Rse Week 4

MECH-1370
Refrigeration and Air

Conditioning
Evacuation
Learning Objectives
• Discuss refrigeration auxiliaries
• Describe refrigeration system leak test procedures
• Describe how a refrigeration system is dried and charged prior to startup
• List the steps of adding oil to an in-service refrigeration compressor
• Describe start-up and shut-down procedures for a compression refrigeration
system
• Describe how a refrigeration system is purged of non-condensable gas
• Discuss refrigeration condenser operation and maintenance requirements
• Explain typical problems and resolutions related to refrigeration systems
Pressure Gauges
• Only on larger ammonia systems are permanent analog gauges
installed on systems…sometimes found on package chillers
• Pulsation dampers prevent premature wear
• On smaller systems, service valves and access fittings used to
connect gauges to monitor system pressures
– Piercing valves may be used if no fittings found on a unit (small package equipment)
– Piercing valves are not intended for permanent installation – they will leak.
• Oil pressure is displayed, however net oil pressure must be calculated
– Net Oil Pressure = Pump pressure – Sump pressure
Pressure Gauges
Pressure Gauges
Adjustment
screw
Accumulator / Surge Tank / Surge Drum
• Located in Suction line to prevent (or lessen the
chances) of liquid reaching compressor due to
sudden shift in load.
• Liquid enters the vessel, drops out, and vapor is
drawn off the top.
Refrigeration
Accessories
Accumulators:
This is located on the suction side of the system.
It is meant to stop any liquid that may get through the

evaporator, getting back to the compressor.
Oil Separator
• Refrigerant oil is entrained in the high pressure
vapor leaving the compressor
• Oil that enters the system will coat heat
exchange surfaces and decrease efficiency
• Helical, Impingement, coalescing
• Solenoid or level control/float returns oil to
compressor
“Sterne” Oil Separator
HFC/HCFC Trap
Suction Strainer
Filter Dryer
• “Liquid Line” Filter Dryer – Desiccant or calcium
sulphate to dehydrate
• Pressure drop across drier determines
replacement
• Moisture causes: Freeze ups and acid formation
• Protects metering device from particulate
Refrigeration
Accessories
Sight Glass/Moisture Indicator
• Used to “help” determine charge of a unit
• Just because there are bubbles, does not
indicate a low charge…
• Located as close to expansion valve as
possible.
• Chemical dot changes color with moisture
Sight Glass/Moisture Indicator
Economizers
• Transfers heat from “relatively warm liquid”
in “High Side” flowing to the evaporator to
the vapor being drawn from the evaporator
– Temperature of liquid is reduced
• Reduce flash gas/increase NRE
– Prevent flashing of liquid due to pressure drop
through liquid line
– Help to reduce liquid reaching compressor
Soldered Liquid-to Suction Heat Exchanger
Distributor
• Provides equal distribution of liquid
refrigerant on large multi circuit DX evaps
• Ensures equal coil temperature
Distributor Manifold
Vibrasorber
• Decreases noise by isolating the
compressor from the piping
• Vibration and noise amplified through
piping if ridged piping is allowed
• As close as possible to compressor
• Parallel to crankshaft, perpendicular to
source of vibration
• Secured on downstream side
Refrigerant piping and tubing
• Application determines size and type
• B52 requires components meet ASME B31.5 –
Refrigeration piping and heat transfer components
• Ammonia piping must meet IIAR - International Institute
of Ammonia Refrigeration standard and IIAR2 Standard
for Safe Design of Closed-Circuit Ammonia Refrigeration
Systems
• If a disagreement is found, the most restrictive code
used, however from a jurisdictional perspective
Canadian code takes precedence.
Refrigerant piping and tubing
• All materials must be suitable for the application
– Type of service and temperature
• Ammonia
– Type S – Seamless
– Type E – Electric Resistance Welded
– Cannot be galvanized – no contact with zinc (IIAR2)
– Sch 40 If less than IPS6 (DN150), SCH 80 if less than IPS2
(DN50)
– Any screwed fittings must be SCH80
– ASME B31.5 prohibits malleable iron and cast iron in ammonia
– IIAR2 states only class 3000 or stronger when socket welding or
threading
– Tubing limited to compressor and package systems
HFC and HCFC Service
• Copper or steel (large diameter)
• Type K or L Hard Drawn
– Soft Drawn (annealed) up to 1 3/8”
• Malleable and Ductile Iron Fittings above -
20c
Piping Connections
• Threaded – Tapered, Seal Welded
• Flanged
• Flared
• Compression
• Welded – Butt or socket – Certified Welder
• Brazed (Above 840f) -
• Soldered (below 840f)-prohibited by B52
• Flareless
Ammonia Service
• ASME B31.5 states no threaded joints above 2” (DN50)
• Unions forged without brass seat
• Raised face flanges – Gasket suitable for Ammonia
• Joint compounds approved for use
Other piping concerns…
• Painted
• Sloped in direction of refrigerant flow
• Flares assemble with oil or assembly
lubricant (nylog)
Stop Valves
• B52 requires stop valves
Diaphragm Type Valve
Packed Stem Valve
A Valve Cap is a secondary means of leak prevention on most packed stem valves
Receiver Gauge Glass
• B52 Requires automatically closing valves in the
event of breakage (ball similar to steam gauge
glasses seats if flow is sensed due to broken
glass)
• B52 also requires protection of glass to prevent
breakage
• Reflex glass used to show level since refrigerant
is clear – uses prismatic action to indicate the
presence of clear liquids as black
Safety Type Gauge Glass Fitting
Reflex Glass Level Indicator
Bulls Eye Sight Glass
• Either reflex of clear with colored balls to
indicate level
Purge/Charging Valve
• Purge valve – used to vent non-
condensables from system
• Charging valve – used to charge system
• Both are capped when not in use
Pressure Relief Devices
• B52 7.3 Requires every refrigeration system be
protected from over pressure
• Whenever liquid can become trapped
• No stop valves isolating
• Vent to outdoors if:
– Group A3 or B3
– More than 3kg (6.6lb) or A2, B1, or B2
– More than 50kg (110lb) of A1
Fusible Plugs
• Common on smaller systems
• When link melts, entire charge escapes
– Non-reseating
• Primarily used to protect in event of fire
• Not reliable or accurate overpressure
protection devices
• Reclosing pressure relief devices such as
spring loaded safety valves are preferred
Safety Valves
• Noticeably different than hot water service,
no exposed spring or test lever. Cannot
be manually tested, instead must be
replaced every 5 years (Part 8.4 of B52)
• B52 requires pressure vessel containing
liquid refrigerant having an internal gross
volume exceeding 0.085m3 and can be
isolated by valves to be protected by a
relief device
Safety Valves
• Relief device must not allow vessel pressure to
rise more than 10% above setting of relief
device
• This requirement negates the use of fusible
plugs as the sole method of over pressure
protection for larger volume vessels
• Volumes greater than 0.28m3 require 2 full
capacity valves in parallel and must be installed
with a 3 way valve
3 way valve on oil separator of screw chiller
High side relieving into low side
• B52 part 7.3 allows this provided:
– High side pressure relief devices not effected by back
pressure
– Low side of system equipped with pressure relief
devices
– Relief on low side has sufficient capacity to protect
pressure vessels that are relived into low side and to
protect low side of system
– Low side pressure relief devices are piped to outside
of building
Compressors
• Every positive displacement
compressor with a stop
valve must be equipped
with a relief between –
piped to low side or outside
Relief piped
into low side
Emergency Discharge
Firefighter
Box
• 7ft
above
grade
• E-stop
for plant
and
valve
-4.6m above
any adjoining
ground level
or accessible
roof level
-7.7m from
any window,
ventilation
opening, or
exit
Leak Testing
• Inert gas – Dry nitrogen is used
• Not insulated or painted
• Introduced slowly
• Table 4 of B52 shows pressures for high and low side (or
use system design pressures) – isolate so as not to
over-pressurize
• Nitrogen tank and reg having: shutoff valve, bleed valve,
regulator, pressure relief, calibrated pressure gauge
Procedures on B-52 page 4-27
• Not to exceed 130% of design pressure of
any component
• Depressurized before making any repairs
• Use of “tracer gas”
• Sub-atmospheric pressure testing more
difficult to detect leak – must break
vacuum and use nitrogen
Leak Detectors
• Electronic
• Litmus
– Change color in prescience of acid or base
– Red Litmus paper turns blue in prescense of base and Blue litmus paper
turns red
– Ammonia dissolves in water to produce a basic ammonium hydroxide
solution
• Phenolphthalein Paper
– More sensitive than litus
• Sulfur Sticks
– This white smoke created – sulfur dioxide – irritating and toxic
• Soap or leak detection liquid
Most Common
https://www.youtube.com/watch?v=mPYBC
JhW6gA
Now that the system has been pressure tested and is sealed.
We need to remove all the air and moisture from the system.
To do this we use a vacuum pump.

We now use the vacuum pump to
pull a deep vacuum on the system
through the service gauges.
This is then broken by dry nitrogen.
Then back to a deep vacuum again.
We keep the vacuum on the system

till charging.
We watch the gauges to see if any

pressure movement occurs.
Dehydrating and Evacuating
• Moisture left in system causes freeze ups
and formation of acid (In CFC/HCFC)
causing oil sludge and copper plating on
bearing surfaces and valves – decreasing
clearances and causing mechanical failure
• Drawn to 500 Microns
• Book mentions ambient above “20c”
Dehydrating and Evacuating
• Moisture will evaporate and be removed
from system as vacuum level is reduced
• “Triple Sweep” vacuum, N2, repeat.
• Non-condensables “air” left in system
causes high head pressure.
Charging a System
• Refrigeration Mechanic and ODP holder
• Purged air from hoses
• Charge as Liquid
– Some refrigerants (CO2, Ammonia) initially charged
as vapor, then to liquid once certain pressure is
reached – Triple point – Dry Ice
• Charge determined by receiver level or weight
• Frost on suction line is not always a sign of overcharge
• Sight glass full not always an indication of proper charge
Adding Oil
• Refrigerant is under pressure in oil sump
• Oil may not be low, but may be in system or separator…
Always be sure oil level is actually “low” before adding
additional oil
• Greatest concern is NOT introducing non-condensables
(Air)
• POE oil is highly miscisible, open containers should not
be reused
• Lower temperature applications use lower viscosity oil
• As temperature increases – viscosity (resistance to flow)
decreases
Adding oil using compressor suction
Compressor Oil
Oil
Pots
Valve A: Dead man Valve B: Guard Valve to isolate oil return line
Valve C: Allows oil flow from separator Valve D: Draws refrigerant into suction
Oil Pot
• Liquid Ammonia is “less” dense than oil
• A frost line shows the level of oil in the oil
pot because of Liquid Ammonia sitting on
top of oil
Start-up and Shut-down - Recip
• Understand system and manufactures instructions
• Understand system bypass valve, and throttling of
suction
• Watch operating pressures
• Pump down system if shutting down
Centrifugal Start-up Shut-down
• See book, but understand system as each
system is different.
Operator Log
• B52 Requires…
Compliancy causes…
• Failure
• Cost
• Downtime
• Injury
• See book for PM schedule

Non-condensible gas
• Cause a rise in high side pressure
– Resulting in increase power consumption
– Reduced capacity
– Damage to equipment (High temperature, high
pressure)
• Introduced during maintenance, due to
service issues or on sub-atmospheric
systems
Manual Purge
Purging Procedures
• Procedures detailed in book
• All systems are different
– Know the system you are working on
Auto Purge
Chilling coil condenses

vapor refrigerant from non-
condensable gas mixture.
Liquid refrigerant settles in
thermal trap and is returned
to receiver by automatic
float valve
Condenser Operation
• Condenser fowling, non-condensables, oil
logging effect efficiency, capacity, and
operation
• Water quality must be maintained for
operation as well as health (legionella)
• Blow down helps to eliminate solid buildup
at bottom of sump
Air Cooled Condensers
• Dirt and debris block airflow through
condensers
Fans
• Check hub condition
• Check belt tension and condition
• Inspect/grease motor and bearings
Troubleshooting
• Troubleshooting is a learned skill
• Practice is the best teacher
• Flow charts are also helpful
• Electrical schematics are most beneficial
as MOST issues are electrical in some
way.
• Always look deeper then the overserved
issue, to what may have caused the issue

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MECH-1370

Refrigeration and Air

This is located on the suction side of the system.

It is meant to stop any liquid that may get through the

To do this we use a vacuum pump.

This is then broken by dry nitrogen.

Then back to a deep vacuum again.

We keep the vacuum on the system

We watch the gauges to see if any

• See book for PM schedule

Chilling coil condenses

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