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refrigeration equipment:
High Pressure control implementation
August 2011 / White paper
by Christophe Borlein
AFF and lIIF-IIR member
Foreword
High Pressure control implementation is fairly easy. However
refrigerating systems are not always adapted to this regulation and
require in depth checks and sometimes modifications.
Knowing the effect of High Pressure control on the efficiency of
the installation allows to increase energy saving. Being aware of
appearance of a problem allows to take preventive actions rather
than stopping the High Pressure control, which is the case on many
installations.
II
p = aV
Danfoss data
In other words, if the pressure is reduced by 50 %,
the flow accross the valve downd by 30 %. There
should thus be a refrigerating power loss.
Figure 1 : TE Thermostatic Valve
R-22 fluid, evaporating at -12 C (2,3 bar)
condensing at 40 C (14,3 bar) down to 20 C (8,1
bar) will have a volume reduction approximately
equal to 30 % (negletcting the density variation)
1- Thermostatic Element
2- Input cartridge
3- Valve body
4-Overheating adjustment rod
5- Pressure balance
High Pressure
15
030
1.6
5
1.7
s=
0.020
1.8
0.0
s=
30
1.8
20
15
0
1.9
10
0.050
1.9
0.060
.030
2.0
v= 0
40
v= 0.0
2.0
60
180
s=
80
x = 0.10
s = 1.00
0.20
218
0.30
1.20
0.40
256
0.50
1.40
294
0.60
0.70
0.80
1.60
332
Enthalpy [kJ/kg]
2.1
-20
v= 0.0
v= 0.10
0.90
370
s=
-20
0.10
-10
v= 0.0
3.00
2.00
0.070
0.080
0.090
s=
s=
v= 0
-10
0.040
s=
10
.0
v= 0
5.00
0.030
0
.008
v= 0
0
1
.0
v= 0
s=
20
140
40
.020
4.00
0.015
50
060
7.00
6.00
s=
60
030
0.0
40
0
0
.
=0
v
v=
1.7
0
70
50
0.0
v=
30
Pressure [Bar]
10.00
9.00
8.00
70
020
v=
40
20.00
0.0080
0.0090
0.010
80
60
30.00
0.0060
0.0070
160
s=
40.00
0.005
0.00
1.60
90
40
0.0
s=
00
02
0.0
0.
90
50.00
80
60.00
-20
408
20
40
60
80
100
446
484
120
0.15
High Pressure
The R-404A, evaporating at -12 C (3,1 bar)
condensing at 40 C (17,2 bar) down to
20 C (9,9 bar) with a reduction of volume
approximately equal to 31 % (identical to R-22)
(see refrigerating cycles figure 3). The enthalpy
is 112 kJ/kg @ 40 C and 143 kJ/hg @ 20 C.
Power loss is of 9%. This variation is acceptable
and does not prevent the installation to operate
correctly.
20
00
0.
30.00
03
0.0
50
20.00
50
0.0060
0.0070
120
0.0080
0.0090
0.010
0.00
1.60
60
40
0.00
s=
40.00
0.015
40
s=
0
1.8
0.040
s=
8.00
0.030
s=
1.7
5
1.6
10
100
1.7
20
10.00
9.00
0.020
s=
7.00
0.050
1.8
6.00
0.060
s=
5.00
-10
0.070
Pressure [Bar]
30
1.9
4.00
0.080
0.090
s=
1.9
0.10
s=
3.00
-20
x = 0.10
2.00
180
-30
0.20
s = 1.00
0.30
216
0.40
1.20
0.50
252
0.60
0.70
1.40
288
0.80
0.90
1.60
324
Enthalpy [kJ/kg]
-20
360
20
40
396
60
80
0.15
432
High pressure
This is illustrated by the selection tables of the pilot-control valves manufacturers (Danfoss):
R22
Nb of outlets
2
10
12
16
14
TX 2/TEX 2-0.3
TX 2/TEX 2-0.7
TX 2/TEX 2-1.0
TX 2/TEX 2-1.5
TX 2/TEX 2-2.3
TX 2/TEX 2-3.0
TX 2/TEX 2-4.5
TEX 5-3
TEX 5-4.5
TEX 5-7.5
TEX 5-12
0X
0
1
2
3
4
5
6
1
2
3
4
0.37
0.79
1.6
2.2
3.9
5.8
7.4
9.1
11.1
15.4
22.7
32.3
0.47
0.96
2
2.9
5.1
7.6
9.6
11.8
14.3
19.7
28.7
41.1
0.53
1.1
2.3
3.3
5.9
8.7
11
13.5
16.3
22.4
32.7
46.8
0.57
1.2
2.5
3.6
6.4
9.5
16 18 %
12
14.7
17.7
24.3
35.6
51
0.6
1.2
2.6
3.8
6.8
10.1
12.8
15.6
18.8
25.7
37.8
54.1
Nb of outlets
2
TS2/TES 2-0.11
TS2/TES 2-0.21
TS2/TES 2-0.45
TS2/TES 2-0.6
TS2/TES 2-1.2
TS2/TES 2-1.7
TS2/TES 2-12.2
TS2/TES 2-2.5
TES 5-3.7
TES 5-5.0
TES 5-7.2
TES 5-10.3
0X
0
1
2
3
4
5
6
1
2
3
4
0.33
0.66
1.2
1.7
3
4.4
5.6
6.9
10.1
13.9
20.4
29.1
0.38
0.73
1.4
1.9
3.4
5
6.4
7.8
11.3
15.6
23
32.9
0.39
0.4
0.76
0.78
1.4
1.5
2
2
3.6
3.7
5.4
5.5
6.8 5 9 % 7
8.3
8.5
12
12.4
16.6
17
24.5
25.1
35
36
0.63
1.3
2.7
4
7.1
10.5
13.3
16.2
19.5
26.7
39.4
56.3
0.64
1.3
2.8
4.1
7.3
10.8
13.6
16.6
19.9
27.3
40.4
57.7
0.64
1.3
2.8
4.1
7.3
10.8
13.8
16.8
20.1
27.6
40.9
58.4
R404A/R 507
12
0.4
0.78
1.5
2
3.7
5.5
7
8.5
12.4
17
25.2
36.2
14
0.4
0.78
1.5
2.1
3.7
5.5
7
8.5
12.3
16.9
25.2
36.1
16
0.4
0.78
1.5
2.1
3.7
5.5
6.9
8.5
12.2
16.8
25.2
36.1
Conclusion
A refrigerating equipment using R-404A and
correctly sized regular pilot-control valve can
move to High Pressure control with no change.
Flash gaz
cooling;
condensation;
oil cooling;
cylinder heads cooling.
System instability
For various reasons the system can become
unstable in LP or HP.
Regarding HP side, instability leads to frequent
startings of fans, which can reduce motors life
time.
This dysfunction may have 2 origins:
An incorrect adjustment of the PID loops (or
another kind of regulation). In this case, it is just
necessary to make a correct adjustment,
Not enough regulation stages of the fans. Work
on the PID can reduce the problem. It might be
necessary to use more ventilation stages or a
variable speed drive.
Regarding LP side, frequent starting cycles of
the compressors strongly increase the risks
of breakage. The regulation cannot really be
blamed since normally it was not changed. When
the HP is reduced, the compressors provide
much more refrigerating power. Operating time
between 2 thresholds is thus reduced. When the
number of compressors is small, this problem is
frequent. Use of a variable speed drive is thus a
perfect solution.
Schneider Electric SA