4 - Refrigerant Pumping - Monika Witt Presentation PDF

Refrigerant Pumping
and
low charge Ammonia
Refrigeration systems
TH. WITT Kltemaschinenfabrik GmbH
Trends and drivers
Regulation
Safety
Reduce the risk of personal injury, by
designing safe systems
following safe procedures for maintenance
educating the operation staff
Quality
Reliable refrigeration systems will increase food
and product quality
Maintaining a cold chain will avoid waste
Environment
Sustainable refrigeration systems
Use natural refrigerants with no ODP and no/low
GWP
Make efficient use of materials and operating fluids
(e.g. less lubricants, less water consumption)
Consume less energy
Cost and profitability

Profitable refrigeration systems
Allow for reliable operation
Operate energy efficient
Reduce cost for operating supplies (no
leakages, less lubricants, less water
consumption)
Reduce down time
Increase productivity
Reduced refrigerant charge

Possibilities to reduce the refrigerant charge
Design of a low pressure receiver instead of high pressure
receiver system (LP receiver systems have 10 20% less
charge comprared to HP receiver systems)
Compact design with short piping, design with water
cooled condensers
Use of low charge components, particularly condensers
Use of indirect systems

HP system = 100%
100
90
80
70
60
50
40
30
20
10
0
HP system
LP System
Indirect system / air

cooled condenser
Indirect system /
water cooled
condenser
7

Condenser design
Tube and shell condensers have the largest
charge but they can be cleaned easily
Plate and shell condensers contain only 10 20%
charge compered to tube and shell condensers
to clean them they need to disassembled
(gasketed version) or back-flushed (fully welded)
Microchannel condensers can reduce the charge
by 25 50% compared to plate and shell

Comparison of condenser types
Tube & Shell condenser = 100%
100
90
80
70
60
50
40
30
20
10
0
Tube & shell
Plate and shell
Microchannel
Typical refrigeration charges
Source: Courtecy of Nils Vestergaard, Danfoss Denmark

10
LP refrigerant systems
The liquid refrigerant from the condenser is
completely expanded to the low pressure side
no high pressure receiver
The charge is mainly on the low pressure side
increased safety
The liquid is normally drained with high side float
regulators at ambient temperature reduced
energy consumption
11
LP refrigerant systems
Additional aspects
During stand-still the pressure is equilized the
compressor can start unloaded
Stable pressure situation no pressure
fluctuations due to regulating-/ automatic control
valves
Easy mechanical design failsafe, no no need
for settings/adjustments
Maintenance-free
12
High pressure float regulator

system
In Europe the technical common solution
Used since 1900 to automate the refrigeration system
13
High pressure float regulators

Two stage plant design
avoid high gas temperatures for the second stage
improved efficiency
14
Principle of the high side control

Simple mechanical solution of expanding liquid
refrigerant from the high pressure to the low
pressure side, without gas passing
no wiring or controls required
low condensing temperatures are utilized
the refrigerant charge is stored at low pressure
liquid hammer is avoided
15
Operation of a high side float

regulator
Refrigerant enters at top inlet
valve
Liquid level in the housing raises
Float ball starts to lift
Lever system moves slide stone
on an orifice opening to release
refrigerant to the bottom outlet
valve
Refrigerant is expanded in the
orifice opening, releasing low
pressure liquid/gas mixture to
the LP surge drum
16
Design of a standard float

regulator
Service valve
for venting
Low pressure
nozzle
Inlet valve
Protective cap
for hand lever
control
Control unit
(float ball with lever
Outlet valve
Connection for
safety valve
arm and orifice)

Service valve
for draining
17
Installation of high pressure float

systems
A high side float regulator should be installed right
behind the condenser
Avoid heat intake in the liquid refrigerant supply
line to avoid too much gas formation
Float regulators without internal low pressure
nozzzle must be located with a slope to the
regulator housing to allow for free draining
One float regulator for each condenser is
recommended
18
Function of a low pressure

nozzle
a small tube is
connected to the outlet
connection, with a
defined orifice opening
gas is purged to the
LP side
The pressure in the
float housing is
reduced
No need to place the
regulator underneath
the condenser
possible above or up
to 30 m away
19
Considerations of high pressure

float systems
High pressure receivers are normally not allowed,
because the will prevent the self recovery effect
(exemption are systems with oil coolers, but then
good system design is required)
Non-condensables are not allowed in the system,
beacuse the float ball will be blocked (also the
efficiency of heat-exchanger will be decreased)
Behind the float regulator is a two phase flow
risers must be designed accordingly
20
Self recovery effect of float

regulators
When the float regulator was selected too small,
refrigerant will back up in the condenser
The effective condenser surface is decreased
Condensing pressure will raise until float regulator
is capable to drain the condensate
21
Correct connection of high side

float regulators
Gas intake should be avoided, because this will
block the float ball
A and B not correct!!!
Gas intake
C and D correct!!!
no gas intake
22
Parallel condensers with one

float regulator
It is possible to connect one float regulator to
parallel condensers provided they are the same
type and have similar operating conditions
To compensate for different pressure losses
sufficient static head of the liquid supply line is
necessary
23
Parallel condensers
System design
Courtesy of Evapco: to be supplied later
24
Examples
25
Indirect refrigeration systems

Indirect systems use the refrigerant to cool down a brine
the refrigerant is limited to the machinery room/condenser
A heatexchanger cools down the brine
A brine is pumped to the coolers
Using CO2 as a brine allows for stable temperature in the
cooler, because the brine is evaporating
Consideration
The additional heatexchange will increase the energy
consumption
26
Indirect refrigeration systems
27

Considerations
Refrigerant charge reduction as reasonable as
possible not as low as possible!
Attention
Reduced HX surface will decrease the component
size and reduce charge, but
Reduced HX surface will increase T and therefore
increase energy consumption
28
Advantages / Disadvantages
Indirect refrigeration system
Advantages
Low refrigerant charge
Refrigerant charge limited to the machinery room (safety
increased)
Easy handling of the brine
Disadvantages
Additional heat exchanger required
Less efficient than direct systems (e.g. brine pumps use
more energy than refrigerant pumps)
29
Principle of flooded system
30
Principle of flooded system
In the return line is a mixture of liquid and gas F

Overfeed rate should be 1.2 1.5
31
Examples of flooded systems
32
Compact flooded systems

Fully welded plate heatexchanger
33

Example welded Plate HX
34

Example gasketed Plate HX
35

considerations
Plate heatexchangers are sensitive towards liquid
hammer or vibrations
Uncouple compresor and HX frame
Brine pumps should not push into the
heatexchanger, but be installed behind the HX
Use slow acting valves on the brine side
Make sure the buffer reservoir on the brine
side is sized sufficiently large enough
36
direct refrigeration system
37
refrigerant pumps supply evaporators
Direct evaporation of refrigerant in the
coolers
Due to overfeed of refrigerant the coolers
operate as flooded heat exchangers
38
Advantages / Disadvantages
Advantages
Easy control of the refrigerant due to overfeed
Energy efficiency maximised
Disadvantages
Larger refrigerant charge than indirect systems
39
Why refrigerant pumps?

Easy distribution of refrigerant to evaporators
advantages of flooded operation
Due to the available delivery head even
remote evaporators are supplied evenly Simple control
Surge drum separation of liquid / gas
increased safety for the compressor
The entire surface is used for evaporation
due to overfeed efficient and energy saving
40
Types of refrigerant pumps

Open refrigerant pumps
With flanged motor
Double Shaft seals with oil barrier
Common shaft for pump and motor or
coupling, which enables use of standard motors
41
Types of refrigerant pumps

hermetic refrigerant pumps
With integrated, canned motor
one shaft for pump and motor
42
Pro / Contras open pumps

PRO
Robust, simple design
Easy to maintain
Trouble-free operation even in contaminated
systems or dry-run conditions (for seconds)
Use of standard motors possible
Lower investment cost than hermetic pumps
CONTRA
Maintenance required
43
Pro / Contras hermetic pumps

PRO
No maintenance required
No leackages
CONTRA
More sensitive (always liquid refrigerant needed,
no dirt or oil contamination allowed)
More complex work when repair is needed
44
Required suction head

NPSH for refrigerant pumps?
Low density of ammonia does not provide much
subcooling
Refrigerant in a boiling condition (no subcooled liquid)
Gas bubbles will form during pull-down conditions and
varying loads
Always provide refrigerant pumps with liquid refrigerant :
1 1,5 m suction head is normally sufficient
Refrigerant pumps should be able to handle liquid/
vapour mixtures!
45
Sub-cooling at 10m suction head

30
subcooling [K]
25
-40C
20
-10C
15
0C
+35C
10
0
R134a
R404A
Ammoniak
CO2
46
Velocity in the suction line
downleg
Liquid droplets
boiling
Gas bubbles
Sideglass
v < 0,3 m/s
v = 0,3 m/s v > 0,3 m/s

47
Velocity in the suction line

Velocity in the downleg of ammonia systems
should always be
< 0,3 m/s
so gas bubbles can rise back to the surge drum
48
Pump arrangement
allow for sufficient space around the pump for
normal ice accumulation around the pump and
to clean filters and execute maintenance
Straight runs will not improve pump operation
when using refrigerants = boiling liquids
(compared to e.g. operation with water)
Top connection of the pump is recommended to
allow gas bubbles can rise
Piping and fittings should avoid gas
accumulation
49
Pump arrangement
Two pumps in operation
50
Pump arrangement
One pump in stand-by
51
Pumping vessel design

Horizontal low pressure surge drums will
give more surface area for settlement of oil
compared to vertical surge drum
Never connect pumps to an oil dome (except
as shown bevor with the down leg well
above the bottom of the surge drum
Protude the downleg into the vessel and use
vortex breakers
52
Downleg design
Protude the downleg about 30 40 mm into the surge
drum
Use vortex breakers
53
Valve installation
Liquid trapped
gas trapped
Valve spindles in liquid lines should always be installed

in a horizontal poistion!
54
Safety procurements
55
Safety procurements
Refrigerant pumps must be supplied with liquid at all
times!
Install a low level switch (LLS) that will shut off the pump if
the liquid level above the vortex breaker is less than 15 mm
56
Safety procurements
Protect the pump against contamination
Use shot-blasted pipes and vessels
Install a start-up filter when contamination is
likely (no shot-blasted pipes available)
Clean the start-up filter frequently during the
first weeks of operation until clean
57
Start-up filters
Use diameter of the downleg for the filter
58
Safety procurements
Protect hermetic pumps against contamination
with oil
Frequently drain oil from the system, because oil
avoids proper cooling of the internal motor and
bearings with liquid refrigerant
Use automatic oil draining systems wherever
possible (this will also increase system safety and
avoid waste of lubricants)
Change over of pumps in operation and stand-still,
so pump in stand-still will not fill up with oil over
time
59
Safety procurements
Never operate refrigerant pumps against closed
discharge!
Install a differential pressure operated overflow valve
and set the pressure lower than the max. permitted
delivery pressure
60
Safety procurements
Never operate refrigerant pumps against
closed discharge!
Use a diffential
pressure switch with
a delay of 30 60
sec. If the pump has
not built up pressure
during that time the
pump is switched off
61
Safety procurements - summary

Control the minimum level in the surge drum
fit an overflow valve protect the pump against closed
discharge
connect the temperature protection
avoid multiple starts/
stops within short
periods of time
run the pump frequently
avoid oil/debris can
collect
fit a differential pressure
control
62
Required delivery head
Pressure losses
pressure losses during pump cycle
63
Required flow
more liquid refrigerant is pumped to the evaporators
than needed for evaporation. That way the surface
is always fully wetted.
mass flow pump
mpump
Recirculation rate = ----------------------------- -------evaporated refrigerant m Q0
e.g. recirculation factor = 4 means:
1 part refrigerant is evaporated and 3 parts are
returned as liquid
64
Typical recirculation rates

Recirculation factor
Refrigerant
NH3
R22
CO2
Air Cooler
3 - 4
2 - 3
1,2 - 2,0
Plate Freezer
7 - 10
5 - 10
5 - 10
Liquid Chiller
1,2 1,5
65
Pump discharge line

Velocity in the discharge line typically 1,5 m/s
When more than one pump is installed or
evaporators are located above the surge drum a
check valve is needed to avoid backwards flow
Check valves shoulb be installed as close to the
pump as possible to prevent a gas buffer (or an
additional vent line is needed right before the check
valve)
66
Pump discharge line

Behind the evaporator there is a two-phase flow
Design the piping to avoid liquid hammer or slugging
67
Vent line
It is important the pump is vented properly before
started
Some hermetic types have an internal vent line to the
suction side. For these types the suction downleg must
be open during stand still or suffictly long enough
before start. For pumps that vent to the suction side
there is no additional piping required.
Vent line must be individually piped for each pump, so
there is no interference between pump in stand-still and
pump in operation
Install vent line with a constant slope (no traps) to avoid
liquid hammer
68
Typical vent line arrangement
69
Minimum flow line

Also known as Qmin line for hermetic pumps
Since hermetic pumps require liquid refrigerant at all
times a bypass line is recommended with overflow
valve to provide sufficient flow when too many
evaporators close
Some manufacturers require a permanent open bypass with a defined orifice (Qmin orifice) to allow for a
constant by-pass flow.
The Qmin orifice is sized individually for the selected
pump.
70
Qmin flow
Attention
The Qmin flow must be added to the required system
flow that is calculated by the design engineer.
The pump curves normally do not consider by-pass
flows.
Differential set overflow valves only open when the
pressure reaches the set differential pressure (normally
the maximum permitted pump pressure). Therefore no
additional flow has to be considered
71
Motor cooling/ reverse circulation

line
72
Motor cooling/ reverse circulation

line
73
Motor cooling line

Also known as reverse circulation piping
To provide the required liquid refrigerant flow at all
times it is also possible to install a bypass line at
the end of the motor back to the surge drum
As with the minimum flow line mentioned before, a
defined flow is required. To adjust the flow it is
possible to use a defined orifice or a flow meter
with needle valve.
The Qmin orifice is sized individually for the
selected pump.
74
Reverse circulation flow

Attention
Alway connect the reverse circulation line to the
gas area!
Avoid traps and install the line with a constant
flow upwards!
The reverse circulation flow must be added to the
required system flow that is calculated by the
design engineer. (The pump curves normally do
not consider by-pass flows.)
Make sure the reverse circulation piping is
supported properly, so it cannot get ripped off
75
Qmax orifices
Most hermetic pumps are only allowed to operate
in a defined range. The permitted range is defined
by the manufacturer, depending on the design
condition.
In order to provide sufficient back pressure most
manufaturers will require a Qmax orifice, that is
calculated individually for the selected pump and
operating conditions.
It is also possible to use constant flow valves
instead that will avoid the high pressure loss of
Qmax orifices,
76
Qmax orifices
Attention: Qmax orifices create an additional
pressure loss that must be considered by the
design engineer.
Qpump
The effective pump

curve is lower than
the pump curve
given in the
documentation
77
Constant flow valve

Attention:Constant flow valves will ensure a
constant flow at all times, but this may not be
good for the operating conditions
Flow and
pressure no
longer
corresponding
78
Control system
Operating conditions normally vary due to
evaporators being opened/closed
79
Demand control
Easiest way to control a liquid pumping system
Requirement:
Automatic valves that signal open/closed position
Pump is switched on when one or more evaporators
are open and stopped when all evaporators are closed
Attention: Avoid frequent starts/stops (as this will
reduce the pump lifetime) by programming a minimum
stand-still period and run time
80
Influence of by-pass flow

Bypass with overflow valve (set for a differential pressure)
opened only when the max. permitted pressure is exceeded
81
Two pumps in operation

Operating two pumps will not double the flow
due to greater overall resistance!
82
Pressure control
Since delivery head and volume flow is normally
corresponding it is possible to use pressure control for
switching on/off a second pump
Delivery head to switch off the second pump is with
ammonia typically 0,7 bar higher than the minimum
pressure
It is recommended to program a minimum run time to avoid
frequent starts/stops
Attention: Too small programmed differences btween
minimum and maximim pressure may result in instable
operating conditions
83
Frequency converters
Frequency converters will keep te pressure fairly stable
and safe energy.
The evaporator
with highest
pressure loss
should be
supplied
properly at
minimum
frequency
The set point should be about 0.3 bar higher than the
minimum required pressure
84
Frequency converters
Check minimum and maximum permitted
frequencies with the manufacturer (normally between
40 Hz and 60 Hz).
Maintain the pressure in the system stable (typically
with a proportional-integral (PI) control system
Ramping times should be short to allow the check
valve behind the pump opens fast enough
85
Minimum stand-still period

To allow for proper venting after the pump has been
switched off and
avoid frequent starts/stops (which will reduce the
lifetime of any pump)
More than 6 starts/stops per hour should not occur!
Stand-still periods of 5 minutes are normally sufficient
to vent an ammonia pump properly (with long Qmin or
reverse circulation lines this may be longer)
86
Minimum operating time

The highest impact takes place when the starting
torque of the pump consumes the highest current.
A minimum run-time of 2 minutes - better 5 minutes
is recommended!
Contiunous operation will increase the life-time of the
pump.
87
Evaltuation ammonia systems

Direct ammonia systems have a very good
record in Europe very few accidents (similar to
systems using synthetic refrigerants)
Most cases of accidents occur during
maintenance good education of service
personnel will avoid incidents
Cascade systems with evaporating CO2 offer an
alternative when no ammonia is accepted in
populated areas
88
Balance between refrigerant

charge, efficiency and safety
Pumped refrigerant systems offer highest
efficiency
Refrigerant charge about 3 l per KW capacity in
Europe
Safety should be in the focus during design (risk
analysis), installation and operation by following
codes of practice and regulations
Use of prefabricated units will increase reliability
89
Refrigerant charge reduction

as reasonable as possible
not as low as possible!
90

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Refrigerant Pumping

TH. WITT Kltemaschinenfabrik GmbH

Trends and drivers

TH. WITT Kltemaschinenfabrik GmbH

TH. WITT Kltemaschinenfabrik GmbH

TH. WITT Kltemaschinenfabrik GmbH

Cost and profitability

TH. WITT Kltemaschinenfabrik GmbH

Reduced refrigerant charge

TH. WITT Kltemaschinenfabrik GmbH

Reduced refrigerant charge

TH. WITT Kltemaschinenfabrik GmbH

Indirect system / air

Reduced refrigerant charge

TH. WITT Kltemaschinenfabrik GmbH

Reduced refrigerant charge

TH. WITT Kltemaschinenfabrik GmbH

Plate and shell

Typical refrigeration charges

Source: Courtecy of Nils Vestergaard, Danfoss Denmark

TH. WITT Kltemaschinenfabrik GmbH

High pressure float regulator

TH. WITT Kltemaschinenfabrik GmbH

High pressure float regulators

TH. WITT Kltemaschinenfabrik GmbH

Principle of the high side control

TH. WITT Kltemaschinenfabrik GmbH

Operation of a high side float

Design of a standard float

arm and orifice)

Installation of high pressure float

Function of a low pressure

Considerations of high pressure

Self recovery effect of float

TH. WITT Kltemaschinenfabrik GmbH

Correct connection of high side

TH. WITT Kltemaschinenfabrik GmbH

Parallel condensers with one

TH. WITT Kltemaschinenfabrik GmbH

Courtesy of Evapco: to be supplied later

TH. WITT Kltemaschinenfabrik GmbH

TH. WITT Kltemaschinenfabrik GmbH

Indirect refrigeration systems

Indirect refrigeration systems

TH. WITT Kltemaschinenfabrik GmbH

Reduced refrigerant charge

TH. WITT Kltemaschinenfabrik GmbH

TH. WITT Kltemaschinenfabrik GmbH

Principle of flooded system

TH. WITT Kltemaschinenfabrik GmbH

Principle of flooded system

In the return line is a mixture of liquid and gas F

Examples of flooded systems

TH. WITT Kltemaschinenfabrik GmbH

Compact flooded systems

TH. WITT Kltemaschinenfabrik GmbH

Compact flooded systems

TH. WITT Kltemaschinenfabrik GmbH

Compact flooded systems

TH. WITT Kltemaschinenfabrik GmbH

Compact flooded systems

TH. WITT Kltemaschinenfabrik GmbH

TH. WITT Kltemaschinenfabrik GmbH

TH. WITT Kltemaschinenfabrik GmbH