrifugal compressors
–Consider external oil c oolers and heat recovery
–Allow head pressure to ‘float’ to make the most of
ambient conditions
–Consider VSDs for condenser fans linked in with

Condensers and
head compressor pressure control
cooling towers
–Use a condenser with high surface area to achieve
a lower condensing temperature,and hence
lower energy consumption
–Consider using evaporative condensers rather
than cooling towers only
–Link the control of the cooling towers to floating head
pressure control to drive condensing water as cold
as practicable
Summary of design considerations for refrigeration systems 23

Best Practice Guide
Expansion valves –Use electronic expansion valves where possible

on small systems
–Link expansion valve control with head pressure controls
Motors, drives, pumps –Use high-efficiency motors and drives

–Consider VSDs for loads that vary
–Use high-efficiency pumps and refer to the best
practice guides on pumping system designs
Controls –Use a control system that is responsive to

compressor head pressure
–Aim to achieve highest possible suction
pressure and lowest possible head pressure
at all times, and reduced temperature lift
Secondary distribution –Insulate pipework

system –Select a secondary cooling fluid with appropriately
high heat capacity
–Use large-diameter pipes to minimise pumping pressure
–Use an energy-efficient system design
Refrigerant selection –Use a refrigerant that is most appropriate for

your needs, considering efficiency, toxicity,
and ozone and greenhouse impact
Maintenance –Institute an ongoing maintenance plan

–Train operators in maintenance for energy efficiency
Service provider –Use a qualified, experienced service provider that

takes a system approach, examining both refrigeration
supply and demand
Summary of design considerations for refrigeration systems 24

Best Practice Guide
7 Selecting a service provider
Upgrading and improving your refrigeration system Will the provider examine the demand side as well
can take considerable time depending on your as the supply?
circumstances. While you may want to follow the steps While the supply side equipment such as the compressor,
in this guide, you may not have the time or resources condenser, expansion valve and evaporator are important
available to do so. Refrigeration service providers can considerations, the provider should also be investigating
supply the services required to assess, upgrade or the demand side of your system, including the distribution
install your refrigeration system. You may wish to ask network, temperature regulation, the end uses and the
them to assist you with some or all of the process. profile of the demand.
In either case, there are some questions you should
ask before you begin. What analysis services do they offer?
In order to ensure your refrigeration system runs as
Will the provider take a systems approach? efficiently as possible, the provider must first conduct
It is important that your service provider considers a detailed analysis of various aspects of your system.
how to optimise your entire refrigeration system, Your provider should also be able to measure and
not only one or two of its components. analyse the load profile of your system and the
Ensure that the provider will include the following related power consumption to report on performance.
in their investigation if asked: Other questions to ask of your provider include:
• control system optimisation • What training do the staff have?

• refrigerant leak management assessment • Are they qualified to work on all refrigeration systems?
• pressure levels throughout the system • Can they service and install equipment such as
• flow throughout the system compressors, evaporators, filters and piping?
• heat recovery potential. • Do they provide emergency service response?
• Will they take care of parts shipping?
• Will they contract out any of the work themselves?
• Do they have the capability to remotely monitor
your system?
Selecting a service provider 25

Best Practice Guide
Appendix A
Industrial refrigeration system overview
Refrigeration cycle overview Stage 1: The refrigerant is in a cold gaseous state,

having just changed state from a liquid to gas after
Several types of refrigeration cycles are used in industry,
but the most common is known as a vapour compression absorbing heat in the evaporator from the process
cycle. Figure 5 shows the components of a typical vapour (or air). A refrigerant in liquid form will absorb significant
compression refrigeration system and provides a simple amounts of heat during evaporation – it is this phase
explanation of how such a system works. change that enhances the cooling effect in the
refrigeration process.
The basic components of a mechanical compression
system include an evaporator, compressor, condenser Stage 2: The gas is then compressed by the compressor
and expansion valve. The heat transfer liquid (refrigerant) and discharged as a hot gas. It enters the condenser
changes state from gas to liquid throughout the vapour where it releases its latent heat of evaporation to either
compression cycle stages as described below. water or air. The heat released is equivalent to the heat
absorbed by the refrigerant in the evaporator plus the
heat created by compression input.15 In this stage,
the refrigerant will become liquid again.
Stage 3: The refrigerant leaves the condenser as a hot

liquid and then passes through the expansion valve,
which expands the hot liquid into a cold liquid.
Stage 4: The cold liquid flows into the evaporator

where the cycle begins again. The fluid is boiled off
(that is, evaporated) to a cold gas by the heat of the
Figure 5: A typical vapour compression product being refrigerated. The cold gas returns to
refrigeration cycle.10 the inlet (or suction) of the compressor.10
In industrial situations, the refrigeration cycle can be

used in two ways:
• Directly – refrigerant is pumped to the cooling load
(for example, a process cooling heat exchanger or tank).
• Indirectly – refrigerant cools a secondary fluid like
water, glycol or brine to ‘transfer’ the ‘cooling energy’
to a point of use on a distribution network.

Best Practice Guide
Industrial Refigeration
Cycle and system efficiency A chiller with a high COP under common
There are two commonly quoted refrigeration operating conditions is a good starting point for an
efficiencies: the efficiency of the chiller subcomponent energy‑efficient system. Although chiller manufacturers
and the efficiency of the system as a whole. Efficiency can accurately measure and quote the chiller COP
is denoted as the coefficient of performance (COP) and over a wide range of conditions, the end user should
is calculated by dividing the cooling duty (the amount ultimately be concerned with optimising the total
of cooling being carried out) by the power input: system COP over a typical production schedule, as
this will determine the cost of supplied refrigeration
COP = cooling duty (kW) / power input (kW) energy. Taking a whole-system approach is the best
way of achieving energy-efficiency gains and represents
The theoretical COP of the chiller includes only the industry best practice.
compressor power input at a nominal load, whereas
a real ‘as installed’ system COP includes the power A pressure-enthalpy diagram, as illustrated in Figure 6,
input to fans and pumps, and takes into account the is a common means of representing the work done in
part-load operation over time. The whole-system COP the refrigerant cycle. The COP can be thought of as the
is therefore less than the chiller COP. The system COP enthalpy change in the evaporator divided by the enthalpy
varies with refrigeration temperature, heat rejection change in the compressor. Without going into too much
temperature, outdoor temperature and humidity, detail, an efficient system minimises the work done by
condenser type, pipe size and length, production the compressor, and maximises the heat transferred
profile, and many other factors. out of the process through the evaporator.
Pressure Pressure
4 3
Liquid
Vapour
1 2
Enthalpy dh1 dh2
Enthalpychange Enthalpychange
in evaporation in compression
Figure 6: Common refrigeration pressure-enthalpy diagram.10

Best Practice Guide
System Components
Evaporators
Refrigerant in liquid form first passes through an There are different types of compressors, including
expansion device, dropping in pressure and temperature, screw, centrifugal and reciprocating. More information
and then enters the evaporator where it ‘boils’ into is provided in Solution 2 on determining which type
gas and chills the air or liquid flowing past the tubes. should be used. Screw compressors are most
Evaporators come in many forms, for example: commonly used in industrial situations, but many
• shell and tube or plate heat exchangers sites also have reciprocating units.
• wet geo-fabrics
• coil in tank Condensers
• jacketed vessels where the evaporation occurs Condensers reject heat from the refrigeration system
on the external wall of the vessel. and come in many forms, including:
• evaporative condensers (water and air is used
Compressors in a cooling tower type arrangement for cooling
Compressors are usually run by an electric motor the refrigerant)
and are the main power consumers in refrigeration. • dry condensers (air is passed directly over
The compressor is the driver of the refrigerant and the condenser)
serves two main functions: • water-cooled condensers
• To compress low-pressure refrigerant gas to a • plate heat exchangers.
higher pressure (and therefore higher temperature)
so that heat can be more easily rejected. A comparison between the three main types
• To remove vapour from the evaporator to maintain of condensers is presented in Table 11
a low boiling point (and hence low temperature for
cooling brine or process flows).
Table 11: Condensor types.

Condensor Energy Advantages Disadvantages
Type Consumption
Air-cooled Fan power, higher compressor No risk of legionella Higher head pressures lead to
power input for a given refrigerant No water consumption lower COP
load No pumping
No spray drift
Appropriate in humid
environments
Water cooled Circulating pump plus More efficient Water pumping and maintenance
cooling tower components Lower condensing Water consumption
pressures (higher COP) Higher maintenance costs
Higher summer capacity Legislative compliance on
legionella and other bacteria
Evaporative Fan and pump power Most effective in dry Water consumption
environments Water pumping and maintenance
Highest efficiency due to lowest Legislative compliance on
head pressure legionella and other bacteria
More refrigerant required

Best Practice Guide
Air-cooled condensers are generally used for smaller Controls

systems.8 Water and evaporative cooled condensers To maintain correct operating conditions and optimise
have the advantage of operating at lower condensing the efficiency of the refrigeration system, control systems
temperatures, improving the efficiency of the refrigeration are essential. In large systems, programmable computer
cycle. The power consumption and water use associated controllers are generally used in conjunction with control
with operation should be taken into account during the switches, valves and regulators. Control of compressors,
selection process. evaporators and condensers should be done in a way
that maximises overall efficiency. Control switches respond
Expansion valves to physical changes such as pressure, temperature,
Expansion valve performance is vital to the running of liquid level and flow velocity. Pressure and temperature
a refrigeration system overall. They primarily allow the controls utilise mechanical adjustments of elements
refrigerant to change state from a hot liquid to a cold such as diaphragms or discs to instigate the required
liquid at a lower pressure. Different types of expansion adjustment. Level-responsive controls use floats, balance
valves include: tubes or electronic probes for detection. Valves are used
to start, stop and regulate the flow of refrigerant to meet
• orifice plates the required pressure differentials, temperature and
• thermostatic, electronic or balanced port fluid-flow.
expansion valves
• float valves Secondary distribution system for cooling
• hand expansion valve and level switch. (coolant, pumps, pipes, valves, controls)
Secondary or ‘indirect’ distribution systems are becoming
Expansion valves have a very significant role to play in increasingly common in industry. Cooling is supplied
the overall energy efficiency of a refrigeration system throughout a plant by use of a secondary fluid or coolant.
– for example, 20% savings have been demonstrated This distribution system utilises pumps, pipes, valves
from the use of electronic valves.16 and controls. There are many system designs for pumped
systems with various impacts on controllability, system
Motors and drives response times and efficiency. Pipes should be sized
Motors and drives for many components often come to minimise coolant pressure drop. Balancing valves
as part of an overall package. It is important to look or orifices in each of the multiple feed lines help
into the efficiency of drives in order to maximise energy control and distribute the coolant.
savings. Many good energy-efficient motors are available,
and variable-speed drives should also be considered as Transfer fluids (coolants)
they provide energy savings when installed as part of Transfer fluids, also known as secondary refrigerants,
an overall control strategy and help to efficiently meet distribute the cooling energy created by the primary
varying load demands. refrigerant around a processing plant within the secondary
distribution system. Heat transfer fluids include brines,
coolants, glycol, calcium chloride, potassium formate,
propylene glycol, ethylene glycol, low-temperature
fluids, cryogenic fluids, chilling fluids and many other
heat transfer fluids. Commonly, a coolant mix of water
with 20% glycol and corrosion inhibitors or brine
(using salt) is used. A relatively new concept is that
of an ice-slurry, which has very high energy-carrying
capacity (MJ/kg). Carbon dioxide, which has lower
overall environmental impact than many other
refrigerants, is a natural refrigerant that can be
used in both primary and secondary cooling loops.

Best Practice Guide
Appendix B
Life cycle assessment
The increased awareness of the importance of There are four phases in an LCA study:
environmental protection, and the possible impacts
associated with products, both manufactured and • The goal and scope definition phase – the scope,
consumed, has increased interest in the development of including the system boundary and level of detail,
methods to better understand and address these impacts. of an LCA depends on the subject and the intended
One of the techniques being developed for this purpose use of the study. The depth and the breadth of LCA
is life cycle assessment (LCA). LCA can assist in: can differ considerably depending on the goal of a
particular LCA.
• identifying opportunities to improve the environmental • The inventory analysis phase – the life cycle inventory
performance of products at various points in their analysis phase (LCIA phase) is the second phase
life cycle of LCA. It is an inventory of input/output data with
• informing decision makers in industry, government regard to the system being studied. It involves
or nongovernment organisations (for example, for the collection of the data necessary to meet the goals
purpose of strategic planning, priority setting, product of the defined study.
or process design or redesign) • The impact assessment phase – the life cycle
• the selection of relevant indicators of environmental impact assessment phase (LCIA) is the third phase
performance, including measurement techniques of the LCA. The purpose of LCIA is to provide
• marketing (for example, implementing an eco-labelling additional information to help assess a product
scheme, making an environmental claim, or producing system’s LCI results so as to better understand
an environmental product declaration). their environmental significance.17
• The interpretation phase – the final phase of an LCA.
LCA addresses the environmental aspects and potential The findings from the inventory analysis and the impact
environmental impacts (such as use of resources and assessment are combined together, or, in the case
the environmental consequences of releases) throughout of the life cycle inventory studies, the findings of the
a product’s life cycle from raw material acquisition through inventory analysis only, consistent with the defined
production, use, end-of-life treatment, recycling and goal and scope in order to reach conclusions and
final disposal (that is, cradle-to-grave). recommendations.18
Appendix B Life cycle assessment 30

Best Practice Guide
Appendix C
General maintenance checklist
Logging the refrigeration system performance will help

identify changes. Obtain the maintenance schedule to
ensure the following is being undertaken:
Regularly: Monthly:
• Check the temperatures of cold stores. • Check compressor motor temperature and ensure
• Check evaporator and condenser coils for dirt it is operating as recommended by the manufacturer.
or debris and clean them if required. Also, check • Check and treat cooling water entering the system.
for missing or plugged nozzles. Reduce scale, corrosion and biological growth, as this
• Regularly check the entire piping system, especially ensures heat transfer is efficient.
joints, seals, valves and glands for leaks. • Check all oil pump and compressor joints and fittings
• Check the refrigerant sight glass for bubbles. and all relief valves in the system for leaks.
Bubbles in the sight glass often mean a system is • Check all insulation of pipes, valves and cooler or
leaking. Find the leaks and repair them before the freezer areas for condition and appropriate thickness.
system is recharged with refrigerant. Refrigerant
top‑ups should only need to be undertaken annually. Annually:
Contaminated refrigerant should be purged and
automatic purging controls are now readily available. • Check the compressor motor assembly and oil system
• Report and repair any vibrating pipe work, as this to ensure it is operating at maximum efficiency.
is likely to cause a leak over time. • Clean evaporator and condenser tubes during
• Check that compressor oils are at the right level. a shutdown.
• Check that product is not impeding the air flow
of evaporators.
• Ensure that fans, motors and belts have sufficient
air circulation.
• Check for plugged line filters.
• Check evaporators are defrosting and pan lines
are clearing properly.
• Report ice on the floor and walls of cold rooms as
this indicates that excessive air is entering the room,
which becomes a defrosting and safety problem.
Check usage procedures.
Appendix C General maintenance checklist 31

Best Practice Guide
Appendix D
Glossary
chiller A generic name for a packaged refrigeration system

that often includes a compressor, evaporator heat
exchanger, condenser water heat exchanger and
control system
compressor Device that accepts gaseous refrigerant from the

evaporator and compresses it to a higher pressure
before it is sent to the condenser for heat rejection
condenser Device for rejecting heat from the refrigeration system

into the atmosphere. It can refer to a heat exchanger
on the side of a packaged chiller, or an evaporative-
style unit that incorporates a fan and pumped water
system, where hot refrigerant gas becomes a hot liquid
coolant Secondary refrigerant used to transfer cooling energy

created in the refrigeration system around a wider area
(for example, a process plant)
cooling duty The amount of useful cooling work being carried out
by a refrigeration system
cooling tower A structure that provides cooling through the

evaporation of water as it passes across a surface,
with ambient airflow supplied by a fan
coefficient of measure of the efficiency of a refrigeration system

A
performance (COP) defined as cooling duty (kW) / input power (kW)
distribution system A coolant distribution system that distributes the

cooling work done by a refrigeration system into
another physical area
energy balance A tool providing useful information on the breakdown

of energy use in a facility ‘balanced’ against a known
total energy consumption
enthalpy Total heat content including sensible and latent heat
Best Practice Guide
evaporator Heat exchanger where refrigerant fluid is changed from

liquid to gaseous state absorbing heat in the process
expansion valve
expansion valve Valve that is used to reduce the pressure in the

refrigerant, allowing it to change from hot to cold liquid
head pressure Pressure of gas exiting a refrigeration compressor
heat recovery The process of recovering waste heat from refrigeration

system for other purposes, such as preheating
domestic hot water
mass flow rate The rate of movement of a given mass of fluid, usually
measured in kg per second
pressure-enthalpy diagram Thermodynamic chart commonly used to represent a

refrigeration cycle
refrigerant Heat exchange fluid that is vaporised and condensed in

the refrigeration cycle to achieve cooling
refrigeration/cooling load The amount of heat that must be rejected from an area
to keep a refrigerated area or process within permissible
limits
solar gain Heating of a process or area from exposure to sunlight
specific heat capacity The amount of heat required to raise a given substance
by 1oC
suction pressure Pressure of refrigerant at the intake end of the compressor
temperature lift The difference between evaporative and condensing

temperatures of a refrigerant
variable-speed drive A control mechanism that allows control and variation in

(VSD) the speed of a pump or other drive system such as a
refrigeration compressor
Best Practice Guide
Appendix E
Further reading/references
The following articles and websites provide more detailed Good Practice Guide 280, Energy Efficient Refrigeration
technical information and exhaustive best practice Technology – the fundamentals
methods for improving industrial refrigeration efficiency: www.rit.edu/~jdweme/emem416/Fundamentals%20
of%20Refrigeration%20Technology.pdf
Further reading How Continuous Energy Improvement Reduces
Costs and Improves System Performance,
Best Practice Design, Technology and Management,
Industrial Efficiency Alliance
Sustainability Victoria
www.industrialefficiencyalliance.org/documents/
www.sustainability.vic.gov.au/resources/documents/
Refrigeration4-pager20060508LETTER.pdf
Module5.pdf
Industrial Refrigeration Best Practices Guide,
Carbon Trust Networks Project: Operational Efficiency
Industrial Efficiency Alliance
Improvements for Refrigeration Systems, Guide 3, p4,
www.industrialefficiencyalliance.org
Carbon Trust, UK
www.ior.org.uk/ior_/images/pdf/general/REIG5%20
Integrated Pollution Prevention and Control (IPPC)
Site%20Guidance%20Topics%20-%20Final%20Jul-07.
Energy Efficiency
pdf
www.environmentagency.gov.uk/commondata/acrobat/
interimenergy.pdf
Commercial Refrigeration, Energy Smart
www.sedo.energy.wa.gov.au/uploads/
10 Cooler Ideas For Refrigeration System Efficiency,
comm_refrig_28.pdf
Variable-speed condenser fans, Douglas T. Reindl
www.plantservices.com/articles/2007/188.html
Energy Audit Tool – Chillers Greenhouse Challenge, pp5&9
www.climatechange.gov.au/challenge/publications/
pubs/energyaudit-vol3.pdf
Energy management control system for refrigeration

plant at Nestlé Ice Cream plant, Mulgrave, Module 5,
Sustainability Victoria
www.seav.vic.gov.au/ftp/advice/business/case_studies/
NestleEnergyMgeCase0_a.pdf

Best Practice Guide
References
9
ater chiller selection and optimisation of operation,
W
1
Commercial Refrigeration, Energy Smart Sustainability Victoria
www.sedo.energy.wa.gov.au/uploads/ www.sv.sustainability.vic.gov.au/manufacturing/
comm_refrig_28.pdf sustainable_manufacturing/resource.asp?action=show
_resource&resourcetype=2&resourceid=24
2
Carbon Trust 10
co-efficiency Toolkit for the Queensland Food
E
3
umping Tip Sheets (Sep 2005 to May 2007),
P Processing Industry, Queensland Government
US Department of Energy – Energy Efficiency and www.dtrdi.qld.gov.au/dsdweb/v3/documents/
Renewable Energy www1.eere.energy.gov./industry/ objdirctrled/nonsecure/pdf/6694.pdf
bestpractices/motors.html 11
ustainable Manufacturing, Sustainability Victoria
S
4
eco Australia
T www.seav.vic.gov.au/manufacturing/
www.teco.com.au sustainable_manufacturing/resource.asp?action=
show_resource& resourcetype=1&resourceid=42
5
.S. Gas Electric
U
www.usgaselectric.net/page2.html
12
ptimisation of Industrial Refrigeration Plants
O
https://txspace.tamu.edu/bitstream/handle/1969.1/
6
Integrated Pollution Prevention and Control (IPPC) 5624/ESL-IE-06-05-09.pdf?sequence=1
Energy Efficiency
www.environmentagency.gov.uk/commondata/
13
nergy Efficiency Best Practice Programme –
E
acrobat/interimenergy.pdf www.resourcesmart.vic.gov.au
7
nergy Audit Tool Volume 3 Chillers, Australian
E
14
Peter Brodribb, Expert Air
Government Department of Climate Change
www.climatechange.gov.au/challenge/
15
efrigeration – an introduction to the basics, p9, Danfoss
R
publications/pubs/energyaudit-vol3.pdf www.turbocor.com/literature/pdfs/product_literature/
TurbocorProductBrochure.pdf
8
arbon Trust Networks Project: Food & Drink Industry
C
Refrigeration Efficiency Initiative – Site Guidance
16
est results from a 25 kW DX plant: a comparison of
T
Topics,Guide 5, p4, Carbon Trust, UK thermostatic and electronic control, Landis & Staefa,
www.ior.org.uk/ior_/images/pdf/general/ Switzerland
REIG5%20Site%20Guidance%20Topics%20%20
Final%20Jul-07.pdf
17
ISO 14040:2006 Environmental management –
Life cycle assessment – Principles and framework
18
S/NZS ISO 14040:1998 Environmental
A
management – Life cycle assessment – Principles
and framework
Sustainability Victoria would like to acknowledge Frigrite

Refrigeration Pty Ltd for their review of this guide.

Best Practice Guide
For further information and enquiries, please contact:
Sustainability Victoria:
Urban Workshop
Level 28, 50 Lonsdale Street
Melbourne
Victoria 3000
Ph: +61 (03) 8626 8700

Fax: +61 (03) 9663 1007
Email: [email protected]
www.sustainability.vic.gov.au
The Energy Efficiency Best Practice Guides and

accompanying case studies are available from:
www.sustainability.vic.gov.au/eebp
Energy Efficiency Best Practice Guide Industrial

Refrigeration © Sustainability Victoria 2009.
Sustainability Victoria gives no warranty regarding
this publication’s accuracy, completeness, currency
or suitability for any particular purpose and to the
extent permitted by law, does not accept any
liability for loss or damages incurred as a result of
reliance placed upon the content of this publication.
This publication is provided on the basis that all
persons accessing it undertake responsibility for
assessing the relevance and accuracy of its content.
Refrigeration should be attributed to Sustainability
Victoria.
Refrigeration is licensed under a Creative Commons
Attribution-No Derivatives 3.0 Australia licence.
In essence, you are free to copy and distribute
the work, as long as you attribute the work, do not
adapt the work and abide by the other licence terms.
To view a copy of this licence, visit:
http://creativecommons.org/licenses/by-nd/3.0/au/
Acknowledgements
Sustainability Victoria would like to acknowledge
Climate Managers for preparing this report and Frigrite
Refrigeration Pty Ltd for their review of this guide.

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What are some of the opportunities mentioned to improve refrigeration system performance and efficiency?

What are some of the opportunities mentioned to improve refrigeration system performance and efficiency?

What are the different solutions proposed in the document to improve an existing refrigeration system?

What are the different solutions proposed in the document to improve an existing refrigeration system?

3

2 The business benefits of efficient refrigeration 5

3 What is your opportunity? 6

4 Solution 1 – Improve the efficiency of your existing system 7

5 Solution 2 – Design a new system 18

6 Summary of design considerations for refrigeration systems 23

7 Selecting a service provider 25

Appendix A Industrial refrigeration system overview 26

Appendix B Life cycle assessment 30

Appendix C General maintenance checklist 31

Appendix E Further reading/references 34

Figure 1: Cooling energy balance. 8

Table 1: Typical refrigeration-related electricity use. 5

By following this guide, you will be able to determine

2 The business benefits of efficient refrigeration

Chilled ready meals 50%

Frozen food 60%

Cold storage 85%

The business benefits of efficient refrigeration 5

3 What is your opportunity?

What is your opportunity? 6

4 Solution 1 – Improve the efficiency

Often, a refrigeration system runs inefficiently because

• Large-scale improvements can require replacement

However, even if a complete upgrade cannot be

A suggested process to follow when designing a new

Step 1 Step 2 Step 3 Step 4 Step 5 Step 6

Solution 1 – Improve the efficiency of your existing system 7

4.1 Step 1: It is often difficult to estimate how much heat is being

• poorly situated and uninsulated pipework Unaccounted for

Solution 1 – Improve the efficiency of your existing system 8

Creating a high-level energy balance for the

4.1.3 Reduce the cooling load

Solution 1 – Improve the efficiency of your existing system 9

Table 2: Cooling load issues.2

Table 3: Cooling load issues.2

Cool store temperature Incorrect control Adjust thermostat

Solution 1 – Improve the efficiency of your existing system 10

4.2 Step 2: Review insulation 4.3.2 Adjustable and variable-speed

Solution 1 – Improve the efficiency of your existing system 11

Energy Energy Energy Energy

Annual Energy 44000 35200 148000 118400

Annual Energy $4,400 $3,520 $14,800 $11,840

Annual Energy $880 $2,960

VSD Cost $1295 $3,460

Payback 1.5 years 1.2 years

Table 4: Savings due to installation of variable speed drives.4

Solution 1 – Improve the efficiency of your existing system 12

4.4 Step 4: Review refrigeration 4.4.3 Common compressor suction

Solution 1 – Improve the efficiency of your existing system 13

4.4.6 Compressor sequencing and control

Table 5: Control systems issues.2

In cool weather, Incorrect head pressure Check head pressure

4.4.7 Variable-speed compressors 4.4.8 Raise suction pressure

Solution 1 – Improve the efficiency of your existing system 14

• Large-scale improvements can require replacement

Ensure all control Maintain pumps and fans

• Review current and estimated future cooling

–Use automatically controlled (on-demand) defrost

Compressors –Ensure you enquire about compressor efficiency (COP)

–Consider VSDs for condenser fans linked in with

Expansion valves –Use electronic expansion valves where possible

Motors, drives, pumps –Use high-efficiency motors and drives

Controls –Use a control system that is responsive to

Refrigerant selection –Use a refrigerant that is most appropriate for

Service provider –Use a qualified, experienced service provider that

chiller A generic name for a packaged refrigeration system

compressor Device that accepts gaseous refrigerant from the

condenser Device for rejecting heat from the refrigeration system

coolant Secondary refrigerant used to transfer cooling energy

cooling tower A structure that provides cooling through the

coefficient of measure of the efficiency of a refrigeration system

distribution system A coolant distribution system that distributes the

energy balance A tool providing useful information on the breakdown

enthalpy Total heat content including sensible and latent heat