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GuidetoGoodCommercial

RefrigerationPractice

Part2

SystemDesignandComponent
Selection

BritishRefrigerationAssociation

InstituteofRefrigeration

Issue1September2009

GuidetoGoodCommercialRefrigerationPracticePart2
SystemDesignandComponentSelection

CONTENTS

2.0.0 SYSTEMDESIGNANDCOMPONENTSELECTION

2.1.0 INTRODUCTION
2.1.1 GENERAL
2.1.2 EFFICIENCY
2.1.3 COEFFICIENT OF PERFORMANCE (COP) AND SYSTEM EFFICIENCY
INDEX(SEI)
2.1.4 METHODSOFMAXIMISINGCOSP
2.1.5 ANNUALRUNNINGCOST
2.1.6 TEWI(TOTALEQUIVELANTWARMINGIMPACT)

2.2.0 COMPRESSORS
2.2.1 GENERAL
2.2.2 SUCTIONRETURNTEMPERATUREANDSUPERHEAT
2.2.3 LIMITSOFOPERATION
2.2.4 SUBCOOLING
2.2.5 LIQUIDINJECTEDANDECONOMISEDCOMPRESSORS
2.2.6 EFFICIENCY
2.2.7 ADDITIONALIMPORTANTCONSIDERATIONS

2.3.0 EVAPORATORS
2.3.1 GENERAL
2.3.2 EVAPORATINGTEMPERATURE
2.3.3 EVAPORATORSELECTIONMETHODS
2.3.4 ACTUALEVAPORATORSELECTIONEQUIPMENTBALANCE
2.3.5 ADDITIONALIMPORTANTCONSIDERATIONS

2.4.0 CHILLEDANDFROZENFOODCABINETS
2.4.1 GENERAL
2.4.2 TESTSTANDARDSANDPUBLISHEDINFORMATION
2.4.3 PRACTICALCONSIDERATIONS
2.4.4 CHOICEOFCABINET
2.4.5 PERFORMANCEANDENERGYEFFICIENCY
2.4.6 ADDITIONALENERGYEFFICIENCYFEATURESTOBECONSIDERED

2.5.0 CONDENSERS
2.5.1 GENERAL
2.5.2 AIRCOOLEDCONDENSERS
2.5.3 MAINTENANCEOFDISCHARGEPRESSURE
2.5.4 POSITIONOFREMOTEAIRCOOLEDCONDENSERS
2.5.5 FINBLOCKMATERIAL
2.5.6 WATERCOOLEDCONDENSERS

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2.6.0 EXPANSIONVALVES
2.6.1 INTRODUCTION
2.6.2 THERMOSTATICEXPANSIONVALVESELECTION
2.6.3 LOWAMBIENTCONDITIONS
2.6.4 CAPACITYCONTROL
2.6.5 ADDITIONALIMPORTANTCONSIDERATIONS
2.6.6 ELECTRONICEXPANSIONVALVES

2.7.0 OTHERCOMPONENTS
2.7.1 PRESSURERELIEFVALVES
2.7.2 TEMPERATURECONTROLS
2.7.3 TEMPERATURESENSORS
2.7.4 SUCTION/LIQUIDHEATEXCHANGERS
2.7.5 OILSEPARATORS
2.7.6 PRESSUREREGULATORS
2.7.7 LIQUIDLINESIGHTGLASSES/MOISTUREINDICATORS
2.7.8 NONRETURNVALVES
2.7.9 HANDSHUTOFFVALVES
2.7.10 OILDIFFERENTIALPRESSURESWITCHES
2.7.11 SAFETYCUTOUTS(SWITCHES)
2.7.12 SOLENOIDVALVES
2.7.13 PRESSURECONTROLTUBING

2.8.0 REFRIGERANTPIPEWORK
2.8.1 INTRODUCTION
2.8.2 PRESSUREDROP
2.8.3 SIZING
2.8.4 OILRETURN
2.8.5 REFRIGERANTVELOCITY
2.8.6 OILANDLIQUIDTRAPS
2.8.7 VERTICALSUCTIONRISERS
2.8.8 DOUBLESUCTIONRISERS
2.8.9 MULTISTUB
2.8.10 RADIALMAINSYSTEM
2.8.11 GUIDANCEDATAFORCOMPUTERSELECTIONOFPIPEWORK
2.8.12 PIPEWORKMARKING
2.8.13 PIPESELECTION
2.8.14 PIPEWORKINSULATION

2.9.0 DESIGNCONSIDERATIONS
2.9.1 DESIGNFORMINIMALLEAKAGE
2.9.2 SUCTIONANDCONDENSINGPRESSURE
2.9.3 REFRIGERANT CHARGE AND ISOLATION FOR MAINTENANCE
PURPOSES
2.9.4 PUMPDOWNCYCLE
2.9.5 DEFROSTMETHODS
2.9.6 ELECTRICDEFROSTMETHODOFOPERATION
2.9.7 VIBRATIONANDNOISE

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2.10.0 LOADCALCULATIONS
2.10.1 INTRODUCTION
2.10.2 GATHERINGDATA
2.10.3 COOLINGLOADDATA
2.10.4 TYPESOFCOOLINGLOAD
2.10.5 SENSIBLECOOLINGLOAD
2.10.6 LATENTHEAT
2.10.7 HEATOFRESPIRATION
2.10.8 CONDUCTIONHEATGAINS
2.10.9 INFILTRATION
2.10.10 ANCILLARYCOOLINGLOADS
2.10.11 MARGINS(COMMERCIALEQUIPMENT)

2.11.0 PLANTROOMDESIGN
2.11.1 INTRODUCTION
2.11.2 VENTILATIONREQUIREMENTSFORCONDENSINGUNITS
2.11.3 VENTILATIONREQUIREMENTSFORCOMPRESSORS
2.11.4 VENTILATIONFANCONTROL
2.11.5 LEAKDETECTIONEQUIPMENT
2.11.6 VENTILATIONESCAPEOFREFRIGERANT

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2.0.0 SYSTEMDESIGNANDCOMPONENTSELECTION

2.1.0 INTRODUCTION

2.1.1 GENERAL

Systemdesignisacomplexsubjectmadeevenmoresoinrecentyearsbyenvironmental
mattersandtheincreaseinsafetylegislationaffectingtheindustry.Safetyisparamount,
alldesignsshouldconformtoallregulationsandCodesofPractice.(seeSection3)
Thefollowingpointsneedtobeconsidered:
1 Is the capital cost of the system a reasonable cost taking into account energy
efficiency.
2. Willthesystemdesignbeassimpleaspossiblewithdueregardtothetaskitwillbe
carryingout.
3. Willtheequipmentbereliableandgivemanyyearsoftroublefreeoperation.

The essence of good design is simplicity overcomplication may lead to unreliable
operation.Itisimportantthatbeforedesignworkisevenattempted,thedesignengineer
isawareofalltheinformationregardingtheapplicationtoenablehim/hertoconsiderall
aspectssothattheclientreceivesthemostcosteffectiveandefficientresult.
Thevastmajorityofcommercialsystemsareofthedirectexpansionaircooledtypeand
thedesignpointsreferprimarilytothistypeofsystem.

Indirect systems are sometimes proposed for supermarkets and a number of these
systems have been successfully installed. An indirect system, or secondary loop system,
utilisesabrineorothersecondaryfluidwhichiscooledbyaliquidchiller.Ammonia(orany
other nonA1 classed fluid) could be used as the refrigerant in the chiller. The brine is
circulatedtocoolerswithinthecoolroomsorcabinets.Theliquidchillerwouldnormally
beinstalledasafactoryassembledcomponent.Chillerandsecondaryrefrigerantsystem
designsarenotcoveredbythisGuide.

Carbon dioxide systems have also been successfully employed. This refrigerant requires
special considerations, and may be employed either in direct expansion mode or as a
secondarycoolant.Detailedsystemspecificationsmustbeobtainedfromtheinstallersof
such systems, and guidance can be found in the IOR safety code for carbon dioxide
systems.

2.1.2 EFFICIENCY

The electrical energy consumed by refrigeration equipment in the United Kingdom is


estimated a 17% of the national total and it is most important that energy is used
efficientlybecauseofitsenvironmentalconsequencesandcost.Thefollowingarethekey
stepsforenergyefficiencyandreductionofenvironmentalimpact:

1. Reducethecoolingload.Examples:betterinsulation,prechillfreshair.
2. CorrectSystemDesign.Examples:Maximisesuctionpressure,splitloadsontodifferent
suctionlevels,consider2stageoreconomisedcycles

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3. Correct Control Philosophy. Examples: Consider conditions at which most running
hoursoccur,avoidheadpressurecontrol,avoidfixedspeedauxiliaries
4. Optimise selection of components includingcompressors, heat exchangers, and
refrigeranttoensurethattheyaresuitedtotheoveralldesign.
5. ProperOperationandMaintenance.Example:fixrefrigerantcircuitleakssothatproper
chargelevelismaintained,ensureheatexchangesurfacesarenotdirty/fouled,etc.

2.1.3 COEFFICIENTOFPERFORMANCE(COP)ANDSYSTEMEFFICIENCYINDEX(SEI)

COPisamethodofcomparingtheefficiencyofrefrigerationsystems.

COP = RefrigerationCapacity
PowerInput

ThecompressorCOPdefinitionsimplyrelatesthecoolingcapacityandpowerinputofthe
compressor,takingasimplecyclewithnopressuredropsornonusefulheatgains.Amore
meaningfuldefinitionistheCoefficientofSystemPerformance,COSP,whichtakesactual
evaporatorcoolingcapacityandincludespowerinputtoauxiliariessuchasfansandpumps

The System Efficiency Index is the ratio of COSP to the ideal COP for the process
temperatures (load temperature and outside air temperature). A rating model for SEI is
availablefromtheInstituteofRefrigeration.

2.1.4 METHODSOFMAXIMISINGCOSP

Theratiooftheevaporatingandcondensingpressuresshouldbeaslowaspossible.This
increasesthecapacityandreducesthepowerrequiredatthecompressor.Minimisingthe
compressionratiocanbeachievedbyacombinationof:
theuseoflargercondensers
theuseoflargerevaporators
lowpressuredropsinpipeworkandcomponents
The nonuseful heat gain between the evaporator and compressor should be kept as
low as possible because it reduces effective compressor capacity and results in
unnecessarypowerconsumption.Thenonusefulsuperheatcanbereducedbyuseof
closecoupledsystemsandinsulationofsuctionlines.
Subcooling contributes to capacity without demanding more power at the
compressor.Subcoolingcanbemaximisedbyincreasingcondensersizetoincludesub
cooling coils but this will preclude the use of a liquid receiver. A suction/liquid heat
exchangeris a useful way of reducing the heat loss/gain effects arising from long
unavoidablylongsuctionandliquidlines.
Correctcompressorchoice(SeeSection2.2.1)
COP can be improved with enhanced cycles such as economised/2stage systems
particularly for low evaporating temperatures. These solutions require proper
calculation for optimum results, and software to assist with this is available from a
numberofsources.

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2.1.5 ANNUALRUNNINGCOST

Low outdoor temperatures make up a high proportion of the UK annual temperature


profile,andthehoursspentrunningatthedesigncondensingconditionwillbeveryfew,
andmaybezeroinsomeyears.Mostoftherunninghourswillbeatmoderatecondensing
temperatures well below the design maximum. Installations should be optimised for air
temperaturesinthe10Cto15Crange,whilstretainingtheabilitytooperateanddeliver
sufficientcapacityatanoutdoorairtemperatureof,say,35C.Theefficiencycomparison
ofcompressoroptionsshouldbemadeatrealisticrunningconditions.

To gain maximum benefit from the outdoor air temperature profile, it is necessary to
considerfanpowerinadditiontothecondensingtemperatureeffectandthecompressor
characteristics.Itmaybeadvantageoustoreducefanspeedorturnoffcondenserfansat
low ambient conditions, in preference to allowing further condensing temperature
reduction.Incrementalcompressorpowerreductionbelow20Ccondensingcanbequite
small. In other words it often becomes more effective (in overall COSP) to reduce the
condenserfanpowerinput.

2.1.6 TEWI(TOTALEQUIVALENTWARMINGIMPACT)

TEWIisusedasameasureofthelifetimeglobalwarmingimpactofasystem.Itincludes
theeffectsofrefrigerantleakage,refrigerantrecoverylossesandenergyconsumption.The
largest element of the TEWI for the vast majority of refrigeration systems is energy
consumption. TEWI should be calculated when comparing system design options for
specific applications, and it should be noted that the load pattern must be identical for
eachsystemtobecomparedifarealisticcomparisontobemade.Comprehensivemethod
detailswithcalculationexamplesaregivenintheBRA/IORTEWIGuidelines.

2.2.0 COMPRESSORS

2.2.1 GENERAL

Compressorperformancedataisnormallygivenforarangeofevaporatingandcondensing
temperatures. The parametersusedtoselectthecompressorapplytotheconditionsat
the compressor suction and discharge service valves. Allowance must be made for
pressuredropsbetweentheevaporatorandthecompressor,andbetweenthecompressor
and the condenser. The suction line pressure drop is the more important. If this is not
takenintoaccountthecompressorcanbeundersized.
Ratingconditionsforallrefrigerantsshouldbecheckedwiththemanufacturer.

2.2.2 SUCTIONRETURNTEMPERATUREANDSUPERHEAT

For compressor rating purposes all suction superheat is usefully obtained in the
evaporator, i.e. contributes to the stated capacity. The actual operating conditions will
varyfromtheseratingconditions,therefore,correctionsmustbeappliedtocalculatethe
actualperformanceonanyapplication.

Inarealsystemtheusefulsuperheatwouldtypicallybebetween5and10K(thesuperheat

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settingofthevalve)andallowancemustthereforebemadefor:
theactualsuctionreturntemperatureatthecompressor
thenonusefulsuperheat

Compressor manufacturers software usually enables these corrections to be made. A
reductioninusefulsuperheatwilltendtoreducethecompressorcapacityfromthatgiven
attheratingcondition,butwithoutreducingthepowerinput.Thesystemefficiencywill
therefore be lower than the compressor efficiency indicated in the manufacturers
publisheddata.Whenmakingefficiencycomparisonsfordifferentcompressors,itisvery
importantthatidenticaloperatingconditionsareused.

2.2.3 LIMITSOFOPERATION

The maximum and minimum pressures and temperatures shown in compressor


performancedatamustbestrictlyadheredto.Themaximumevaporatingandcondensing
temperaturesareusuallydeterminedbythemotorcapability.Ifexceeded,themotormay
overheat,reducingitsreliabilityandincreasingpowerconsumption.

The minimum evaporating temperature at any particular condensing temperature is
usually fixed by the maximum discharge temperature limit. It may also be necessary to
sustainsufficientmassflowtocoolthemotor.Vacuumoperationshouldbeavoideddueto
thepossibilityofairingress.

Foragivencapacityandoperatingconditiontheremaybeachoiceofmodeltype.Some
typesareoptimisedformediumtemperatureapplicationsandsomeforlowtemperature
applications. A smaller motor may be used for lower evaporating temperatures. In
addition to the primary requirement of delivering the necessary capacity at the design
conditions, care should be taken to investigate operation at all likely conditions and
efficiencyattypicalrunningconditions.Costwillalsobeaconsideration.

Maximum suction return temperatures are often given. If these are exceeded, the
dischargetemperaturemaybecometoohighandcauseahightemperaturetrip.Without
dischargetemperatureprotectionexcessivetemperaturescauseoilbreakdownandhence
lubrication problems. This can result in partial or total seizure, thus increasing power
consumption or causing complete compressor failure. The manufacturers data usually
indicateswhereadditionalcompressorcooling,suchasafanmaybeneededtoavoidthe
dangerofexceedingtheoperatinglimits.

Theapplicationofacapacitycontrolledcompressormaybemorerestrictedthanthesame
machine operating on full load. This should be checked when selecting compressors for
thistypeofapplication.

2.2.4 SUBCOOLING

Some degree of subcooling is always necessary to avoid flash gas in liquid lines and the
subcooling can vary depending on length of liquid lines. This subcooling increases the
systemcapacitywithoutincreasingthepowerconsumption.Toassessthecorrectcapacity
andhenceefficiency,theeffectofsubcoolingmustbeknown.Correctionsforsubcooling

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canusuallybefoundinmanufacturerssoftware.Furthersubcooling,sometimestermed
mechanicalsubcoolingmaybeprovidedbyanadditionalheatexchangerwith2stageor
economisedsystems(seebelow),orbyasuction/liquidheatexchanger.Inthelattercase
the superheat will also be affected and the evaporator capacity is determined by the
enthalpydifferencebetweentheexpansionvalveinletandtheevaporatoroutlet(notthe
heatexchangeroutlet).

Whencalculatingthecapacitygainresultingfromliquidsubcoolingitisimportantthatthe
actual liquid temperature at the expansion valve entry is used, not the temperature of
liquidleavingthesubcooler.

2.2.5 LIQUIDINJECTEDANDECONOMISEDCOMPRESSORS

Some low temperature compressors incorporate liquid injection. This is to cool the
compressor and allow operation over a wide range of condensing temperatures. Data
supplied by the manufacturer will be dependent on use of the recommended liquid
injectioncontrolmethod,andtheavailabilityofsuitablesubcooledliquidsupply.

Economised scroll or screw compressors require an additional heat exchanger, usually a


plateheatexchangerwithaliquidstreamexpandingintheheatexchanger.Thisisusedto
subcool the working refrigerant before it is sent to the expansion valve(s) and
evaporator(s).Thevapourgeneratedinthissubcoolingprocessisfedtoanintermediate,
or economiser port on the compressor. This process results in a significant gain in
compressor capacity and COP. It is essential that the liquid reaching the heat exchanger
expansiondeviceispresubcooledtosomeextent.Naturalsubcoolinginthelinefromthe
condenserwillnormallysuffice,providedthesystemiscorrectlycharged.

Datasuppliedbythemanufacturerwillrefertotheliquidtemperatureattheoutletofthe
economiser heat exchanger, which may be considerably lower than the surrounding
temperature.Itisthereforeessentialtoinsulatetheliquidlinesfromtheheatexchangerto
the expansion valves. Corrections to the published data may be necessary to allow for
liquidtemperaturegain.

2.2.6 EFFICIENCY

Users can either compare information from manufacturers or can obtain comparative
information from the ECA (Enhanced Capital Allowance) Energy Technology List (ETL).
ManufacturersASERCOMcertifieddatahasbeenindependentlyverified.TheECAisaUK
Governmentoperatedschemethatidentifiesenergyefficientproductsandliststhemon
theETL(www.eca.gov.uk/).TheperformanceofallcompressorslistedontheETLhasalso
beenindependentlyverified.

2.2.7 ADDITIONALIMPORTANTCONSIDERATIONS

The performance, efficiency and operating range will be different for a compressor
operatingoncapacitycontrol.Thismustbeexaminedwhenselectionsandcomparisons
aremade.

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Supplementarycompressorcoolinge.g.airfanorliquidinjectionmaybenecessaryfor
some applications to reduce discharge temperatures. Such additional cooling must be
fitted when recommended by the compressor manufacturer to maintain efficiency and
reliability.

Crankcaseheatersmaybenecessarytopreventliquidmigrationtothecompressorduring
itsoffcycle.Ifsuchheatersarenotfittedandcorrectlyused,acceleratedbearingwearcan
occur,reducingreliabilityandefficiency.

Wherereducedstartingcurrentmethodsareusedstardeltaandpartwind,forexample
somemethodofreducingthestartingloadmayberequired.

Thispreventsthecompressoroverloadwhenstartingandstalling,thuseffectivelystarting
direct on line and drawing the locked rotor current for a longer duration. Some
compressor types have an internal bypass valve to route the compressor's discharge gas
backintoitssuctionviaasolenoidvalvejustfortheshortstartduration.Manufacturers
recommendationsregardingstartingshouldbefollowed.

System pressure switch settings should ensure that the compressor is prevented from
operatingoutsideitsdesignrangeandanoildifferentialswitchisnormallyappliedwherea
highpressurelubricationsystem(oilpump)isusedinthecompressor.

2.2.0 EVAPORATORS

2.3.1 GENERAL

Correctly sizing the evaporator is important, both to ensure that it will achieve the
requiredairofftemperatureandtherequiredspaceorproducttemperature.Maintenance
ofanacceptablelevelofhumiditywhichiscriticalforthequalityofstoredorprocessed
produceisalsonecessary.Thespaceorproducttemperaturewillhavebeenspecifiedby
the user. The appropriate humidity will depend upon the type of product, its packaging
and its temperature, and is affected by the difference between the evaporating
temperatureandtheairon/airofftemperature.Itisalsoaffected,toalesserextent,by
theoperatingtimeoftherefrigerationsystem.

The following factors affect the efficient operation of an evaporator and need to be
addressedwhenselectingamodeltomatchaparticularapplication:
finspacing
airvelocity
methodofdefrosting,wherenecessary
Aironhumidity
large/smallairontoevaporatortemperaturedifferences
dooropeningstospace

FINSPACING Fin spacing varies from 3mm (6 fins/inch) to 12mm (2 fins/inch). It is
necessary to use the wider fin spacing on applications where there will be a build up of
frost due to low evaporating temperatures, or where there could be airborne
contamination.However,anarrowerfinspacinggivesagreaterheattransfersurfacearea

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andhenceahighduty,butwouldrequiremorefrequentdefrostingonlowtemperature
applications.

AIRVELOCITY Low air velocity evaporators are used in areas which are occupied and to
cooldelicateproduce.Highvelocitiesaretypicallyusedforblastfreezing.Thegreaterthe
airvelocityoveragivenfinblockthegreaterwillbethecoolingcapacityoftheevaporator.
Theairvelocitymustnotbetoohighoritwillblowfreewaterintothecoldroom.

DEFROSTING The evaporator must be selected to suit the type of defrosting operation
thathasbeenspecifiedinthesystemdesign.Snapcoolingofthecoilisrequiredtofreeze
freewaterontothefinspriortostartingthefansafterdefrostingcoil.

2.3.2 EVAPORATINGTEMPERATURE

Takingtheairontotheevaporatortemperatureasthereference(roomtemperature),the
maximumdifferencebetweenthisvalueandtheproducttemperatureshouldbeselected
asfollows:

3K productssuchasfruitandvegetablesthatdehydratequickly
5K productsneedinglessthan80%relativehumidity
10K productswhichwillnotdehydrate

A system with a higher evaporating temperature will operate more efficiently but will
requirealargerevaporatorwhichwillincreasetheinitialcapitalcostoftheinstallation.By
using a larger evaporator, compressor size could be reduced, thus reducing overall cost.
Wherethereisnospecifichumidityrequirement,evaporatorsshouldbeselectedona67K
temperaturedifferencetooptimizeefficiency.

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2.3.3 EVAPORATORSELECTIONMETHODS

Therearetwomethodsofcoolerselection:MTDmeantemperaturedifferenceorlogMTD

MTD LMTD
ThetemperaturedifferenceistakenastheLogarithmic temperature difference
air on (t1) + air off (t2) divided by 2 minus (NaperionLog)
theevaptemperature
MTD=(t1+t2)te LMTD=TD1TD2
2 LnTD1
TD2
t1=airon TD1=Airontoevap.difference
t2=airoff TD2=Airofftoevap.difference
te=evaporatortemperature.

Figure2.1TemperatureDifferences

Usingthesemethodswillgivetotallydifferentresults.Onlyifthecoolerperformancetable
isbasedonsimpleMTDwoulditbecorrecttouseMTDs.OtherwisetheLogMTDshould
be used. There is a danger of undersizing the cooler and system will not achieve the
requiredroomtemperatureatdesignorpeakcondition..

2.3.4 ACTUALEVAPORATORSELECTIONEQUIPMENTBALANCE

Whensufficientinformationhasbeenobtainedtoallowanevaporatortobeselected,its
actualoperatingconditionscanbeestablishedbyusingasuitablecomputerprogrammeor
byconstructingabalancegraphwiththecompressor.

By incorporating different sized evaporators into a balance graph, a comparison of the
operatingconditionscanbeobtained,Figure2.2

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Figure2.2Equipmentbalancegraphexample

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Itshouldbenotedthattheequipmentillustratedabovewillonlyremaininbalanceifthe
conditions illustrated are prevailing. If the ambient temperature falls and causes the
condensing unit/compressor duty to increase a new balance will occur with the
temperaturedifferenceincreasingsothatthedutyoftheevaporatormatchesthatofthe
condensingunit/compressor.

Due allowance should be made when carrying out the above procedure for suction line
pressuredrop.Thefollowingmethodstoovercometheaboveshouldbeconsidered:
(i) The TD between the room temperature and the compressor saturated suction
temperature should allow 1 or 2K for pressure drop in the suction line, i.e. for a
roomtemperatureof20oC,assumingasuctionlinepressuredropequivalentto2K
andanevaporatorTDof6Kthecompressorsaturatedsuctiontemperaturewould
be28oC.
(ii) The resulting (reduced) compressor capacity should be plotted against the actual
evaporatorevaporatingtemperatureandTD26oCand6K.

2.3.5 POSITIONINGOFEVAPORATORSWITHINTHECOLDSTORE

Air circulation and the velocity of the air circulated contributes directly to the overall
system performance. It is important that good air circulation is available. It may be
economicaltoselectforexampletwoevaporatorstoproduceacertaindutyforacondition
butfourevaporatorscouldgivebetteraircirculation.Thenumberofevaporatorsselected
must represent the most effective air circulation performance. In some instances the
evaporatorfan'airthrow'maybetoosmallforthesizeofthecoldstoreandinthisinstance
supplementary air circulation fans may have to be considered. These would produce
additionalheatthatneedstobetakenintoaccount.
Thefollowingpointsshouldalsobeconsidered:
Installevaporatorsoppositeentrancedoors
Directairflowsalonggangwaysandshelving
Donotinstalltransversesupportsteelworkwhichcanblockairflow
athighlevel
Ensurefreeairflowoverguards,i.e.,donotstacktoohigh

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Figure2.3Examplesofcorrectevaporatorinstallationincoldstores



Figure2.4Examplesofincorrectevaporatorinstallationincoldstores

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2.3.6 ADDITIONALIMPORTANTCONSIDERATIONS

For refrigerant mixtures with glide manufacturer's ratings for evaporators refer to dew
pointevaporatingtemperature.

Evaporatorsincoldroomsshouldnotbedefrostedseparatelyhowevermanycoolersthere
are in the room. If the evaporators are defrosted at different times moisturegenerated
duringdefrostwillmigratetotheotherunits.

2.4.0 CHILLEDANDFROZENFOODCABINETS

2.4.1 GENERAL

Selection of a retail display cabinet is dependent on a number of factors. The cabinet


shouldbeselectedonitsabilitytoperformthefunctionrequired(intermsoftemperature
control, amountandwayfoodcanbedisplayedandtheoverallusabilityofthecabinet).
Additionalfeaturessuchasenergyconsumption,flexibility,lifeofthecabinetandhygiene
andsafetyshouldalsobeconsidered.

2.4.2 TESTSTANDARDSANDPUBLISHEDINFORMATION

InEuropethemajorityofcabinetsaretestedtoBSENISO23953parts1and21(formerly
EN441). This provides a measure of the temperature control and energy usage of the
cabinet. In this standard temperature control is divided into several levels as shown in
Table1.Itisusualformanufacturerstostatethattheircabinetcomplieswithoneofthese
temperaturelevelsalthoughsometimestightertemperaturebandsareappliedtocabinets
designedforspecialfunctions.

Highest temperature of Lowest temperature ofLowest temperature of


Class warmest Mpackage2 lesscoldest Mpackage greaterwarmest Mpackage greater
thanorequalto thanorequalto thanorequalto
C
L1 15 18
L2 12 18
L3 15 15
M1 5 1
M2 7 1
H1 10 1
H2 10 1
S Specialclassification
Table1.TemperaturelevelsdefinedinEN23953.

1 BSENISO23953:Refrigerateddisplaycabinets.BSENISO239531:2005Vocabulary.BSENISO23953
2:2005Classification,requirementsandtestconditions.
2 Measurementpack.

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BS EN ISO 23953 also defines a method to measure energy consumption. For integral
cabinets(thoseoperatingdirectlyfromaplugandwitharefrigerationsystemcontainedon
board) the energy directly used by the cabinet is stated (termed TEC or Total Energy
Consumption).

For remotely operated cabinets the heat extracted by the evaporator is converted to an
equivalent electrical power consumption called Refrigeration Energy Consumption (REC).
The conversion is based on typical efficiencies of the refrigeration circuits to which they
willbeattached.Thedirectenergyusedbyfans,lights,defrostheateretcarethenadded
toprovidetheDEC(DirectEnergyConsumption).DEC+RECequalstheTEC.

ForremotecabinetsthemajorityofmanufacturersdefineRECandDECseparately.Thisis
becauseinmostlargesupermarketstheenergyusedtoextractheatfromtheevaporator
willbepartoftherefrigerationpackelectricalloadandthedirectenergywillbepartofthe
shopserviceselectricalload.
The heat extracted by the evaporator at a defined evaporating temperature may be
suppliedinadditionto,orasanalternativetoREC.

Theambientconditionsatwhichcabinetsaretestedinaredefinedinthestandard.These
conditions are therefore the conditions at which the ratings apply. For retail cabinets
designedforsupermarketsthemajorityofcabinetsaretestedinclimateclass3conditions
(Table2).Insupermarketstheambientconditionsaregenerallyaround2021Candlower
inhumiditythanthoseusedtotestthecabinets.Thismayleadtoalowerheatextraction
rateinrealitythaninthetestsanditiscommonformanufacturerstomakeanadjustment
forthis.

Forcommercialservicecabinetsforkitchenswheretheambientconditionsarewarmerthe
climateclassconditionsaregenerallyclimateclass4.

Testroom Drybulb Relative Watervapourmassin


Dewpoint
climateclass temperatureC humidity dryairg/kg
0 20 50 9.3 7.3
1 16 80 12.6 9.1
2 22 65 15.2 10.8
3 25 60 16.7 12.0
4 30 55 20.0 14.8
5 27 70 21.1 15.8
6 40 40 23.9 18.8
7 35 75 30.0 27.3
8 23.9 55 14.3 10.2

Table2.ClimateclasslevelsdefinedinEN23953.

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2.4.3 PRACTICALCONSIDERATIONS

Theconditionsdefinedinthestandardrequirelightingtobeonfor12hoursoutofevery
24hourperiod.Inmodernsupermarketstrading24hoursadayitshouldbenotedthat
lightingloadislikelytobehigherthanthis.Forcabinetswithdoorsthestandarddefines
door openings over a 12 hour period. Actual usage may be more severe, or in some
situations less severe, and therefore the location and type of supermarket needs to be
taken into account and the heat extraction rate for cabinets with doors adjusted
accordingly.
A number of display cases can eitherbeconnectedtoonecondensingunit,onestub,or
branch of a central plant installation. Each of the cabinet extraction rates are added
togethertomakethetotalloadforthecondensingunitorstuborbranch.Insuchasystem
the compressor(s) must operate to achieve the lowest evaporating pressure required by
theattachedcabinets.Thereforecareneedstobetakentoensurethatafewcabinetsdo
not require a lower evaporating temperature than others on the same pack as this will
raiseenergyconsumptionunnecessarily.

In addition, as most cabinets in UK supermarkets are not operated with evaporator
pressure regulators, the cabinets must operate at the pack pressure and this may differ
fromthecabinetdesignconditions.

2.4.4 CHOICEOFCABINET

Cabinetsareusuallyselectedtostoreacertainfoodinacertainmanner.Thelocationof
the cabinet and size of the retail outlet usually define whether a remotely operated or
integralcabinetispreferable.Whetherthefoodstoredinthecabinetshouldbechilledor
frozen is also usually clear. Once these are defined the type of cabinet selected is
dependentonhowfoodwillbemerchandised,availableareatolocatethecabinetandany
otherfeaturessuchasenergyconsumption.

2.4.5 PERFORMANCEANDENERGYEFFICIENCY

Once a cabinet type has been determined users can either compare information from
manufacturers or can obtain comparative information from sources such as Eurovent or
theECA(EnhancedCapitalAllowance)EnergyTechnologyList(ETL).
Eurovent(www.euroventcertification.com/index.php.en)
isatradeschemethatcertifiestheperformanceratingsofrefrigerationproductsaccording
to European and international standards. Manufacturers can list products if they are
membersoftheschemeandacertainnumberofproductsareindependentlyverifiedeach
year. The ECA is a UK Government operated scheme that identifies energy efficient
products and lists them on the ETL (www.eca.gov.uk/). The performance of all retail
cabinetslistedontheETLshouldbeindependentlyverified.

Both the above schemes use BS EN ISO 23953 to define performance of cabinets. The
overall performance is usually listed as the TEC divided by the Total Display Area (TDA).
TDAisameasureofthevisibleareaofthefoodwithinthecabinetandsoisameasureof
themerchandisingfieldofviewthattheconsumersees.ItshouldbenotedthatTDAisnot

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a good reflection of cabinet volume and that if storage volume is important in a cabinet
selectionthatTDAshouldnotbeconsideredinisolation.

Eventhoughsuchschemeshelpidentifythebestperformingcabinetsthereisstillalarge
variation in performance of cabinets listed on such schemes. By selecting the very best
performingcabinetsconsiderableenergysavingscanbeachieved.





















Figure2.5overthepage,presentsdatafromtheETLshowingTDAagainstTECforM1and
M2 cabinets. It can be seen that in certain instances there is considerable differences
between cabinets and that by careful selection of a cabinet considerable energy savings
canbeachieved.









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80

M1 M2
70

60

50
TEC (kWh/day)

40

30

20

10

0
0 1 2 3 4 5 6 7 8
2
TDA (m )


Figure2.5DatafromETLforM1andM2cabinets(Jan08).


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2.4.6 ADDITIONALENERGYEFFICIENCYFEATURESTOBECONSIDERED

Technology Application Notes


Chilledandfrozenmulti
Addingdoorstodisplaycases Barriertoconsumers
decks
Savingsdependentonstore
Antisweatheatercontrols Freezercabinets
conditions
Freezers(chillersshouldbeMaybepartofsupermarketcontrol
Defrostoptimisation
operatedonoffcycle) systemratherthancabinetitself
Efficientstandardlighting
Allcabinetswithlights Mostoptionsalreadyused
system
Electronicballasts Allcabinetswithlighting
Enhancedheattransfer,Increased
Evaporatorcoilrifling Allcabinets
UA
Highefficiencyfansmayhave
EvaporatorfanECMmotors Allcabinetswithforcedair
additionalbenefitssuchas
andhighefficiencyfanblades convection
improvedairdistribution
Savingdependsonnumberoflights
LEDlighting Allcabinetswithlights andradianteffectofconventional
lighting
Liquidsuctionheat
Allcabinets
exchangers
Cabinetswithglass(half
Lowemmissivity/reflective
glassdoors,fullglass Reductioninradiantheatgain
glazing(Kglass)
doors,delicatessen)
Assumesretailoutletclosesforpart
Chilledmultidecks,well
Nightblinds ofday,correctfittingisessentialto
freezers
capitaliseonenergysaving
Assumesretailoutletclosesforpart
Chilledmultidecks,well
Nightcovers ofday,correctfittingisessentialto
freezers
capitaliseonenergysaving
Useofweirplatestoreduce
Chilledmultidecks,well infiltration,cabinetwithlow
Optimisationofaircurtain
freezers infiltrationwithhavelowheat
extraction
Assumescorrectfitting,energy
Stripcurtains Chilledmultidecks
savingdependsonusage
Allcabinets,primarily
Thicker/betterInsulation
frozen

Table3

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2.5.0 CONDENSERS

2.5.1 GENERAL

Therearetwotypesofcondenserusedinthecommercialrefrigerationindustry:
aircooled
watercooled
Thecondensermustbesizedtorejectalloftheheatabsorbedbytherefrigerationsystem
atalloftheplant'soperatingconditions,soitisimportantthatthisiscorrectlycalculated
foraccuratecondenserselection.Heatrejectionconsistsof
Compressorcapacity+Powerabsorbedbythecompressorheatlosses
Note that the actual compressor capacity for condenser selection also incorporates non
useful superheat. Heat losses represent heat dissipation from the compressor body, and
thisisnormallylessthan10%ofthepowerinput.Thisfigurecanbehigherinthecaseof
aircooledcompressors.Inmanycasestheheatrejectioncanbefoundfromcompressor
manufacturerssoftware.

Itisimportantthatthetotalheatofrejectionisalsocheckedatconditionsotherthanthe
basicdesigncondition.Forexampleapplicationsthatinvolveartificialformsofdefrostor
blast freezer/blast chiller applications i.e. where a rise in suction pressure may occur,
whichcangiverisetoincreasedcapacityandhenceincreasedheatrejection
Defrost and blast freezer/blast chiller applications will, during the process, cause
evaporating temperature rise and therefore the equipment will have a larger duty. It is
importantthatthisincreaseinthedutyoftheequipmentistakenintoaccountduringthe
selectionofthecondenser.

Generallythelargestpracticalcondensershouldbeselectedsincetheenergyefficiencyis
higher atthelowercondensingpressures.Theoperatingcostsareveryimportantwhen
selecting condensers a higher investment in a larger model can usually be offset by a
reductionintherunningcostswithinareasonableperiod.However,ifwithanaircooled
condenser, the larger model has more fans, then the extra power required to run them
mayseverelyreduceorevencancelanysavingthatistobegainedfromthemoreefficient
operationofthecompressor.

Typicallymaximumcondensingtemperaturesshouldnotbemorethan4043C.

Itismoreefficienttoincreasethecondensersizetoreducecondensingtemperaturethan
toincorporatesubcoolingcoils.

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2.5.2 AIRCOOLEDCONDENSERS

The performance of an air cooled condenser will be a function of the following


parameters:
sizeofthefinblock
Finspacing(usually23mm)andtypeoffincoating
finblockmaterial
airflowthroughthefinblock
refrigerant
temperatureoftheairontothecondenser
Somecondensersaredesignedtoincorporatewatersprayforadiabaticcooling.

Data will be available from manufacturers giving the capacity of a condenser for a
particular refrigerant, as a function of the TD of the air into the fin block and the
refrigerantcondensingdewpointtemperature.Thevariationinthecapacityofdifferent
condensermodelswillbeaffectedbythefirstfourfactorslistedabove.Userscaneither
compare information from manufacturers or can obtain comparative information from
sources such as Eurovent. Eurovent (www.euroventcertification.com/index.php.en) is a
tradeschemethatcertifiestheperformanceratingsofrefrigerationproductsaccordingto
European and international standards. Manufacturers can list products if they are
membersoftheschemeandacertainnumberofproductsareindependentlyverifiedeach
year.

2.5.3 MAINTENANCEOFDISCHARGEPRESSURE

Expansion valves that will operate effectively over the full range of desired condensing
temperaturesshouldbechosenIfthevalverequiresaminimumpressuredroptooperate
effectively then the condensing pressure can be regulated to achieve this. But the
additional compressor running cost resulting from maintainingheadpressureinthisway
needstobeconsideredinconjunctionwithanalternativevalveoption.

Electronic expansion valves and balance port thermostatic expansion valves are not so
reliantonpressuredropandthereforesystemsmaybeabletooperateatlowercondenser
pressures/temperatures. With these types of valves it is acceptable during low ambient
conditions to aim for discharge pressure equivalent to 20C condensing temperature for
systems operating at high temperatures, and discharge pressure equivalent to 15C for
thoseoperatingonlowtemperature.

Somethermostaticexpansionvalvesneedapressuredropacrossthemof6bartooperate
effectively. To maintain this type of pressure drop the following methods of condenser
controlshouldbeconsidered:
1.Pressureswitchcontrolofthecondenserfans
2.Speedcontrolofthecondenserfans
3. Splitting the condenser heat exchange surface area into a number of passes and
isolatingthepasstoreducethesurfaceareaofthecondenser.

Whereconsiderationisgiventotheswitchingofthecondenserfanstomaintaindischarge

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pressure,thefollowingshouldbeconsideredinrespectofthecontroloftherefrigeration
system.Withallfansoff,1015%ofthecapacityofthecondenserwillstillbeavailable
onhighairvolumecondensers.Withlowairvolumecondensersthesameheatexchanger
maybecapableof30%ofthedesigncapacity.Theisolatedsectionshouldhaveadequate
meansoftransferringrefrigeranttotheoperationalpartofthesystem.
Furthermore, and particularly on twin coil condenser models, it is necessary to consider
thearrangementofthestagingofthecondenserfans:
Alwaysrunthefanorfansnearesttheinletandoutletconnectionsfirstandthen
cyclethefannexttoitandsoon.
Onlarger(12fancondensers)thefanscanberuninpairsovereachcoil,onsmaller
condensers(fourfan)itmaybepreferabletoselectan'inline'fourfanmodel.

Care must be taken when operating in low ambient conditions because liquid
accumulationcanoccurinthecondensercausingliquidshortage.

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2.5.4 POSITIONOFREMOTEAIRCOOLEDCONDENSERS

Remoteaircooledcondensersshouldnotbepositionedinfullsunonflatroofsasthiscan
addupto10Cinsolargainandwillaffectperformance.Screensmaybeusedtoreduce
solargain.


Fig2.6Locationofremoteaircooledcondensers


Fig2.7InstallationandLocationofremoteaircooledcondensers

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2.5.5 FINBLOCKMATERIAL

Aluminium is the most commonly used but corrodes in salt or polluted atmospheres.
Alternativesare:
Polyestercoating
Copperfins
Copperfinselectrotinned

2.5.6 WATERCOOLEDCONDENSERS

The performance of a water cooled condenser is a function of a number of parameters


similartoaircooledmodels:
surfaceareaofthetubebundle
tubedesignandmaterialplainorextendedsurfacetubes
tubesizeandpitch
refrigerant
quantityofwaterflow
watertemperatureenteringthecondenser
arrangementofthewatersidebaffling
Numberofpasseswaterside
waterfoulingfactors

Again different models will have capacity ratings which are a function of the first three
parameters.Thewatertemperatureenteringthecondenserwilldependuponitssource.
Theflowratewillbeafunctionofitssupply;eitherapumpifitisacirculationsystemusing
acoolingtower,orthemainspressure.

Ingeneralthedesignengineerhasagreaterselectionwithwatercooledcondensersthan
withaircooledtypes,butthesameoverallfactorsaffectenergyefficiency.

Control of head pressure can be achieved by the use of a 3way valve controlling water
flowthroughthecondenser.Thevalvecaneitherbetemperatureorpressurecontrolled.
Evaporativecondensersarenotgenerallyemployedoncommercialrefrigerationsystems.
There are several methods of introducing water so that it evaporates to lower the air
temperatureoverthecoil.Anysuchmethodmustutilisepurposedesignedcondensersand
watertreatmentsystemstoavoidbuildupofdepositsandanyriskoflegionella.

2.6.0 EXPANSIONVALVES

2.6.1 INTRODUCTION

Themostgeneraltypeofexpansiondeviceusedoncommercialrefrigerationinstallations
isthestandardthermostaticexpansionvalve(TEV).

Aslongasitisproperlyselectedandadjustedforthecorrectsuperheat,itisareliableand
efficientcontroldeviceforsystemswithreasonablyconstantloads.

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Ifwidevariationsintheoperatingpressuresareexpected,aswithsystemshavingcapacity

controlorafloatingheadpressure,thenanalternativevalvehavingmoreflexiblecontrol
characteristics should be used for example, a balanced port valve or an electronic
expansionvalve.

The balanced port valve is similar in appearance and operation to a standard TEV.
However, its internal design and construction allows it to operate with much closer
clearances.Thisallowsthevalvetomaintainanacceptablelevelofcontrolontheflowof
refrigerant over a much wider range of pressure differentials. The cost compared to a
standardvalveistypically20%more.

2.6.2 THERMOSTATICEXPANSIONVALVESELECTION

Accurate selection of expansion valves is essential to achieve good system control and
optimum efficiency. Special care must be taken when selecting TEVs for systems which
operatewithcapacitycontroltopreventliquidreturntothecompressoronpartload.
Data on expansion valves for use with a particular refrigerant is usually presented in
tabular format covering both a range of evaporating temperatures and high to low side
pressure drops. The data is rated for a given superheat and liquid temperature. When
operatingatdifferenttemperatures,correctionfactorshavetobeapplied.

The pressure drop across the expansion valve must be calculated. This is the difference
betweenthecondensingandevaporatingpressurestakingalltherelevantpressuredrops
into account. It will include losses in pipes and fittings, static pressure drops in vertical
liquidlines,andtheeffectofadistributorifoneisusedwiththeevaporator.
Thevalve'scapacitywillvaryiftheliquidrefrigeranttemperatureisdifferentfromthatof
theratedcondition.Correctionfactorsarepublishedbythemanufacturer,whichmustbe
appliedtothestatedcapacity.

An externally equalised valve must be used if the pressure drop through the evaporator
exceedsthelevelspecifiedbythevalvemanufacturer.Thiswillvarywiththeevaporating
temperature and refrigerant. If the evaporator is fitted with a distributor, the resulting
pressuredropwillnecessitatethefittingofanexternallyequalisedvalve.
On evaporators with a low pressure drop there is no disadvantage in specifying an
externallyequalisedvalve.

Differentphialchargesareavailabledependinguponthesystemandoperatingconditions.
Typical of the variations available are charges which limit the operating pressure (MOP
charge).Thiswillpreventanoverloadconditionatthecompressorifpeakperiodsofhigh
loadarepossibleforinstance,justafteradefrostoperation(MOP=MaximumOperating
Pressure.

2.6.3 LOWAMBIENTCONDITIONS

Theexpansionvalvecapacityrelatestothepressuredropacrossthevalve.Inlowambient
conditionsthepressuredropacrossthevalveissmallerandthereforethedutyofthevalve

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issmaller.Itisthereforeimportantthatwhenexpansionvalvesareselected,theminimum
operating condensing pressure is considered. In some instances this may make the
expansionvalvetwicethesizeoftheoneselectedforthedesignambientconditionsbut
expansionvalvescanthrottledownto,andcontrol,atleast20%oftheirdesigncapacity.

2.6.4 CAPACITYCONTROL

Topreventliquidreturningtothecompressoronsingleevaporatorsystemsanexpansion
valve with a capacity as close as possible to the full load condition should be selected.
Mostvalveswilloperatewithoutcausingliquidreturnatcapacitiesdownto20%oftheir
ratedfullloadcondition.Ifvariationsgreaterthanthisareexpected,twoormorevalves
fittedinparallelmayberequired.Alternativelyamoreversatiletypecanbeused,suchas
anelectronicorbalancedportvalve.

2.6.5 ADDITIONALIMPORTANTCONSIDERATIONS

TEVs are available with alternative phial charges and connections, so these must be
specifiedbythesystemdesigner,asmusttherequirementforthevalvetobeinternallyor
externallyequalised.

At their rated capacity, valves are not fully open. This allows some compensation for
intermittentproblemssuchas:
shortperiodsofincreasedloadorlowambientconditions;
occasionalsmallquantitiesofflashgas;
slightshortageofrefrigerant;
minorerrorsinselection.

Althoughthereissomelatitudeinthesizingofexpansionvalves,itisimportanttoensure
thattheselectionisasaccurateaspossible.Bothoverandundersizingavalvecancause
inefficiencies.

Oversizingavalvecanleadtothefollowingsystemfaults:
liquidrefrigerantreturningtothecompressor;
expansionvalvehunting.
Liquid refrigerant returning to the compressor will often result in failure or reduced
efficiency. If the valve is too large for the required duty, any adjustment made in an
attempt to control the superheat will result in excessive fluctuations in the flow of
refrigerant. This will cause alternate flooding and starvation of the refrigerant in the
evaporator,andsubsequentlossofefficiency.Thisisknownashunting.

Suctionaccumulatorscanbeusedasapreventativemeasuretoavoidliquidcarryoverto
thecompressor.

Under sizing a valve will starve the evaporator of refrigerant as there will be insufficient
capacitythroughthevalvetomaintaintherequiredexitsuperheat.Thiswillagainreduce
theevaporator'scapacity.

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2.6.6 ELECTRONICEXPANSIONVALVES

Electronicexpansionvalvesareavailableintwotypes:
1. Steppermotor
2. Pulsesolenoid(PulseWidthModulated)

In each case a controller is used in conjunction with the valve. The controller is pre
configuredfortherefrigerantandvalvetypeanditreceivestheinformationfromsensors,
for example, pressure and temperature at the evaporator outlet. This enables the
superheat to be determined. The output signal to the valve initiates the orifice
adjustment.Thesteppermotorarrangementoperatesontheprinciplethateachindividual
stepofthemotorwillopentheorificebyacertainpercentage.

InthecaseofthePulseWidthModulated(PWM)valveitistherelationshipbetweenthe
openingandclosingwhichdeterminesthecapacityofthevalve.Thevalveiseitheropenor
closedandeachtimeintervalofafewsecondswillincludeanopeningperioddepending
onthesignal.

ThePWMvalvealsoeliminatestheneedforaliquidlinesolenoidvalveandinmostcases
evaporator pressure regulators. Liquid hammer can occur with this type of valve and
refrigerantliquidlinevelocitiesshouldbenomorethan1m/sec.

The other important advantage in applying electronic expansion valves is that they can
operateonanytypeofrefrigerant,thereforeiftherefrigerantischanged,thevalvedoes
notrequirereplacing.TheyaremorecostlythanTEVs.

The turndown capability of the electronic expansion valve means that unlike its
conventionalcounterpart,thevalvecanoperatesatisfactorilyatvirtuallyanycondensing
pressure, providing it is properly selected. This means that operation with very low
condensingpressuresispossible(egduringthewintermonths).

2.7.0 OTHERCOMPONENTS

2.7.1 PRESSURERELIEFVALVES

BS EN3782 sets out in detail requirements for pressure protection. This includes safety
valves, bursting discs and other pressure limiting devices, including for example, high
pressurecutoutswitches.

2.7.2 TEMPERATURECONTROLS

Temperature controls cover a wide spectrum of types, from the simple bimetal strip
arrangement,throughthecapillaryandbellowstype,tothemodernelectronictype.The
mainfunctionofathermostatistoeitherstoporstartacondensingunitorcompressor,
dependentonthetemperaturesetting.Thiscanbeachievedbyoperatingasolenoidsuch
as described under pump down cycle or by directly controlling the operation of the
condensingunit/compressor.

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Temperaturecontrolsarealsousedforthefollowingpurposes:
1. Defrosttermination
2. Evaporator fan delay after defrost (to cause a snap freezing of any free water on
surfaceofcoilafterdefrost)
3. Liquidinjectioncontrol

Capillarytemperaturecontrols/thermostats
Capillary Temperature Controls have a bellows attached to a remote bulb by a length of
capillary tube. Bellows, capillary tube and bulb are evacuated and partly or wholly filled
withamedia(sometypeswithtwomedia).

Increaseordecreaseoftemperatureatthebulbcausespressurechangeswithinit.These
pressurechangesaretransmittedthroughthecapillarytubeintothebellowslocatedinthe
thermostat. The bellows expands or contracts as the pressure inside of the bellows
changesandmovesthemechanismoftheelectricalcontact.

Themediumusedtoconveythetemperaturechangeinformationmayvaryrelativetothe
requirement, and the temperature range. Sensing bulbs also vary in size and shape
dependentonthecharge.

Electroniccontrols
Electronic expansion valves are described in Section 2.3.2. Case/coldroom controllers
consist of small printed circuit boards situated within a small electrically safe protective
box.Mostcontrollersneedahandheldunittoaccessthememory.Oncethisisavailableit
becomesconvenientforallthecommissioninginformationandsettingstobeassignedto
thecontroller

whenserviceisrequiredwiththehandheldunitinplace,accesstoalldataisavailable.

Displaycase/coldroomcontrollerscancarryoutthefollowingfunctions:
1. Initiatedefrost
2. Terminatedefrost
3. Controlaironandairofftemperaturebyoperationofliquidlinesolenoidvalves.
4. Initiatetemperaturealarms

Thetypeofinformationthatisavailablefromcase/coldroomcontrollersisasfollows:
1. Defrostinitiationtimes
2. Defrostterminationtemperature
3. AirOnevaporatortemperature
4. AirOffevaporatortemperature
5. Superheatacrosstheevaporator
6. Alarmtemperaturesettings

Electroniccontrolsofferthefollowingadvantages:
(a)EnergySaving
Electronicexpansionvalvescansaveenergycostbecausetheycanoperateatlower
superheatsandthereforetheevaporatorcontainsmoreliquidrefrigerant.

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Floatingdischargepressurecansaveupto30%inenergycosts.Thisismorelikely
tobeachievedusinganelectronicexpansionvalvebecausethepressuredifference
acrossthevalvehasalesssignificantimpactonthevalveoperatingefficiently.

(b)Reductioninmaintenancecosts
Case/coldroom controllers are convenient to use and give access to information
quickly;thisreducesmaintenanceandtroubleshootingtime.

(c)Productqualityenhancement
Temperature control and defrost control play a big part in the life of a product
under refrigerated storage. Storage life can be shortened considerably if the
correcttemperaturewithinthecase/coldroomisnotachieved,orifdefrostisnot
terminatedcorrectly.Withcase/coldroomcontrollersthisproblemisreduced,due
totheeaseatwhichtemperaturesettingsetc.,canbecheckedandadjusted.

2.7.3 TEMPERATURESENSORS

Platinumresistancesensors
PlatinumresistancesensorsaremorecommonlyknownasPT100sorPT1000s.Thesehave
resistancesof100and1000ohmsrespectivelyat0C.Their

resistance increases at around 0.35 & 3.5 ohms/degree respectively. More accurate
characteristicsarepublishedinBS1904.Thesensorsaremoderatelypriced,canbeusedin
afairlywiderangeoftemperatures,andbecausetheircharacteristicsdependonthebasic
properties of platinum, they are internationally available. The output signals are small
howeverandrequiremoderatelyaccurateresistorstorecovertemperatureinformationin
Celsius.

Thermistors
Thermistors are resistors whose resistance varies rapidly with temperature. Thermistors
are made from semiconductors and in refrigeration normally take the form of a disk
encapsulated in a metal or plastic housing. A typical thermistor might have a resistance
change of about 4% per degree C. Thermistors are particularly suitable for measuring
temperaturesnormallyencounteredinrefrigeration.Thermistorscomeintwotypes,PTC
and NTC thermistor. PTC (Positive Temperature Coefficient) thermistors are those
whereby the resistance of the probe increases with temperature. There is a type of
thermistorwheretheresistancechangesquiteabruptlyfromsome10sofohmsto10,000s
at some specified temperature. They are quite commonly used for thermal protection
applications.

The other type NTC (Negative Temperature Coefficient) thermistors, are those whereby
theresistanceoftheprobedecreaseswithtemperature.Thethermistorsareusedbythe
controller to measure the temperature within the cases or coldroom. The exact
temperature to resistance relationship will be dependent on the probe type and will be
importanttotheoperationofthecontroller.


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Thermocouples
Thermocouples are economical, small, fast acting, suitable for a wide range of
temperatures, and can be made to withstand harsh environments. The thermocouple
senses temperature by measuring small voltage differences that occur when connecting
dissimilarmetals.Thismeansthatthesignaloutputissmall(typically40uVperdegree).
Thethermocouplemeasuresthetemperaturedifferencebetweenthesensingelementand
the indicating device. A controller which uses thermocouples therefore needs an
additionalsensortomeasureitsowntemperature.

2.7.4 SUCTION/LIQUIDHEATEXCHANGERS

This heat exchanger is used to subcool liquid refrigerant entering the expansion valve,
usingrefrigerantvapourexitingtheevaporator.Consequently,thereisanincreaseinthe
superheatofthecompressorsuctionvapour..Theincreaseinsuctionsuperheatcanalso
increase discharge temperatures at the compressor and so great care must be taken to
ensure that the compressor operating limits are not exceeded. Suction/liquid heat
exchangersareusedforinsuranceagainstthepossibilitythatanyliquidrefrigerantleaving
the evaporator will reach the compressor. Higher suction line temperature can result in
lessnonusefulheatpickup,andthiswillenhancesystemefficiency,butheatexchangers
should only be used after careful consideration of the system design and operation. The
beneficialeffectofsuction/liquidlineheatexchangersdoesvarywithdifferentrefrigerant
fluidsanditisimportantthatcarefulcompressorperformancemodellingwiththeselected
refrigerantbecarriedouttodeterminewhetherthisistheoptimaloption.

2.7.5 OILSEPARATORS

Allcompressorspumpoilfromthecrankcasestoagreaterorlesserextent.Theamount
ofoilcarryoverdependsonthecompressortypeandtheloadonthecompressoritself.

Oilwithinrefrigerantsystemscancauseproblemsduetoitsmiscibilityandsolubilitywith
refrigerants.Systempipeworkisdesignedtokeeppressuredropsaslowaspossibleandat
thesametimekeeprefrigerantvelocitieshighenoughtotransportoil.

Wherevaryingloadsoccuronsystemsthevelocitieswillattimesfallandthiscanleadto
accumulation of oil in the low pressure part of the system. Large amounts of oil in the
evaporatorcancauseaninsulatingeffectontheevaporatorheatexchangersurfacewhich
resultsindutylossandpooroperationofthesystematalowerevaporatingtemperature
thantheoriginaldesign.

Anoilseparatorcansignificantlyreducetheamountofoilcirculatingthroughthesystem
andshouldalwaysbeconsideredparticularlyonlowtemperaturesystemswithremote
evaporators where the viscosity of the oil/refrigerant mixture in the evaporator can be
high. The lubricant recommended by compressor manufacturer should be used, since
account will normally have been taken of its behaviour in the systems for which the
compressorisintended.

Itisimportanttorecognisethatnoseparatorremoves100%ofentrainedoil,andsystems
mustalwaysbedesignedforadequateoilreturnvelocities.

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Oil separators should be selected in accordance with the manufacturer's information.
Most manufacturers recommend selection is based on the maximum mass flow of the
compressor within the system, and that the inlet and outlet connections of the oil
separatorarenotsmallerthanthesystemdischargelines.

Oilseparationisdependentonthedischargegasvelocity.Withmultiplecompressorsitis
advisable to ensure that under low load conditions the velocity is sufficiently high to
maintain efficient oil separation. Individual oil separators may be required for each
compressor.Whenmorethanoneseparatorisusedacheckvalveshouldbefittedatthe
oil return line from each separator. When subject to low ambient conditions, the oil
separator shell should be heated or insulated to eliminate refrigerant condensing within
theshell.Asolenoidvalveshouldalsobeinstalledintheoilreturnlinetothecrankcaseso
that if liquid refrigerant is present within the oil separator shell, it cannot enter the
crankcaseduringthecompressoroffcycle.

Oilinjectedcompressorssuchasscrewcompressorsdependonahighoilflowthroughthe
machineandusuallyhaveabuiltinseparatorandoilinjectionarrangement.

2.7.6 PRESSUREREGULATORS

Pressure regulators are frequently used to control the refrigerant pressure in an


evaporator at a condition higher than that of the compressor suction. There are two
situationsinwhichthistypeofcontrolisrequired.

Evaporatorpressureregulation
Evaporatorpressureregulators(EPRs)canbeusedonsystemswithmultipleevaporators
working at different temperatures, or they can act as a safety device to prevent water
chillersworkingatunacceptablelowtemperatures.

EPRscontroltheflowofrefrigerantgasbymonitoringandregulatingtheconditionsatthe
exitoftheevaporator.Ifthispressuredropsbelowthesetpointofthevalve,aninternal
pistonprogressivelycloses,restrictingtheflowofgasuntiltheevaporator'spressurerises
tothesetpoint.Ifthesuctionpressureofthecompressor,andhencetheevaporator,is
abovethatofthevalve'ssetpointitwillremaininthefullyopenposition.

FortheEPRtomaintainanaccuratecontroltherewillalwaysbeapressuredropthrough
thistypeofvalve.Themagnitudeofthepressuredropwilldependupontheselectionof
the valve which should meet the system duty and the prevalent operating conditions.
However, any pressure drop in the suction side of a system will reduce the plant's
efficiency.

EPRsshouldnotbeinstalledclosetothecompressorasthismaycausehuntingduetothe
verysmallrefrigerantvolumebetweenthevalveandcompressorsuction.

Crankcasepressureregulation
Where a compressor is limited at higher evaporating temperatures by motor size it is
possibleforthemotortobecomeoverloadedduringthepulldownperiod,andcrankcase

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pressureregulationcanbeusedtolimitthesuctionpressure.

Control is arranged so that when the outlet pressure drops, the valve opens to allow a
greater flow of refrigerant gas to pass through it to the compressor. Conversely, as the
compressorsuctionpressurereachesthevalve'ssetpointitcloses,throttlingthepressure
tothecompressor.

The compressor motor need not be sized for the maximum load or pulldown if this is
eitherofashortdurationorifitcanbeextendedoveralongerperiod.Useofasmaller
motormeansthatduringthemajorityoftheoperatingcycle,whentheloadisatitsnormal
level the motor will be better matched to the application and thus operate more
efficiently.

Pressureregulatorsshouldalwaysbeselectedonaduty/pressuredropbasisandNOTon
pipesize.

2.7.7 LIQUIDLINESIGHTGLASSES/MOISTUREINDICATORS

Liquid line sight glasses should be fitted to all systems and should be installed after the
liquidlinedrierandbeforethethermostaticexpansionvalve.

All sight glasses should be complete with a moisture indicator appropriate for the
refrigerantchargedinthesystem.Forcopperpipeworkbrazedcopperconnectionsshould
beused.

2.7.8 NONRETURNVALVES

A non return valve (NRV) should be fitted in the discharge line when using remote air
cooled condensers if the discharge pipework could allow liquid refrigerant migration
during the off cycle. NRVs on this type of application should be suitable for the system
dischargetemperaturesandpressures.

NRVs are also used in saturated and hot gas defrost systems on a bypass arrangement
aroundthethermostaticexpansionvalve.Thesevalvesshouldbeofthesweattypewith
coppertailsandsizedforfullliquidlineflow.

CareshouldbetakennottooversizeNRVsbecausethevalvemaychatteratreducedflows.

2.7.9 HANDSHUTOFFVALVES

Hand shut off valves should be installed where appropriate to isolate components and
machinery that will require maintenance and to eliminate the loss of refrigerant during
maintenance.

Allshutoffvalvesshouldbedesignedwithgastightstem.Relianceshouldnotbeplacedon
acaptopreventleakagebecausethevalvewillleakgaswhenthecapisleftofforlost.

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2.7.10OILDIFFERENTIALPRESSURESWITCHES

This control should be fitted to all compressors that incorporate a mechanical high
pressureoilpump.Thetimerdelayrangeofthepressureswitcharrangementshouldbeof
the type recommended by the compressor manufacturer. Intelligent oil safety controls
thateliminatetheneedforpressureconnectionsandjointsarepreferred.

2.7.11SAFETYCUTOUTS(SWITCHES)

These should be set and sealed by the commissioning engineer and labelled with their
respectivesettings.

SafetymeansSAFETYnotCONTROL.

Doublebellowstypepressureswitchesarepreferredtoreducerefrigerantleakage.

Pressureswitchesthatconnectdirectlyintothemainpipeworkshouldbeconsidered,as
shouldelectronicarrangementsusingpressuretransducers.refertoEN378.2:2008

2.7.12 SOLENOIDVALVES

Solenoidvalvesinstalledintheliquidlineshouldbeascloseaspossibletotheexpansion
valveparticularlywhenapumpdowncontrolsystemisbeingused.Thesevalvesshould
also be fitted in the oil return line from the oil separator to the compressor where
individualcompressorreceiverorcondensingunitsarebeingapplied.

Thesecomponentsshouldbesizedonrefrigerantflow.Whereservooperatedvalvesare
used,pressuredifferencesshouldbecheckedtomakesuretheyaresufficientforthevalve
tooperate.

2.7.13PRESSURECONTROLTUBING

Flexible nylon capillary tubing with capillary hose fittings may be used for connecting
instrumentsandpressurecontrolsprovidedthematerialisofsuitablepermeabilityforthe
refrigeranttobeused.Coppertubingshouldhavebrazedconnectionsthroughout.

2.8.0 REFRIGERANTPIPEWORK

2.8.1 INTRODUCTION

Thepipeworkshouldbesizedtakingintoaccountthefollowingfactors:
1 Pressuredrop
2 Oilreturntothecompressor
3Minimumrefrigerantcharge
4Liquidrefrigerantcontrol
5 Preventionofvapourlocks
6 Lownoise
7Flexibilityoverentireoperatingrange

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8Minimumheatpickup

Some of these parameters are dealt with elsewhere in this guide. Oil return, system
chargeandnoisearecoveredhere.

2.8.2 PRESSUREDROP

Pipeworkshouldbeselectedtominimisepressuredrop.Theeffectofpressuredropon

performance and efficiency is more significant in suction lines than in other pipework. A
relatively small pressure drop in the suction pipework of a lowtemperature installation
willcauseaseriousreductioninthesystem'sefficiency.

A pressure drop in a discharge line will have no significant effect on efficiency. As the
pressureratioofasystemdecreasessoalsodoestheeffectofasuctionlinepressuredrop.

2.8.3 SIZING

Itisveryimportantthatpipesizingcalculationsarecarriedout.Selectingpipesaccording
totheconnectionsizesoncompressorsandothercomponentswillnotguaranteethebest
design. These connections aresizedtosuitawiderangeofapplications,butwillnotbe
correctforeveryinstallation.

Chartswhichgivepressuredropsforagivenrefrigerantandsystemcapacityoverarange
of evaporating or condensing temperatures are available from a number of sources, and
softwareisalsoavailable.

Fittings and components, such as pipe bends and valves, have pressure drops which are
commonlyexpressedasanequivalentlengthofstraightpipe.Thesecanbeobtainedfrom
manufacturers'catalogues.Thepressuredropsforfittingsspecifiedinsystemsshouldbe
checkedastheremaybeoptionswithlowerpressuredrops.Forexample,asweptbend
willhavealowerpressuredropthanarightanglebendandwillalsohavealongerlife.
Wherethereisanychoice,longverticalupflowpiperunsshouldbeavoided.Inliquidlines
thestaticheadfromsucharisemustbeconvertedintoapressuredrop.Thiswillenable
the equivalent loss in liquid subcooling due to the pressure reduction to be ascertained
andindicatewhetherevaporationofliquidrefrigerantcouldoccurbeforetheTEV.

2.8.4 OILRETURN

The sizing of pipework to ensure that good oil return is maintained is contrary to the
parametersforminimisingpressuredrops.Unlessanadequategasvelocityismaintained,
oilwillaccumulateinthelowpressuresideofthesystemandpossiblyresultincompressor
lubricationfailures.

The final pipe size selection has to be a compromise between a small diameter pipe to
ensurethatthereissufficientrefrigerantvelocitytocarryoil,andalargediameterpipeto
minimiseanypressuredrop.Somepressuredropscanbereducedbycarefulattentionto
thedesignandinstallationofpipework.Limitingthenumberoffittingsandbendswhich

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increasethepressuredropisonewayofachievingthis.

Note!Slopethedischargepipeworkdownfromthecompressor
To give good oil return the pipework should slope towards the compressor. Minimum
slopeof1in400,isrecommended.

2.8.5 REFRIGERANTVELOCITY

Asstatedpreviously,refrigerantvelocitiesinpipeworkareimportantfortherecoveryof
oilbacktothecompressorfromthesystem.Asageneralguide,thefollowingvelocities
shouldbeconsidered:
LiquidExTheCondenser 0.5m/s(100fpm) 0.76m/s(150fpm)
LiquidExTheReceiver 0.5m/s(100fpm) 1.0m/s(200fpm)
Suction 4.0m/s(800fpm) 17.8m/s(3500fpm)
Discharge 10.0m/s(2000fpm) 17.8m/s(3500fpm)

2.8.6 OILANDLIQUIDTRAPS

Itisimportantthattrapsareincorporatedintopipeworksystems,inordertopreventliquid
refrigerant draining back to the compressor(s) during off cycles, and to aid oil return to
compressors during run cycles. This particularly applies where vertical pipework is
involved.Detailsasfollows:

Liquid Traps: On vertical discharge pipe runs, it is usual to take the pipework to the
highest point of the condenser before returning to the inlet connection of the
condenser. This ensures any liquid from the condenser does not drain backwards
down the discharge onto the cylinder head of the compressor(s) during off cycles.
Anothermethodofeliminatingthisproblemistofitacheckvalveinthedischargeline
atthelowestpointafterthepipeworkleavesthecompressor.

Oil Traps: Oil traps are installed in suction lines to ensure oil return to the
compressor(s),theyareusuallyinstalledattheendsofverticalrisers

2.8.7 VERTICALSUCTIONRISERS

To maintain oil return i.e.( velocity), vertically rising suction pipe may need to be of
reducedsize.Theincreasedpressuredropcanbeoffsetbyincreasingthediameterofthe
horizontal part of the suction line. Oil traps should also be provided at 6m intervals to
assistoilreturn.

Where capacity control is utilised, the mass flow may not be high enough to give the
correctvelocityforoilreturn.Doublerisersshouldthenbeconsidered.

2.8.8 DOUBLESUCTIONRISERS

Doublesuctionrisersconsistoftwopipes,onepipesizedtoprovideoilentrainmentwith
the compressor operating at partial load, and the two together capable of lifting oil at
maximumoperatingconditions.

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Oiltrapsmustbeprovidedbetweenthetworisers.Atpartialloadoperationwhenthegas
velocityisinsufficienttoreturnoilthroughbothpipes,thetrapwillgraduallyfillwithoil
untilthesecondriserissealedoff.Therefrigerantgasthentravelsupthefirstpipeonly
with sufficient velocity to carry the oil along with it into the horizontal pipe section.
Precautions must be taken to make the trap as small as possible by close coupling the
fittings.Thisensuresthattheoilholdingcapacityofthetrapwillnotseriouslylowerthe
compressorcrankcaselevel.Italsoavoidsslugbackofoiltothecompressorwhenthetrap
clearsontheresumptionofincreasedloading.

Thesecondriserpipemustbeformedatitsupperlimitwithaninvertedlooptoenterthe
main horizontal suction pipe from above. This prevents oil draining into this riser whilst
idleduringpartialloadoperation.

Whenselectingthecombinationofpipesforadoublesuctionriser,thediameterofapipe
that will ensure oil entrainment at maximum compressor duty; must be established and
alsothediameterofthepipethatwillgivesatisfactoryoperationatminimumduty.The
combined cross section area of the two complementary parallel risers must not exceed
thatofthesinglepipewhichissuitablefortheentrainmentofoilatmaximumduty.

Aclosecoupledtrapshouldbeformedatthelowerendofanysuctionpipeatthepointof
rising to a higher level for the collection of fallback oil during offcycle time. An oil lock
mustbeformedtoretainaslittleoilaspossiblepreventingseriousreductionincrankcase
oillevelwhentheplantoperatesatpartialduty.

IntheexamplesinFigure2.8pipe'A'issizedtoprovideoilentrainmentatminimumduty,
and pipes 'A' & 'B' together provide oil entrainment at maximum duty when the oil lock
clearsduetoincreasedpressuredropinpipe'A'.Pipe'B'mustenterthehorizontalsuction
pipefromabovetoavoidoilcarrieduppipe'A'fromdrainingintopipe'B'whentheplantis
operatingatpartialduty.

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.

Fig2.8Examplesofdoublesuctionriserlayout

2.8.9 MULTISTUB

This term is used to describe a design in which a number of refrigerated fixtures are
assigned to one suction and liquid line. The suction and liquid lines usually run from a
groupoffixturesbacktoamulticompressorpack.Thegroupoffixturesshouldoperateat
approximatelythesameevaporatingtemperature.
This system is relatively simple to design using pressure drop and velocity graphs, or
computer software all that is required is the total duty and the lowest evaporating
temperature of the group of fixtures. This system has been applied in conjunction with
saturatedorhotgasdefrost,whicharenowlessused.
Liquiddistributiontothemultievaporatorsystemisveryimportantifpoorperformanceis
tobeavoidedandthereareseveralmethodsofachievingthis:
HeaderMethod:Theliquidfeedtoanumberofevaporatorsisfedtothecentrepoint
ofaheader.Thisfeedlineshouldhavesufficientcapacitytoensurethattheheader
remainsfullofliquidrefrigerantatalltimes.
RingMainMethod:Thismethodisusuallyemployedwheremanyevaporatorsarefed
fromalargecapacitysinglestub.Theringmain
ensures that liquid refrigerant feeds the supply line to each evaporator from two
directions.
Reducing Method: With this method the liquid refrigerant feed line reduces in size
immediatelyaftertheteeofftoeachevaporator,endingfinallywiththefeedpipesize
usedtofeedeachevaporator.

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2.8.10RADIALMAINSYSTEM

Onaradialmainsystem,theliquidandsuctionpipeworkforcoolersmostdistantfromthe
compressors is comparatively small because it is sized for only one set of refrigerated
fixtures. The added effect of fixtures nearer the compressors requires the main suction
liquidlinestobeincreasedtoallowfortheincreasedduty.Thebranchsuctionandliquid
linesaresizedinexactlythesamewayasamultistubproject.Onthistypeofsystemit
canbeseenthattheactualdutycanvarytremendouslyonthemainsuctionandliquidline.
It is therefore very important that refrigerant suction lines slope back to the multi
compressorpack;allverticalrisersneedaminimumofdoublepipearrangement,ifnotto
threepipearrangement,dependingonthefluctuationinload.

2.8.11GUIDANCEDATAFORCOMPUTERSELECTIONOFPIPEWORK

LTSystem
Superheat(K) 10K
LiquidTemp 5KBelowCondensingTemp
Suctionpressuredrop 2K
HeadDifference 0
Liquidlinepressuredrop 1K
Riserstobedesignedtoreturnoilatminimum33%capacity.

HTSystem
Superheat(K) 10K
LiquidTemp 5KBelowCondensingTemp
Suctionpressuredrop 2.5K(2.OK)CondensingUnits
HeadDifference 0
Liquidlinepressuredrop 1K
Riserstobedesignedtoreturnoilatminimum33%capacity.
LiquidTempFactorAssumesNoMechanicalSubcooling.

2.8.12PIPEWORKMARKING

AllPipeworkcarryingrefrigerantshouldbemarkedinthefollowingmanner.
The label shall be in accordance with BS1710 Specification for the identification of
pipelinesandservices

Anadhesivelabelshallbeprovidedwhichwillnotundernormalcircumstancespulloffor
fallawayfromthecopperpipeworkorinsulation.Thelabelmustbeaffixedatintervalsof
nomorethan2mintervals.

Thelabelshallcontainthefollowinginformation.
RefrigerantNo
DirectionofFlow
RatedPressure
Theinformationshallnotbeeasilyremovedfromthelabel.

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2.8.13PIPESELECTION

It is extremely important that the correct gauge of copper pipe is selected and the
followingpublicationsshouldbeconsulted:
EN 3782:2008 refrigerating systems and heat pumps safety and environmental
requirements,Piping.

2.8.14PIPEWORKINSULATION

Insulationisessentialonallsuctionlinestoeliminatecondensationandreducenonuseful
superheat.Liquiddirectfromacondenserorreceiverbenefitsfromadditionalsubcooling
(natural subcooling) which can occur in the line, and so insulation is not then required.
Whereaheatexchangerisemployedtoprovidesubcoolingliquidlinesshouldbeinsulated
toreduceheatpickup.

Theliquidlineshouldnotbepassedthroughanareaofhighambienttemperatureasthis
will reduce the subcooling and may cause evaporation of liquid before the expansion
device.Ifliquidlinesmustpassthroughareasofhighambienttemperatures(i.e.where
ambienttemperaturesexceedsliquidrefrigeranttemperature)theymustbeinsulated.
Thus liquid lines on conventional systems do not normally require insulating especially if
passingthroughareaswheretheambienttemperatureislowerthantheliquidrefrigerant
temperature.However,insomecasessuchasfalseceilings,insulationmayberequiredto
reduceheatpickup.

Insulation of discharge lines should be considered for safety reasons, The insulation
specification depends on such environmental conditions as maximum ambient
temperature, Air Dew Point, Relative Humidity and Air Flow. Manufacturers' technical
informationshouldbeconsultedfordeterminingtherequiredinsulation.
Care should be taken to make sure that the insulation conforms to the correct fire
regulationsrelatingtothesite.

It is important that pipework insulation is carried out by competent technicians suitably
trainedinsuchinstallationwork.Alljointsshouldbegluedtomakeanairtightassembly.

2.9 DESIGNCONSIDERATIONS

2.9.1 DESIGNFORMINIMALLEAKAGE

Prioritymustbegiventominimisingpotentialsourcesofleaksinallaspectsofthedesign.

2.9.2 SUCTIONANDCONDENSINGPRESSURE

Examination of compressor performance data will illustrate the effect of condensing


pressure,powerconsumptionandcapacity:

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EXAMPLE:Bitzer6H25.2,R404AEvaporatingat5C
CONDENSINGC CAPACITYkW ABSORBEDkW
43 70.7 28.2
30 87.9 23.5
20 101.1 19.32
PerformancefigurescourtesyofBitzerUKLimited.

Thecompressorcapacityincreasesascondensingtemperaturesfall,thenetresultisless
runningtimeforthecompressor.

Notethat
Considerablesavingscanbemadeevenwithsmallcondensingtemperaturereductions.
Heat recovery projects, where very high condensing pressures are maintained
throughout the year, may prove to be less effective when compared to the above
savingswhichtheypreclude.
With water cooled condensers, there can be significant variations in the water
temperature which necessitate some form of condensing pressure regulation for
conventional expansion valves to work correctly. Use of electronic expansion valves
allowslowertemperatures,whichapplyformostoftheyear.

The increased efficiency in a system that can be achieved if the suction pressure is
increasedisillustratedbelow.

EXAMPLE:Bitzer4J13.2,R404A,Condensingat43C
SATURATEDSUCTION CAPACITYkW ABSORBEDkW
C
10 33.4 14.43
8 36.1 15.01
PerformancefigurescourtesyofBitzerUKLimited.

Although the power consumption may increase, the increased capacity will result in a
compressorrunninglesshours.

2.9.3 REFRIGERANTCHARGEANDISOLATIONFORMAINTENANCEPURPOSES

Thefirstconsiderationischargelimitation.Pipesizesandpiperunsshouldbekeptassmall
as possible to reduce system working charge. Head pressure control by flooding the
condenser with liquid refrigerant should not be considered. However due consideration
should be given to the pressure drop of the selected pipework. Refrigerant receivers
should be as small as possible, horizontal refrigerant receivers require larger working
chargesthanverticaltypes.Thisisbecausetheareabetweenthebottomofthereceiver
andthediptubeislargeronhorizontalreceiversthantheverticaltype.
Pumpdownofthefullworkingchargeshouldbeaccommodatedwithinthereceiverplus
theremoteaircooledcondenserheatexchangesurfacearea.

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Toenablecomponentstobechangedwithoutlossofrefrigerant,handoperatedisolation
valveswithsealingcapsshouldbeconsidered.

Bypassarrangementssothatliquidlinedrierscanbechangedwhilsttheequipmentisstill
operatingshouldbeinstalledonthelargertypeofsystem.

Consideration should be given to the isolation of equipment such as solenoid valves and
expansion valves. EN3782:2008 should be consulted regarding maximum charge of
refrigerantandrestrictionsonuse.Considerationshouldbegivenwhencheckingisolation
valves to ensure liquid refrigerant is not trapped in pipework and allowed to rise in
temperature, this causes a hydraulic effect and dangerously high pressure can occur
causingfracturingofpipeworketc.

2.9.4 PUMPDOWNCYCLE

When a refrigeration system is not in operation for long periods of time, and if the
compressor becomes colder than other parts of the system, the refrigerant charge may
migrate to the compressor. At the compressor crankcase this refrigerant vapour may
condense into the oil, until the oil is completely saturated with refrigerant, causing
lubricationproblems.

Themosteffectivemethodofreducingthemigrationofliquidtothecompressorcrankcase
is by the use of a pump down cycle. This involves the isolation of the refrigerant in the
highsideoftherefrigerationsystem,Fig2.9.

The cycle operates by closing a solenoid valve located in the liquid line between the
expansion valve and the receiver. The liquid line solenoid valve is controlled by a
thermostatreadingthefixturetemperature.

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Fig2.9Physicalandelectricalarrangementforatypicalpumpdowncycle

The compressor continues to operate, pumping the refrigerant into the condenser,
receiverandliquidline.Theoperationofthecompressoriscontrolledbytheuseofalow
pressure switch sensing the suction pressure. The suction pressure drops until the
compressorisswitchedoffbythelowpressureswitch.Thistypeofcyclecanbeusedon
most thermostatic expansion valve systems, providing the high side of the system is

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adequateincapacitytoholdthesystemcharge.

Afterthepumpdowncycle,itislikelythatsmallamountsofrefrigerantwillleakpastthe
solenoidvalve.Thiswillcausethesuctionpressuretoriseagain.Thereforethisprocess
mustberepeated.

Acrankcaseheatermayalsobefittedtothecompressortokeeptheoilwarmenoughto
preventrefrigerantfromcondensingintotheoil.Thecrankcaseheatershouldbeswitched
onatalltimeswhenthecompressorisnotoperating.

2.9.5 DEFROSTMETHODS

Therearefourcommonmethodsofdefrostusedincommercialrefrigeration.
a. Offcycle
b. Electric
c. HotGas
d. SaturatedGas

Theadvantage/disadvantageofthesesystemscanbesummarisedasfollows:

a. Offcycle
Off cycle defrost does not use any form of artificial defrosting technique such as
electric heater, or refrigerant gas, to raise the temperature of the evaporator for
iceremoval.
Offcycledefrostisnotemployedonapplicationswherethetemperatureisbelow
+2C.Insomeinstancestheicebuildupthatmayoccurontheevaporatorheat
transfersurfaceisremovedduringthenormaloffcycle.Analternativemethodisto
employ a definite off cycle process when a timer shuts down the refrigeration
equipmentforafixedperiodoftime.
b. Electric
Electric defrost is simple to operate, control, and does not rely on any external
serviceforthesupplyofheat.Electricdefrostcanbeusedonalltypesofsystem.
c. Hotgas
Hot gas defrost uses the discharge gas as the source of heat, i.e. discharge gas is
circulated through the evaporator and an external heat source is not required.
However, coldrooms/display cases on the system need to be in the refrigeration
modetogiveaheatsourceforthedefrost.Thismayleadtoinefficientoperationof
thesystemduringlowloadandlowambientconditions.
Repeated expansion and contraction of pipework and joints during the defrost
cycles may lead to refrigerant leakage and premature failures of pipework and
evaporators.Forthisreason,thesesystemsarenolongerwidelyused.
d. Saturatedgasdefrost
Saturatedgasdefrostusesrefrigerantvapourwhichisformedabovetheliquidin
the refrigerant receiver. Therefore the temperature of the gas is the same asthe
condensing temperature for the system. The disadvantages and advantages are
similar to hot gas defrost. Expansion and contraction of pipework is not quite so
critical,butneverthelessthesesystemsarenolongerwidelyused.

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2.9.6 ELECTRICDEFROSTMETHODOFOPERATION

A controller/timing device initiates defrost by disconnecting the electricity supply to the


liquidlinesolenoidvalve.Atthesametimethecontrollerconnectstheelectricitysupply
to the defrost heater, on the larger type of application this may be via an electrical
contactor. Where coldrooms are concerned, the evaporator fans are switched off once
defrost is initiated, this eliminates heat from the defrost heaters being blown into the
coldroom.

Defrostwillbeterminatedoneithertime,orbysensingthetemperatureoftheevaporator
heatexchangesurfaceusingathermostatorsensor.

Once defrost is completed the defrost heaters are switched off, the liquid line solenoid
valveisthenopenedandrefrigerationrecommences.

In the case of coldrooms, the fans on the evaporators will not start to operate until the
moisture on the evaporator heat exchange surface has been refrozen. This eliminates
moisturebeingblownintothecoldroom.
Condensing unit applications may employ a pump down cycle as described in section
2.9.4.

Forsupermarketapplicationsitiscommonpracticetohaveupto4sectionsofthesame
typeofdisplaycasesconnectedeithertoonestubonamulticompressorapplication,orto
one condensing unit. Individual case defrost termination is probably the most energy
efficientandcosteffectiveintermsofproductenhancement.

Allsectionsaredefrostinitiatedatthesametime.However,aseachcasesectionwillhave
itsowndefrostelectricalcontrol,oncethecasesectionhasachieveddefrost,thedefrost
terminationthermostatwouldinterrupttheelectricitysupplytothedefrostonthisspecific
casesection.

All case sections would terminate and refrigeration would then be initiated by a timer.
Therefore a wait period would occur between all the case sections being defrost
terminatedontheirdefrostterminationthermostatandtherefrigerationbeinginitiatedby
thetimer.

Individualcasecontrolcanbeachievedbyathermostat/controllerpercasesection,thus
controlling a solenoid valve situated in each case liquid line. In this situation the defrost
initiation timer would interrupt the electricity supply to all the individual case liquid line
solenoidvalves,defrostterminationwouldproceedaspreviouslydescribed.

2.9.7 VIBRATIONANDNOISE

There are some basic measures that can be taken which can significantly help to reduce
both vibration and noise to an acceptable level. Attenuation is a specialist subject and
noise and vibration specialist should be consulted if problems arise, or specific

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requirementsarespecifiedorneeded.

How pipework assemblies are designed and installed has an important impact on
controllingthegenerationandtransmissionofnoiseandvibrationinarefrigerationplant.
Careshouldalwaysbetakenwhenassemblingpipeworktoavoidrigidfixing.

To avoid amplification of compressor vibrations, the compressor should be mounted
accordingtomanufacturersrecommendations.Thisisparticularlyimportantformultiple
compressorinstallations.

Adistanceofapproximately15pipediametersshouldbeallowedbetweenthecompressor
andthefirstpipesupportonsuctionanddischargelines.Thisallowsalongenoughlength
ofpipetoprovideflexibility.Itshouldbenotedthatthedistancetothepipesupportdoes
not need to take into account the otherwise lengthening effect of the bend. If the pipe
risesverticallyfromthecompressorvalve,thiscanalsoincludethebendwhichisplaceda
shortdistancefromthevalve.

Components carried in pipelines, such as liquid traps andmufflers,shouldbesupported.
The additional heavy mass of some of these items can pose significant extra stress on
pipelineassemblies.Toreducenoisegeneratedthroughthecontactofapipewithinapipe
clamp,asmallpieceofresilientanddeadeningmaterial(suchasneoprene)shouldbeused
tostopmetaltometalcontactandtherebyreducechatterandmayproviderefrigerant
leakageatalaterdate

When a pipe passes through a wall, a liner should be placed within the hole and the
openingproperlyrendered.Theopeningshouldbemadelargerthanthepipediameterto
avoidthepossibilityofdirectcontact.Theinterveningspaceshouldbefilledwithresilient
material such as fibre glass or polyurethane foam to seal it, deaden sound and protect
fromingressofdustandtheelements.

Flexiblehoses/vibrationeliminators
In some refrigeration and air conditioning applications the refrigerant lines must be
flexible,forexampleconnectionstocontrolsorgauges.(SeeSection2.7.13).Thistubingis
usuallyofasmallerdiameter,eg,OD5/8ODbeingthemostcommonsizes.

Where vibration may be a problem i.e., pipework connecting to compressors, vibration
eliminatorsareofteninstalledinthesuctionanddischargelinesasneartothecompressor
aspossible.Vibrationeliminatorsshouldalwaysbeinstalledinparalleltothecompressor
crankshaft, i.e. horizontally for piston compressors and vertically for vertical scroll
machines.

Dischargemufflers
A muffler in the compressor discharge line can dampen discharge gas pulsations. The
purpose of the muffler is to reduce vibrations and noise which would otherwise be
transmittedandamplifiedbythepipeworksystem.Amufflerconsistsofaperforatedpipe
passingthroughalargediametercylinderwhichformsachamberwithbaffles.
The device is usually placed in the horizontal or vertical pipe immediately leaving the
compressor.Itisnotusualtofitadischargelinemufflerinsystemsequippedwithanoil

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separator;theoilseparatorcanitselffunctionasamuffler.

2.10.0 LOADCALCULATIONS

2.10.1 INTRODUCTION

Whenarefrigerationsystemisatthedesignstage,orwhenevaluatingthesuitabilityofa
givensystemforaparticularpurpose,itisnecessarytoknowthemaximumdutyrequired.
Amoredetailedunderstandingofcoolingloadsallowsdesignersto:
Identifyopportunitiestoeliminateorreduceloads.
Optimisethetemperaturelevelsoftherefrigerationsystem.
Correctlyselect,sizeandcontrolcompressors.
Evaluate energy savings, for example the use of more efficient compressors, heat
exchangerswithlargersurfaceareasandthepossibilityofthermalstorage.

2.10.2GATHERINGDATA

Gatheringrelevantdataforthecoolingrequirementsisnotalwaysaneasytask.Foreach
coolingload,detailedinformationisrequired.Thisinformationissummarisedbelow.
Thedataisrequiredforallcoolingloadsifafullanalysisistobecarriedout.
To collect the information it is necessary to understand in some detail the process or
systemthatrequirescooling.

If the task of selecting the refrigeration equipment is left to personnel who do not have
access to the relevant information for the duty requirements, then there is a possibility
thatinefficientplantwillbeselectedandinstalled.

2.10.3COOLINGLOADDATA

Maximumcoolingdemand.
Variationsincoolingdemand.
Timingofthedemand
Durationofthecoolingdemand.
Initialandfinaltemperaturesoftheproductsorfluidstobecooled.
Specificheat,latentheatandrespirationoftheproducts.
Other data includes constraints on condensing medium and diversity of heat
generatingequipmentforexample.

The best source for this information is discussions with key personnel, production
managersandengineers.

2.10.4TYPESOFCOOLINGLOAD

Coolingloadscanbegroupedasfollows:
Sensible: thecoolingoffluidsorsolids.
Latent: freezingandcondensing.
Heatofrespirationfromfruitandvegetables.

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Insulation: coldrooms:pipesandvessels:etc.
Infiltration: throughcoldstoredoors.
Ancillaries: evaporatorfans,chilledwaterpumpsandlighting
Other: peopleandtrucksincoldstores:etc.

2.10.5SENSIBLECOOLINGLOADS

Sensiblecoolingloadsarethereductionoftemperatureofasubstancewithoutachangeof
phaseoccurring.
Examplesincludethechillingofwater,air,oraproduct.
Thecoolingloadisiscalculatedasfollows

Q=mCp(TiTf) Equation1

where: Q=Coolingload (kW


m=Mass (1kg)
Cp=Specificheatcapacity (kJ/kgC)
TiInitialtemperature (C)
Tf=Finaltemperature (C)

Specificheatcapacitychangeswithtemperature,althoughitcanoftenbeapproximatedas
a constant. Values for specific heat capacities for common substances can be obtained
fromstandardrefrigerationandengineeringreferences.

2.10.6LATENTHEAT

Latent heat is heat added or removed at constant temperature when a change of state
takesplacei.e.evaporation,condensing,meltingandfreezing.

Thelatentheatoffusionistheenergyrequiredtochangealiquidtoasolidorviceversa.

Fusion (freezing or melting) occurs at the fusion temperature (freezing/melting point) of
thesubstance.Fusiontemperaturesvaryslightlywithpressure.

Thelatentheatofcondensationorevaporationistheenergyrequiredtochangeagastoa
liquidorviceversa.

Condensationorevaporationtakesplaceatatemperaturewhichishighlydependenton
prevailingpressure.

Thelatentcoolingloadiscalculatedasfollows

Q=mL Equation2

where: Q=Coolingload (kW)


m=Mass (kg)
L=Specificlatentheatoffusionorvaporisation (kJ/kg)

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Values for freezing points, saturation temperatures/pressures and latent heats of fusion
andvaporisationcanbefoundinstandardtexts(seeAppendix1).

2.10.7HEATOFRESPIRATION

Productssuchasfruitandvegetablesarelivingtissuesandthereforeproduceheatiswhich
hastobeconsideredaspartoftheheatloadcalculations.

Thisrespirationeffectcanoccuralsoinchemicalcoolingorfermentationandisknownas
theheatofreaction.

Theheatofrespirationiscalculatedasfollows:

Q=MR Equation3

where:Q=Coolingload (kW)
M=Massflow (kg/s)
R=Respirationheatfactor (kJkgC)

Peoplealsogenerateheatthishastobeallowedforinheatloadcalculations.Theamount
ofheatgeneratedwilldependontheiractivity.Tablesareavailablewiththeappropriate
value in respect of both activity and room temperature. For air conditioning calculations
both the sensible and latent loads should be considered. Whereas for refrigeration
applicationstotalheatloadsareused.

2.10.8CONDUCTIONHEATGAINS

Thisloadistheheatgainthroughthewalls,ceilingandfloorandforacoldstore,chillroom
orairconditionedarea.
Theloadiscalculatedasfollows:

Q=UA(T2T1) Equation4

where: Q=Coolingload (kW)


U=Heattransfercoefficient (kW/m2C)
A=Surfacearea (m2)
T1="Cold"sidetemperature (C)
T2="Hot"sidetemperature (C)

The"U"valueisbaseduponthethermalconductivityoftheinsulationmaterial(wall,roof,
floor,etc)andthethicknessofthematerial:

U=kl Equation5

where: U=Heattransfercoefficient (kW/m2C)


k=Thermalconductivity (kW/mC)
l=Thicknessofmaterial (m)

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Foracompositewallorroofstructuretheoverall"U"valuemustbecalculatedbasedupon
thethicknessandthermalconductivityoftheindividualelements."k"and"U"valuesare
publishedforawiderangeofconstructionmaterialsinstandardtexts.

Theinternal("coldside")temperatureofacoldroomisnormallyconstantthroughoutthe
year. The external ("hot side") varies with the seasons. It is important to consider the
impactofthevariationinseasonalexternaltemperaturesonthepeakcoolingloads.

If the structure being cooled is subject to direct solar radiation, an allowance must be
madefortheincreaseinsurfacetemperature(i.e.T2the"hotside"temperature).

Theincreaseintemperatureisdependentupon:
Thetimeofyear.
Emissivityandtheorientationofthesurface.

Theelevatedtemperaturecausedbysolarradiationisknownasthe"solair"temperature.
Valuesofsolairtemperaturescanbefoundinstandardtexts.

Cooling loads for large cold stores may be reduced at the design stage by careful
orientationofthebuildingandchoiceofexternalsurfacecolourtoreduceheatabsorption.

Pipes and vessels containing or circulating cold fluids also represent a significant cooling
load.

2.10.9INFILTRATION

Infiltration loads (the ingress of warmer air into acoldspace)aresignificant,particularly


forcoldstores.Thefreezingofmoistureenteringwiththeairwillbealatentloadinthe
storeandsubsequentlythefrostremovalwillbeanadditionaldefrostload.
Theinfiltrationcoolingloadiscalculatedasfollows:

Q=m(hihf)(kW) Equation6

where: Q=Coolingload (kW)


m=Airingress (kg/s)
hi=Inletenthalpy (kJ/kg)
hf=Finalenthalpy (kJ/kg)

Valuesforenthalpycanbereadfromapsychometricchartortable,ifthetemperatureand
humidityinsideandoutsidethestoreareknown.

Theprimaryleakageofairintocoldandchillstoresisthroughopendoors.
Aftertheopeningofacoldstoredooravelocityprofileisquicklyestablishedacrossthe
dooropeningwithdensecoldairfallingoutofthebottomoftheopeningandwarmmoist
airenteringnearthetopoftheopening.

The infiltration cooling load caused by cold store doors can be reduced by having the

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minimum possible height of door, reducing opening time (by using automatic closing
systems),

Theuseofstriporaircurtainscanreducetheinfiltrationload.

In practice, it is difficult to calculate infiltration loads without the aid of computer


software,althoughequationscanbefoundinsomestandardtexts.

Analternativemethodentailstheuseofstandardtablesafteradecisionhasbeenmade
intotheamountofinfiltrationthatwilloccur,i.e.Low,ModerateorHigh

Q=m3xACRxgh Equation6a

where:Q=Coolingload (kW)
M3=Cubiccapacityofenclosure (m3)
ACR=Airchangerate
gh=Heatremovedincoolingairtostoragetemperature(kJ/m3)

Averagenumberofairchangesper24hoursforstorageroomsduetodooropeningand
infiltration:
ABOVE0C
AIR AIR AIR
ROOM AIR
CHANGE ROOM CHANGE ROOM ROOM CHANGE
VOLUME CHANGE
3 PER24 VOLUME PER24HRS VOLUME VOLUME PER24HRS
m PER24HRS
HRS
2.5 70 20 22 100 9 600 3.2
3.0 63 25 19.5 150 7 800 2.8
4.0 53 30 17.5 200 6 1000 2.4
5.0 47 40 15.0 250 5.3 1500 1.95
7.5 38 50 13.0 300 4.8 2000 1.65
10.0 32 60 12.0 400 4.1 2500 1.45
15.0 25 80 10.0 500 3.6 3000 1.3

BELOW0C
AIR AIR
ROOM AIR AIR
ROOM CHANGE ROOM ROOM CHANGE
VOLUME CHANGE CHANGE
VOLUME PER24HRS VOLUME VOLUME PER24HRS
m3 PER24HRS PER24HRS

2.5 52 20 16.5 100 6.8 600 2.5
3.0 47 25 14.5 150 5.4 800 2.1
4.0 40 30 13.0 200 4.6 1000 1.9
5.0 35 40 11.5 250 4.1 1500 1.5
7.5 28 50 10.0 300 3.7 2000 1.3
10.0 24 60 9.0 400 3.1 2500 1.1
15.0 19 80 7.7 500 2.8 3000 1.05

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Comments:
1.Forheavyusagetheabovefiguresshouldbemultiplyby2.
2. The above values have been established for many years and should only be used for
traditionalchillandcoldroomswithonedoor.Thetablesmustnotbeusedforroomswith
morethanonedoor,dockloadingbaysorareasthatarethroughloaded.Interpolationis
permitted,butextrapolationisnot.

Heattoberemovedincoolingairtostorageroomconditions(kJ/m3)

OUTSIDEAIRCONDITION
5C D.B. 10C D.B. 15C D.B. 20C D.B. 25C D.B. 30C D.B. 35C D.B. 40C D.B.
70%R 80% 70% 80% 70% 80% 50% 60% 50% 60% 50% 60% 50% 60% 50% 60%

H RH RH RH RH RH RH RH RH RH RH RH RM RH RH RH
S 15C 2.77 7.0 16.8 23.3 34.5 42.7 56.4 66.4 81.4 96.5
T 10C 10.5 13.8 16.6 20.9 30.87 37.5 48.8 57.7 70.1 81.2 96.5 112
O 5C 9.6 12.0 22.8 26.2 29.0 33.5 43.7 50.5 62.1 70.6 83.9 95.4 111 127
R 0C 9.1 10.9 20.8 23.3 34.4 37.9 40.8 45.4 55.9 62.9 74.9 83.7 97.4 109 125 141
A 5C 19.2 20.9 31.0 33.5 44.6 48.2 51.2 55.8 66.4 73.5 85.5 94.4 108 120 136 153
G 10C 28.7 30.5 40.8 43.4 54.8 58.4 61.4 66.1 77.0 84.2 96.6 106 120 132 148 165
E 15C 37.8 39.7 50.2 52.8 64.5 68.2 71.3 76.1 87.2 94.6 107 116 131 143 160 177
20C 46.1 48.0 58.8 61.5 73.4 77.1 80.4 85.3 96.6 104 117 127 141 154 171 189
T 25C 55.1 57.1 68.0 70.8 82.9 86.8 90.1 95.1 107 114 127 137 152 165 183 201
E 30C 64.2 56.2 77.5 80.1 92.6 96.5 99.8 105 117 125 138 148 163 177 195 213
M 35C 73.3 75.3 86.7 89.6 102 106 110 115 127 135 149 159 174 188 207 225
P 40C 83.3 85.4 97.1 100 113 117 121 126 138 147 161 171 187 201 220 231
DB=DryBulbTemperature,RH=Relativehumidity

2.10.10ANCILLARYCOOLINGLOADS

Ancillary loads come from fans, lights, production machinery, defrost equipment and
pumps.

Thedutyrequiredtooffsettheheatgeneratedbyanancillaryloadsisequaltothepower
absorbedbyeachload.

Itisimportanttonotethatauxiliaryheatloadsfromdevicessuchaspumps,fansorlights
have a "multiple energy penalty". Electricity is first consumed to operate the ancillary
equipmentandthenfurtherelectricityisconsumedbytherefrigerationsysteminorderto
removetheheatgenerated.

Itisbeneficialtoreduceauxiliaryloadstoaminimum.Inthecaseofproductionmachinery
orprocesspumps,itisbeneficialtohavethedrivingmotoroutsidetherefrigeratedspace.

It is important to remember that small electrical motors i.e. motors up to 3.0 kW are
inefficient(particularlysinglephasemotors)andcanproducemoreenergy/heatgainthan
themotornameplaterating,orabsorbedpower.

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2.10.11MARGINS(COMMERCIALEQUIPMENT)

Allloadsmustbeassessedandaddedtogether,afterwhichsuitablysizedequipmentcan
beselected.Itisnormalpracticetoselectequipmentsothatithassufficientcapacityto
copewiththedailyloadwithoutoperatingcontinuously.Thiswillleavesufficienttimefor
defrosting.

Dailyrunningtimestoallowfordefrostingwilldependifdefrostingisactive(electricorhot
gas)fortemperaturesbelow3C.Passivedefrostingcanbeusedforroomtemperatures
above4Cwhenroomairiscirculatedthroughthecoolerwiththerefrigerationcondensing
unitstooddown.

Passiveoffcycledefrost 16/18hourscondensingunitrunningtimeperday.
Activeelectricorhotgasdefrost 18/20hourscondensingunitrunningtimeperday.

Itisrecommendedthatasafetymarginisaddedtothecapacityoftheequipmenttocover
forheatloadsthatmaybehigherthananticipated.

The accuracy of information available will depend on the margin required. This can vary
from510%.Smallcommercialapplicationswouldnormallyhaveamarginof5%.

2.11.0 PLANTROOMDESIGN

2.11.1 INTRODUCTION

Fortheefficientoperationofequipmentinaplantroomthereshouldbe:
adequateventilationtoremoveheatdissipatedbycompressorsoranyheatexchangers
positionedintheroom
sufficientspacearoundcomponentsforeaseofmaintenance
accesstothecriticalfeaturesofcompressorslikesightglassesandservicevalves
liftingequipmentforhandlingmajorpiecesofequipment

Thecapacityandnumberoffansrequiredtoachieveadequateventilationwilldependon
theshapeandsizeoftheroomandamountofheatrequiredtoberemoved.

Toreducetheenergyconsumptionofventilationequipmentfanscanbethermostatically
controlledbytheuseofathermostatsotheyonlyoperatewhenrequireddeterminedby
plantroomtemperature.

Twomainfactorsmustbetakenintoaccount:
agoodoverallairflowthroughouttheplantroomarea
asuitableinletoroutletventtopreventanyrestrictionoftheairflowto,orfrom,the
fan

Whenaircooledcondensingunitshavebeeninstalledwiththeairflowfromthecondenser
dischargingintotheplantroom,adequatemeansforremovingthisquantityofairmustbe
madeavailable.Thiscanbeachievedbyairextractfans,orexhaustducts.
Failure to provide adequate ventilation will reduce the operating efficiency of both

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compressorsandcondensers.

Highplantroomtemperatureswill:
increase the suction gas temperature entering the compressor reducing cooling
capacity
reducetheheatexchangecapabilityofaircooledcondensersincreasingtheiroperating
pressureandloweringthesystemefficiency.

2.11.2VENTILATIONREQUIREMENTSFORCONDENSINGUNITS

To estimate the total air volume required, consult manufacturers data to establish the
HeatRejectionforeachcondensingunitandfindthetotalheatrejection,Q.Ifthisdatais
notavailabletheheatrejectionmaybeestimatedasfollows:
Assumeatemperatureriseacrossthecondenserof10K
Thefollowingcalculationwillestablishtheairquantityrequiredforventilationpurposes.

TotalHeatRejection(kW)=mxsphtxTD

where:
m =massflowrateofair kg/s
spht =specificheatofair = 1.0kJ/kgC
TD =temperatureriseorchangeacrosscondenser

AirvolumeV(m3/s)=Qxspvol
sphtxTD

wherespvol=specificvolumeofairinm3/kg

AlternativelyAirvolumeV(m3/s)= Q
sphtxdensityxTD

wheredensity=densityofairinkg/m3

Analternativemethodwouldbetoselecttheventilationfanbasedonthetotalairvolume
ofallthecondensingunits.Airvaluesforthecondenserfansofthecondensingunitsare
availablefrommanufacturersdata.

Itisimportanttorememberthatcondenserfanswhichformpartofcondensingunitsare
ratedatfreeairconditions.Dueconsiderationshouldthereforebegiventothelayoutand
type of louvres that are used to introduce air into plant rooms, and also the free area
availableforfreshairtothecondensingunit.

There may be situations that require the use of noise control equipment. Noise
consultantsshouldbeapproachedasearlyaspossibleifthissituationformsarequirement
ofthecontract.

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2.11.3VENTILATIONREQUIREMENTSFORCOMPRESSORS

Whereremoteaircooledcondensersareutilised,theamountofheatdissipatedintothe
plantroombycompressorswillvary.

Asaguidethefollowinginformationcanbeused.
Semi hermetic andhermeticallysealedcompressorsarenormallysuctiongascooledand
dissipate small quantities of heat to the plant room. Taking between 5% and 10% of the
electricalpowerinputofthemotorisappropriate.Tothismustbeaddedanyheatinputs
fromoilseparatorvesselsanddischargegaspipework,
Fan cooled, direct drive and belt driven compressors dissipate more heat from the high
side of the compressor. Heat is also dissipated from the drive motor. The smaller the
motorthegreaterwillbetheproportionalheatdissipation.

2.11.4VENTILATIONFANCONTROL

Utilising one air circulation fan with on/off control may lead to unacceptable swings in
temperaturewithintheplantroom.Notalltheequipmentwilloperateatthesametime
duetoloadchangesandthevaryingambienttemperatures.

Itmaybeadvisabletoinstallanumberofaircirculatingfansandcontrolviaamultistep
thermostatoralternativelytousespeedcontrolledfan/s

2.11.5LEAKDETECTIONEQUIPMENT

ThisshouldbeinstalledasrequiredintheFgasdirective
The manufacturer of leak detection equipment should be consulted with regard to the
position of sensors. Reference should be made to BS EN 3783:2008 Section 7 and 8
AlarmsandDetectors.

2.11.6VENTILATIONESCAPEOFREFRIGERANT

ReferenceshouldbemadetoBSEN3783:2008Section5MachineryRooms
Itshouldbenotedthatoneairchangeisequivalenttotheplantroomvolume(assuming
theplantroomdoesnotcontainanyequipmentetc).

Whenleakageofrefrigeranthasoccurredandtheamountofrefrigerantintheatmosphere
has reached the maximum exposure level, all the fans should operate. Evacuation of
personnelfromtheplantroomtoasafeplaceisrequired.

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ThisGuideispublishedinthefollowingParts:

Part1Introduction
Part2SystemDesignandComponentSelection
Part3SafetyRegulations,StandardsandDirectives
Part4SystemInstallation
Part5SystemCommissioning
Part6SystemMaintenanceandService
Part7SystemandComponentDecommissioningandWasteDisposal
Part8RefrigerantsandRetrofitting
Part9AssessmentofSkillsRelatedCompetenceandTraining

TheBRAandIORdisclaimallliabilitytoanypersonforanythingorforthe
consequencesofanythingdoneoromittedtobedonewhollyorpartlyinreliance
uponthewholeoranypartofthecontentsofthisGuidancedocument.

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SystemDesignandComponentSelection

PublishedBy:

BritishRefrigerationAssociation
2WalthamCourt,MilleyLane,HareHatch,Reading,Berkshire,RG109THUnitedKingdom
TelNo:+44(0)1189403416FaxNo:+44(0)1189406258
email:info@feta.co.uk

InstituteofRefrigeration
KelvinHouse,76MillLane,Carshalton,SurreySM52JR,TelNo:+44(0)2086477033FaxNo:+44
(0)2087730165 e
mail:ior@ior.org.uk

BritishRefrigerationAssociation InstituteOfRefrigeration
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