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Types of refrigerants
Refrigerants are categorised by their chemical composition of
chlorine, fluorine, carbon and hydrogen. We have four
categories that we use and below is mentioned examples of
refrigerants in the different groups and their composition.
CFC: Chlorine-Fluorine-Carbon
HCFC:
Hydrogen-Chlorine-Fluorine-Carbon
HFC: Hydrogen-Fluorine-Carbon
HC:
Hydrogen-Carbon
Category Type
CFC
R-11
Freon,
(100) trichlorofluoromethane
Chemical name
Genetron,
Frigen 11 R-11
CCl3F
R-12
Freon, Genetron,
(100) dichlorodifluoromethane (CCl2F2)
Frigen 12 R-12
2
trifluoromethane (CHF3)
R-134a
Klea,
1,1,1,2-tetrafluoroethane (CH2FCF3)
R-404a Suva HP62, Atochem FX-70
R-125/143a/134a (44/52/4) R-413a Isceon 49 Rodia
R-218/134a/600a (9/88/3) - R-417a Isceon 59 Rodia
R-125/134a/600 (46,6/50/3,4) - HC & natural
R-290 Propane HC-290 (100) CH3CH2CH3
R-600a Isobutane R-600a (100) CH(CH3)2-CH3
R-717 Ammonia R-717 (100) NH3
R-744 Carbon Dioxide R-744 (100) CO2
Safety considerations
Refrigerants have to be handled correctly and one has to
observe the correct safety precautions to avoid accidents.
There are three factors that have to be taken into
consideration:
1. Poisonous products develop when refrigerants are
exposed to high temperatures, which is why smoking is
forbidden around refrigeration installations. Before any
soldering or brazing is performed on piping or components the
system has to be emptied of refrigerant.
2.Leaking refrigerant can cause freezer burns as the boiling
point temperature of refrigerants at normal atmospheric
pressure are well below the freezing point. Goggles and gloves
have to be worn when handling refrigerants.
4
Global warming
One impact that the burning of fossil fuels has had on the earth's
environment has been the increase of carbon dioxide (CO2) in the
earth's atmosphere. The amount of atmospheric CO2 apparently
remained stable for centuries, at about 260 ppm (parts per million),
but over the past 100 years it has increased to 350 ppm.
The significance of this change is its potential of raising the
temperature of the earth through the process known as the
greenhouse effect. Carbon dioxide in the atmosphere tends to
prevent the escape of outgoing long-wave radiation from the earth to
outer space; as more heat is produced and less escapes, the
temperature of the earth increases.
5
Ozone layer
The Ozone Layer, in nature, a region of the atmosphere from 19 to 48 km
(12 to 30 miles) above the earth's surface. Ozone concentrations of as
much as 10 parts per million occur in the ozone layer. The ozone forms
there by the action of sunlight on oxygen. This action has been taking place
for many millions of years, but naturally occurring nitrogen compounds in
the atmosphere apparently have kept the ozone concentration at a fairly
stable level.
Concentrations this high at ground level are dangerous to human health;
but because the ozone layer protects life on earth from the full force of the
sun's cancer-causing ultraviolet radiation, it is critically important.
Therefore, scientists were concerned when they discovered, in the 1970s,
that certain chemicals called chlorofluorocarbons, or CFCs (compounds of
fluorine) - long used as refrigerants and in aerosol spray cans - posed a
possible threat to the ozone layer. Released into the atmosphere, the
chlorine-containing chemicals rise and are broken down by sunlight,
whereupon the chlorine reacts with and destroys ozone molecules. For this
reason, the use of CFCs in aerosols has been banned in many countries.
Other chemicals, such as bromine halocarbons, and nitrous oxides from
7
fertilisers, may also attack the ozone layer.
Ozone Destruction
In the 1970s and 1980s, scientists began to find that human activity was
having a detrimental effect on the global ozone layer, a region of the
atmosphere that shields the earth from the sun's harmful ultraviolet rays.
Without this gaseous layer, which is found at about 40 km (25 miles) above
sea level, no life could survive on the planet. Studies showed the ozone
layer was being damaged by the increasing use of industrial chemicals
called chlorofluorocarbons (CFCs, compounds of fluorine) which are used in
refrigeration, air conditioning, cleaning solvents, packing materials, and
aerosol sprays.
Chlorine, a chemical by-product of CFCs, attacks ozone, which consists of
three molecules of oxygen, by taking one molecule away to form chlorine
monoxide. Chlorine monoxide then reacts with oxygen atoms to form
oxygen molecules, releasing chlorine molecules that break up other
molecules of ozone.
It was initially thought that the ozone layer was being reduced
gradually all over the globe. In 1985, however, further research
revealed a growing ozone hole concentrated above Antarctica;
50 per cent or more of the ozone above this area of the earth
9
Refrigerant
Years
ODP
GWP
R-11 (CFC)
60
1.00
R-12 (CFC)
120
0.93
R-22 (HCFC)
19
0.05
R-134a (HFC)
16
0.00
0.28
R-717 (NH3)
<2 weeks
0.00
0.00
1.00
3.20
0.34
11
In the list the ODP and GWP are relatively figures and made in
relation to CFC R11, which is chosen as reference. According to this
for instance R22 is 20 times better than R11 on ODP and 2.5 times
better on GWP.
Another Method to calculate the environmental impact of refrigerants
is Total Equivalent Warming Impact (TEWI), which is the sum of the
direct effect and the indirect effect. The indirect effect includes the
environmental impact during the energy production for the operation
of the refrigeration plant, and thus the efficiency of the refrigerant as
such is considered.
If - regionally or internationally - an environmental duty based on
CO2-emission is decided, it will be a calculation of the TEWI that
should be taken into consideration when choosing a refrigerating
plant and/or a refrigerant.
12
14
15
16
Evaporation vs Boiling
Bothstartwithaliquidandendwithagas.Buttheyare
differentprocesses.
Evaporation:
Strictlyasurfacephenomena
Occursatanytemperature
Somehotter(faster)-than-averageparticlesovercomethe
forces
theyfeelfromtheirneighborsandescapethe
liquid,takingtheirheatenergywiththem.
Forcesonlyfeltfromparticlesbeneaththem
18
Evaporationinaclosedcontainerwillproceeduntil
thereareasmanymoleculesreturningtotheliquid
fromthevaporabovetheliquidasthereare
escaping-thevaporisthensaidtobesaturated.The
pressureofthatvaporiscalledthesaturatedvapor
pressure.
19
Boiling:
Happens throughout the liquid.
Occurs at the boiling point/temperature
Average motion of particles is fast enough to
overcome the forces holding them close
together - all the particles are trying to escape
- liquid turns to vapor
Forces felt from particles all around them
Boiling point dependent on atmospheric
pressure - steam bubbles form in liquid only
when vapor (steam) pressure exceeds
atmospheric pressure (plus pressure of water
20
pushing down)
Mass of water=M
Mass of ice =m
Refrigeration cycle
26
Refrigeration unit
27
Refrigeration cycle
28
Cold Room
29
30
31
Compressor types
34
Refrigeration Compressors:
Types:
1. Reciprocatingcompressors.
2. Screwcompressors.
3. Centrifugalcompressors.
4. HermeticorSemi-Hermeticcompressor.
5. ScrollCompressors
35
Compressor
37
Fridge compressor
Compressor bodies
are normally of close
grained castings of
iron or steel. Modern
valves are of the
reed or disc type
mounted in the head
and are of high grade
steel on stainless
steel seats with a
usual lift of about
2mm. Connecting
rods are aluminium
with steel backed
white metal big ends.
The crankshaft is
spheriodal graphite
iron.
38
Fridge compressor
Fridge compressor
Fridge compressor
41
43
Mechanical seal
The carbon seal and
flexible bellows is
fixed in way of the
mounting plate and
the hard running
surface is allowed to
rotate.
This is the opposite to
the set up for seals
mounted on pumps.
The finish of the running
surface of the seal is
extremely fine.
44
Mechanical seal
Semi Hermetic
Compressors
In semi-hermetic compressors
the electrical motor and the
compressor are built together
and the shaft seal is avoided
The electric motor is cooled by
means of the refrigerant
vapours being sucked through
the motor before entering the
cylinder. The whole compressor
is usually air cooled, e.g. on
reefer containers by means of
air from the condenser
ventilator or on stationary
systems by means of a
separate ventilator.
Lubrication by forced lubrication
46
system
47
Hermetic compressor
Hermeticcompressorsare
hermeticallysealedmeaningthat
thecasingofthecompressoris
fullywelded.
Usedinsmallerrefrigeration
plantsassmallairconditioning
units,domesticrefrigeratorsand
domesticfreezers.
Fromthefactorytheseplantsare
filledwithanadequateamountof
refrigerantandlubricatingoil.
If the compressor breaks
down it has to be renewed as
you can not repair it.
48
Hermetic compressor
Therefrigerantvapoursare
suckedintothecasing,through
theelectricmotorforcoolingand
intothecylinder.
Fromthecylinderthe
compressedvapoursare
dischargedthroughtheoutlet
pipeonthecompressor.
Thesurroundingairusually
providessufficientcoolingofthe
compressor.
Aswiththeothercompressorsthe
lubricationoilisincontactwith
therefrigerantandmustbe
compatiblewiththerefrigerant
beingused.
49
HERMETIC COMPRESSOR
PISTON TYPE
50
HERMETIC SCROLL
Scroll compressors
Compression mechanism of Scroll
Compressor.
Thescrollcompressorisarotating
compressorandworksbymeansoftwo
helices,onestationaryandonemakingan
eccentricmotion.
Asthemovablehelixrotatesavolumeis
capturedandcompressedbybeingforced
towardsthecentreofthehelix.
Anoutletvalveisplacedinthecentreand
thecompressedgassesleavethe
compressorhere.
Thescrollcompressorisahermetic
compressorandtherefrigerantvapoursare
suckedintothecasing,throughthe
electricmotorandintothehelicesinthe
51
top.
HERMETIC SCROLL
53
FUNCTION - SCROLL
54
scroll compressors
Compressioninthescrolliscreatedbytheintersectionofanorbiting
spiral.Gasentersanouteropeningasoneofthespiralsorbits
55
56
57
58
Rotary Compressor
These compressors
are used mainly in
house hold
applications but
modern practice sees
there use in cargo
conditioning.
A variation on this is
the multi blade type
where the rotor has
slots cut in it, fitted to
which are spring
loaded blades.
Alternately the blades
may rely on
centrifugal force. 59
Rotary Compressor
61
62
Centrifugal compressor
63
Centrifugal compressor
64
65
66
unloader
Normal oil
pressure moving
sleeve down
against the spring
pressure.
Unloaded
condition the oil
pressure is
released pin
moves upward by
the spring
pressure causes
the valve to lift
67
from its seat.
unloader
68
Lubricants
Lubricatingoilisnecessaryfortheoperationofthe
compressorandastheoilinrefrigerationsystemsisin
contactwiththerefrigerantapartofthisoilwillbe
transportedwiththerefrigerantintothepipesand
components.
Theimportantissuehereisthattheoilmustbesolublewith
therefrigerantinorderfortheoiltobetransportedbackto
thecompressorwiththereturningrefrigerant.
Abalancebetweentheoilbeingtransportedintothepipesand
theoilreturningtothecompressorwilloccurandthe
amountofoilinthecompressorwillbeconstant.
69
1.Crankcasesuctionpressureentersherefromcapillary
tubeSurgechambercushionsrapidpressurefluctuation
2.Ariseincrankcasepressurebecauseofrisein
evaporatorloadincreasethepressureagainstthebellows
andcompressestherangeadjustingspring.
3,compressionoftherangeadjustmentspringsallows
thevalvespringstomovethepushpinsandvalve
needlepointtowardthevalveseat
4.Thevalvethrottletheflowofcontroloiltothe
crankcasecausingthecontroloilpressuretobuild
up,oilenterscapacitycontrolcircuitthroorifice
fromcompressoroilpumpcircuit.
5.theincreasedoilpressurepushestherelaypiston
againstthespringopenspassagesbetweentheoil
pumpandtheunloaderpowerelements,
6.thepumpoilpressureintheunloaderpower
elementsforcesthepistonupwardspivotingthelifting
fork
7.Thelifterpinsdropandseatthesuctionvalve
loadingthecylinder
71
Condenser
72
74
75
Tube stack
76
Condenser1
Generally a water cooled tube cooler.
A safety valve and vent are fitted. The purpose of the
vent is to bleed off non-condensibles such as air which
can enter the system when the suction pressure is
allowed to fall below atmospheric or can be contained
within the top up gas.
The presence of non-condensibles is generally indicated
by a compressor discharge pressure considerably above
the saturation pressure of the refrigerant.
The coolant flow to the condenser is sometimes
temperature regulated to prevent too low a temperature
in the condenser which can effect plant efficiency due to
the reduction in pressure.
77
Receiver
Sight Glass
79
Moisture indicator
Green ~ Dry
Yellow ~ Wet
Thermostat
These two elements form the main temperature control
of the cold rooms.
The Thermostat is set to the desired temperature and
given a 3 to 4 degree differential to prevent cycling.
When the temperature in the room reaches the pre-set
level the thermostat switch makes and the room
solenoid is energised allowing gas to the refrigerant
liquid to the expansion valve.
A manual over ride switch is fitted as well as a relay
operated isolating contact which shut the solenoid when
the defrost system is in use.
81
SOLENOIDE VALVE
SOLENOID VALVE
83
Filter Drier
Can be either a compacted solid cartridge or bags of
dessicant. The main purpose of this unit is to remove the
moisture from the refrigerant.
Moisture cause two main problems.
Firstly it can freeze to ice in the evaporator and cause
blockage.
Secondly it can form acids by reaction with the freon
refrigerants. This acid attacks the copper in the lines and
deposits its in other parts of the system.
This can become particularly troublesome when it is
deposited on the compressor mechanical seal faces
leading to damage and leakage.
Fine particles which could possible block the expansion
valve are removed.
84
FILTER DRIER
85
Filter Drier
1.Gauge
connection
10.Casing
2.Cover
11.Inlet
connection
3.Joint
12.Ovalflange.
4.Withdrawing
handle.
13.Charging
connection
5.spring
14.Centerbolt.
6.Distancepiece 15Dryingagent.
7.Divisionplate. 16.Retaining
sleeve.
8.Feltwashers.
17.Outlet
9.Gauzeplates. connection.
86
Filter Drier
Driers are used in the
liquid line to remove
any water moisture
accidentally admitted
to the system.
The common drying
agents are silica gel
and activated Alumina
which can be activated
by heating
87
89
Cold rooms
Meat Room-Low temperature room typically working at
-17oC
Veg/ handling room-typically working at +4oC
Compressor
Generally of the single stage, reciprocating type. Larger
systems have multiple cylinders with an unloader system
using the suction pressure as its signal.
Refrigerant is compressed in the compressor to a
pressure dependent upon the temperature of the cooling
water to the condenser, and to a lesser extent the volume
of gas in the system.
As the temperature of the cooling water rises so does the
minimum temperature of the refrigerant liquid rise, and
90
with it the corresponding saturation pressure.
94
P1
Membrane
P2
P3
95
When the bellow moves downwards, the valve stem will open for
the supply of refrigerant to the evaporator. This opening will
lead to cooling down of the bulb and thereby a pressure drop in
the bulb. The pressure P1 will decrease.
The bellow will begin to move in an upward direction, if the
pressure and the spring are unchanged. The valve will try to
prevent deviation from taking place.
When the valve cone moves toward closing, the amount of liquid
flowing into the evaporator will decrease. When a smaller
amount of liquid is supplied to the evaporator, the superheating
temperature at the evaporator outlet will increase.
The increased temperature will increase the pressure P1 in the
bulb, and the valve will begin to open. The relation between the
three pressures in the valve, will determine how much the96valve
will open.
Thermostatic
Expansion valve
Bernoulli Effect
For horizontal fluid flow, an increase in the velocity of
flow will result in a decrease in the static pressure.
98
Thermostatic
Expansion valve
Thermostatic
expansion valve
Thermostatic
expansion valve
102
103
ELECTRONIC TEMPERATURE
CONTROL SYSTEM
If,forexample,theair
temperaturerisesthemotor
willmovethespindleup.The
springforcewilldecrease,the
pressureontopofthepistonof
themainvalvewillincrease,
andthevalvewillmoveopen
slightly.Asaresult,the
evaporatorpressureand
temperaturewilldecrease,the
capacitywillincreaseandthe
airtemperaturewillfallagain.
Intheeventofamalfunction,
theregulatingsystemshould
becheckedinaccordancewith
theoperatingmanual 106
Thesevalvesareusedinconnection
withfloodedcoolersorevaporators
toensurethattheliquidlevelremains
constant,thevalvesbeingcontrolled
byafloatarrangementinthe
evaporatororcondenser.The
simplestcontrolofthissortisadirect
acting,ballfloatvalve.
Forfloodedevaporators,e.g.shell
andtubeevaporatorswithrefrigerant
intheshell,theexpansionvalveare
automaticallycontrolledtomaintain
aconstantliquidlevelineitherthe
evaporatororcondenser.
107
Thesimplestcontrolofthis
sortisadirectacting;
float-controlledvalveis
showninthefigure
above.Whenliquidis
condensed,itflowsinto
thefloatchamberandthe
valveopenstoallow
passagetotheevaporator.
Topreventgaslocking
occuringassomeofthe
liquidrefrigerantinthe
floatchamberevaporates,
aventpipeisfittedtothe
evaporator.Thisventpipe
hastoincorporatea
capillarytube,orvery
smallorifice,toprevent
excessiveflow:faulty
operationofthistypeof
valvecanbecausedby
blockageinthisventpipe
108
Thesevalvesareusedin
connectionwithflooded
coolersorevaporatorsto
ensurethattheliquidlevel
remainsconstant,thevalves
beingcontrolledbyafloat
arrangementintheevaporator
orcondenser.Thesimplest
controlofthissortisadirect
acting,ballfloatvalve.
Forfloodedevaporators,e.g.
shellandtubeevaporators
withrefrigerantintheshell,
theexpansionvalveare
automaticallycontrolledto
maintainaconstantliquid
levelineithertheevaporator
109
orcondenser.
110
Hp cut out
Thebellows
connectedbysmallbore
pipebetween
compressorand
condenser
Excesspressure
expandsthebellowand
movestheswitcharm
catcharounditspivot.
Theupperendslipsto
therightofthestepand
releasestheswitcharm
sobreakingelectrical
contactcausingthe
115
compressortocutout.
Hp cut out
116
117
118
It is also used as a
control stopping and
starting the compressor
to maintain the desired
pressure and hence the
119
temperature
Lp cut out
Thepushpin
operatestheswitchthro
acontactwhichis
flippedopenorclose
throacoiledspring
plate
Withthecontactopen
thespringiscoiled
Outwardmovement
ofthepincompresses
thespringandthisthen
flipsthecontactto
closethecompressor
startingcircuit.
120
Lp cut out
121
CAUSES
Too much liquid refrigerants being fed through
the expansion valve.
Sensing bulb not fixed properly
Leaky suction valves.
RECTIFICATION
Adjust the expansion valves and check the
sensing bulb.
Remove the cylinder covers, check all the
valves, repair or renew and test.
122
OIL SEPERATOR
Oil separator
usually fitted in
the discharge
line from the
compressor .
The separation
of oil is
mechanical, the
slowing down
and change of
direction of the
gas/oil stream
throwing out the
oil.
124
126
Pressure gauge
Pressure gauge
129
131
CAUSES
Insufficient gas in system.
Too much oil circulating in system.
Improper adjustment of expansion valves.
Blockage in liquid pipe, expansion valve or
suction filters.
RECTIFICATION
1. Evacuate, isolate, remove, inspect and clean
filters.
2. Charge with more refrigerant.
3. Inspect to see whether oil has accumulated
anywhere in the system. If accumulated, then
retrieve the collected oil back into compressor
4. Set the expansion valves to feed more
134
refrigerant.
CAUSES
1. Too much cooling water to the condenser.
2. Cooling water is too cold.
3. Liquid refrigerant is coming back from the
evaporator.
4. Leaky delivery valve or worn out/broken piston
rings.
RECTIFICATION
1. Regulate the water supply and adjust by
regulating the water flow to get correct
condensing temperature.
2. Adjust the expansion valve and check that the
expansion valve bulb in contact with evaporator
pipe and fastened correctly.
135
4. Remove the cylinder cover, inspect the valve
Defrost system
138
PRESSURE SWITCH
CAUSES
Condition may be due to
Insufficient water flowing through condenser.
Clogged condenser.
High pressure cutout incorrectly set, adjusted
incorrectly.
System overcharged with refrigerant.
RECTIFICATION
Determine if water has been turned off.
Adjust water regulating valves.
Check for scaled or fouled condenser and clean the
condenser.
Check setting of high pressure cutout.
High pressure cutout may be tripping due to
139
insufficient condenser capacity because condenser
1. The pumping down of the gas to be carried out to collect the complete
system gas to the condenser and later close the condenser outlet valve.
2. Switch off the circuit breaker.
3. The empty Freon gas cylinders must be cooled in a fish room to bring
the temperature approx. -18 deg C.
4. The cooled cylinders are connected to the charging valve between the
condenser and filter drier unit.
5. Open the empty cylinder valve and condenser outlet valve, the liquefied
gas from the condenser is transferred to the bottle due to the
differential pressure.
6. Renew bottles to collect all the gas present since single bottle would not
be enough to collect the gas.
7. The reason for more gas bottles is that temperature of bottles rise
during collection process equalizing the pressure of the condenser and
bottle.
8. Renew silica gel on completion of removing the entire contaminated
refrigerant.
9. Charge fresh Freon gas to the system to normal condenser level.
10. It may be required to renew silica gel couple of times even after
renewing the refrigerant, due to left over moisture adhering to the
143
walls of condenser.
INDICATION
The presence of moisture is indicated in the sight
glass fitted in the liquid line
Moisture in the System comes with the ingress of air in
the system.
CAUSES
145
147
SYSTEM
INDICATION:
The liquid level in the condenser is too high (high
condenser gauge reading). This will reduce the available
condensing surface, with corresponding increase in the
saturation temperature and pressure.
High pressure switch of the refrigerant compressor
activates and stops the compressor.
There is possibility of excessive liquid refrigerant getting
to the evaporating, giving icing at the compressor suction,
and a pressure drop across the expansion valve.
The cold room temperature may rise, if the evaporator is
flooded.
CAUSES:
It may be due to the reason that excessive refrigerant
has been charged in the system.
High delivery pressure may also be due to
148
air/incondensable gases present in the system.
SYSTEM, contd.
ACTION:
Remove the refrigerant from the system. This is done by
connecting a cylinder to the liquid line charging valve,
starting the compressor, and then operating the charging
valve.
Purge the air from the system and maintain effective
cooling. While purging there is always some gas will pass
along with air hence the regulation says the purging has
to be collected in recycling cylinders and same has to be
recorded.
Remove ice from the regulator by using any of the
defrosting methods
149
150
TROUBLE SHOOTING
1. AIR IN THE SYSTEM:
1.High condenser pressure.
2.Presence of small bubbles in the sight glass
2. MOISTURE IN THE SYSTEM :
1.High condenser pressure.
2. Low evaporator pressure.
3. Compressor stops.
3.UNDER CHARGE:
1.Low condenser pressure.
2. Large bubbles in the sight glass.
3. Compressor works hot.
4. Room temperature goes up.
151
4.OVER CHARGE:
1.High condenser pressure.
2. Sight glass shows full.
3. Insufficient cooling of rooms.
5.LUB OIL IN THE SYSTEM:
1.Condenser temperature goes high.
2. Evaporator temperature gets high.
3. Frost on the suction pipe of the compressor.
6.FROSTING ON THE EVAPORATOR:
1.Room temperatures goes high.
2. Freon liquid may return to the compressor.
152
Refrigerants
Desirable properties of a refrigerant
1.
Refrigerants
5.High critical temperature (temperature above which vapour
cannot be condensed by isothermal compression)
6.Non corrosive and non solvent (pure and mixed)
7.Stable under working conditions
8.Non flammable and non explosive
9. No action with oil ( the fact that most refrigerants are
miscible may be advantageous e.e. the removal of oil
films, lowering pour points etc, provided separators are
fitted
10.Easy leak detect
11.Non toxic
12.cheap, easily stored and obtained
158
Refrigerant 12
R12 is halogenated hydrocarbon derived from
methane (CH4) with the hydrogen being displaced by
chlorine and fluorine. The resulting compound is
Dichlorodifluoromethane (CCl2F2) also known as Freon
12
R12 is considered non-toxic except in high
concentration producing oxygen deficiency. However on
contact with flame it breaks down to form chlorine gas
and phosgene (COCl2).
R12 escaping under pressure can cause skin
damage on contact. It is non-irritant and not considered
flammable.
Working pressures and temperatures are moderate
and the high critical temperature (112oC) is well above
the working range
159
163
Refrigerants
The production of R12 and R11 has now stopped under
the Montreal Protocol and EU regulation on ozone
depleting gasses.
A short term solution has been conversion to HCFC's
such as R22 (HCFC's have an Ozone Depletion Rate
{ODP} 2-15% of CFC's) but this refrigerant also has a
harmful effect on the environment, although far less
damaging than R12.
HCFC's are also targeted for eventual production phase
out as controlled substances, with usage totally banned
by the EU in new equipment rated at 150kW and over
from the 1st Jan 2000.
In some countries such as Germany and Sweden tighter
164
restrictions are in force.
Alternative refrigerant
The suitable alternative refrigerant for R12 and R502
currently limited to R22,ammonia(R717) and R134a.R22
will continue to be the first choice for all new marine
installations.
Ammonia (R17) is receiving serious consideration as an
alternative refrigerant as it has ODP and GWP of 0.
R134a has been developed as an alternative for R12, it
has an ODP of 0 and GWP of one tenth that of R12. But it
has a drawback in being un suitable for use with mineral
oil, and is expensive.
At present R134a is considered to be an acceptable
refrigerant for small system (below 5hp) operating at high
evaporating temperature and low condensing
temperature.
165
166
167
168
169
170
171
172
System Protection
System Protection
An alternative to this
is to fit solenoid
valves before the
compressor, as in
the diagram above,
which open only
when the fan is
running.
The compressor will
trip on Low suction
pressure.
The purpose of both
these systems is to
prevent liquid
returning to the 176
compressor.
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182
183
184
185
186
187
Fivespacestwoevaporatorsonebrineheaterandoneinjection
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Maintenance
Theimportanceofmaintenance1.topreventlossofrefrigerantcausedbyleakage2.to
keepaircoolersorevaporatorsfreefromfrost3.topreventneitherairormoisture
enteringintothesystem4.TomaintainOillevelinthesystem.
Dailymaintenance:1.Checkthatthecondensingpressureandevaporatingpressureare
correctandthattheoilpressuredropacrossthefilteriswithinthespecifiedvalue.
2.Inspectthecompressorunitforanyabnormalnoiseandvibration.
3.Checkthesuction,dischargeandoiltemperaturewithinlimits,Thehighestoil
temperatureisapproximately60degC.
4.checktheoillevel.
5.checkthetightnessofoilseal.oilleakagescanbetoleratedwhereasgasleakagecan
not.
6.ifanoilseparatorisinstalled,checkthatoilisreturnedtothecrankcaseandthatthe
oilreturnlineiswarmerthanthecrankcase.
PERIODICMAINTENANCE:Periodicmaintenancedependsupontheoperationtime
andisdifferentfordifferenttypesandmakesofcompressors.
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Refrigerant charging
Systemwhichhavebeenopenedtotheatmosphereduring
repairshouldbeflushedthroughtoremovesolidparticlesand
evacuatedtoremovemoistureandnoncondensablegases.
Flushing:fitafinemeshfilterorstockinthestrainerinthe
compressorsuctioninlet
2.Chargethesystemwiththepressuretestmediumandrun
thecompressortocirculatethegasthrothesystem.
Topreventblockagetheexpansionvalveandotherregulating
controlswithsmallorificemustbebypassed.
3.stopthecompressoratintervalsandcleanthefilterrepeating
thisprocedureuntilnoparticlesarefound.
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Refrigerant charging-2
Drying by evacuation: 1.connect a vacuum pump to system using
a short length of large bore pipe and open all valves in the system.
2.evacuate the system to a pressure of 6mm hg.
3.close the line between the system and vacuum pump. ( the
pressure in the system may not rise more than 2mmhg with in 5
mins.A rise in pressure indicates presence of water and/ or
leak.where water is present the system will be colder.than
surrounding.)
4. Check for water and/ or leaks carry out any repair and repeat
evacuation procedure until the pressure rise is less than 2mmHg.
When this is achieved the system is free of moisture and non
condensable gases and ready for refrigerant charging.
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Refrigerant charging-3
1.Connectthecylindertothechargingvalveandpurgethelineofair.
2.Openthechargingandcylindervalvesandrunthecompressor.
3.Allowtheliquidtoflowintothesystem.
Iftheliquidischargedwithoutacompressorrunningthemustbe
slightlywarmerthanthesystem.
Precautions:1.liquidrefrigerantmustneverbechargeddirectlyintothe
compressorsuction.
2.Properlytestedcharginghosesareused,andthatnonreturnvalvesare
fittedwhenchargingintothehighpressuresideofthesystem.
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194
Double seated
service valve
Front seat
Service Port
Protective cap
Stem
195
Defrosting
Provisionandrefrigeratedplantsaretobemaintainedregularlyto
controlthefrostdeposits.
1.Theriseofdeliveryairtemperatureincargochambersundernormal
operatingstatusisthefirstindicationoffrostbuiltuponthecooling
coils.
2.Theheattransfercoefficientbetweenairandtherefrigerantreduces
andthesuctionpressuremaygraduallydecreaseresultinginalossof
refrigerationcapacity.
3.Heavyfrostonthecoilwillreducetheairflowthroughthecooler
(evaporator).
Henceitisimportantthatthedefrostinghastobecarriedoutatthe
correcttimeintervalbythethemethodavailable.
Regardlessofthesystemcoolerfansarenotstartedbeforetheaircooler
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coiltemperatureisreducedbycirculatinglowtemperaturerefrigerant.
Contaminants of refrigerant
MOISTURE:Ifmoisturepresentinthesystemexceedstheamountthat
therefrigerantcanholdinsolutionitwillexistsasfreewater.
Attemperature0degCthefreewaterwillfreezeintoice,restrictingthe
flowinevaporatorsandothercontrols.
Andalsoitformscorrosivecompoundswhichcausethefollowing.
1. Pittingandotherdamagetovalves,seals,bearingjournalsandother
polishedsurfaces.
2. Corrosionandstainingofvalvesetc
3. Prematurefatiguefailureofcompressorvalvespringsandreed
plates.
198
Contaminants of refrigerant
4.Detoriarationofthelubricatingoil,andtheformationofmetallicand
othersludgewhichtendtoclogvalvesandoilpassages.
5.Topreventmoisturerelatedproblems
A.Thesystemshouldbegastightanddriedthoroughlybyevacuating
beforechargingfreongas.
B.Drierunitsshouldbefitted.
C.Thesystemshouldbeinspectedregularlyforleaksandmaintained
gastighttopreventingressofmoistureladenair.
D.Whenaddingoiltothecompressorcleanoilfromanairtight
containershouldbeused.
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Contaminants 2
Oil in the system:1.Thepresenceofoilinthesystemreducestheheat
transfercapacity,theproblembeinggreatestatevaporator,sinceoil
becomesmoreviscousatlowtemperature.
Toprevent,theoperationoftheoilseparatorshouldbecheckedregularly
toensureoilisbeingreturnedtothecompressorlubricatorsystem.
Theamountofoiladdedtothelubricationshouldbecloselymonitored.
Air and non condensable gases:Causeshighcondensingpressure,
excessivedischargetemperature,lossincompressorcapacityand
efficiency,excessivepowerconsumptionandpossibleoverloadingof
drivemotor.
Toprevent,thesystemshouldbeinspectedregularlyandairmi\ustbe
purgedoutandtheleakdetectedandrepaired.
200
Contaminants
Solid particles:Thepresenceofsolidparticlescancauseproblemsby
blockingthecontrolvalves,damagingcompressorbearingsandother
rubbingsurfaces.
Toavoidtheseproblemstakeprecautionswhencarryingoutrepair.
Fitclothfilterinthecompressorsuctionstrainer.
201
204
205
206
Bernoulli Effect
For horizontal fluid flow, an increase in the velocity of
flow will result in a decrease in the static pressure.
207
208
209
210
211
212
213
Air conditioning
Air conditioning is the control of humidity, temperature,
cleanliness and air motion.
Winter conditioning relates to increasing temperature and
humidity whilst
summer conditioning
relates to
decreasing temperature and increasing humidity.
Specific humidity-Is the ratio of the mass of water vapour
to the mass of dry air in a given volume of mixture.
Per cent relative humidity-is the mass of water vapour per
m3 of air compared to the mass of water vapour per m3 of
saturated air at the same temperature.
This also equals the ratio of the partial pressure of actual
air compared to the partial pressure of the air if it was
saturates at the same temperature. i.e. m/mg = p/pg
214
Dew point1
When a mixture of dry air and water vapour has a
saturation temperature corresponding to the
partial pressure of the water vapour it is said to
be saturated. Any further reduction of
temperature (at constant pressure) will result in
some vapour condensing.
This temperature is called the dew point, air at
dew point contains all the moisture it can hold at
that temperature, as the amount of water vapour
varies in air then the partial pressure varies, so
the dew point varies
216
Dew point2
It can be seen that cooling
a superheated vapour at
constant
pressure
will
bring it to the saturated
vapour line, or Dew point.
It can also be seen that
cooling
at
constant
temperature raises the
partial pressure until the
dew point is reached.
217
Dew point3
Psychrometric chart
For R12, formed by reacting methane with flourine and chlorine. This forms a molecule
containing 1 carbon atom, 2 flourine atoms and 2 chlorine atoms
Number of Carbon atoms
minus 1
number of flourine
atoms
0 (1-1)
1 (0+1)
For R22, again formed by reacting methane with flourine and chlorine. This forms a molecule
containing 1 carbon atom, 1 hydrogen atom and 2 chlorine atom
0
220
221
Onespaceandoneevaporator
222
Fivespacesandoneevaporator
223
Fivespacesandtwoevaporator
224
exposed to refrigerant ?
Basic Rules for First Aid
When moving affected persons from low-lying or poorly ventilated
rooms where high gas concentrations are suspected, the rescuer
must be wearing a lifeline and breathing apparatus, and be under
continuous observation from an assistant outside the room.
Inhalation
Move the affected person into fresh air immediately. Keep the
patient still and warm and loosen clothing restricting breathing.
If the patient is unconscious, immediately call a doctor/ambulance
with oxygen equipment.
Administer artificial respiration until a doctor authorizes other
treatment.
Eye Troubles
Force eyelids open and rinse with a sterile isotonic (0.9%) NaCIsolution (salt water)
or pure running water continuously for 30 minutes.
Skin Injuries - Frost Sores
Wash immediately with large quantities of lukewarm water to reheat
the skin. Continue for at least 15 minutes, removing contaminated
clothing carefully while washing
Avoid direct contact with contaminated oil/refrigerant mixtures225
from
226
ENGINE ROOM
VENTILATION
232
233
234
General
Ventilation for the ER is supplied via a ducted air system by three axial
flow fans. Fans 1 &2 are non-reversible and Fan 3 is reversible. 1 & 2 are
eachdriven by a 25kw motor at 1765 rev/min. And each have a capacity of
1000m3.min. at 75mmAg. Fan 3 is driven by 25kw motor at 1765 rev/min
and has a capacity of 1200m3/min at 70mmAg.
Fans 1 &2 are positioned on B Deck and Fan 3 on C Deck.
Air intake is through ventilator grilles, each of which is fitted with a
pneumatically operated fire damper. Each fire damper can be operated by
both remote and local manual control.
Excess air is exhausted from the ER through a grille which is located on
the aft side of the funnel at Compass deck level. A fire damper is lowered
to block the excess air grille in the event of a fire or release of CO2 in the
ER.
A small exhaust fan is provided at the welding booth position in the
workshop and is used to rid the position of smoke and fumes when welding
takes place. The fan has a capacity of 20m3/min. At 10mmAq.
Following a fire or release of CO2 gas, the smoke and/or gas may be
cleared from the engine room by running Fan 3 in the reverse direction.
All fans in the ER are stopped automatically as part of the CO2 release
procedure.
procedure
235
Purifier Room
The Purifier Room in the ER is supplied with air trough the
ducted air system but has a separate exhaust system The
exhaust fan has a capacity of 280m3/min. At 40mmAg. And is
driven by a 4.8kw motor at 1725 rev/min. The fan discharges
to atmosphere via ducting terminates at the funnel.
Emergency Generator Room
Although not a part of the ER, the Emergency Generator
Room, located in the Accommodation on the Upper Deck, is
still a machinery space and is included here.
The room is equipped with a suooly fan which has a capacity of
40m3/min. At 20mmAg. This fan is fitted into the
compartment external bulkhead and is complete with an inlet
weather cover..
The Emergency generator fan is automatically stopped when
the accommodation ventilation is group stopped in the event of
fire.
236
Alarms
Fan 1, abnormal
Fan 2, abnormal,
Fan 3, abnormal,
Purifier room fan abnormal,
ECR No.1 unit cooler abnormal,
ECR No.2 unit cooler abnormal,Workshop unit
cooler abnormal.
237