Plate Heat Exchangers as Refrigeration Condensers

ISHRAE, February 25th Pune, India

Dr. Claes Stenhede

Fouling.
The majority of condensers probably operate with cooling tower water. Treatment of cooling tower water depends on the actual water quality, the air quality, and some-times varies with the season and is normally best done by a specialized company, with experience of the particular conditions at the site.

The only special consideration is that a PHE is sensitive to fibre like particles, such as grass, seaweed, and leaves. Agglomerations of micro organisms, which can be found in cooling tower water, can also cause problems. A good screening with a mesh size about half the channel height is usually sufficient.

3 Do not mistake fouling for corrosion. The figure shows a plate with hard, rust like deposits. It was initially thought that it was corroded, but the plate was made of titanium, which simply does not corrode in the brackish water used. Moreover, corrosion of titanium does not produce insoluble, rust like deposits. A closer investigation showed that the deposits originated from the connecting, steel pipe work.

Non condensable gases.

Sources of non-condensable gases (inerts, air) in a refrigeration system can be: Insufficient removal before start up due to either a faulty vacuum pump or a faulty pressure gauge. A part of the system is shut off from the rest during the initial evacuation of the air. The evaporators operate below ambient pressure, especially in case of multiple and large unit coolers. The frost can easily break a tube in a unit cooler if the defrosting is not properly Decomposition products. This is normally a minor source except in ammoniawater absorption systems. Under certain conditions, ammonia decomposes to hydrogen and nitrogen, especially if nickel is present. This decomposition mixture has a lower density than ammonia, which can affect the vent position.

The effects of non condensable gases.

Both the heat transfer coefficient and the temperature difference are decreased, see the figure. The denomination air is used here, as this is the most common inert gas. When the condensation proceeds: The relative concentration of the vapour decreases and thus the saturation temperature and the temperature difference decrease as well. There will be an increasingly thick layer of air saturated with vapour close to the condensing surface. The vapour has to diffuse through this layer. The result is a decreasing heat transfer coefficient. Some refrigerant remains in the vapour, regardless of the exit temperature. Ex.:1000 kg R22, containing 1 % air, condenses at 45 C. After the condenser (P =
Temperature C

Pure vapour

Vapour with air

Heat load

100

The inert gases affect the temperature difference, the heat transfer coefficient and the condensing efficiency.

0.1 bar), the temperature has decreased to 40 C and 193 kg R22 remains at the exit.

A. Troubleshooting matrix for refrigeration condensers, mainly valid for PHEs.

Causes Observations
1. Too high condenser pressure.6 Yes, if the expansion valve lets air pass or if a finite amount accumulates A. Air B. Condensate blocking of conden-ser surface Yes. See also 6.D. C. Restric-tion in refrigeration line.* Yes * * D. Fouling or blocking of water channels E. Too small con-den-se r.*** <=

<=

2. The pressure continues to increase until the com-pressor HP cut-out. 3. Discharge pressure > condenser pressure. 4. The condensate exit temperature is much colder than the pure vapour saturation temperature. 5. A sight glass at the exit shows both a vapour and a liquid phase.

For small amounts, normally not. For larger amounts yes, but it takes time ( minutes) until enough con--densate (air) has collected. No Yes. <= Yes. See also 6. D.

Yes * *

Yes, but a slow process, (months, years) No <=

Yes, rapid (< minute) <= <=

Yes, if before condenser No

The presence of vapour/ liquid surface at the exit is no sure sign of air, it could simply be that the condenser is well drained and thus there is no large liquid level at the bottom. No, not typical.

No, condensates moves up into the surface but it could also be a small vapour bulk, which cannot escape. <=

Yes * *

No, presumed a well drained condenser

<=

6. An unequal tem-perature distribution along the plate pack. (Possibly more marked on the water side) (Use of a thermal camera) 7. Even temperature along the plate pack (refrigerant side) but a clear difference between top and bottom.

Yes. If abnor-mal P in the port

Yes. If many blocked channels, the water temperature will not increase here.

No

Yes, a fair temperature drop from the top to the bottom

Yes, possibly a marked change where the condensate level is.

**

If a vapour with a large superheat, the top part could be different from the bottom. This is valid for a correct PHE as well. <=

8. The discharge manometer Yes No <= <= needle vibrates, 3.3. Especially useful for halo-carbons * Anywhere between the compressor and the expansion valve. ** A restriction can cause a condensate back-up, which then can have various effects, see column B. *** Either because of incorrect physical properties, design errors, an incorrect duty specification, too high water temperature, etc.

7 B. Troubleshooting matrix for refrigeration condensers, mainly valid for PHEs.

Causes Observations
9. Venting from the top of the condensate exit pipe. 10. Venting into a bucket with water (For ammonia) 11A. There is a temp. diff. on the water exit pipe just after the exit. Between left and right . This indicates a maldistribution over the channel width. 11B. As 11A. Between top and bottom. This indicates a maldistribution along the plate pack. 12. Water pressure drop is too high. 13. Vapour pressure drop is too high. Gas or vapour emerges Bubbles emerges. Yes, especially if low pressure drops on both sides. A. Air B. Condensate blocking of conden-ser surface Liquid emerges, see also 5B. No bubbles, no air No C. Restric-tion in refrigeration line.* <= * * <= <= D. Fouling or blocking of water channels E. Too small con-den-ser .*** <= <= No

Gas/vapour should emerge if well drained. <= Yes, If uneven fouling over the channel width

No, not typical. .

<=

Yes. If abnor-mal P in the port <= Yes

Yes, if water chan-nels close to either frame plate are blocked. See 6D Yes, If several blocked channels. No

No

No Yes, especially if the con-denser is a brazed PHE with a distributor (normally used as an evaporator). Yes No, normally not

<= Yes, but a conden-sate level is the re-sult, not the cause. <= See fig. 7 A -C.

Yes Yes.

14. Water exit temp. too low. Note: Check flow rate. 15. Condensate blocking part of the surface (This can be both a cause and a result) 17. Vapour emerges uncondensed.

<= Yes, together with a faulty EQ line, Fig. 7 A - C. No

<= Blocked channels create an internal EQ line on the vapour side, Fig. 7. Yes, but initially should be OK

<= No

Yes

No

Yes, from start

* ** ***

Anywhere between the compressor and the expansion valve. A restriction can cause a condensate back-up, which then can have various effects, see column B. Either because of incorrect physical properties, design errors, an incorrect duty specification, too high water temperature, etc.

Detection of noncondensables.
See the troubleshooting matrix in slides 6 & 7 and figures in slides 10 and 26 - 28. It can be very difficult to distinguish if it is air or condensate, which is blocking the surface. A thermal camera is a good help but the pictures might be inconclusive. An undampened, i.e. not filled with liquid, pressure gauge, type Bourdon, shows the small, rapid pressure variations, which arise when a vapour containing air is compressed. The needle vibrates, to the point that it can hardly be seen. Compressing a pure vapour is a stable process, thus there are no needle vibrations. It obviously means that the compressor exhibits these pressure variations but piston, screw and scroll compressors do. It is thus a good indicator on the presence of air. Venting can be used see the slides below how to install a vent but it is a negative test: If the venting is done for a long enough time and there is no improvement of the performance, there was obviously no air present. Unfortunately, a lot of refrigerant has then escaped. Ammonia is a special case. Ammonia is extremely soluble in water. If the vent is connected to a hose and the exit from the hose is the dipped into a bucket filled with reasonably cold water only air will emerge at the surface, it bubbles. Pure ammonia whether liquid or vapour dissolves in the water. There are no bubbles, only some noise and movements on the surface. See the case study in slide 26 - 28.

Venting.
Ammonia. Ammonia is easy to vent, see slides 10 and 26 - 28. Vent always into water to avoid the ammonia smell. Halocarbons are expensive and usually forbidden to vent to the air, thus especially recovery units are used. It also a danger if venting into a confined space, where the vapours could collect in a low space and cause suffocation. Hydrocarbons can be vented to the air, but collect in low places where they can ignite or cause suffocation. Carbon dioxide also collects in low places and can cause suffocation. It can be vented to the air but the vent should not be connected to a downstream pipe as highpressure carbon dioxide will solidify when the pressure suddenly decreases below 5.2 bar. This is an especially important consideration for emergency valves.

Venting position.
A.PHE, all types.
For all vapours, vent from:  A bottom port (the one opposite the condensate exit)  A liquid receiver  The pipe work Do not vent from an upper port only.

10

B. S&THE: Venting shall be done at the end of

the heating surface, close to the exit.

a) Top vent (Inerts lighter than the vapour).

 There is usually a vent at the top of the shell. I. All vapours except ammonia & water. II. Ammonia, if hydrogen is present.

b). Bottom vent. (Inerts heavier than vapour)

 A vent close to the condensate exit (but usually none present).  The pipe work.  A liquid receiver I. Water. II. Ammonia, if no hydrogen. The water inlet follows the vent: Top vent => Top Bottom => Bottom

C. Venting of ammonia (PHE or S&THE):

1. Let a hose from the vent discharge below the surface in a bucket with water. 2. Bubbles emerges 3. No bubbles => air => no air.

The basic principle is that the vent should be placed at the end of the condensation, i.e. close to the water inlet or maybe vice versa. In case of a plate heat exchanger that is easy, the vapour inlet is one of the upper port and the water inlet the other side, lower port. The venting shall thus be done from the bottom port. As the condensate leaves a bottom port as well, the venting is thus done from the opposite port or after the condenser. A S&THE is more complicated. Vents are practically always placed on top of the shell. However sometimes the vent should be close to the bottom.

11

Desuperheaters and subcoolers

Pinch point.

Desuperheater section

Condenser section

Desuperheater section

Condenser section

Note that there is pinch point, where the temperature difference approaches zero. The cooling media cannot pass this point and cooling of the water to a high temperature is not possible. Use two separate heat exchangers.

In the desuperheater, tap water is heated to a temperature approaching the inlet temperature, albeit with a lower capacity corresponding to the superheat load. In the condenser, the condensing heat is dumped into a suitable heat sink

Cooling of a superheated vapour.

Condenser and subcooler in the same unit.

1. The liquid level controls both the condensing surface and the subcooling surface but in opposite directions. A simultaneous control of both the capacity and the condensate temperature is not possible as both are dependent on the condensate level. 2. Air cannot escape. If inerts are present there will be a gradual decrease of both the heat transfer coefficient and the temperature difference. 3. A liquid level is not allowed in ammonia or water condensers. The excellent thermal properties of both fluids means rapid temperature changes, which can lead to thermal fatigue. 4. The design is thus somewhat questionable. 5. Better is a separate subcooler, possibly with different cooling fluids.

12

Condenser and subcooler in separate units.

13

1. Separate control of the condenser and subcooler is now possible.

2. Air can now be vented.

3. The subcooler can sometimes be operated with a considerably colder cooling medium than the condenser, e.g. well water especially in case of an air cooled condenser. The colder the condensing temperature is, the better the evaporator capacity and COP will be.

Condensate exit and liquid receivers.

Some considerations.

14

Possible vent positions

Some refrigerant evaporates because of heat influx from the surroundings

The condenser is connected to the liquid receiver via large condensate pipe. This pipe is not filled of condensate. Vapour can flow in counter current to the condensate.

Through liquid receiver.

Condensate exit and liquid receivers.

No equalization line is permitted

Some considerations.

15

Possible vent positions

Some refrigerant evaporates because of heat influx from the surroundings

The condenser is connected to the liquid receiver via large condensate pipe. This pipe is not filled of condensate. Vapour can flow in counter current to the condensate.

Through liquid receiver.

Condensate exit and liquid receivers.

Some considerations.

16

An oil cooler can be attached to a surge liquid receiver. The vapour recondenses via the EQ line Vent not possible

Equalization (EQ) line Vent

Vent

h)

Condensate level

To overcome the pressure drop in the condenser a liquid column is created in the condensate pipe.

Surge liquid receiver.

Condensate exit and liquid receivers.

A through LR (either type) is less sensitive to outside heating than a surge LR.

Some considerations.

17

Equalization (EQ) line Vent

Vent not possible

Vent

The condensate enters in to the bottom of the LR below the refrigerant surface.

Through liquid receiver with equalization line.

18

Condensate blocking of the surface.

A. Contrary what is generally thought, the reason for a condensate back up in the condenser is normally not some obstruction in the condensate line. After all, there is a very large and efficient obstruction in the condensate line the expansion valve , which does not impede a proper flow of the condensate. B. One reason for a condensate back-up is a misplaced equalization line (Slide 22-23) or a too high pressure drop anywhere in the system and not only in the condensate pipe - between the equalization lines connection points and a LR not designed for this, see slides 15 17. C. Another reason is that condensers of different pressure drops are installed in parallel and there is not sufficient height in the adjoining condensate pipes to create the necessary equalizing liquid column, see slide 24 & 25. D. The third reason is a too large refrigerant filling in the system, e.g. either temporary when e.g. condensers are shut down in winter or by incorrect refrigerant charge. We can distinguish three cases:

19

Condensate blocking of the surface.

Too large refrigerant filling: 1. A dry expansion system. The part of the system from the liquid receiver to the compressor has a refrigerant filling, which varies very little. Consequently, this part cannot accommodate an excessive refrigerant filling. This leaves the part from the liquid receiver to the condenser to do this. A condensate blocking of the surface is then a risk. 2. A flooded system with multiple evaporators must have the expansion valve controlled by the liquid level in the LP receiver(s). The liquid filling will be more or less constant from the HP receiver to the compressor and a change of the refrigerant filling have to occur in the condenser-HP receiver part, with a flooded condenser as a possible result. 3. A flooded system with only one evaporator can have the level control in the HP receiver. The filling is now constant in the condenser HP receiver part and possible variations in the liquid filling occur in the LP receiver. There is now no danger of flooding the condenser (i.e. from overfilling of refrigerant) but in extreme cases, the resulting refrigerant overfilling in the LP receiver can cause liquid droplets to leave this and damage the compressor.

Some general considerations.

There can be a temporary condensate flooding of the condenser if the expansion valve is placed far above the condenser. When the valve closes, condensate might flow back to the condenser and flood this. This can happen if the pipe is very wide, i.e. it cannot hold a liquid column or if vaporization starts because the pressure has decreased at the top of the column. This can also lead to a decrease of the capacity of the expansion valve as a vapour enters together with the liquid. In general, avoid placing the valve above the condenser. The system can work perfectly but troubleshooting in case something goes wrong can be close to impossible. If a rooftop placed condenser is used, avoid long condensate lines, even insulated, on the roof, in the sun. During a plant stop, even a short one, vaporization occurs in the lines. When the plant restarts, the resulting vapour plug can easily pass a valve or other restriction. The subsequent liquid plug then accelerates and hits the valve and can easily destroy it. Do not let vapour lines, especially HP vapour, pass through a cold store. This can easily happen if the entire building is a cold store. Refrigerant can condense in the lines and the resulting liquid plug can damage a valve or other equipment.

20

21

Some general considerations.

Install a solenoid valve as close to the expansion valve as possible. If a large distance and especially if a large diameter, the liquid content between the solenoid and the EV is large. A pump-down of the evaporator can then cause freezing of a water-cooled evaporator. Equally important, when the solenoid opens, the entering liquid plug will only meet vapour. The vapour easily passes the expansion valve and the evaporator but the liquid plug does not. Again, possible damage of the expansion valve can happen. Be especially on guard when a saturated vapour is entering a subcooled liquid body. It should not happen in a well-designed system but it can happen, e.g. at a later extension, when the original layout maybe has disappeared. The vapour can then collapse the phenomenon is equal to cavitation and noise as by liquid hammering can occur with a risk of damage to the equipment. All three liquid hammering effects can cause such large noises and vibrations that the pipes can be damaged.

22

Troubleshooting case studies.

Desuperheater Condenser Equalization line

Surge LR

A flooded condenser.

23

Troubleshooting case studies.

Desuperheater Condenser Equalization line connected to just before the condenser

Surge LR

A flooded condenser.

24

Troubleshooting case studies.

S&T condenser

S&T condenser

SWPHE condenser

Low (P

Low (P

High (P

Flooding

A flooded condenser.

25

Troubleshooting case studies.

S&T condenser

S&T condenser

SWPHE condenser

Low (P

Low (P

High (P

h
A flooded condenser.

26

Troubleshooting case studies.

SWPHE condenser for ammonia

21.0 C

21.0 C

Flooded condenser or inerts?

Compressor HP cutout

27

Troubleshooting case studies.

SWPHE condenser for ammonia

21.0 C

21.0 C

Vibrating manometer => Inerts

Compressor HP cutout

28

Troubleshooting case studies.

30 C SWPHE condenser for ammonia

29.0 C

21.0 C

Compressor HP cutout

29

Troubleshooting case studies.

Surge drum

Expansion valve The capacity of the condenser oscillated between 75 % and about 100 % with a period of about 15 min SWPHE condenser

An investigation showed that the vertical feed to the expansion valve was almost 10 metres and a about 100 mm in diameter.

Occasionally flooding of a condenser

Liquid receiver

30

Troubleshooting case studies.

Surge drum

Expansion valve
When the expansion valve closed, the liquid column in the pipe could not be maintained. The liquid then eneterd the LR and the condenser.

SWPHE condenser

Occasionally flooding of a condenser

Liquid receiver

31

Troubleshooting case studies.

Surge drum
The surge drum was lowered. This had the extra benefit that the evporator operated better.

SWPHE condenser

Expansion valve

Occasionally flooding of a condenser

Liquid receiver

32 A water cooled condenser - CDEW 550/T - for R22 did not give the rated capacity. The nominal thermal duty was: CDEW 550/T S, 860 kW R22 70 C -> 45 C, P = 13 kPa Water 39 C <- 32 C, p = 60 kPa, 106 m3/hr The actual capacity was below 400 kW. Moreover, the P between the compressor discharge exit and the liquid receiver after the condenser was more than one bar, unclear where. The condenser should have only 0.13 bar. This corresponds to a decrease of the actual condensing temperature to a little more than 43 C and a corresponding decrease of the MTD, less 2 K. The decreased MTD explains part of the capacity decrease but, by no mean, all.

Performance problem of a CDEW 550/T at a refrigera-tion plant for the Mauritius Freeport Development Co. Ltd.
Claes Stenhede, Alonte, Sept. 21st, 2005

33 A too small heat exchanger. Unlikely, as similar units had performed well. Too high water temperatures, too low water flow rate and/or too low condensing temperature were ruled out as all were found to be in order. Fouling of the water side. This was ruled out as it was a closed circuit. Inerts in the vapour. Preliminary tests were inconclusive. Flooding of the condenser. Flooding turned out to be the most likely cause of the underperformance but the reason for the flooding could not be found.

It was difficult to find the exact reasons for these phenomena.

34

Roof mounted air condensers.

A view of the cold storage.

35

During the cyclone (= Hurricane, typhoon) season there is a danger that the air condensers will be damaged. That would mean a loss refrigerant and maybe a total break down of the system.

A view of the cold storage.

36

The air cooled condensers are thus shut down and an emergency circuit for about half the capacity is activated. This is composed of an evaporative cooler integrated into the wall and placed inside the building. The water cools a S&T condenser also placed inside the building.
Air exit S&T condenser Air inlet Evaporative cooler

A view of the cold storage.

The main air cooled condensers

37

Closed Open Controlled MP receiver To/From storage LP receiver To/From freezer

During the normal operation, the air cooled condensers operates at the full capacity, about 1760 kW.

Outline of the refrigerant circuit.

38

Closed Open Controlled MP receiver To/From storage LP receiver To/From freezer

During the cyclone season the air cooled condenser is shut off from the system. The valves to the emergency circuit open and connect the S & T condenser to the system. The S&T condenser takes over for the emergency operation with about half the capacity. Only one compressor works.

Outline of the refrigerant circuit.

39

Problem: The condenser is flooded or full of inerts.

That flooding was the basic problem and not inerts became clear when liquid refrigerant left the vent during a venting. The flooding could be caused by the much larger liquid volume in the air condensers entering the HP LR & the S&T condenser during the switch-over to the emergency circuit when a cyclone approaches. As the HP receiver is drained into the very much larger MP and LP receivers by the level controlled HP expansion valve, this was probably not the problem. It was possible to drain the condenser completely and almost regain the nominal capacity by a forced opening the HP valve.
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To MP receiver From MP

The essential parts of the condenser circuit.

40

Problem: The condenser is flooded or full of inerts.

A very high pressure drop was measured between the discharge exit and the HP receiver. To MP receiver From MP The conclusion was that the condensate exit was too small and this caused the high pressure drop and condensate backup in the condenser.

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40

The essential parts of the condenser circuit.

41

1st solution:
To MP receiver From MP A new condenser with double condensate exits was installed. No result, the condenser was still flooded.

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Double exit condenser.

42

2nd solution:
To MP receiver From MP The old condenser was fitted with two, double as large exits. No result, the condenser was still flooded.

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Double exit condenser.

43

Under condition that:

The equalization line is closed. The condensate remains subcooled in the LR, i.e. no evaporation from the liquid surface. The expansion valves keeps the liquid level constant. The condenser will then drain and there will be a smooth condensate flow from the condenser to out of the LR, despite a high P somewhere in the flow path.

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43

A closer inspection of the system.

44

Height of liquid column

An inspection at the site showed:

The oil coolers of both the HP and LP compressors were cooled by refrigerant from the HP receiver in a thermosiphon loop. The vapour then produced in the HP receiver is supposed to leave by the equalization line back to the condenser for recondensing. The pressure at the condenser inlet is higher than in the LR due to the high P. To overcome the pressure difference, a liquid column has to build up in the condensate line. Liquid then floods the condenser.
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A closer inspection of the system. :

M3 M2 V1

45

M4

M1

The measurements showed: M2 M3 = 1.0 bar M3 M4 = 0.1 bar M4 M1 0 bar To check the inlet P, the valve V1 interior was removed and the tests repeated: M2 M3 = 0.7 bar (without V1) Over V1 = 0.3 bar (Calculated) The result showed that the inlet had a very much larger pressure drop than foreseen and this caused the flooding.

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Determination of the site of the high pressure drop.

46
The nominal 50 mm inlet was somewhat too small for the required 860 kW The internal diameter was further reduced to about 43 mm by the threads used at the pressure tests The resulting velocity was more than 50 m/s, far too high for a high density vapour

This high velocity vapour hit an impingement plate and forced to deflect 90 . The result was the very high inlet pressure drop.

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Reasons for the high inlet pressure drop.

47

By increasing the level difference between the condenser and the LR, the effect of the high P the flooding - is removed.

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Suggested solution I.

48

By connecting the equalization line to the service connection, the effect of the high P the flooding - is removed.

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Suggested solution II.

49

The old and the new condensers are mounted in parallel. The equalization line is connected to the service connections.

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Suggested solution III.

50
The equalization line is be connected to the service connection on the S&T condensers.

Either one of the old condensers or a completely new one are fitted with an at least double as large inlet.

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Suggested solution IV.