TEXT & REFERENCE TECHNICAL DEVELOPMENT PROGRAM ¢ DESIGN CONSIDERATIONS ¢ LAYOUT PRACTICES ¢ SIZING PROCEDURESREFRIGERANT PLPING SYSTEMS TABLE OF CONTENTS Page Introduction 1 Design Considerations . feeennee eee essure Drap 2 O11 Return i Compressor Protection 4 Layout & Sizing Procedures fee A Suction Line Design... . a7 Oi} Return = Minimum Load. . feed Double Suction Riser . 21 Double Suction Riser Pressure Drop. . . . 16 Liquid Line Design . . 18 Pressure Drop - Accessories . 20 Liquid Subcool ing eee 21 | Hot Gas Discharge Line Design... 2... ee. 23 Oi] Entrainment - Kot Ges Risers... 2 2. 2d Compressor Protection... 2... 2... 25 | Summary. ee . . 26 AppendixREFRIGERANT PIPING SYSTEMS w FOR PACKAGED EQUIPMENT SPLIT SYSTEMS INTRODUCTION Refrigerant suction and liquid lines are an essential part of split systems These Tines connect the air handler and condensing unit together and permit. them to operate as a system, Evaporator eee ge CONDENSER. ¢ ne aR Flow FLOW = LINE LIQUID LINE. AIR HANDLER CONDENSING UNIT 7 Figure 1 The emphasis in this session will be placed on the layout and sizing of the "suction" and "liquid" Lines shown on Figure 1. The suction line carries cool, low pressure vapor from the evaporator to the Compressor inlet or suction connection, The liquid line carries relatively hot, high pressure liquid from the condenser outlet to the metering device on the evaporator cail. DESIGN CONSIDERATIONS Refrigerant piping lines require the same general design considerations as any Tiquid transport system. However, there are additional factors that have a Significant effect on refrigerant line design. These are: PRESSURE DROP OIL RETURN COMPRESSOR PROTECTIONEe Pressure Drop The flow of refrigerant vapor in the suction line should be accomplished at minimum pressure drop to avoid penalizing compressor capacity and power input to the compressor. Table 1, shows the effect of suction line pressure drop on compressor capacity and kW input per ton of capacity TABLE 1 SUCTION LINE PRESSURE DROP = Compressor saturated Suction Line Temp. Drop Capacity | kW/Ton | Pressure Drop| meen Z| (psi) _| 100.0 No Loss, ootiee 102 8 4 o2nceees leet: Based on R-22 & 42 F Saturated Evaporator Temperature, 95F Air Entering Cond With R-22 refrigerant, a 2F drop in saturation temperature in the suction Tine is equivalent to about 3 pound drop in pressure and a 4F drop is equivalent to about 6 pound drop in pressure At air conditioning levels, with R-22, it can be assumed that a 1.5 1b drop in pressure occurs with each 1 degree drop in saturated suction pressure. Since system designers think and work in terms of saturated suction and condensing temperatures, it is easier and more consistent to express friction loss in refrigerant lines in terms of equivalent saturated temperature rather than saturated pressure differences It is also apparent from Table 1, that each degree decrease in saturated suction temperature reduces system capacity by about 2% and increases kW per ton by about 1* It is standard practice to size the suction line for a pressure drop not exceed- ing 2F in saturated suction temperature. This results in a good balance between size and cost of the suction line and penalty on compressor capacity and kW input-3- The pressure drop in liquid lines is not as critical as with suction lines. Normal practice is to limit pressure in the liquid line itself to a 2 degree change in saturation temperature. Additional pressure drop occurs from acces~ sories such a5 strainers, dryers, and service valves. Excessive pressure drop in liquid lines can result in the generation of “flash gas", which can cause faulty operation of the metering device at the evaporator. If a vertical liquid riser over 10-15 feel is required, liquid subcaoling is highly desirable to prevent generation of flash gas. This will be illustrated later Oi} Return A second design consideration is the réturn af lubricating oil to the compressor crankcase. Reciprocating compressors are force-feed lubricated with an oil pump in the same manner as an automotive engine. It is natural for a small amount of oi! to work past the piston rings. This oil is entrained in the refrigerant vapor dis~ charged from the compressor and circulates through the system. The amount of oi1 leaving the compressor during normal operation is increased since halogen type refrigerants like R-12, 8-22, and R-502 are misable with lubricating oil, This means that the refrigerant and ail are compatible and will mix in any proportion like alcohol and water. To complicate matters, lubricating oi) has a low vapor pressure, which attracts refrigerant whose vapor pressure is very high Oi] is capable of absorbing large quantities of refrigerant. The oil on cylin- der walls, pistons and valve assemblies is absorbed by refrigerant vapor and accelerates the rate at which oil leaves the compressor and circulates through- out the systems This oi must be returned to the compressor crankcase, at the same rate it leaves, to insure proper and continuous compressor lubrication. The designer must make certain that suction line velocities are sufficient to entrain oil in the suction line and carry it along to the compressor at all loading conditions. This will be discussed later in connection with the sizing and layout of suction linesSts Compressor Protection The layout of the refrigerant lines and the cycle controls should protect the compressor during bath operation and shutdown. The quantity of refrigerant required in a single piece packaged unit is small because of the short refrigerant lines within the unit cabinet. The ratio of refrigerant to oil is low enough that refrigerant absorption in the compressor crankcase is limited and does not cause a problem on start-up. In a split system the refrigerant charge ‘increases by the amount necessary to fill the liquid line This increase is proportional to the size and length of the liquid line. For example, it would take about 6 pounds of R-22 to fill a 5/8" OD liquid line 50 feet long. It would take 12 pounds of R-22 to fill a 7/8"0D liquid line 50 feet long In a split system the ratio of refrigerant to oil in the system is often such that too much refrigerant can be absorbed in the compressor crankcase during shutdown and this cam cause slugging and potential damage to, the compressor on ee ee the crankcase and be absorbed by the oi1. This refrigerant rich oi1 comes into equilibrium with the ambient temperature On startup the pressure in the crankcase is reduced, approaching the suction level. This rapid reduction in pressure causes an almost explosive foaming of the oil-refrigerant mixture, In the case of hermetic compressors, with gas cooled motors, the foam vents back through the motor compartment and out into the suction line. The oil is picked up by the suction gas and is carried out into the system with the compressor discharge gas In split systems the compressor(s) should be equipped with a crankcase heater which is energized when the compressor is: shutdown. The purpose of the heater is to maintain the temperature of the oil in the crankcase at a higher tempera- ture than the temperature in the evaporator. This prevents or minimizes re- frigerant migration in the compressor. Refrigerant is always attracted to the lowest temperature area in the system. LAYOUT & SIZING PROCEDURES There are a few general design principles that should be kept in mind during the layout stage of a refrigerant piping system.or All refrigerant lines should be run in as simple and direct manner as possible. Unnecessary complications add to the cost, increase operating losses, and increase the possibility of leaks. Vad Y i EER THEM SIMPLE esta Level Figure 2 Horizontal lines should be installed level and hangers should be provided Frequently enough to prevent obvious saqs and pockets A real effort should be made to avoid traps as illustrated in Figure 3. Poor layout or complicated layout of lines can result in traps or pockets in which oi] can collect, particularly at partial compressor capacity. Under full load conditions the oi! may return as a stug and cause compressor damage. ne Figure 3 Allowance should be made for expansion and vibration absorption Copper tubing expands at a rate of approximately 0.6" per 100 feet for each 50 degrees in- crease in temperature. Compressors are frequently mounted on springs or rubber for sound and vibration isolation and move an appreciable amount when started and stapped. Under these circumstances, Flexibility in the form of offsets or loops should be provided to absorb this movement and avoid line breakage Figure 4aoe The refrigerant piping should conform to all codes, laws, and regulations applying at the installation site Copper tubing and solder type wrought fittings are used for the vast majority of refrigeration piping systems, although steel pipe with welded fittings are used for large lines and certain industrial applications Copper tubing is available in a number af sizes and three standard weights. The weights are designated as kK, L, &@ Mand each has a different wall thickness for agiven tube size, A typical example is shown in Table 2 Table 2 OUTSIDE WALL INS TOE WEIGHT oury DIAMETER THICKNESS DIAMETER LN x (400 psi) * HEAVY 0.995 T (250 psi) * MEDIUM 1.025 iy - - — (250 psi) # LIGHT 1.055 * WORKING PRESSURE Refrigerant tubing size is specified by outside diameter (00). The variable wall thickness results in a small variation of the actual inside diameter for a given size tube Type L, with a working pressure of 250 psi, is the weight most commonly used for refrigeration lines. Type M also has a working pressure of 250 psi, but is is not reconmended for refrigeration lines for it is too easily deformed on the job site and it requires additional: support to prevent sagging. Most Type M tubing is used in the manufacture of heating and cooling coils. Type Ky with a working pressure of 400 psi, may be required for compressor discharge lines when using R-22 at high condensing temperatures. For example, at 125 F condensing temperature, the gage pressure with R-22 is 277.92 psi. This exceeds the working pressure of Type L tubing, indicating the need for Type k. Data on the physical properties of copper tubing is available in the Appendix. Tubing for refrigeration service should be free of dirt and scale and should be capped with plastic seals to prevent contamination before use. Bright annealed copper tubing that has been deoxidized is best for refrigeration serviceepe SUCTION LINE DESIGN The suction line has been selected first for layout and sizing. It is perhaps the most critical line in regard to the three major design objectives started earlier, These are 1. Pressure drop at full load must be kept within reasonable limits. Oil return must be maintained at minimum load conditions The design should minimize, (1) the possibility of liquid refrigerant draining or migrating to the compressor during shutdown, and (2) minimize the possibility of oi! or refrigerant returning to the compressor in slugs during operation Let's first explore sizing procedures to assure a reasonable pressure drop at design load. Figure 5, shows the chart used for sizing suction lines SUCTION LINES—COPPER TUBING For Pressure Drop Corresponding to 2F 500 “0 3 EQUIVALENT LENGTH(ET) $38 8 3 8 TONS. OF REFRIGERATION AD FSF H/I05 F Sct wins sans FNS FSC Figure 5-8- This chart is for refrigerant-22. It is based on 40F saturated suction tempera- ture and 105F saturated discharge temperature. Correction factors are used to adjust for other operating levels The chart is set up in terms of tons of refrigeration on the horizontal scale versus equivalent length of the suction Vine for a pressure loss corresponding to a 2F change in saturation suction temperature The solid Vines running upward and tipped to the left represent capacities of various coemercial sizes of Type L copper tubing when no subcooling is provided. The dashed lines should be used when 15F liquid subcooling is pravided by the condenser. If in doubt about available subcooling, use the solid lines. Suction Line Sizing - Illustrative Example Use of the chart is best illustrated Convensina up with an example. Figure 6 shows a simplified layout of a suction line with vertical risers and horizontal lines. This arrangement provides the flexibility needed to absorb expansion “ and contraction of the line. g i The design load is 18.5 tons, with 40F % saturated suction and 120F saturated - G4 sce condensing temperatures. The condenser provides 15F subcooling. Line.loss is not to exceed 2F The following procedure is recommended for sizing refrigeration lines 1. Find the length of straight tubing, in feet. Referring to Figure 6, this iss (1+ 2+3+6+ 14+ 6) = 32 Feet. - Figure 6-9- 2. Add 50° fitting allowance to obtain a trial equivalent length, 3. If a pressure drop other than the sizing chart basis (2F) is desired, multiply the total equivalent length by the correction factor under NOTE 1, Figure 7, for the desired pressure drop In this case we wish to design her than 40 F saturated suction, 108 Fcendenting, muiply the lod in tons by the fotos below and cond wi the product in seading the that (5 Suton, MG” Hat Gov! no] 3 | ve | wep aay wel aera oe Boo] Tae] are T Ie Soe] tar] 078) Loe | ae) tea] oar, or oe) 2.90] a0] 028 3] oa] aes] ose Na) oo] roa] a7 we |= |= | 300] o9o| 244 no] 200 [oar] 145{ ana] tar) ova] 13] 075 Nore frien Br ro | ss | ao | as | ao | ao | se | 40 Figure 7 4. Correct for suction and condensing temperatures. Figure 7, shows tonnage multiplier for 40F saturated suction and 120F saturated condensing is 1.08 Adjusted tons for entering the suction sizing chart are 1,08 x 18.5 tons = 19.98 = 20.0 tons say. 5. Now enter the sizing chart at 20 tons adjusted load and a trial equivalent length of 48 feet to determine a line size that will permit us to determine size of the fitting required A 1-5/8" 0D tube will handle 20 tons, with 15F subcooling, at 80 feet equivalent length and a pressure drop equivalent to 2F. So 1-5/8" tubing and elbows are tentatively selected 6. The equivalent length of the elbows in the suction line may be determined from Figure 8. Data in this table may be used for screwed, welded, & flanged, or solder type fittings. Wrought copper elbows have a long radius and correspond to a 90 long radius elbow.- 10 - FITTING LOSSES IN EQUIVALENT FEET OF PIPE Screwed, Welded, Flanged, Flared, and Brored Connections wommar | oo. "Sonn we ej Wl : dak 5 7 7 4 1 oe hv 33 ” | | ry * x o 8 a Figure 8 Figure 8, is based on the nominal size of pipe or tubing. The nominal size of copper tubing is 1/8" less than its 0D size, so the nominal diameter of 1-5/8" 0D tubing is 1-1/2". Each 1-1/2" elbow in the suction line has a friction loss equivalent to 2.6 feet of straight copper tubing. The actual total equivalent length of the suction line, including elbows is: Straight tubing = 32.0 Feet 6 ells at 2.6° 15.6 Feet 47.6 = 48.0 Feet say Actual Equiv. Len. Since a 1-5/8" 0D line will handle the adjusted 20 ton load up to 80 feet, the 1/58" 0D line is Ok The actual pressure drop may be determined from a simple ratio: Actual Equivalent Length, Ft. x 2F Towable Length for 2F brop, Ft. = (48 x 2)/80 = 1.2F Actual Pressure Drop| - abe Oi) Return - Minimum Load At this point we have sized a suction line which will handle the design load at a pressure drop corresponding to 1.2F. Since vertical risers are involved consideration should now be given to oil return at minimum load Figure 9, shows the values of Minimum Tonnage for Oi] Return Entrainment Up Suction risers, for R-22. MINIMUM TONNAGE FOR OIL ENTRAINMENT UP SUCTION RISERS 1 Lie ae ee oe 140 | 35 e7_}as fies | wnt ° aa [ 9 [39 30 “Tea 143 [ ane Oe CEC 1a 189 | a6 wo fo ae ae a tarp 720 [a2 Pipe 00 ~at*« “lx —mtm mlm) lol on) “Minimum tonnage voles ove boxed on the ration emperotrns (SST with 15 Fof wperheat and 90 F avid Temperotre, For 12,822 an 300 reduce or neeoye Hable values 1% for 10 F lows or mare speshect or R502 reduce o iereote table vues 2% for 10 F les or mare wpeshect, For ligld temperotves oes thon 90, mls the toble woes ‘by he corresponding fstos Fed Inthe Flowing table guid Tenperetree F ae ee ee persone ia [a0 Pe Pier [100 [ee fan] 98 20 Ugud femperatre equals cording fanperotvra minus whcoalng Figure 9 To illustrate use of this data, let us assume that the compressors used in our example are capable of unloading to 20% of the 18.5 ton design load. Minimum capacity then equals 18.5 tons x 20% = 3,7 tons. It is also assumed the suction temperature still equals 40F at minimum load. The following procedure is recommended 1, Inspection in Figure 9, shows that the minimum capacity of a 1-5/8" 0D line at 40F for of} return is 4.1 tons. This is higher than our minimum load of 3.7 tons, so oi] will not be returned at those times the load is less than 4.1 tons. A means must be found to prevent this from occurring and insur- ing 017 return at 3.7 tons load.-12- 2. In such circumstances, the designer should first try reducing the suction viser by one size. Data in Figure 9, shows that a 1-3/8" OD line at 40F suction will return oil at a minimum load of 2.7 tons, which is below our requirement of 3.7 tons To find out if this approach is feasible, the pressure drop using 1-3/8" OD risers should be calculated to determine if a reasonable pressure drop will occur at a design load of 20 adjusted tons First we must find the equivalent length of the two suction risers shown on Figure 6. Each riser has two 1-3/8" 00 elbows. Riser equivalent length is Straight Tubing = (3 + 14) = 17 Feet 4, 1-3/8" 0D el] at 2.3 Feet = _9.2 Feet Total Equivalent Length 26.2 Feet Referring to the Suction Sizing Chart, Figure 5, we find that a 1-3/8" 00 suction Tine, with I5F subcooling, is good for 35 feet equivalent for a 2F drop The actual pressure drop in the riser at design load is (26.2 Ft. x 2F)/35 Ft. LSE The remaining portion of the Tine will stil1 be run with 1-5/8" 0D tubing as determined earlier. These portions of the suction line have an equivalent length of Straight Tubing = (1+ 24646) = 15 Feet 2, 1-5/8" 0D ells at 2.6 = 8.2 Feet Total Equivalent Length = 20.2 Feet It will be recalled that a 1-5/8" 0D line will carry 20 adjusted tons up to 80 Feet for a 2F line loss. The actual loss in the 1-5/8" 0D line is (20.2 Ft. x 2F)/80 Ft, = O.SIF The total line drop fram evaporator to compressor is 15 + 0,51 2.01F = 2F-2B- This is just equal to the specified line loss of 2F maximum. By reducing the vertical risers in Figure 6 from 1-5/8" to 1-3/8" the suction line was kept simple and easy to install and at the same time assured that oi? would be returned to the compressor at minimum load. Double Suction Riser When suction lines are short and direct with suction temperatures between 35 to 45F, the designer will frequently find that a double suction riser is not required, Since a reduced size riser will meet the situation, as just demon- strated, However, there are circumstances that may indicate the use of a double suction riser to insure oi] return at minimum load and prevent excessive pressure drop in the riser at design load As the length of the suction line increases, a larger diameter line is required for a given load to keep pressure drop reasonable at design load. If a single suction riser is sized for oi] return at minimum load, its area may be so small compared to full load requirements that excessive pressure drop will result. A double suction riser can be designed to overcome this problem when it occurs. Another situation which may require a double suction riser occurs when units have multiple compressors which can unload to a minimum capacity of 20% or less of design capacity. A double suction riser is usually required under this circumstance Figure 10, illustrates two methods of constructing a double suction riser. wo Figure 10- 14 - Referring to Figure 10, the minimum load riser "A" is sized so that it returns oi} at the minimum possible load The other riser "B" is usually larger than riser "A" and is sized so that, with parallel flow through both risers, the pressure drop at full load is reasonable A trap is introduced between the two risers as shown, As the Toad decreases and the gas velocity is insufficient to return oi! up both risers, the trap gradual - ly fills with oi} until riser "B" is sealed off. When this occurs, the suction gas travels up only riser "A", at a sufficient velocity to move oi] up the riser to the horizontal suction line and return it to the compressor The Fittings making up the trap should be close coupled so that a mininum amount Gohl ies) Ce a ed he preferred method, for this reason It may be noted that riser "BY taps into the horizontal main through an inverted trap and enters the horizontal Tine at the top. This loop prevents of! drainage into the riser when it is inoperative during part load operation. Double Suction Riser To illustrate the sizing procedure for a double suction riser, Tet us assume that all the conditions are the same as in the previous example, except the distance between the evaporator and compressor is increased, resulting in a vertical suction riser 28 feet long. Now the suction line layout is as shown on Figure 11, using a double suction riser. To refresh our memories, the design load is 18.5 tons. The minimum load is 20% of This or 3.7 tons. The operating levels are 40F saturated suction and 120F sat~ Eremoearen ® urated condensing temperature. The correction factor for 40SST & 120SCT is ze 1.08. Adjusted design load is 18.5 x 1.08 = 20 tons. Refrigerant is R-22. Figure 11 FOF EERE¢ Here is the suggested sizing procedure 1. Determine the feet of straight tubing from the evaporator to the compressor via riser "B" Straight tubing = 1+ 1+84 29424146 = 48 Feet Add 50° fitting allowance = 24 Feet Trial Equivalent Length 72 Feet Determine size of suction line required, from Figure 5, Page 7. A 1-5/8" OD line is good up to 80 feet with a 20 ton load, 2F drop and 15F subcool ing. "for oil return at minimum load, A 1-3/8" OD line will Determine riser return oi] at a minimum load of 2.70 tons at 40 SST which is less than our minimum load of 3,7 tons. 4, Determine size of supplement riser "B", such that the cross-sectional areas of riser "A" plus riser "B" equals or exceeds the area of the 1-5/8" OD line. The areas of various tube sizes are shown at the top of Figure 9 Area of 1-5/8" 0D = 1,78 Sq. In Area of 1-3/8" 0D = 1.25 Sq. In Difference = 0.53 Sq. In. A 1-1/8" OD line has an area of 0.825 Sq. In If riser "B", as just determined, is smaller than riser "A" then they should be reversed so that "A" is the smaller line. Now, riser "A" at 1-1/8" is capable of returning of1 at a minimum load of 1.6 tons, and makes oil return very positive. We have now sized the complete suction line, Referring to Figure 10, riser "A" from the (1) to tee (5) is 1-1/8" 0D. Riser "BY from tee a to tee (5) is -3/8" 0D and the horizontal lines from the evaporator to tee (1)and from tee (5) to the compressor at (7) are 1 - 5/8". Double Suction Riser Pressure Orop Now we should determine if the pressure drop from the evaporator to the compres- sor is reasonable at full loadeiGe The first step 1s to determine the equivalent length of both riser "A" and riser "8" from tee 1 to tee 5 - iser "AY 7 Riser "BY (1-3/8" 00) Side Inlet Tee ae ecro) Side Inlet Tee = 78 Straight Tubing = 28.0 180° Return Bend = 9.6 en cel Straight Tubing = 29.0 Straight Flow Tee = 17 2 Ells at 2.3 = 46 Total = BBB Ly Branch Tee Be = id) Total oe Now we need to determine the ratio of La/ty = 53.2/38.8 = 1.37 Use of this value will be shown shortly We also need to determine the ratio of the inside diameter of the 1-1/8" 00 & 1-3/8" OD Lines (See Appendix Page 1) Dys (1-1/8) = Type L = 1,025 In Dad ee eampen ea 1,256 In and the ratio Dy/O, * 1.025/1.256 = 0.810 Xq = FRACTION OF TONNAGE IN RISER 8-We Figure 12, may now be used to determine the fraction of design tons in riser pe Enter the horizontal scale with a value of Dy/y = 0.81, and project vertical- Ty to intersect the curved lines Lp/L, between lines having values of 1.0 and 2.0, Now estimate the value of tp/L, = 1.37 on the 0.81 Dq/Dp line. Projecting to the left read a value of ty = 0.60. Tons in riser "6" (1-3/8" 00) = 20 x 0.60 = 12 Tons Tons in riser "A" (1-1/8" OD) = 20 - 12 = 8 Tons to Tee must be the same regardless of the The pressure drop from Tee! path, In other words, at full load, the pressure drop in riser "A" or riser "B" must be the same To prove the point we will determine the pressure drop in both lines. From Figure 5, Page 7 The 1-3/8" OD Tine (Riser "8") will carry a load of 12 tons up to 93 Feet for a 2F drop, with 15F subcool ing. Pressure loss in Riser “B" = (53.2 Ft x 2F)/93 = 1.14F The 1-1/8" 00 Vine (Riser "A") will carry an 8.0 ton load up to 68 feet for a 2F Friction drop, with 15F subcool ing Pressure drop in riser "A" = (38.8 Ft x 2F)/68 = L.14F Pressure loss in the 1-5/8" OD horizontal lines is: Straight tubing = 1+148+46 = 16 Ft 2 - 1-5/8" ells at 2.6 Ft 5.2 1 Flow-thru e11 = 8.0 1 Str-thru flow tee, red 1/4 37 Total Equivalent Length + 32.9 = say 33 Fect- 18 - 1-5/8: 0D tubing will carry a 20 ton Toad up to 80 feet for a 2F pressure drop, with L5F subcool ing Pressure drop in the 1-5/8" 0D lines: = (33 FL x 2 F)/80 = 0.825F Total pressure drop from evaporator to compressor is Horizontal Lines = 0.83 Risers = Lad . Total Friction Drop = 1.97 So by designing a double suction riser, we have accomplished two things 1. By installing two parallel riser lines, 1-1/8" & 1-3/8" 0D, the pressure drop in the complete suction line has been held to a reasonable level at the design load of 20 corrected tons 2. O11 return to the compressor has been assured. Riser "A", 1-1/8" 00, is capable of returning oil at a minimum load of 1.7 tons at 40 SST. This is substantially less than our minimum load of 3.7 tons. This ts @ good situation, which assures positive oi] return at minimum load LIQUID LINE DESIGN Liquid lines are perhaps the easiest to design and size since oj) is sufficient- ly misible with refrigerant to assure adequate mixing and oil return. Low Tine velocities and traps in liquid lines do not pose oi! return problems. The amount of allowable pressure drop is dependent on the amount of subcool ing which is provided by the condenser. Wormal practice is to size the Viquid Tine itself for a pressure drop not exceeding 2F. ive Problem Liquid Line Sizing - Ilustr The procedure for sizing liquid lines is the same as that already established for suction lines. Figure 13, shows an extension of the problem shown on Figure 6, Page 8, to now include the liquid Tine and possible accessories.-19- ALI loads and operating conditions ate Convenser assumed to be the same as previously 7 established. Liquid line pressure drop Is) = Js not to exceed 2F 4 Figure 14, shows the chart for sizing 4 3 liquid lines with R-22 ‘ 8 It may be noted that the range of this 8 NS chart is from -40 to SOF suction and 2. 80 to 160 saturated condensing temper- ez ature. So it may be used with our Sarr gsnssy problem at 40 SST and 120 SCT condition ay em DN : Yupee thout correction. The chart is bas Exnovsion wi tho ection. The chart is based sxmaws poe on a Friction drop of 2F 7 Eve rocnyon Figure 13 LIQUID LINES COPPER TUBING Berm 9 For Promure Orop Corresponding to 2F LENT Gener (eT) 33 8 3 TONS OF REFRIGERATION Sto nfwise supsos e ser tones ol Chat HON WISH sHpI08 Fy018 Esc Figure 14- 20 - Following is the reconmended sizing procedure: 1. Find the length of straight tubing. Referring to Figure 12 this is (8412424641) = 29 Fret” 2, Add 0% fitting allowance = 29 x 1.5 = 44 Feet 3. Determine tentative line size from Figure 13. The load is 18.5 tons (no correction). Inspection of the chart shows that a 5/8" 0D line will handle the design load at 43 fect for a 2F line Joss, with 15F subcooling. This is slightly less than our tentative equivalent length, but is worth @ try 4. Determine Actual Equivalent Length Straight tubing = 29 Feet 8 Ells, 5/8" 00 at 1.0 = _8 Feet Total E.L 37 Feet 5. Determine Actual Pressure Drop Actual Drop = (37 Ft x 2F)/a3 Ft = 1.7F So the 5/8" 0D line is adequate and will carry the load within the 2F limit. Pressure Drop - Accessories It is not unusual for a few accessories to be included in the liquid line such asa filter drier, a moisture indicator and sight glass, and a thermal expansion device Thermal expansion devices are rated and selected on the hasis of having 100% liquid at the inlet of the device. The presence of flashgas in the Tiquid Tine reduces the capacity of the flow device and this in turn reduces system capaci- ty Most condensers, in use today, provide a minimum of 5 degrees of Tiquid subcool- ing. Some types are available with liquid subcooling circuits which provide as much as L5F subcool ing. The layout of the liquid line and accessories shown on Figure 13, can be used to determine whether or not subcooling is needed to prevent generation of flashgas due to pressure drop in the liquid line- ale The first step is to determine the pressure drop in the filter drier. Page 9 in the Appendix gives capacity ratings and pressure drops for filter driers. These devices are rated in tons far a 2 psi pressure drop. A C-307S Sealed Type filter has a refrigerant flow capacity of 28.8 tons for a 2 psi drop, with R-22, For an Q.£.M. self-contained application it has a recom- mended capacity of 20 tons, with R-22 Full flow moisture and liquid indicators in small sizes are assumed to have zero resistance to Flow and may be neglected for determining pressure drop. Liquid Subcooling Now we can tabulate the pressure losses in the liquid Tine so that the amount of subcooling needed to prevent generation af flash gas can be determined. First, however, we should determine the pressure drop through the filter drier with an 18.5 ton load. Pressure drop varies as the square of the tons load versus tons capacity for a 2F pressure drop. Therefore, filter drier pressure drop at 18.5 tons is: (18.5/28,8)° x 2 psi = 0.825 = 0.83 psi Now we need to determine the pressure drop in the Tiquid line in psi units corresponding to 1.7F pressure drop 1. Pressure loss in Liquid Tine 120F Sat. Temp. = 259.9 psi 118F Sat. Temp. = 252.9 psi Difference = 7.0 psi for 2F psi drop for 1.7F = (1.7/2.0) x 7.0 = 5.95 = 6.0 2. Pressure drop in the liquid Tine plus accessories is: Liquid Line = 6.00 Filter Orier = 0.83 Sight Glass 0.00 Total Drop 6.83 psiReference to Figure 12, indicates that the condenser outlet is located 15 feet higher than the filter drier. This represents a static head which will help to offset a portion of the liquid line pressure drop ‘At normal liquid temperatures, one foot of R-22 is equivalent to 2 psi For our example, with R-22 and 15 ft head, the liquid column is equivalent to 15/2.0 = 7.5 psi So in this case, the static head, at 7.5 psi, exceeds the 6.83 psi pressure drop in the liquid line. Therefore, no subcoaling is needed to prevent generation of flashgas in the liquid Tine, however, this will not always be the case. To illustrate, assume that the position of the evaporator and condenser are exchanged and that the tubing dimensions remain the same. In this case the pressure drop in the liquid line will rémain the same at 1.7 F which corresponds to a pressure drop of 6.0 psi. The pressure drop through the filter drier also remains the same at 0.83 psi At the rate of 2 psi per foot the pressure at the evaporator will be 18 ft/(2 psi/ft) or7.5 psi less than at the condenser outlet. The pressure corresponding to 120F condensing temperature is 259.9 psig. The pressure at the inlet of the expansion device at the evaporator will be 253.9 7.5 = 252.4 psig. The temperature corresponding to 252.4 psig is ae = 254.1 psig x 3.33.4 252.4 13F 2so.ah 1-6 T X = 113 + (Lx 1.6/3.3) = 113 + 0.5 = 113.5 F Therefore, to prevent generation of flashgas, the liquid temperature at the evaporator expansion device must be 113.5 F, This requires liquid subcooling in the amount of 120 - 113.5 = 6.5F. Qur illustrative problens have assumed that the refrigerant has been subcooled by 15F in the condenser. If the condenser provided only 5 degrees of subcooling a-2- then some flashgas would be generated in the liquid line. This would reduce the capacity of the evaporator by a small amount HOT GAS DISCH INE_DESIGN The occasion may arise where it is necessary to rum a hot gas line from the compressor discharge to a remote condenser The design objectives for this line are similar to those for suction lines There are three major considerations and these are 1. Pressure at full load should be kept to a reasonable level 2. Oi] return or circulation must be maintained at all loads including minimum conditions Protecting compressor during shutdown Hot Gas Line Sizing Procedure . The sizing procedure for hot gas lines is the same as that for suction lines. ferme 2 HOT GAS LINES—COPPER TUBING For Presiure Drop Corresponding to ? wed \ \ \ NS 833 83 3 3 EQUNALENT LENGTHIET) s TONS. OF REFRIGERATION Jo EPs F sn/v0s scr — aD S/S FSHYOS FAIS Se Figure 1524 - Figure 15, shows the chart used for sizing hot gas lines. This chart is for Refrigerant 22 and is based on 40F saturated suction and 105F saturated dis- : charge temperatures. Correction factors are used to adjust for other operating levels. These factors, along with suction correction factors, are shown on Figure 7, Page 9, under the columns headed HG Following is the reconmended sizing procedure 1, Find length of straight tubing 2. Add 50% for Fittings to find trial equivalent length 3. Find tons correction factor from Figure 7 and determine corrected tons for Figure 15 4. From Figure 15 determine tentative size of tubing and fittings. 5. Determine actual equivalent length 6, Find actual friction loss Oi) Entrainment - Hot Gas Risers If a riser is involved in the layout, the line size determined for full load should be checked for oil return at minimum Toad. The data in Figure 16 is used to determine minimum tonnage for oi] return versus line size. MINIMUM TONNAGE FOR OIL ENTRAINMENT UP HOT GAS RISERS Figure 16