GOOD REFRIGERATION

PRACTICES
WHAT IS REFRIGERATION?
Refrigeration is the removal of heat
from a confined space and its
disposal into the atmospheric air
where it has little or no effect at all
using a refrigerant in order to
preserve perishable foods as well as
control temperatures.
 WHAT IS AIR CONDITIONING?
Air conditioning is a process which involves the
following;
a) Temperature control of the air where by
cooling is achieved the use of a refrigeration
circuit and heating through heaters, gas
furnaces or circulation of hot water.
a) Air distribution through the use of fans to
circulate air in the air conditioned room/
space.
 AIR CONDITIONING?
c) Air cleaning of the circulated air to trap any
dirt which may be in it and this is usually
achieved through the use of an air filter
which is mounted on the evaporator coil.
d) Humidity control which is achieved by
passing the warm air to be cooled over a cold
evaporator coil so that if there is any
moisture or humidity in the air it will stick on
the walls of the evaporator as ice. This
explains why every off cycle an air
conditioning unit defrosts.
 WHAT IS HEAT
Heat- is a form of kinetic energy. It
is transferred in three ways:
conduction, convection and radiation.
Heat transfer (also called thermal
transfer) can occur only if a
temperature difference exists, and
then only in the direction of
decreasing temperature.
 METHODS OF HEAT
TRANSFERENCE
⇨Conduction- by direct contact from one
molecule to another especially in solids.
⇨Convection- by volumetric weight
where warm air is lighter than cold air.
⇨Radiation- transference of heat through
space and vacuum
 LAWS OF REFRIGERATION
Correct operations of Refrigeration systems
depends on five thermal laws;
1 Fluids absorb heat while changing state from
liquid to vapour state and give up heat while
changing state from vapour to liquid
2 Temperature at which a change of state occurs
is constant during the change provided the
pressure remains constant.
 LAWS OF REFRIGERATION
3 Heat flows only from a body which is at a
higher temperature to a body which is at
lower temperature (hot to cold).
4 Metallic parts of the evaporating and
condensing units should be made of
metals which have high heat conductivity
like copper, brass & aluminium.
 LAWS OF REFRIGERATION
5 Heat energy and other forms of energies
can not be destroyed but are
interchangeable.
Examples:
Electrical to heat energy
Heat to electrical energy
Kinetic to heat energy
 TYPES OF REFRIGERATION
SYSTEMS
1 Mechanical Refrigeration- these are systems
which have compressors to provide pressure
difference throughout the entire system.
2 Dry Ice Refrigeration- these use dry carbon
dioxide which changers directly from ice to
gas cooling in the process and these are used
by ice cream vendors.
 TYPES OF REFRIGERATION
SYSTEMS
3 Absorption Refrigeration- these are
systems which uses a combination of
Ammonia mixed with water but needs a
source of heat such as an Electric heating
element, Gas burner or Paraffin burner
 MECHANICAL REFRIGERATION
Mechanical refrigeration can be divided into:
►Domestic Refrigeration- house hold refrigerator
► Commercial Refrigeration- Cold Rooms,
Freezer Rooms, Island Freezers/Chillers, Open
Display Freezers/Chillers, Beverage Coolers etc.
► Industrial Refrigeration- these systems for large
storage and Industrial manufacturing processes
such as meat curing at Cold Storage
WHAT IS A REFRIGERANT
Refrigerant is a heat carrying fluid
(liquid or gas) which has a low boiling
point which absorbs heat in the
evaporator when changing state from
being a liquid to a vapour (vaporization)
and looses the gained heat in the
condenser changing state from being a
vapour to a liquid (condensation).
CLASSIFICATION OF
REFRIGERANTS
 REFRIGERANT BLENDS
Zeotropic blends (400Series)
(mixture of more than two
refrigerants). These should be
charged only as liquids cylinders
upside down. The components have
different vapour pressure and boiling
points. Examples: R404A, R406A,
R410A
 REFRIGERANT BLENDS
Azeotropic blends (500Series)
(mixtures of only two refrigerants).
At atmospheric pressure, this
composition will not change as it
evaporates or condenses. Examples:
R500 and R502
 DESIRED PROPERTIES OF
REFRIGERANTS
⇨ Zero ozone depletion potential (ODP)- Ozone
friendly
⇨ Nil or very low Global Warming potential (GWP)
⇨ Low boiling point.
⇨ Low wax content
⇨ Chemically stable
⇨ Non explosive
⇨ Non flammable*
SAFE HANDLING OF REFRIGERANTS

⇨As low temperature liquefied gases never

touch them with bare hands they cause
frostbite.
⇨Do not inhale refrigerants as they can lead to
suffocation.
⇨ Do wear protective clothing such as dust
coats/overalls/boiler suits, including safety
goggles and leather gloves when handling
refrigerants and masks when handling
ammonia.
STORAGE OF REFRIGERANTS
⇨Always store refrigerants in cool, dry and well
ventilated places away from heat sources. No
direct sunlight.
⇨Do not mix refrigerant containers store
separately and label clearly
⇨Do not store ODS cylinders in direct sun light
or near heat sources.
⇨Do not use or light open flames in storage
rooms
STORAGE OF REFRIGERANTS
⇨Do equip storage areas/rooms with
appropriate fire extinguishers.
⇨Do inspect access valves for leaking glands
and gaskets.
⇨Refrigerant cylinders should always be kept
upright with valves at the top with valves
tightly closed.
⇨Do not eat, drink or smoke in storage areas or
near ODS or ODS products /equipment
 NOMENCLATURE NAMING OF
REFRIGERANTS
There is some technical reasoning behind the
naming convention (or nomenclature) for
refrigerants. The graphic below demonstrates
the procedure used by chemists to come up
with the seemingly strange names. A single C
represents a Carbon atom, a CL stands for
Chlorine, H is Hydrogen and F is Fluorine.
NAMING OF REFRIGERANTS
BASIC REFRIGERATION CYCLE
 SYSTEM COMPONENTS
Compressor provides pressure difference in the externally
driven system.
► Screw compressor with two mated screws.
► Scroll compressor with one stationery and one orbiting
scroll.
► Reciprocating compressor with piston and cylinder
setup
► Hermetically sealed type
► Semi-hermetic type
► Open type
► Rotary type
► Centrifugal type fluid flow engine
 SYSTEM COMPONENTS
►Discharge line
► Oil separator
► Condenser –heat loss surface (change of state
from vapour to liquid)
► Air cooled type forced conversion and natural
conversion.
►Water cooled type
► Evaporative type using both air and water
► receiver-liquid refrigerant container (
horizontal/ vertically mounted)
► Liquid line filter drier
 SYSTEM COMPONENTS
► Sight glass which may incorporate a moisture
indicator
► Liquid line solenoid valve
► Metering/expansion devices:
- Thermostatic expansion valve ( TEV)
- Automatic expansion valve (AEV)
- Capillary tube
- Electronic Expansion Valve (EEV)
- Manual valves
 SYSTEM COMPONENTS
► Evaporator-heat gain surface (change of state
from liquid to vapour)

► Suction accumulator

►Crank case/Suction/Back pressure regulator

►Suction line
RECIPROCATING COMPRESSORS
Piston and cylinder set up
 Hermetically sealed type
Hermetic type
 Semi-hermetic type
Semi-hermetic type
 Open type externally driven
Open type externally driven type
 Rotary Compressors
Rotary compressor
 Rotary Compressors
Rotating blade type
 Rotary Compressors
Stationery blade type
 Scroll Compressors
Scroll type
 Screw Compressors
Screw Type
 Centrifugal type (fluid flow) engine
Centrifugal type fluid flow engine
OIL TYPES
RECOMMENDED OIL TYPES
MUFFLER & VIBRATION ABSORBER
DISCHARGE SERVICE VALVE
OIL SEPARATOR
 WATER COOLED CONDENSERS
Standard tube-in- tube condenser
 WATER COOLED CONDENSERS
Co-axial type
 WATER COOLED CONDENSERS
Shell and Tube
 WATER COOLED CONDENSERS
Shell and coil
Evaporative type using both air and water
Liquid receiver-liquid refrigerant container

Vertically mounted/ Horizontally mounted

Liquid line filter drier
Sight glass which may incorporate a
moisture indicator
Liquid line solenoid valve
 Metering/expansion devices
Capillary tube Hand Manual valves
 Thermostatic expansion valve ( TEV)

Thermostatic type (TEV)

 Automatic Expansion Valves (AEV)
Automatic type (AEV)
DATA ON EXPANSION VALVES
EXTERNAL EQUALISING VALVES

• TEX2 R22

• TEN2 R134a

• TEF R12

• TES2 R404A
DATA ON EXPANSION VALVES
INTERNAL EQUALISING VALVES

• TX2 R22

• TN2 R134a

• TF R12

• TS2 R404A
Electronic Expansion Valve
Electronic Expansion Valve
 Evaporator Protection
SUCTION /LIQUID HEAT EXCHANGER
Suction Accumulator
Crank case/Suction/Back pressure regulator
Check Valve
Suction line service valve
Activities involved in Good Refrigeration
practices:
-Good jointing methods
- Pressure testing with Nitrogen
- Leak testing
- Evacuation/ pulling vacuum
- Recovery of refrigerants
- Recycling of refrigerants
- Reclaim of refrigerants
- Retrofitting
- Drop-in of refrigerants
 Good jointing methods
- Flared joints: correct cutting and proper
preparation of pipes.
- Welded (brazed/soldered) joints: using
correct alloy eg. Silver Solder.
- Venting of dry Nitrogen through the pipes
when welding pipes.
- Correct installation procedure like fitting
filter drier last.
- Welded or brazed joints are always
recommended
 Leaks, causes and leak detection
Symptoms of leaks
- Traces of oil on joints and components.
- Insufficient cooling of evaporator coil (not
making full coil).
- On commercial systems hissing of expansion
valve.
- Short cycling on Low Pressure Switch LPS.
 Causes of leaks
- Vibration and frictional wear.
- Incorrect material selection.
- Pressure/ temperature changes.
- Poor quality control.
- Poor connections of components.
- Electrical short circuits on pipes.
- Accidental damage.
 Pressure Testing Methods
NEVER USE OXYGEN FOR PRESSURIZING A REFRIGERATION
SYSTEM.
 Leak detection methods
- Soapy solution also known as bubble test.
- Halide leak torch.
- Electronic leak detection
-Ultra Violet lamp detection
- Sulphur candles.
N.B Always carry out leak test after finishing joining
pipes and also after pinching-off (Domestics) or
closing service valves & caps (Commercials).
HALIDE LEAK DETECTOR
Ultra Violet Lamp detection method
Ultra Sonic leak Detection Method
Evacuation/ pulling vacuum
 Triple Evacuation
A triple evacuation is best:
• 1st evacuation
• break vacuum with dry nitrogen
• 2nd evacuation
• break vacuum with dry nitrogen
• 3rd evacuation
*Note: By introducing dry nitrogen into an evacuated
system a couple of times you help to "blot up"
residual moisture. Dry nitrogen is capable of
absorbing a small quantity of moisture.
Vacuum Gauge
Units of measurement of vacuum
 Recovery of Refrigerants
• Recovery is the removal of refrigerant from a
system into an external container for either re-
use or disposal through recommended
methods.
- Refrigerants should never be vented into
the atmosphere as some are harmful to the
Ozone layer and some contribute to Global
warming
 Recycle of Refrigerants
• Recycle is the cleaning of recovered
refrigerant using a Recycling
machine to remove oil, moisture as
well as air (impurities) for re-use
 Reclaim of Refrigerants

Reclaim is the purification of

recovered refrigerant in a
laboratory by fractional
distillation and chemical analysis
to restore it to almost its original
state (virgin quality).
 Retrofit of Refrigerants
Retrofit is the updating of a system using Ozone
depleting refrigerants to Ozone friendly refrigerants
which are friendly to the environment for example
changing over from R12 (CFC) to R134a (HFC).
-This involves changing oils from Mineral Oil (MO)
to Polyol Ester Oil (POE).
- Changing metering/ expansion devices.
- Changing liquid line filter driers.
- Changing labels to show the new refrigerant which
is now in use.
WHAT TO EXPECT FROM A RETROFIT
 Drop-in of Refrigerants
Drop-in is the replacement of Ozone Depleting
refrigerants with interim refrigerants which has
a low Ozone Depletion Potential (ODP) for
example replacing R12 with R406A. This
process is no longer recommended as the
phase-out dates have also been brought
forward
 COMMON BAD PRACTICES DONE BY
TECHNICIANS DURING SERVICING
• Releasing refrigerants into the atmosphere
• Charging without evacuation
• Mixing refrigerants in systems or cylinders & refilling
cylinders.
• Overlooking leak testing
• Charging systems without gauges results in overcharging
/ undercharging
• Charging wrong oils into compressors/ using used oils.
• Pressurizing systems with any refrigerant for leak
testing
• Wrong jointing methods
 COMMON BAD PRACTICES DONE BY
TECHNICIANS DURING SERVICING
• Blowing dirty coils like condenser with
refrigerants
• Breaking vacuum without pressurizing system
• Heating refrigerant cylinders with naked flames-
rather warm with hot water
• Wrong addition of oils into compressors eg by
pouring.
• Charging liquid refrigerant through the low side
• Wrong sizing of components
 COMMON BAD PRACTICES DONE BY
TECHNICIANS DURING SERVICING
• Using wrong tools e.g. swaging using a screw
driver/ long nose.
• Reconditioning of hermitic compressors
• Refilling of unsuitable cylinders
• Failure to follow manufactures instructions
during installations or repair
• Failure to observe safety regulations
• Wrong sizing of refrigerant piping
• Leaving pipes or systems open
 COMMON BAD PRACTICES DONE BY
TECHNICIANS DURING SERVICING
• Failure to change oil in vacuum pumps
and recovery machines regularly
• Cooling hot pipes with liquid refrigerant
• Cooling hot pipes with damp cloth.
• Blowing pipes using one’s mouth.
• Pinching off using pliers or rubber.
• Sealing leaks on evaporators using
trinepon.
 COMMON BAD PRACTICES DONE BY
TECHNICIANS DURING SERVICING
• Keeping/ storing refrigerant cylinders
exposed to the sun.
• Setting LP/HP switches without using
gauges

• Defrosting evaporator coils using screw

drivers and hammers.
RECOMMENDED WAY OF CARRYING
REPAIR WORKS
 Recovery of Refrigerant using a recovery machine.

 Removal of old compressor.

 Cleaning of condensing unit.

 Removal of filter drier.

 Joining of pipes on compressor.

 Installation of filter drier.

RECOMMENDED WAY OF CARRYING
REPAIR WORKS
• Leak detection.

• If no leaks are found recovery of refrigerant

used for leak detection.

• Evacuation of system.
RECOMMENDED WAY OF CARRYING
REPAIR WORKS
• Breaking of vacuum by pressuring to above
zero on compound gauges.

• Connection of electrics.

• Charging of refrigerant as either vapour

(unit running) or as liquid (unit static).
 RECOMMENDED WAY OF
CARRYING REPAIR WORKS

• On completion of charging refrigerant

carryout final leak testing.

• Updating of unit labels to show new

refrigerant.
I THANK YOU

ALL