495 - Colmac DX Ammonia Piping Handbook 2nd Ed (Rev 0)

P.O.
Box 571 | Colville, WA 99114 | USA

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www.colmaccoil.com
DXAMMONIAPIPINGHANDBOOK
2ndEdition
BruceI.Nelson,P.E.

TABLEOFCONTENTS
Page
Background 2
SystemConfiguration 4
SystemStability 4
EvaporatorSelectionandOperation 6
DT1vsDTMRatings 6
SensibleHeatRatio,Roomrh%,andEvaporatorRatings 7
OptimizingSystemTD 10
EffectofTDonExpansionValveOperation 15
TypesofFrostandSelectionofFinSpacing 16
CondenserSelectionandOperation 22
Subcooling 23
PipingGeneral 26
LiquidLines 27
SuctionLines 28
HotGasLines 28
EffectsofWaterinAmmoniaandItsRemoval 29
Separation 32
DistillationandDisposalofAmmoniumHydroxide 32
LiquidTransfer 36
EffectsofOilonEvaporatorPerformanceandOilSeparation 39
EstimatingDXEvaporatorRefrigerantChargeInventory 43
ColmacSmartHotGasDefrost 45
CalculatingtheCostofDefrost 45
SmartHotGasSequenceofOperation 48
DefrostWaterVolumeandDrainLineSizing 49
References 52
APPENDIXADXAmmoniaP&ID 54
FigureA1SingleStage
FigureA2SingleStageEconomizedScrew
FigureA3TwoStage

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I. Background

Ammoniarefrigerationsystemshavetraditionallyemployedevaporatorssuppliedwith
liquidbyeithergravityflooding(withsurgedrums),orpumpedoverfeed(eitherwith
mechanicalpumpsordischargegasdrivenvessels).Bothofthesedesignstypicallyuse
bottomfeedcoilcircuitingwhichfeedsliquidammoniaatthelowestpointinthecoilcircuit
andcausestheammoniatoflowupwardandpercolatethroughthecoilinascending
passestotheoutletatthetopofthecircuit.Thesecoildesignsalsotypicallyuselarge
diametertubingwhichmeansrelativelylargecoilinternalvolume.Thiscombinationof
refrigerantfeed,circuiting,andtubediameter,resultsinthegreatestevaporatorcharge
inventorypossible.

Endusersofammoniarefrigerationsystemsareincreasinglyinterestedinreducingthe
chargeofammoniainevaporators(andintheoverallsystem)intheinterestofminimizing
therisktoworkersandproductsassociatedwithammonialeaks.Oneveryeffectivewayto
significantlyreduceevaporatorammoniachargeistodesignandoperatetheevaporator
usingdryexpansion(DX)circuitingandcontrols.UsingDXammoniacanreducethe
evaporatorchargebyasmuchas30to50timescomparedtobottomfeedfloodedor
pumpeddesigns.Themagnitudeofthisreductioninammoniachargemayalsomitigate
regulatoryrequirements(PSM,RMP),andpotentiallyreduceinsuranceriskandpremiums.

DXammoniahasbeenusedforsometimeinmediumandhightemperaturesystems
(suctiontemperaturesabove+20degreesF)withsomesuccess.However,inspiteofthe
chargereductionadvantagesmentionedabove,todateDXammoniahasnotbeenapplied
successfullyatfreezertemperatures.Atsuctiontemperaturesbelowabout+20F,the
followingparticularcharacteristicsofammoniaresultinextremelypoorperformanceof
evaporatorsunlessaddressedandmitigated:

1. Separationofliquidandvaporphases.Theveryhighratioofvaportoliquidspecific
volumeofammoniaatlowtemperaturescombinedwithitsveryhighlatentheatof
vaporizationcausesanunavoidableseparationofvaporandliquidphasesinside
evaporatortubes.Thisseparationofphasescausestheliquidammoniapresenttorun
alongtheverybottomofthetubesleavingthetopofthetubescompletelydry.The
resultisextremelypoorevaporatorperformanceandlowerthanexpectedsuction
temperaturesduringoperation.TosolvethisproblemColmachasdeveloped(and
patented)anenhancementtechnique,whichwhenappliedtotheinsideofevaporator
tubes,causestheliquidammoniapresenttocoattheentireinsidesurfaceofthetubes
bycapillaryaction.PerformancewithColmacenhancedtubetechnologyresultsinDX
ammoniaperformanceatlowtemperatureswhichisasgoodorbetterthan
performancewithbottomfeedpumpedammoniacircuiting.
2. Refrigerantdistributortechnology.Traditionallythedistributionofexpandedrefrigerant
tomultipleparallelevaporatorcircuitshasbeendoneusingarefrigerantdistributor
havingafixedorificeplate.Thisdesigndependsonarelativelylargepressuredrop
(approximately4045psi)acrossthefixedorificetothoroughlymixandequally
distributortheliquidandvaporphasesbeforetheyenterthedistributortubesand
evaporatorcircuits.Thisrelativelyhighpressuredropacrossthedistributorreducesthe
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pressuredropavailablefortheexpansionvalve,andconsequentlylimitshowlow
condensingpressurecanbeallowedtofallduringperiodsoflowambienttemperature.
Theveryhighlatentheatofvaporizationofammoniaresultsinlowrefrigerantmass
flowrateandconsequentlyaverysmallorificediameterforagivencoolingload(the
orificecanbeassmallas1/16diameterinsomecases).Thissmallorificesizeisprone
tofoulingandbeingblockedbyevensmallsizedebris.Otherdisadvantagesofthis
distributordesigninclude:
a. Performanceisverysensitivetoliquidtemperature(subcooling)atthe
expansionvalve.
b. Operatingrangeissmall,atmost50%to125%ofratedcapacity.
c. Theorificeanddistributortubesrestricttheflowofhotgasduringahotgas
defrostcycle.
d. Themaximumnumberofparallelevaporatorcircuitsavailableinasingle
distributorislimitedtoonly15.
ToaddresstheseshortcomingsColmachasdevelopedanew(patentpending)
refrigerantdistributortechnology,theColmacTankDistributor,havingthefollowing
characteristics:
a. RefrigerantpressuredropacrosstheTankDistributorduringoperationisvery
low,only24psi.
b. AnyoilordebrisenteringtheTankDistributoriscapturedinadropleg(whichis
integraltothedesign)beforeitcanenterthecoilandfoultubesurfaces.
c. PerformanceoftheTankDistributoriscompletelyinsensitivetoliquid
temperature(subcooling).
d. Graduatedorificesineachdistributortubeallowequaldistributionof
refrigeranttoallcircuitsoveranextremelywideoperatingrangeof0%to700%
ofratedcapacity.
e. Graduatedorificesandlargediameterdistributortubesallowfullflow(minimal
restriction)ofhotgasduringhotgasdefrost.
f. ThenumberofparallelevaporatorcircuitspossibleinasingleTankDistributor
canbeashighas48.
3. Removalofwaterfromammonia.Asdescribedelsewhere(Nelson2010),evensmall
amountsofwater(13%)intheammoniawillsignificantlypenalizeDXammonia
evaporatorperformance.Watermustbeeffectivelyremovedduringoperation,
particularlyinfreezingsystemswhichoperateatsuctionpressuresbelowone
atmosphere(inavacuum).Currently,theonlyeffectivewaytoremovewaterfrom
ammoniaisinaheateddistillationvessel(anammoniastill).Thisverynegativeeffect
ofsmallamountsofwateronevaporatorperformancehasnotbeenfullyrecognizedin
thepast,butmustbeaddressedduringthedesignoftheDXammoniasystem.Colmac
hasdevelopedaneffectiveammoniadistillationvesseldesignandinstallationstrategy
whichisdescribedwithinthisHandbook.

Colmachasdeveloped,tested,andpatented(Nelson2011)anewLowTemperatureDX
Ammoniasystemwhichcorrectlyaddressesalloftheaboveissuespeculiartoammoniaasa
refrigerantthathaveheretoforepreventeditsuseatlowsuctiontemperatures.Itisnow
possibletosuccessfullyapplyDXammoniaatsuctiontemperaturesdownto50degreesF.

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ThisPipingHandbookisintendedtoguidethereaderthroughtheprocessofsuccessfully
designingandimplementingDXAmmoniafrom+50Fto50Fandrealizingthebenefitsof:

Dramaticallyreducedammoniacharge
Simplifiedcontrols
Energyefficientdrysuctionline
Reducedlinesizes
Eliminationofammoniarecirculatorpumps
II. SystemConfiguration

ColmacDXAmmoniacanbeappliedtoanytemperaturelevelandsystemconfiguration.
P&IDdiagramsforvarioustypicalsystemsareshowninAppendixA,simplifiedforpurposes
ofclarity.Selectionandsystempipingdetails(reliefvalves,purgers,isolationvalves,vessel
designs,etc)shouldfollowindustryguidelinesasfoundintheIIARAmmoniaPiping
Handbook(IIAR2004).Thediagramsarenotintendedtopresentanexhaustiverangeof
configurationseveryindustrialrefrigerationsystemwillhaveuniquefeaturesand
requirements.Thisinformationispresentedtoillustratethegeneralsystemfeatures
particulartoasuccessfulDXAmmoniadesign.

a. FigureA1SingleStageSingleTemperatureLevel
b. FigureA2SingleStage(EconomizedScrew)MultipleTemperatureLevel
c. FigureA3TwoStageMultipleTemperatureLevel
III. SystemStability

Withliquidoverfeedandgravityfloodedsystems,liquidreturntotherecirculatorvesselor
thesurgedrumisnormalandexpectedthroughthewetsuctionline.Therecirculatorvessel
orsurgedrumeffectivelyseparatesreturningliquidfromvaporandinsuresthatthedry
suctionlinecarriesonlyvaporbacktothecompressor.

DXsystems,ontheotherhand,aredesignedtooperatewithadrysuctionlineandareby
definitionmoresensitivetoliquidfloodback.IndustrialDXsystemsshouldincorporatea
suctionaccumulatorvesseltopreventliquidsluggingofthecompressorduringafloodback
event,however,excessivefloodbackfromevaporatorscancausehighlevelalarmingand
systemshutdownuntiltheexcessliquidinthesuctionaccumulatorcanbetransferredback
tothehighpressuresideofthesystem.Stableandsmoothoperationofthesystemandthe
evaporatorexpansionvalve(s)iscriticaltoavoidingliquidfloodback.Instabilitiesand/or
rapidchangesindischargeandsuctionpressuresduringoperationarethetypicalcauseof
unstableoperationofexpansionvalvesandshouldbeconsideredcarefullybythesystem
designerandoperator(s).

Rapidchangesinsystemdischargepressurecancausesysteminstabilitiesinanumberof
ways.Asuddenreductionindischargepressurecanresultinundesirableflashingofliquid
refrigerantinliquidlinesandwillalsobeaccompaniedbyasympathetic,albeitsmaller,
reductioninsuctionpressure.Asuddenincreaseindischargepressurewillbeaccompanied
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byasympathetic,albeitsmaller,increaseinsuctionpressure.Anincreaseinsuction
pressure,iflargeenoughandrapidenough,willsuppressboilingintheevaporatorswhich
candirectlyleadtoliquidfloodbackfromtheevaporatorstothesuctionaccumulator.

Rapidchangesindischargepressurearenormallycausedbyoneormoreofthefollowing
events:
a. Condenserfanscyclingonandoff,
b. Evaporativecondenserpumpscyclingonandoff,
c. Evaporator(s)initiatinghotgasdefrost,
d. Compressor(s)cyclingonandoff

**NOTE:Designthesystemtolimittherateofchangeincondensingtemperaturetono
morethan5degF/minute.

Rapidchangesinsystemsuctionpressurecanalsoresultinsysteminstabilityandpoor
performance.Itisasuddenincreaseinsuctionpressurethathasthehighestpotentialfor
liquidfloodbackfromDXevaporators.Thissuddenincreaseinsuctionpressureraisesthe
temperatureoftheevaporator,reducestheimposedload,andresultsinliquidrefrigerant
exitingtheevaporatorbeforetheexpansionvalvecanrespondandreducetheflowof
refrigerantenteringtheevaporatoraccordingly.

Rapidchangesinsuctionpressurearenormallycausedby:
a. Compressor(s)cyclingonandoff
b. Multipleliquidfeedsolenoidscyclingonandoff
c. Evaporatorfanscyclingonandoff
d. Evaporatorsstartingorfinishingdefrost
e. Suddenchangesinimposedloadonevaporators

**NOTE:Designthesystemtolimittherateofchangeinsuctiontemperaturetonomore
than2degF/minute.

Followingarerecommendedsystemdesignfeatureswhichwillservetomaximizesystem
pressurestabilityandminimizethepotentialforliquidfloodbackfromevaporators.
1. CondenserFans
a. UseofVFDfanspeedcontrolinsteadoffancyclingforcontrolofheadpressureis
recommended.
2. CondenserPumps
a. Itisalsorecommendedthatevaporativecondensersumpwaterpumpsbeoperated
continuouslyratherthancyclingonandoff,providedambientweatherconditions
allow.
3. CompressorCapacityControl
a. UseofVFDspeedcontrolforcapacitywherepossibleandappropriate.
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b. Limitcapacityloading/unloadingsteps(on/off)tonomorethan10%oftotalsystem
capacity.
c. Limittherateofchangeofsuctiontemperature(speedofscrewcompressorslide
valvemovement)tonogreaterthan2degF/minute.

4. EvaporatorDefrost
a. Defrosttheminimumnumberofevaporatorsatonetime.
b. Useableedlinetoequalizepressureslowlyattheendofdefrost.

5. EvaporatorFans
a. FanspeedandcoolingcapacitycanbecontrolledbyVFD,howeverthefollowing
guidelinesmustbeobservedwhenappliedtoDXevapaorators:
o Rateofchangeinfanspeedmustbegradualandlimitedtoresultinno
morethan2degF/minutechangeinsuctiontemperature.
o Minimumfanspeedmustbesettoproducenolessthan250ft/minface
velocity.
b. Iffansaregoingtobecycledon/offforcapacitycontrol,nomorethan10%ofthe
totalnumberofevaporatorfansshouldbecycledonoroffatthesametime.

6. LiquidFeedSolenoids
a. Avoidcyclingmultipleliquidfeedsolenoidsallatthesametime.i.e.Liquidfeed
solenoidsshouldbecycledsequentially.

7. SuddenchangesinloadonEvaporators
a. Avoidlocatingevaporatordirectlyabovedoorways.
b. Mitigateintermittentprocessloadslocatedclosetoevaporators.
IV. EvaporatorSelectionandOperation

1. DT1vsDTMratings

Asexplainedindetailelsewhere(Nelson2012(a))evaporatormanufacturerstypically
presenttheircapacityratingsusingoneoftwodefinitionsoftemperaturedifference,
DT1orDTM.SomemanufacturerspublishratingsbasedonbothDT1andDTMand
allowthedesignertochoosethepreferreddefinition:

DT1=AirOnTemperatureEvaporatorTemperature
DTM=Average(Room)AirTemperatureEvaporatorTemperature

Figure1belowgraphicallyillustratesthesetwodefinitionsoftemperaturedifferencefor
thesameevaporatorandtheireffectonLMTD(LogMeanTemperatureDifference),and
henceratedcapacity.Inthisexample,thesameevaporatorhavinga20degF
evaporatingtemperatureratedusingDTMproduces33.3%(DTMLMTDof9.6degF
versusDT1LMTDof7.2degF)morecapacitythanthesameevaporatorratedusing
DT1!

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Inshort,byusingtheDTMratingmethodamanufacturercanshowcoolingcapacities
thataremuchhigher(30to40%higher),andsoofferalowercostevaporatorwith
muchlesssurfaceareathanthemanufacturerusingtheDT1ratingmethod.

Unfortunately,onecannotgetsomethingfornothing.Eventhoughevaporators
selectedusingDTMratingswillbecheaperinitiallybecausetheyhavelesssurfacearea,
theywillcausethesystemtorunatalowersuctionpressurewithhigheroperatingcosts
thanevaporatorsselectedusingDT1ratings.Thisdifferenceinoperatingcostbetween
DTMandDT1evaporatorshasbeencalculatedandtheincrementalreturnon
investmentshowntodramaticallyfavorselectingevaporatorsusingDT1ratings(Nelson
2012(b)).Additionally,inthesamearticletheauthorshowsthatthebasicDTM
assumptionthattheaverageairtemperaturewithintheevaporatorequalstheaverage
roomtemperatureisafundamentallyflawedandfalseassumptionbecauseofair
entrainmentandmixingintheroom.

FIGURE1
TemperatureProfilesforDT1vsDTM
(a) DT1=10F(AirOn)TempDifference(b)DTM=10F(Average)TempDifference
DT1 LMTD = 7.2 F DTM LMTD = 9.6 F
Inconclusion,ColmachighlyrecommendsthatevaporatorsbeselectedusingDT1ratings
ratherthanDTM.

2. SensibleHeatRatio,RoomRelativeHumidity(rh%),andEvaporatorRatings

Accuratepredictionoftherefrigerationload,bothsensibleandlatentcomponents,is
importanttoproperrefrigerationsystemequipmentselectionandsuccessfuloperation
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(Nelson2012(a)).Varioustypesofsensiblecoolingloadsmustbeanticipatedand
includedinthecalculation,suchas:lighting,electricmotors,forklifts,product
cooling/freezing,transmissionofheatthroughwalls,ceilings,andfloors,andcoolingof
infiltrationair.Latentcoolingloadsarepresentwhenevermoistureisaddedtotheairin
therefrigeratedspace.Sourcesofintroducedmoisturetypicallyinclude:infiltrationair,
respiringfoodproducts,surfacemoistureonproducts,packagingandotherobjects
enteringthespace,residualwaterleftonfloorsafterwashdown(processrooms),
humanrespiration,andhumidificationequipment(abovefreezing).

Roomrelativehumidity(rh%),whichistheindicationofhownearlytheairinthe
refrigeratedspaceissaturatedwithwatervapor,willbetheequilibriumcondition
resultingfromthebalanceofmoistureintroducedintothespacewiththemoisture
removedfromspacebytheevaporatorcoils(Cleland2012).

Wheneverevaporatorsurfacesoperateattemperaturesbelowthedewpointoftheair
beingcooled,watervaporintheairstreamiscondensedtoliquid(attemperatures
above32F(0C))ordepositedtoformfrost(below32F(0C)).Thecoolingeffect
associatedwiththisdehumidificationoftheairstreamistermedlatentcooling.The
sumofthesensiblecoolingloadandlatentcoolingloadistermedthetotalload.The
ratioofthesensiblecoolingloaddividedbythetotalcoolingloadiscalledtheSensible
HeatRatio(SHR)anddefinestheslopeoftheairprocesslineonapsychrometricchart.

(1)

Refrigeratedspaceswithproductbeingtransferringinandoutthroughdoorwayswill
verytypicallyhavearelativehumidityinthe85to95%rangeduetoinfiltrationand
othersourcesofmoisture.Lowerroomrelativehumiditymaybefoundinsome
exceptionalcaseswheretrafficthroughdoorwaysisverylight,productistightly
packaged,dehumidificationequipmentisusedatdoorways,etc.Therelationship
betweenroomrelativehumidityandSHRisshowninTable1below:

TABLE1
SHRFORDT1=10degFATVARIOUSTEMPERATURESANDROOMRH%
SensibleHeatRatio,SHR

RoomTemperature,F(C) 65%rh 75%rh 85%rh 95%rh
45(7.2) 1.0 0.84 0.67 0.56
32(0) 0.98 0.84 0.73 0.64

10(12.2) 0.98 0.92 0.87 0.83

0(17.8) 0.98 0.95 0.92 0.89

10(23.3) 0.99 0.97 0.95 0.93

30(34.4) 0.99 0.99 0.98 0.97

TheroomrelativehumidityandresultingSHRcanhavealargeeffectonevaporator
coolingcapacity,especiallyathigherroomtemperatures.
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Usingacomputermodeldevelopedtoaccuratelycalculatefinefficiencyandsurface
effectivenessforbothsensibleandcombinedsensibleandlatentheattransfer,a
predictionoftheincreaseinevaporatorcoilperformanceasafunctionofSHRhasbeen
made(Nelson2012(a)).ResultsofthepredictedcapacityincreaseasafunctionofSHR
foranammoniarefrigerationevaporatorcoiloperatingoverawiderangeofroom
temperatures(+45Fto30F)andhavingtypicalfinspacingsandgeometrywithDT1=
10FareshowninFigure2below.

FIGURE2
TotalCoolingCapacityFactorvsSHR
1.5

CapacityFactor,Qtotal/Qsensonly
1.45

1.4
1.35
1.3
1.25
1.2

1.15

1.1

1.05
1
0.6 0.65 0.7 0.75 0.8 0.85 0.9 0.95 1
SensibleHeatRatio,SHR

Tomakethingsabitmorecomplicated,someevaporatormanufacturersincludethe
effectofroomrh%intheirratings,othersdonot.AsshowninFigure2,thelowerthe
SHRthegreaterthetotalcoolingcapacityoftheevaporator.Amanufacturerwhoshows
theirevaporatorratingsasallsensible(SHR=1)willbemoreconservative(havemore
surfacearea)thanthemanufacturerwhoshowstheirratingsat85or95%rh.

Selectingevaporatorsusing85to95%rhratingswillresultinevaporatorshavingless
surfaceareaandlowerfirstcostcomparedtoevaporatorsselectedusingallsensible
ratings.Theriskinthisapproachisundersizingtheevaporatorsinthecasewherethe
actualoperatingroomrh%islessthantherh%usedduringtheselectionprocess.

Conclusion:Thelatentloadshouldalwaysbeestimatedandincludedinthetotal
calculatedrefrigerationload.Sizeevaporatorsforthedesigntotalcalculated
refrigerationloadattheestimatedroomrelativehumidity.Ifroomrelativehumidityis
difficulttoestimateorcannotbeestimated,thenaconservationapproachistoselect
evaporatorsbasedonalowroomrelativehumidity(i.e.65to75%rh)orusingsensible
onlyratings.

3. OptimizingSystemTD
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Theproductbeingstoredorprocessednormallydeterminestheroomairtemperature
inarefrigeratedfacility.Appropriatetemperaturesforstoringandprocessingvarious
foodsandfoodproductscanbefoundelsewhere(ASHRAE2009).

Oncetheroomtemperatureisdetermined,theevaporatortemperaturemustbe
decideduponbythedesigner.Compressorpowerandenergyconsumptionisastrong
functionofthesuctionpressureandtemperature.Thehigherthesuctionpressurethe
moreefficientlythecompressorwillrunandthelesspowerwillbeconsumed.Energy
efficiencycanbecharacterizedbyaratiotermedCoefficientofPerformance(COP),
definedas:

(2)

Inthecaseofarefrigerationcompressor,

,
(3)
,

Figure3belowshowstypicalammoniascrewcompressorCOPvsSST(SaturatedSuction
Temperature).Thefigureassumes2Stagecompressionisusedbelowasuction
temperatureof20degF.

FIGURE3
R717ScrewCompressorCOPvsSST
(SCT=85DegF)
8
CompressorCOP
1
50 40 30 20 10 0 10 20 30 40
SST,DegF
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ItwouldappearfromFigure3thatasmallerTD(TD=RoomTemperatureEvaporator
Temperature)wouldalwaysbedesirablefromanenergyconsumptionstandpointsince
thesmallertheTD,thehighertheevaporator(SST)temperatureandcompressorCOP.
This,however,isnotthecase.

Heatistransferredfromtheroomviatheaircirculatedbytheevaporators.Thecooling
capacityofanevaporatorcanbecharacterizedbytheNTUeffectivenessequation.This
equationindicatesthatforaconstantcoolingcapacityandevaporatoreffectiveness(an
expressionofhowcloselytheleavingairtemperatureapproachestheevaporating
temperature),theflowrateoftheairwillbeinverselyproportionaltotheTD.

(4)

Where:

Evaporatoreffectivenessis,infact,verynearlyconstantoverthetypicalnarrow
operatingrangeofarefrigerationevaporator.Theeffectivenessequationshowsthatas
TDbecomessmaller,theairflowratemustbecomelargerinthesameproportionfora
givencoolingcapacity.

Fanpowercanbecalculatedusingasimpleequationasfollows:

(5)

Where:

Theairpressuredropthroughtheevaporatorcoil,andthereforefanpower,willbe
affectedby:
1. Thecoilfacevelocity,
2. Tubediameter,spacing,andpattern,
3. Numberofcoilrowsdeep,
4. Finspacingandpattern
5. Frostthickness
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TherelationshipsaboveindicatethatcompressorCOPwilldecreasewithincreasingTD
whileFanCOPwillincreasewithincreasingTD.Figure4showstheserelationshipsforan
exampleevaporatorcoilhaving8rowsdeepand3FPIfinspacing.

FIGURE4

COPvsTD
8Row3FPI,R717,AirOnTemp=10DegF

7

6

5

4
Fan(500FPM)x10^1
COP
Fan(750FPM)x10^1
3
Fan(1000FPM)x10^1

2 Compressor

1

0
0 5 10 15 20 25 30 35
TD=AirOnTemp SuctionTemp,DegF

Figure4impliestherewillbesomemaximumcombinedCOPforcompressorandfans
whichwillrepresenttheoptimumoperatingTDintermsofenergyefficiency.This
combinedCOPisshownbelowinFigures5,6,and7,foratypicalammoniaevaporator
coilhavingthefollowingcharacteristics:

Tubing:7/8ODAluminum
TubePattern:2.25Staggered
Fins:ConfiguredAluminumPlateType
RowsDeep:8
FaceVelocity:500,750,and1000FPM
FinSpacing:2,3,and4FPI
AirOnTemperature:10degF
FrostThickness:0mm

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FIGURE5

Compressor+FanCOPvsTD
2.4

2.2

2

1.8

CombinedCOP
1.6
500FPM
1.4
750FPM
1.2 1000FPM

1

0.8

0.6
0 5 10 15 20 25 30 35

FIGURE6


2.6

2.4

2.2

2
CombinedCOP

1.8 500FPM
750FPM
1.6
1000FPM
1.4

1.2

1
0 5 10 15 20 25 30 35
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FIGURE7



2.6

2.4

2.2

2
CombinedCOP

1.8 500FPM
750FPM
1.6
1000FPM
1.4

1.2

1
0 5 10 15 20 25 30 35

ThefollowingisobservedfromFigures5through7:
a. CombinedCOPisaverystrongfunctionofcoilfacevelocity.COPat500FPMis
approximately10%higherthanCOPat750FPMand20%higherthanCOPat
1000FPM.
b. CombinedCOPincreasesasthedistancebetweenfinsisincreased.Coilswith
2FPIspacingwillhavehighercombinedCOPthancoilswith3FPI,whichwillhave
higherCOPthan4FPI.
c. Theoptimum(maximum)TDincreaseswithincreasingfacevelocity.
d. Inallcases,combinedCOPdecreasesveryrapidlybelowabout7degFTD.

InordertomakethefinaldecisionaboutselectingtheoptimumTD,thecostofpower
aswellasinstalledcostofthecompressor(s)andevaporatorsmustbeknown(or
estimated).Thesevariablescanthenbecombinedtocalculatetheincrementalreturn
oninvestmentcomparingdifferentevaporatordesigns(facevelocityandfinspacing)in
termsoffirstcostvsoperatingcost.

Sincethesecostsarehighlyvariable,thefinalreturnoninvestmentcalculationmustbe
madeonacasebycasebasisandpresentedtotheclientinawaywhichallowsthefinal
decisiontobemadegiventheprojectfinancialconstraintsandrequirements.

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Conclusions:
1. ForhighestsystemCOP/energyefficiency,selectevaporatorsforthelowestface
velocityandwidestfinspacingfinanciallypractical.Colmacrecommendsmaximum
facevelocityof600FPMandfinspacingof3FPIorwider(lowerFPI).
2. Forcoilfacevelocitiesbetween500and750FPMadesignTDbetween10degFand
15degFisrecommended.
3. FinaloptimizedevaporatordesignandTDmustbedeterminedbasedonspecific
projectfinancialconstraintsandacceptablereturnoninvestment.
4. EffectofTDonExpansionValve(EV)Operation

Withdirectexpansion(DX)evaporatorstheflowofrefrigeranttotheevaporatoris
meteredbyanautomaticexpansionvalveinresponsetoacontrolsignalmeasuredat
theevaporatoroutlet.Thecontrolsignalisnormallytheamountofsuperheatinthe
refrigerantsuctiongas.Thetheoreticalmaximumamountofsuctiongassuperheatthat
canbegeneratedisequaltotheoperatingTD(TD=AirOnTemperatureEvaporating
Temperature).

Theamountofsuperheatrequiredforstableoperation(modulation)oftheexpansion
valvevarieswiththetypeofvalveemployed.Twobasictypesofexpansionvalvesare
currentlyavailableonthemarket,Thermostatic(TEV)andElectronic(EEV).Bothuse
superheatinthesuctiongasasthecontrolsignal.

Thermostaticexpansionvalvesmeasureandmechanicallycalculatesuperheatbymeans
ofatemperaturesensingbulbandpressureequalizingline.Thesevalvesandtheir
operationaredescribedindetailbythevalvemanufacturers.Theadvantageofthistype
ofvalveistheirlowcostandcompactness.Withthistypeofvalve,temperaturesensing
isaccomplishedbyarefrigerantfilledbulbstrappedtotheoutsideofthecoilsuction
connection.Adisadvantageofthissystemistheadditionalsuperheatrequiredto
overcomethethermalresistanceofthepipewall.Thisadditionalsuperheatforcesthe
operatingTDtobeapproximately5degFgreaterthanforanelectronicexpansionvalve
thatusesatemperaturetransducertomeasuretemperaturedirectly.

Electronicexpansionvalvesoperatebasedonasignalreceivedfromasuperheat
controllerwhichreadssuctiongastemperatureandpressurefromacombinationof
sensors.Theexpansionvalveitselfmayoperatebasedonanopen/close(pulsing)
principleoronamotorizedpositioningprinciple.Advantagesofthistypeofvalve
includemoreaccurateandresponsivesensingofsuperheatwhichallowsstable
operationatsmallerTDthanthermostatictypevalves.PIDcontrolparameterscanalso
beadjustedinthecontrollertofinetuneoperationoverawiderangeofconditions.
Theprimarydisadvantageofelectronicexpansionvalvesisthehigherfirstcost
comparedtothermostaticvalves.This,however,ischangingasvalvemanufacturersare
findinglowercostsolutionsandbeginningtooffercostcompetitiveelectronicvalvesto
themarket.

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MinimumrecommendedTDandsuperheatsettingsforbothtypesofexpansionvalves
areshowninTable2below:

TABLE2
MINIMUMRECOMMENDEDDXAMMONIATDANDSUPERHEATSETTING

ExpansionValveType MinimumRecommended RecommendedSuperheat
TD,degF Setting,degF
Thermostatic 15 12
Electronic 12 10

Note:Colmacoffersfactorysuppliedandmountedexpansionvalvesandcontrollers,
boththermostaticandelectronictype.

5. TypesofFrostandSelectionofFinSpacing
Frostcanaccumulateonevaporatorcoilfinsbyoneoftwomechanisms:

1. Bydeposition,and/or
2. Asairborneicecrystals

Designingevaporatorstoproperlyhandlethesetwotypesoffrostisdescribedinthis
section.

1. Deposition:

Wheneverthetemperatureoftheevaporatorcoilsurfaceisbelowthedewpoint
temperatureoftheroomair,moisturewillcondenseandbedepositedonthesurface
eitherasliquidwater(abovefreezing)orasfrost(belowfreezing).Thismasstransfer
process,whenrelatedtotheformationoffrostiscalleddeposition,andisdrivenbythe
differenceinwatervaporpressurebetweentheairandthesurfaceofthecoil.The
amountofheatassociatedwiththismasstransferprocessistermedlatentheatandis
quantifiedbytheSHR(seepreviousdefinition).WhenevertheSHRislessthan1.0,the
depositionoffrostwilltakeplace.Therateatwhichfrostwillbedepositedonthecoil
surfacescaneasilybecalculatedasafunctionofthetotalcoolingload,theSHR,andthe
surfaceareaoftheevaporator.

Thesurfaceeffectivenessofarefrigerationevaporatorisrelativelyhigh(usuallygreater
than80%)duetothetypicallysmallTDandlowheatfluxcomparedtoairconditioning
andprocessevaporators.Thishighsurfaceeffectivenessresultsinamoreorless
constantsurfacetemperatureanduniformdepositionoffrostovertheentiresurfaceof
theevaporator.Thisassumptionofuniformfrostdepositionismadeinthefollowing
equation:

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1
304.8 (6)

Where:
, /
, /

, 1068 /
, 10.4 / 3
, 2

EXAMPLE:
Anevaporatorhaving8rowsdeepandfinspacingof3FPIisoperatingwitha10degF
TD(DT1)ina+10degF/85%rhroom.Theevaporatorhasacoolingcapacityof240,000
Btu/h(20TR)andoutsidesurfaceareaof4100ft2.Whatwillbetherateoffrost
deposition?

Answer:
FromTable1theexpectedSHRatthisroomairtemperatureandrh%willbe0.87.

240,000 1 0.87
304.8 0.21 /
1068 10.4 4100

Asfrostisdepositedontheevaporatorcoilsurfacesthelocalairvelocitybetweenfins
willincreaseandresultinincreasedairpressuredropacrossthecoil.Theincreaseinair
pressuredropduetoaccumulationoffrostcanbeapproximatedbythefollowing
equation:

1
(7)
1
2
25.4

Where:

,
,
,

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Therateofblockageofthecoilwithfrostandassociatedpressuredropwillresultina
reductioninairflowandcoolingcapacity.Thisreductionincoolingcapacitywill
ultimatelydeterminedefrostfrequencyandefficiency,andoverallsystemenergy
efficiencyandpowerconsumption.
Coolingcapacityoftheevaporatorcanbecharacterizedasfunctionsoffacevelocity,
SHR,andfrostthickness.Knowinghowcapacitychangeswiththeseparameters,
combinedwiththerelationshipsshowninequations5,6,and7above,allowsthe
constructionofasimplemodelwhichwillpredictthechangeincoilcapacityovertime.
Simplifyingassumptionsinthemodelinclude:

o Frostisdepositeduniformlyoverthesurfaceofthecoil
o Frostdensityisuniformandofafixedvalue
o Suctiontemperatureremainsconstant
Normally,refrigerationloadsarecalculatedbasedon16to18hoursofruntimeperday.
Itisnotclearwhenorwhythisruleofthumbcameintopractice.Perhapsitisacorollary
tothe2to1ruleforhotgasdefrosting.Thatis,twocoilsmustbeinoperationwhile
thethirdcoilisinhotgasdefrostinordertoprovideasufficientquantityofhotgasfor
thedefrostcycle.Perhapsitissimplyanadditionalcatchallsafetyfactor.One
industryhistorianmentionedthatthe1618runhoursrulecamefromsplitsystem
applicationswherecapacitydropsoutduringdefrostcomparedtoacentralsystem
whichwouldrebalancetheTDontheremainingevaporators(Welch2013).Itmakesthe
mostsensetotheauthorthattheruntimeadjustmenttothedesignrefrigerationload
shouldbeusedtoaccountforthedegradationincoilperformanceovertimedueto
accumulationoffrost.

Inalargerefrigerationsystemhavingaconstantrefrigerationloadandcompressor
unloadingcapability,thecompressorswillunloadtomaintainaconstantsuction
temperatureasthecoilcapacityfallsoffduetofrosting.Asthecompressorsunloadto
maintainsystemsuctionpressure,theywillrunlongertomaintainroomtemperature.
Thisimpliesthatinordertomaintainroomtemperature,defrostingshouldbeinitiated
whenevaporatorcapacityfallstoalevelequaltothedesignruntimeratio(design
runtimedividedby24).Table3belowshowsthemaximumreductioninevaporator
capacityduetofrostingthatshouldbeallowedbeforedefrostisinitiated.Notethatthis
tableobviouslydoesnotapplytoevaporatorsoperatingabovefreezing.

TABLE3
MINIMUMEVAPORATORCAPACITYTOINITIATEDEFROSTATVARIOUSDESIGN
RUNTIMES

DesignRuntime,h/day MinimumEvaporatorCapacityat
InitiationofDefrost
14 58%
16 67%
18 75%
20 83%
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Theevaporatorperformancemodeldescribedabovewasusedtoexaminetheeffectof
finspacingandSHRonlossofcoolingcapacityduetofrostaccumulation.SeeFigures8,
9,10,and11below.

FromTable1itisclearthatthehighestfrostload(lowestSHR)willoccurinhigh
temperature(+32F)roomswithhighrelativehumidity.Thelowestfrostloads(highest
SHR)occuratfreezertemperatures,evenwhenrelativehumidityishigh.

FIGURE8

CapacityvsTimeforVariousFinSpacings
7/8StaggPattern,0.65SHR
100%
90%

80%

70%

CoolingCapacity,%
60%
50% RBR(Stagg)8R2F
40%
RBR(Stagg)8R3F
30%
RBR(Stagg)8R4F

20%

10%
0%
0 0.5 1 1.5 2 2.5 3 3.5 4
Time,h

FIGURE9

100%
90%
80%
70%

CoolingCapacity,%
60%

50% RBR(Stagg)8R2F

RBR(Stagg)8R3F
40%
RBR(Stagg)8R4F
30%
20%
10%

0%
0 1 2 3 4 5 6 7
Time,h
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FIGURE10

100%
90%
80%

70%

CoolingCapacity,%
60%
50% RBR(Stagg)8R2F
40%
RBR(Stagg)8R3F
30%
RBR(Stagg)8R4F

20%

10%

0%
0 2 4 6 8 10 12
Time,h

FIGURE11

100%
90%
80%

70%

CoolingCapacity,%
60%
50% RBR(Stagg)8R2F
40%
RBR(Stagg)8R3F
30%
RBR(Stagg)8R4F

20%

10%

0%
0 5 10 15 20 25 30 35 40
Time,h

AnumberofobservationscanbemadewhenconsideringFigures811,Table1,and
Table3:

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1. Therateatwhichfrostaccumulatesonanevaporatorincreasesastheroom
temperatureincreasesforagivenroomrelativehumidity.i.e.Frostonan
evaporatoroperatinginaroomat+32Fand85%rhwillaccumulatemuchfaster
thanonthesameevaporatoroperatingat10Fand85%rh.Thisisduetothehigher
watervaporpressureinairathighertemperaturesandtheresultinglowerSHR.
2. Foragivenreductioninevaporatorcapacity,widerfinspacingalwaysresultsin
longeractualruntimebetweendefrosts.
3. Asdesignruntimeisincreased,thenumberofdefrostsperdayrequiredincreases.
Inthecaseofveryhighfrostload(SHRlessthan0.75)usingdesignruntimegreater
than14h/daymayresultinaninabilityoftherefrigerationsystemtomaintainroom
temperature.
4. Figures8through11canbeusedtoestimatedefrostfrequencywhenroomSHR,
designruntime,andcoilfinspacingareknown.
Example:
Anevaporatorhasbeenselectedfora+10F/85%rhroombasedondesignruntime
of16h/day.Finspacingselectedis3FPI.Estimatethedefrostfrequencyusing
Tables1and3,andFigures8through11.
FromTable1:SHR=0.87
FromTable3:CoolingCapacityatTimeofDefrost=67%
FromFigure10:Timebetweendefrosts=5.2h
Therefore,estimateddefrostfrequency=24h/day/5.2h=5defrostsperday
Conclusion:Table4belowshowssuggestedmaximumfinspacing,designruntime,and
defrostfrequencyforvariousvaluesofSHR.Thistableisintendedtobeusedasageneral
guidelineinconjunctionwithTable1.Notethatroomrelativehumidity,andtherefore
SHR,willlikelychangethroughouttheyeardependingonlocationandclimate
conditions.Thisimpliesthatoptimumdefrostfrequencymaybedifferentinsummer
monthsvswintermonths.
TABLE4
SUGGESTEDFINSPACING,RUNTIME,ANDDEFROSTFREQUENCYVSSHR
SHR SuggestedMaximum RecommendedMaximum SuggestedDefrostFrequency,
FinSpacing,FPI DesignRuntime,h/day No.Defrosts/day
0.65 2 14 9
0.75 3 16 8

0.85 4 16 6
0.95 4 18 2

Theabovediscussionandrecommendationsarebasedonfrostaccumulationby
depositionanddonotincludetheeffectsofairborneicecrystalsonfinspacingand
defrostfrequency.Theeffectsofairborneicecrystalsarediscussedinthefollowing
section.
2. AirBorneIceCrystals:

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Thistypeoffrostisformedquitedifferentlyfromthefrostformedbydepositionas
explainedabove.Itaccumulatesonevaporatorsurfacesbyadifferentmechanism,and
ismoredifficulttoquantifyandpredict.

Airborneicecrystalsasatypeoffrostthatcanbedepositedoncoilsurfaceshasbeen
recognizedanddiscussedforsometime(Cleland2002,Stoecker1988).Theseice
particulatesformwheninfiltrationairmixeswithrefrigeratedairtoproducea
supersaturatedcondition.Onapsychrometricchart,asupersaturatedconditionis
indicatedwhenthemixedairconditionfallstotheleftofthesaturation(100%rh)line
(thinkoffogthathasfrozeninmidair).

Ratherthanaccumulaterelativelyuniformlyovertheentirecoilsurfaceasisthecase
withfrostformedbydeposition,airborneicecrystalsaccumulateontheleadingedges
ofthecoilfinsandhavetheprimaryeffectofrestrictingairflow.Thistypeoffrostis
moredifficulttopredictsinceitsformationdependsonnotonlytheconditionoftheair
outsidetherefrigeratedspace,butalsoontheconditionofdoorwaysandhowtheyare
operated.

Whenevaporatorsarelocateddirectlyabovedoorwayswhereairborneicecrystalsare
formedthistypeoffrostcanaccumulateveryquicklyandhaveseriousconsequencesin
termsofdegradedperformanceandinabilitytodefrosteffectivelyduetoexcessive
accumulationofhoarfrostandice.Inoneparticularcaseobservedbytheauthor,two
identicalevaporatorswereinstalledinthesamerefrigeratedspace(a10degFfreezer)
alongthesamewall,onedirectlyoverthedoorwayandthesecondoffsetbetween
doorways.Theevaporatordirectlyoverthedoorwayhadchronicproblemswithrapid,
heavyaccumulationoffrost,andwithdefrostissuesrelatedtoaccumulationoficeon
theunitcabinetandinthedrainpan.Theevaporatorlocatedonly20feetawaybetween
doorways,operatedwithoutaccumulatingiceonthecabinetandorinthepanand
defrostednormallyandeffectively.Itisthereforerecommendedthatevaporatorsnotbe
locateddirectlyabovedoorwayswheneverpossible.

Ifitisknownthattheevaporatorwillbeexposedtothistypeoffrost,variablefin
spacingisrecommended.Thatis,afinspacingarrangementwhichhasfinsonthefirst
onetotworowsontheairenteringsideofthecoilspacedwiderthanintheremaining
rows.Typicalarrangementsare1/2fpi(finsperinch),1.5/3fpi,and2/4fpi.
V. CondenserSelectionandOperation

Anumberofdifferenttypesofcondensersareavailableforusewithammonia.

WaterCooled
AirCooled
Evaporative
Hybrid(Adiabatic)AirEvaporative

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Incertaincasesthetypeofcompressionequipment(screwvsreciprocating)selectedand
theexpectedmaximumambienttemperaturewilldeterminewhetherornotaircooled
condensingwillbepossible.Inothercasestheavailability(orunavailability)ofwatermay
requiretheuseofaircooledcondensing.ThegoodnewsisthatDXammoniaiscompatible
withalltypesofcondensingsystems!

Properselectionandoperationofammoniacondensingequipmentisoutlinedinthe
condensermanufacturersliterature.

Itisrecommendedthatthesystemdesignercarefullyconsiderthefollowingpointswhen
selecting/designingcondensingequipment:
Energyefficiency
Partloadoperation
Lowambientoperation
Internalvolumeandammoniacharge
Gasinletandliquidoutletpiping
Purgingofnoncondensiblegases
VFDcondenserfancontrol(highlyrecommended)

VI. Subcooling

Refrigerantliquidleavingthecondenseristypicallyatornearsaturationtemperatureand
pressure.Iftheliquidhasnotbeensubcooledbeforeitenterstheliquidline,anydropin
pressure,and/oranyheatinput,willcausetheliquidtoboilandflashgaswillbeformed.
Becauseoftheverylargevolumeoccupiedbyvaporcomparedtoliquid,theflashgas
increasestherefrigerantvelocityandcausesanexcessivepressuredropintheliquidline,
Thisreducesthecapacityandinterfereswiththeoperationoftheexpansionvalve,and
consequentlywillreducesystemcapacity.Adequatesubcoolingoftheliquidwillpreventthe
formationofflashgasinliquidlines.
Subcoolingtheliquidafteritleavesthereceiveristhereforeanecessityforpropersystem
operation.Notethatanysubcoolingdonewithinthecondenserorbetweenthecondenser
andthereceiverwillbeeliminatedinthereceiverduetotheequalizerline.Theamountof
subcoolingrequiredcorrespondstotheliquidlinepressuredropandheatgain.Thepressure
dropisthesumof1)thelossinpressureduetoelevationgainintheliquidline,2)liquidline
pressuredropduetofriction,and3)pressuredropthroughserviceandcontrolvalves.

Table5showsthepressuredropinliquidlinesproducedbyelevationgainbetweenthe
receiverandevaporatorswithammonia.

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TABLE5

PressureDropinAmmoniaLiquidLinesDuetoElevationGain
ElevationGain PressureDrop
ft m psi kPa
1 0.3 0.3 1.9
5 1.5 1.4 9.3
10 3.0 2.7 18.7
15 4.6 4.1 28.0
20 6.1 5.4 37.3
25 7.6 6.8 46.7
30 9.1 8.1 56.0

35 10.7 9.5 65.4
40 12.2 10.8 74.7
45 13.7 12.2 84.0
50 15.2 13.5 93.4

Oncethetotalliquidlinepressuredrop(thesumofelevationpressuredropplusfrictional
pressuredroppluspressuredropthroughvalves)iscalculated,therequiredamountof
subcoolingtopreventflashgasinthelinecanbedeterminedfromTable6.Notethatthe
amountofsubcoolingrequiredforagivenpressuredropincreasesascondensing
temperaturedecreases.

TABLE6
TotalLiquidLine RequiredAmountofSubcooling(Ammonia)
PressureDrop 120F(49C)SCT 95F(35C)SCT 65F(18C)SCT
psi kPa degF degC degF degC degF degC
1 6.9 0.2 0.1 0.3 0.2 0.5 0.3
4 27.6 1.0 0.5 1.3 0.7 1.9 1.0
6 41.4 1.4 0.8 1.9 1.1 2.8 1.6
8 55.2 1.9 1.1 2.6 1.4 3.8 2.1
10 68.9 2.4 1.3 3.2 1.8 4.7 2.6
12 82.7 2.9 1.6 3.8 2.1 5.6 3.1
14 96.5 3.4 1.9 4.5 2.5 6.6 3.7
16 110.3 3.8 2.1 5.1 2.8 7.5 4.2
18 124.1 4.3 2.4 5.8 3.2 8.5 4.7
20 137.9 4.8 2.7 6.4 3.6 9.4 5.2

25 172.4 6.0 3.3 8.0 4.4 11.8 6.5
30 206.8 7.2 4.0 9.6 5.3 14.1 7.8
35 241.3 8.4 4.7 11.2 6.2 16.5 9.2
40 275.8 9.6 5.3 12.8 7.1 18.8 10.5
45 310.3 10.8 6.0 14.4 8.0 21.2 11.8
50 344.7 12.0 6.7 16.0 8.9 23.5 13.1
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AcommonlyusedmethodofsubcoolingliquidrefrigerantistermedMechanicalSubcooling.This
istheCOLMACRECOMMENDEDmethodofliquidsubcoolingandreferstousingaportionof
liquidrefrigerantfromtheuncooledliquidlinetoevaporateandcooltheremainingliquid.A
heatexchanger(typicallyaplatetypeexchanger)isinstalledintheliquidlineinsuchawayasto
cooltheliquidrefrigerantononesideoftheexchangerbyevaporatingarelativelysmallamount
oftherefrigerantontheothersideoftheexchanger.Theevaporatingsiderefrigerantis
meteredbyaTXVormotorizedvalveinresponsetoliquidlinetemperatureandtheevaporated
refrigerantthenreturnedtothesuctionline.Thismethodofsubcoolingproducespredictable
resultsunderallconditions,andisrequiredtoinsureproperoperationofColmacDXAmmonia
evaporatorcontrols.Withmechanicalsubcoolingthereisnonetlossofrefrigeratingeffector
systemenergyefficiency.

Alternatemethodsforsubcoolingrefrigerantliquidcanbeapplied,buthavevariousdrawbacks:

AmbientSubcooling.Thisinvolvesusingaseparatecircuitwithinthecondensertoroute
liquidrefrigerantfromthereceivertothesystemcausingtherefrigeranttoapproachthe
ambientairtemperature.Thisisarelativelysimpledesign,howevertheamountof
subcoolingwillbelimitedtothecondenserTD.Thismaynotbeasufficientamountof
subcoolingtoavoidformationofflashgasduringcertaintimesoftheyear.Therefore,this
methodofsubcoolingisNOTrecommended.

LiquidPumping.Herealiquidpumpisinstalledattheexitofthereceivertopressurizethe
liquidlinesufficientlytoovercomethetotalpressuredropduetofrictionandelevationgain.
Whileeffectiveateliminatingflashgasregardlessofoperatingconditions,thismethodadds
complexityandwillcausetheliquidlinetooperateatapressurewhichishigherthan
condensingpressure.Aswithambientsubcooling,thismethodisNOTrecommended.

NOTE:ReferringtoFiguresA1A3,liquidtemperatureleavingthemechanicalsubcoolerisshown
as40degF.Thisliquidtemperatureisconservativeandshouldpreventtheformationofflash
gasinliquidlinesinmostifnotallcases.

SubcoolerPiping:

Figure12belowillustratestypicalmechanicalsubcoolerheatexchangerpiping.

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FIGURE12

SUBCOOLER KIT

SUCTION
HOT LIQUID IN

N.C.

SUBCOOLED LIQUID OUT

TEMPERATURE
TRANSDUCER

T

TEMPERATURE
CONTROLLER

SOLENOID VALVE GLOBE VALVE PRV VALVE

ANGLE VALVE STRAINER T TEMPERATURE GAUGE

Toinsureeffectiveliquidsubcooling,besuretoobservethefollowingrules:
1. Sizepipingandvalvesforthemaximumrefrigerantflowconditionanticipated,i.e.
lowestheadpressure/highestsuctionpressure.Thisconditiontypicallyoccursduring
wintermonths.
2. Alwaysinsulateliquidlinestopreventheatgainandlossofsubcooling.
3. Locatesubcoolerheatexchangerdownstreamofthereceiverattheentrancetothe
liquidline,NOTbetweenthecondenserandreceiver.SeeP&IDexamplesabove.
4. Usegoodpipingpractice,ascanbefoundintheIIARAmmoniaRefrigerationPiping
Handbook(IIAR2004).
MechanicalSubcoolerSelection:

ColmacofferspreengineeredMechanicalSubcoolerswhicharefactorypipedandpackaged
inafreestandingframe,andincludethefollowingcomponents:
Stainlesssteelplatetypesubcoolingheatexchanger
Electronicexpansionvalveandtemperaturecontroller
Service(isolation)valves
Pressurereducingvalveforcontrolledleavingliquidlinepressure
ULlistedandwiredcontrolpanel

SeeseparateEngineeringBulletinforsubcoolerselectionandspecificationdetails.
VII. PipingGeneral

1. Cleanliness.Thesmallinternalpassagesfoundinexpansionvalves(andothercontrol
valves)inDXammoniasystemsareparticularlysensitivetofoulingandpluggingwith
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relativelysmallamountsofdirtanddebris.Forthisreason,particularcareneedstobe
takenduringtheinstallationofsystempipingtoinsurecleanlinessandtominimizethe
introductionofweldscaleanddust,andothertypesofdirtanddebris.

2. EvacuationPriortoChargingtheSystemwithAmmonia.BecausetheperformanceofDX
ammoniaevaporatorsisdramaticallyaffectedbyevensmallamountsofwater,itisvery
importanttofollowgoodpressuretestingandevacuationprocedurespriortocharging
thesystemwithammonia.Recommendedevacuationprocedurecanbefoundinthe
separateColmacEngineeringBulletinonthistopic.

VIII. LiquidLines

Industryacceptedmethodsandpracticeforpropersizingandarrangementofliquidlines
canbefoundintheIIARAmmoniaRefrigerationPipingHandbook(IIAR2004).Additionally,
followtheguidelinesexplainedbelow.

1. Designmassflowrate.Liquidlinesmustbesizedappropriatelyforthetypeofline
(condensertoreceiver,receivertoexpansionvalve,etc.)andtheexpectedmaximum
massflowratecondition.Themaximummassflowrateconditionwilloccurwhen
dischargepressureisatitsminimum,suctionpressureisatitsmaximum,and
compressorsarerunningfullyloaded.Typicallythiswouldoccurwithfloatinghead
pressuresystemsduringwintermonths.Designingliquidlinesforthehottestdayofthe
year(commonlytakenasthedesignpoint)willlikelyleadtoundersizedliquidlines
andhigherthanexpectedpressuredropwiththepotentialofformingflashgasinthe
liquidline.
2. Insulation.Insulationofliquidlinesdownstreamoftheliquidsubcoolerbecomes
criticallyimportantinDXammoniasystemstoavoidheatgainandthepotentialfor
developingflashgasintheliquidlineupstreamoftheexpansionvalves.Usegood
qualityinsulationsystemswithadequateinsulationvalueandprotectionagainst
physicalandweatherdamage.
3. TypeofExpansionValve.ThreetypesofexpansionvalvesarecommonlyusedinDX
systems:1)Thermostatic,2)Motorized,and3)PulsewidthModulating.Thermostatic
andmotorizedvalvesmodulateinresponsetotheimposedloadonthecoilandsoliquid
linesshouldbesizedforthemaximumexpecteddesignmassflowrate(seeparagraph
V.1.above).Pulsewidthmodulating(PWM)expansionvalves,ontheotherhand,
alternatebetweenwideopenandfullyclosedataratewhichcorrespondstotheduty
calledforbytheelectroniccontroller.Becausethemassflowrateofrefrigerantwillbe
determinedbythewideopencapacityofthePWMvalve,thelocalliquidlinefromthe
liquidsupplymaintotheindividualevaporatormustbesizedtohandlethemaximum
capacityofthevalve.WhenPWMvalvesareused,theliquidsupplymainlinemustbe
sizedtohandlethiswideopencapacitybyusingadiversityfactorbasedonthe
numberofevaporatorsexpectedtobeoperatingatthesametimedividedbythetotal
numberofevaporators.
4. PressureRegulatingValve.AsshowninFiguresA1A3,theliquidlinepressureleaving
thesubcoolerassemblyismaintainedat75psigbyapressureregulatingvalve.When
defrosthotgaspressureisregulatedtomaintain90psig(alsoshowninFiguresA1A3)
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thispressuredifferentialallowsdefrostcondensateleavingtheevaporatorsduring
defrosttobefeddirectlybackintotheliquidlineandsenttootheroperating
evaporators.
5. Pipematerialspecifications.RefertotheIIARAmmoniaRefrigerationPipingHandbook
(IIAR2004)andANSI/IIARStandard22008(IIAR2008)fordetailedpipematerial
specificationrequirementsforammonialiquidpiping.
IX. SuctionLines
Unlikepumpedammoniasystems,nowetsuctionlinesareneededforDXammonia.
Althoughtheyshouldbepitchedandtrappedtoaccommodatetheoccasionalpresenceof
liquid,suctionlinepressuredropshouldbecalculatedtoreflectdryoperation.Refertothe
IIARAmmoniaRefrigerationPipingHandbook(IIAR2004)forpropersizingandarrangement
ofdrysuctionlines.Additionally,followtheguidelinesexplainedbelow.

1. Designmassflowrate.Aswithliquidlines,drysuctionlinesshouldbesizedforthe
expectedmaximummassflowratecondition.Again,themaximummassflowrate
conditionwilloccurwhendischargepressureisatitsminimum,suctionpressureisatits
maximum,andcompressorsarerunningfullyloaded.
2. Trappedverticalrisers.Suctionlineswithverticalupflow(suctionrisers)mustbe
installedwithaptrapatthebottom(entrance)oftheriseranddischargeintothetopof
theoverheadsuctionmainpipe.Whenvaryingloadsontheevaporatorareexpected,a
doubleriserdesignshouldbeused.RefertotheIIARAmmoniaRefrigerationPiping
Handbook(IIAR2004)forexamplesofdoublesuctionriserdesigns.
3. Pitchedsuctionlines.Suctionlinesmustbepitchedaminimumof1/8perfoottoward
thesuctionaccumulatortofacilitategooddrainageofanyliquidrefrigerantand/oroil
thatentersthesuctionline.
4. Pipematerialspecifications.Particularattentionmustbepaidtocarbonsteelpipe
materialspecificationsinlowtemperature(suctiontemperaturesbelow20degF),
whichmayrequireimpacttesting.RefertotheIIARAmmoniaRefrigerationPiping
Handbook(IIAR2004)andANSI/IIARStandard2(IIAR2008)fordetailedpipematerial
specificationsandrequirements.

X. HotGasLines

Industryacceptedmethodsandpracticeforpropersizingandarrangementofhotgaslines
canbefoundintheIIARAmmoniaRefrigerationPipingHandbook(IIAR2004).Additionally,
followtheguidelinesexplainedbelow.

1. Designmassflowrate.Hotgas(defrost)linesshouldbesizedforthemassflowrate
correspondingtothemaximumnumberandsizeofevaporatorsexpectedtodefrostat
thesametime.Conventionalwisdommaintainsthateachindividualevaporatorrequires
aflowofhotgasequalto2xtimestheflowrequiredduringcooling,andsothiswould
limitthenumberofevaporatorsbeingdefrostedatthesametimetoamaximumof1/3
thetotalnumberofevaporatorsinthefacility(thetwotoonerule).However,
evaporatorsequippedwithColmacSmartHotGascontrolscaneffectivelydefrostan
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evaporatorwithhotgasflowingtotheevaporatorforonly8to10minutes.Withan
effectivebuildingmanagementcontrolsystem,anddependingonthefrostloadand
frequencyofdefrosting,itispossibletolimittheamountofdefrosthotgasflowingat
anygiventimetoonlythatrequiredforthelargestsingleevaporatorinthefacility.This
approachobviouslyhasthepotentialtoreducethehotgaslineandPRVsizeandcost.
Expectedmassflowrateofhotgasfordefrostofagivensizedevaporatorcanbe
calculatedusingthemethoddescribedbelowintheHotGasDefrostsection.
2. Insulation.Insulationofhotgaslinesiscriticallyimportanttoinsurefastdefrosting.Use
goodqualityinsulationsystemswithadequateinsulationvalueandprotectionagainst
physicalandweatherdamage.
3. PressureRegulatingValve.AsshowninFiguresA1A3,thehotgaslinecomingfromthe
compressordischargelineismaintainedat90psigbyapressureregulatingvalve.When
defrosthotgaspressureisregulatedtomaintain90psigandtheliquidlineis
maintainedat75psig(alsoshowninFiguresA1A3)thispressuredifferentialallows
defrostcondensateleavingtheevaporatorsduringdefrosttobefeddirectlybackinto
theliquidlineandsenttootheroperatingevaporators.Maintainingthehotgasline
pressureatthereduced90psigalsominimizesheatlosstothesurroundingambient.
4. Pitchedhotgaslinesanddriplegs.Hotgaslinesmustbepitchedaminimumof1/8per
foottowardtheevaporatorstofacilitategooddrainageofanycondensedrefrigerant
(condensate)todriplegsinstalledaheadoftheevaporatorcontrolvalvegroup(s).
5. Liquiddrainers.Ashotgasfordefrosttravelsfromtheengineroomtotheevaporators
someofitsenergywillbereleasedtoheatupthepipingitself,andsomereleaseddue
toheatlossthroughinsulation.Condensatewillthereforeforminthehotgaspiping
whichmustthenbeeffectivelytrappedanddrainedbeforeitreachestheevaporators.
Unlessitiseffectivelyremoved,accumulatingcondensedliquidupstreamofhotgas
solenoidvalveswillcausecavitationontheseatsofthesolenoidvalveswhenthevalve
isclosed(Jensen2013).Condensatewillcollectindriplegs(describedabove)andmust
bereturnedtoeitheranearbysuctionline,oracondensatereturnline.Usealiquid
draineroranappropriatelysizedsteamtraptoallowonlyliquidtoleavethedripleg.
Usingliquiddrainersalsoeffectivelykeepshotgaslinescontinuallyheatedandreadyto
supplyfullflowofhotgastoevaporatorsimmediatelyondemandfordefrosting.
6. Pipematerialspecifications.RefertotheIIARAmmoniaRefrigerationPipingHandbook
(IIAR2004)andANSI/IIARStandard22008(IIAR2008)fordetailedpipematerial
specificationrequirementsforammoniahotgaspiping.
XI. EffectsofWaterinAmmoniaandItsRemoval

Asexplainedindetailelsewhere(Nelson2010),thepresenceofevensmallamountsof
waterinammoniahasasignificantnegativeeffectonDXevaporatorperformance.
Unfortunately,waterisdifficulttoentirelykeepoutofindustrialammoniarefrigeration
systemsforanumberofreasons:Residualwaterinpressurevesselsleftfromhydrotesting,
incompleteevacuationofthesystempriortostartup,leaksinpartsofthesystemwhich
normallyoperateinavacuum,etc.

Thisresidualwatergoesintosolutionwiththeammoniaandincreasesandtheboilingpoint
(bubblepoint)temperature.Ataconcentrationof20%(bymass)waterinammonia,the
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boilingpointrisestoapproximately10degFabovetheboilingpointofpureammoniaatthe
samepressure.SeeFigure13below.

Astheammoniawaterliquidenterstheevaporatorcircuititbeginstoboil.Becauseofthe
largedifferenceinvaporpressuresofammoniaandwater,onlyammoniavaporis
generatedduringtheevaporationprocess,leavingthewaterbehindintheremainingliquid.
Sotheevaporationprocessresultsinanincreaseinwaterconcentrationanda
correspondingincreaseintheboilingpointoftherefrigerantasitpassesthroughthecoil
circuit.Inthecaseofanevaporatoroperatingwitha10degFTD,therefrigerantwillstop
boilingoncethewaterconcentrationreachesabout20%sincetheboilingpointwillhave
risenby10degF.Thiscessationofboilingwilloccuratsomepointalongthelengthofthe
evaporatorcircuit,thepointatwhichboilingstopsdependingontheinitialconcentrationof
waterandsuctionpressure.Atthepointwheretheincreaseinthewaterconcentrationhas
causedanincreaseintheboilingpointequaltothecoilTD,liquidrefrigerantwillexitthe
evaporatorandenterthesuctionline.

Figure13belowshowstheincreaseinboilingpoint(bubblepoint)forvariousinitialwater
concentrationinammoniaatvariouspressures.

FIGURE13

IncreaseinBubblePointTemperaturevsComposition
AmmoniaWater
40

35
48.2 psia(3.3bar)
30.4psia(2.1bar)

IncreaseinBubblePointTemperature,F
30 18.3psia(1.3bar)
10.4psia(0.7bar)
25

20

15

10

5

0
0 0.1 0.2 0.3 0.4 0.5
Composition(MassFractionWater)

Anexampleoftheincreaseinbubblepointtemperatureoverthecircuitlengthofan
evaporator,representedbythechangeinvaporquality,isshowninFigure14belowforan
initialwaterconcentrationinammoniaof3%atapressureof10.4psia(40degFSST).In
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thisexamplethebubblepoint(Tbub)hasincreasedby10degFatavaporqualityofapprox.
0.89.
FIGURE14

Incr in Bubble Point vs NH3 Vap Quality, 3.00% Water in NH3,
Tsat = -40.0F

50
45

40

35

Increase in Tbub, F
30

25
20

15
10

5

0
0 0.2 0.4 0.6 0.8 1

NH3 Vapor Mass Fraction (Quality)

Thisincreaseinbubblepointsignificantlyreducesthemeantemperaturedifferenceand
thereforethecoolingcapacityoftheevaporatorisreducedasillustratedinFigure15.

FIGURE15

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Inadditiontotheperformancepenaltyseenwhenrelativelysmallamountsofwaterare
presentintheammonia,thisalsomeansthatthemassfraction(10.89)=0.11,or11%of
themassofrefrigerantexitingtheevaporatorasliquidwillhavetobecaptureddownstream
inthesuctionaccumulator.

Knowingthatammoniawaterliquidofapproximately20%waterconcentrationwill
unavoidablyleavetheevaporatorswheneverevensmallamountsofwaterarepresentin
theammoniaisimportantforthedesignertounderstand.Thesuctionaccumulatormust
thereforebeproperlydesignedtoperformthefollowingfunctions:

i. Separateliquidandvaporrefrigerantandallowonlyvaportoreturntothe
compressor,
ii. Captureanddistill(byheating)ammoniawaterliquidtoaconcentrationthat
cansafelyberemovedfromthesystemfordisposal.
iii. Transferexcesstrappedliquidtothehighpressurereceiver,orintothereduced
pressureliquidline.

1. Separation

Liquidvaporseparationinsuctionaccumulatorvesselsiswellunderstoodanddesign
methodswelldocumented.Refertorecognizedpublishedsizinganddesignmethods
(Stoecker1988,Wiencke2002).

Colmacoffersarangeofpreengineeredfactoryassembledsuctionaccumulator
packagesspecificallysuitedtooperationwithDXammonia.SeeseparateEngineering
Bulletinforselectionandspecificationdetails.

2. DistillationandDisposalofAmmoniaWaterSolution(AmmoniumHydroxide)

Distillation:

AmmoniaishighlysolubleinwaterduetothepolarityofNH3moleculesandtheir
abilitytoformverystronghydrogenbonds(Nelson2010).Thishighsolubilitymakes
ammoniawateragoodworkingfluidpairinabsorptionrefrigerationmachines,taking
advantageofthelargevaporpressuredifferencesbetweentheammoniavaporand
weaksolution.However,thissamebehaviormakeswaterremovalfromammonia
refrigerationsystemssomewhatchallenging.

Asmentionedabove,ammoniawatersolutionconcentratedtoapproximately20%
waterwillreturnfromevaporatorsviathesuctionlinetobetrappedinthesuction
accumulator.Thisaqueousammoniasolution,calledAmmoniumHydroxide,ata
concentrationof80%ammonia(20%water)wouldbeverydifficulttosafelyremove
fromthesystemfordisposal.Furtherdistillationofthesolutionisneededtobringthe
ammoniaconcentrationinthesolutiondowntothepracticalminimumbeforeitis
removed.
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TheonlypracticalwaytodistilltheAmmoniumHydroxideisbyheatinginaseparate
distillationvessel,calledastill.AmmoniumHydroxidetrappedinthesuction
accumulatordrainsbygravityintothestillwhereitisheatedtoatemperature
correspondingtothepointonaPhaseEquilibriumdiagramwheretheslopeofthedew
pointlinechangesrapidlyfromnearlyverticaltomorenearlyflat.Thispointisshownon
Figure16asPointA.Belowthistemperature(between100and120degF),nearlypure
ammoniavaporwillleavethestillandtravelthroughtheventlinebacktothesuction
accumulatorwhereitwillthenbetakenbacktothecompressor.Abovethis
temperature,watervaporwillbegintoleavetheAmmoniumHydroxidesolutionand
exitthestillventlinewhereitwillgobackintosolutionwithanyammonialiquid
presentinthesuctionaccumulator.Basedonthis,theheatingelementinthestillmust
becontrolledtobringthesolutiontemperatureuptoamaximumof100to120degF,
atwhichpointitisreadytoberemovedsafelytoastoragecontainerforfurther
processingand/ordisposal.

FIGURE16

Figure16alsoshowsthatthemaximumwaterconcentrationintheAmmonium
Hydroxidesolutionheatedto100degFvarieswithsuctionpressure.Themaximum
waterconcentrationspossibleareshownasPointsB,C,D,andE,inFigure16,andare
listedinTable7below.Itisapparentfromthefigureandthetablethatthestillisableto
achievehigherwaterconcentrationsatlowersuctionpressures.
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TABLE7
AMMONIAWATERCONCENTRATIONS@100degFvsSUCTIONPRESSURE
SuctionPressure,psia WaterConcentration, AmmoniaConcentration,
(SaturationTemp,F) %bymass %bymass
48.2(+20F) 57.5 42.5
30.4(0F) 65.0 35.0
18.3(20F) 72.5 27.5
10.4(40F) 80.0 20.0

Usingtheaboveinformation,anestimatecannowbemadeofthevolumeof
AmmoniumHydroxidesolutionthatwillbegeneratedbythestillforagivensystem
ammoniachargehavingagiveninitialwatercontent.Table8belowshowsthe
expectedvolumeofAmmoniumHydroxidesolutionperpoundofinitialammonia
chargethatwillhavetoberemovedbythestill(anddisposedof)inorderto
completelyremovethewaterfromrefrigerationsystem.

TABLE8
EXPECTEDVOLUMEOFDISTILLEDSOLUTIONAMMONIUMHYDROXIDE@100F
(GALLONSperPOUNDINITIALAMMONIACHARGE)

InitialWater SaturatedSuctionPressure,psia(SaturatedTemp,F)
Content,% 48.2(+20F) 30.4(0F) 18.3(20F) 10.4(40F)
0 0.00000 0.00000 0.00000 0.00000
1 0.00246 0.00211 0.00183 0.00161
3 0.00738 0.00633 0.00550 0.00484

5 0.01230 0.01055 0.00917 0.00807

10 0.02460 0.02109 0.01835 0.01614

20 0.04920 0.04218 0.03669 0.03229

EXAMPLE:
Asystemhasaninitialammoniachargeof5,000lbswith3%watercontent.Thestill
isinstalledonthe20degFsuctionaccumulator.Whatwillbethetotalvolumeof
distilledAmmoniumHydroxidesolutiondrainedfromthestill?

Answer:
FinalDistilledSolutionAmmoniaConcentrationforDisposal(fromTable7):27.5%
ExpectedVolumeofDistilledSolutionperPound(fromTable8):0.0055gal/lbs

TotalExpectedVolumeof27.5%AmmoniumHydroxideforDisposal:
5,000lbsx0.0055gal/lbs=27.5gallons

StorageandDisposal:

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AmmoniumHydroxideislistedasahazardoussubstanceunderCWA(40CFR
1164.40CFR117.3ReportableQuantityCategoryC.1000lbs/454kg).Assuch,itis
importanttocomplywithalllocalandnationalregulationsforsafehandlingand
disposalofthesolutionremovedfromthesystemstill(Smith2010).

ItisinterestingtonotethatsuitablydilutedAmmoniumHydroxidemaybedisposed
ofonagriculturallandasfertilizer.However,thematerialshouldbekeptfrom
enteringstreamsandlakesasitisharmfultoaquaticlifeandcancause
environmentaldamage.

AmmoniumHydroxidewillreactexothermically(heatisgenerated)withacids,and
soneutralizingofthesolutionbyunqualifiedpersonnelisnotrecommended.

ItisimportanttopreventcontactoftheAmmoniumHydroxidesolutionwith
chemicalssuchasmercury,chlorine,iodine,bromine,silveroxide,and
hypochlorites,astheycanformexplosivecompounds.Contactwithchlorineforms
chloraminegaswhichisaprimaryskinirritantandsensitizer.

Figure16incombinationwithTable7canbeusedtopredictthetemperatureabove
whichammoniavaporwillbegeneratedwhenthedistilledsolutionisstoredinan
opencontainer.Thisvaporneutraltemperatureisfoundusingtheammonia
concentrationsshowninTable7forvarioussuctionpressures,intersectingalineof
constantbubblepointtemperature(Tbub)atatmosphericpressure(14.7psia)on
Figure16.Table9belowshowstheambient(storage)temperaturesbelowwhich
ammoniavaporwillnotbegeneratedfromtheAmmoniumHydroxidesolution
dischargedfromthestill.

TABLE9
RECOMMENDEDMAXIMUMAMMONIUMHYDROXIDESTORAGETEMPERATURES
SuctionPressure,psia AmmoniaConcentration, StorageTemperature,
(SuctionTemp,F) %bymass DegF
48.2(+20F) 42.5 42
30.4(0F) 35.0 64
18.3(20F) 27.5 90
10.4(40F) 20.0 108

AmmoniumHydroxidesolutionhasacorrosivereactionwiththefollowingmaterials
whichshouldnotbeusedtostorethedistilledAmmoniumHydroxidesolution
(LaRocheIndustries1987):
Galvanized(zinccoated)surfaces
Copper
Brassandbronzealloys
Certaintypesofelastomers

ThedistilledAmmoniumHydroxidesolutioncanbesafelystoredincontainersmade
ofthefollowingmaterials:
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Carbonsteel
Stainlesssteel
Aluminum
CastIron

Generallyspeaking,aluminumalloysarenotrecommendedforexposuretoaqueous
solutionshavingapHgreaterthan9.0duetoacceleratedcorrosionandmetalloss.
AmmoniumHydroxidehowever,eveninhighconcentrations,isanexceptiontothis
rule.(Davis1999).

Inconclusion,AmmoniumHydroxidesolutioncollectedfromthestillshouldbestored
inanappropriatelyconstructedcontainerlocatedinacoolspaceoutofdirect
sunlight.Itisrecommendedthatthedistilledsolutionbedisposedofusingalocal
qualifiedwastedisposalvendor.

MoredetailedhandlingandsafetyinformationcanbefoundonMSDSsheets
publishedbysuppliersofAmmoniumHydroxide(TannerIndustries2000,LaRoche
Industries1998).

3. LiquidTransfer

Liquidrefrigerantwillleavetheevaporator(s)andaccumulateinthesuction
accumulatorvesselduringoperationforanumberofreasons:

a. Liquidfloodbackduetowaterintheammonia(seeaboveexplanation),
b. Liquidfloodbackduetoarapidchangeinsystempressureand/orload,
c. Liquidcondensatefromhotgasdefrost.

Aliquidtransfersystemcapableofhandlingthetotalanticipatedvolumeofliquid
refrigerantreachingthesuctionaccumulatorvesselmustbeincludedinthesystem
design.Inordertoproperlysizethetransfersystem,estimatesoftheamountof
liquidreturningfromevaporatorsforthereasonsstatedabovemustbemade.

i. LiquidFloodbackDuetoWaterinAmmonia

Theanticipatedvolumeofammoniawaterliquidleavingtheevaporator(s)basedon
anaverage20%waterconcentrationattheevaporatorexithasbeencalculatedand
showninTable10below.Multiplythevalueshowninthetablebythetotalcapacity
ofthesystemintons(TR)todeterminethevolumeofammoniawaterliquid
returningtothesuctionaccumulator.

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TABLE10
VolumeofAmmoniaWaterLiquidLeavingDXEvaporators

WaterContentin VolumetricFlowrateofAmmoniaWater
Ammonia,% (20%waterconcentration)LeavingDX
Evaporators,ft3/h/TR
0.5 0.01
1.0 0.02
3.0 0.07
5.0 0.12
10.0 0.24

Example:
Ithasbeendeterminedthattheammoniafedtoevaporatorswithtotalcapacityof
200tons(TR)hasawatercontentof3%.Iftheevaporatorsareoperatedasdirect
expansion(DX),howmuchammoniawaterliquidisexpectedtoreturnfromthe
evaporatorstothesuctionaccumulator?

Answer:
VolumeofFloodbackDuetoWater=200TRx0.07ft3/h/TR=14ft3/h=1.8gal/min

Inaproperlydesignedandoperatedsystem,thistypeofliquidfloodbackshould
onlyoccurinitiallyduringstartupsincewaterinthesystemwillbecapturedinthe
stillandthenremoved.

ii. LiquidFloodbackDuetoRapidChangesinPressureorLoad

Thistypeoffloodbackisdifficulttopredict,butfortunatelyis(orshouldbe)
relativelysmall.Aworstcaseruleofthumbmightbetoassumethatanaverage
10%ofthemassofrefrigerantleavesasliquidfrom25%oftheevaporators.Inthat
case,thetransfersystemwouldneedtohandleavolumeofliquidapproximatedby
thefollowingformula:

12,000
, 3/ 0.10 0.25 (8)

Where:
,
, /

, 3/
Example:
200TRofammoniaevaporatorcapacityat25degFsuctiontemperatureis
connectedtothesuctionaccumulator.Whatistheexpectedaveragevolumeof
liquidreturningtotheaccumulatorduetoliquidfloodback?
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Answer:
LatentHeatofVaporization,hfg=550Btu/lbm
ChangeinVaporQualityThroughtheEvaporator,dx=0.8
SpecificVolume(liquid),v=0.024ft3/lbm

,
0.024 0.10 0.25 3.3 3/ 0.4 /
.

iii. DefrostCondensatefromHotGasDefrost
Ifthereisanywaterpresentintheammoniaenteringtheevaporatorduringlow
temperatureoperation,itwillbeheldanddistilledintheporesoftheproprietary
wickingstructureontheIDoftheColmacevaporatortubes.Thislocaldistillation
processdegradestheperformanceoftheevaporatorbyreducingthelocalmean
temperaturedifference(MTD).Hotgasdefrostiscriticaltoremovingthiswater
richliquidfromthewickingstructure.Theammoniahotgascomingfromthe
highpressurereceiver(seeFiguresA1thruA3)isessentiallywaterfreeandoil
freeammonia.ThispureammoniavaporcondensesonthetubeID,dilutesthe
waterrichliquid,andsendsittoeithertheintercoolervesselorthelow
pressuresuctionaccumulatorwhereitcanbedistilledintheammoniastilland
removedfromthesystem.

Thisprocessofflushingtheevaporatorsandthesystemofwaterduringhotgas
defrostingshouldonlyhappeninitiallyduringthestartupphaseforsystemswhich
operatewithalowsuctionpressureaboveoneatmosphere(0psig)andthenonly
periodicallyforsystemswithalowsuctionpressureoperatinginavacuum(blast
freezing).Duringsystemstartup,avalveinthedefrostcondensatereturnlineon
eachevaporatorisopenedtoadmitthecondensatetothesuctionlineand
accumulator(seeFiguresA1throughA3).Intheaccumulatorthewaterladen
ammoniaiscapturedinthewaterstill,distilled,andremovedfromthesystem.
Afterthewaterintheinitialammoniachargehasbeencompletelyremoved(after
anumberofdefrostcycles)andtheammoniaisdry,thevalveinthecondensate
returnlinetosuctionisclosedandthevalveinthecondensatereturnlinetothe
liquidlineisopened.

Duringstartup,excessdefrostcondensatewhichisnotcapturedinthewaterstill
mustbetransferredtothehighpressuresideofthesystem.Thevolumeof
defrostcondensateleavingtheevaporatorscanbeestimatedusingthefollowing
formula:

12,000 1
, 3/ (9)

Where:
, /
, /
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, 3/
0.15

Example:
200TRofammoniaevaporatorcapacityat+10degFroomtemperature/85%rhis
connectedtothesuctionaccumulator.Whatistheexpectedaveragevolumeof
defrostcondensate(liquid)returningtotheaccumulator?

Answer:
LatentHeatofVaporization,hfg=550Btu/lbm
SensibleHeatRatio(SHR)fromTable1=0.87
SpecificVolume(liquid),v=0.024ft3/lbm
DefrostEfficiency=0.15

200 12,000 1 0.87
, 3/ 0.024 90.8 3/ 11.3 /
550 0.15

Thesuctionaccumulator(s)andtheliquidtransfervesselmustthereforebe
designedtohandlethetotalamountofliquidreturningfromevaporatorsdueto
water+normalfloodback,+defrostcondensate.

AliquidtransfervesselisincorporatedintotheColmacPreEngineeredSuction
AccumulatorSkidpackage(seeseparateEngineeringBulletin).Thetransfervesselis
designedtohandleupto5%initialwatercontentinthesystemammoniacharge.
NotethatIndustrialRefrigerationgradeanhydrousammoniaiscertifiedtobe
99.95%pureammonia.

XII. EffectsofOilonEvaporatorPerformanceandOilSeparation

ImmisciblelubricantsarerecommendedovermisciblelubricantsforlargeindustrialDX
ammoniarefrigerationsystemsforanumberofreasons:
o Lowercost
o Easeofseparation
o Relativeinsensitivitytocontaminants(water,dirt)

Eventhoughimmiscibleoilsarepreferredovermiscibletypesforthereasonsstated
above,anyoilreachingtheevaporatorcanpotentiallycoattheinsideofthetubesand
severelydegradeheattransferperformancedueto:
1. Addedresistancetoheattransferasexplainedbelowandshownin
Figure17,and
2. Foulingoftheproprietarywickingstructurepreventingliquidammonia
fromcoatingtheinsideofthetubesbycapillaryaction.

Evenathinlayerofoilcoatingtheinsideofevaporatortubesaddsresistancetoheat
flowasshownbelow.
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FIGURE17

InsideFoulingFactorvsOilFilmThickness
0.006

0.005

InsideFoulingFactor,ft2Rh/Btu
0.004

0.003

0.002

0.001

0
0 0.001 0.002 0.003 0.004 0.005

OilFilmThickness,inches

InatypicalDXammoniaevaporator,thisfoulingfactorcausesasignificantreductionin
coolingcapacityasisshownbelowinFigure18.

FIGURE18

CapacityReductionvsOilFilmThickness

AmmoniaEvaporator,15FSST,5FAirOn
1

0.95

CapacityReductionRatio

0.9

0.85

0.8

0.75

0 0.0005 0.001 0.0015 0.002 0.0025 0.003 0.0035 0.004
OilFilmThickness,inches
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ItisapparentfromFigures17and18abovethatitishighlydesirablefromanenergy
efficiencystandpointtopreventcompressorlubricatingoilfromreachingtheevaporators.
Toachievethis,thefollowingshouldbecarefullyconsideredandspecifiedinthesystem
design:

a. Typeofcompressorlubricatingoil
b. Compressoroilseparatordesignandefficiency
c. Oilcaptureandmanagementattheoutletofthecondenser
d. Oilcaptureinthesuctionaccumulator(s)
e. Oilcaptureattheevaporator

TypeofOil:

Dependingonthetypeofcompressorused(reciprocatingorrotaryscrew),varyingamounts
oflubricatingoilwillunavoidablybedischargedwiththeammoniavapor.Oilwillleavethe
compressorbothinliquiddropletformandasoilvapor.Theliquiddropletscanbecaptured
mechanicallyintheoilseparatorvesselbycontrollingvelocityandbyincorporating
coalescingelements.Theoilwhichiscombinedwiththeammoniainvaporformismore
difficulttocapture.Generallyspeaking,asvolatilityandsolubilityoftheoilincrease,
separationbecomesmoredifficult.Theamountofoilwhichisnotcapturedintheseparator
andreturnedtothecompressorisreferredtoasoilcarryover.

Alllubricatingoilsusedintheammoniarefrigerationindustryareblendsofabasefluid(s)
withadditives(Wierbosch2010).Thebasefluidcontrolsvolatilityandsolubiltyoftheoil.
Today,commonlyusedbasefluidsinclude:
Napthenic
SolventRefinedParaffinic
AlkylBenzene
2StageHydrocracked
PAO/AB

Thearomaticcontentofthebasefluidhasalargeeffectonvaporpressure(volatility)and
solubility.Thehigherthevaporpressureoftheoil,themoreoilvaporwillleavethe
compressorwiththeammoniainthedischargegas(Briley1984).Sincethisoilvaporis
difficulttocaptureintheseparator,itisdesirabletoselectanoilwhichhasthelowestvapor
pressurepossible.AlkylBenzeneandNaphthenicbaseshavethehighestaromaticcontent,
vaporpressure,andsolubility.2StageHydrocrackedbaseshavelowestaromaticcontent,
vaporpressure,andthelowestsolubility.

Itisthereforerecommendedthatammoniarefrigerationoilhavinga2StageHydrocracked
basefluidbeusedintheDXammoniacompressionsystemdesign.2StageHydrocracked
mineraloilmanufacturedbyCPI(CPI100968)isrecommendedforapplicationin
reciprocatingandscrewtypeammoniacompressorsfortemperaturesabove40.

Anotherfactoraffectingoilvaporpressureistheoiltemperature.Thehighertheoil
temperature,thehigherthevaporpressure.Reducingthedischargegas(andoilvapor)
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temperaturebeforeitenterstheseparatorwillthereforereduceoveralloilcarryoverand
increasetheefficiencyoftheseparator.Forexample,desuperheatingthedischargegas
from80degCto35degCreducestheoilvaporpressure,andthereforecarryoverofoil
vapor,byapproximately85%(Wiencke2012).

OilSeparator;

ForsuccessfulDXammoniasystemoperation,anoilseparatorwithcoalescingelements
capableofguaranteeing57ppmcarryovershouldbespecifiedandinstalled.

Forreasonsmentionedabove,itisalsorecommendedthatthedischargegasbe
desuperheatedasmuchaspracticalpriortoenteringtheoilseparator.

NOTE:MeshPadoilseparatorsasfoundonolderscrewcompressorpackagesand
reciprocatingcompressorswillnothavetherequiredseparationefficiencyandarenot
recommended!

Oilcaptureandmanagementattheoutletofthecondenser;

Asmentionedabove,reducingthetemperatureofthedischargegasdowntothesaturated
condensingtemperature(i.e.fullydesuperheating)significantlyreducesthevaporpressure
oftheoilinthedischargegas.Thisreductionoftheoilvaporpressureincreasestheamount
ofoilavailableforcapture.

Consequently,mostoftheoilvaporwhichhasescapedtheoilseparatorvesselwillbe
condensedandheldintheliquidammonialeavingthecondenser.Itispossibletodesignthe
highpressurereceivertocollectandseparatethisoil,nowintheliquidphase,andthen
automaticallyreturnitautomaticallytothecompressors.Itisalsodesirabletotakethede
oiledammoniavaporfromthetopofthehighpressurereceiverratherthanusingoilladen
dischargegasforhotgasdefrost.ThesefeaturesareshowninFiguresA1thruA3inthe
appendix.

Oilcaptureinthesuctionaccumulator(s);

Properlydesignedsuctionaccumulatorsshouldincludeaccompanyingoilpotstocollectand
removeanysmallamountofoilthathasmadeitasfarastheevaporators.SeeFiguresA1
thruA3intheappendix.

OilCaptureattheEvaporator:

Asexplainedabove,itisimportanttopreventfoulingofevaporatortubeswithoil
particularlyatlowtemperatures.Tothisend,ColmachasdevelopedaproprietaryDX
ammoniadistributorwhicheffectivelyseparatesanyoilwhichhasescapedtheoilseparator
andhighpressurereceiverandpreventsitfromenteringtheevaporator.TheColmacTank
Distributor(patented)incorporatesadroplegintothebodyofthedistributortankwhich
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servestocollectoilanddebriswhereitcanbeperiodicallydrainedandremovedfromthe
systemattheevaporator.

Figure19belowshowsacrosssectionoftheColmacTankDistributorwithitsintegraldrop
legfeatureforcapturingandremovingoil.

FIGURE19
COLMACTANKDISTRIBUTOR(CROSSSECTION)

Unlikeconventionalorificeplatetypedistributors,theColmacTankDistributoroperates
withverylowpressuredropandiswellsuitedtothefollowingapplications:
DXammoniautilizingmotorizedexpansionvalves
Floatingheadpressuresystems
Evaporatorsdesignedforoperationwithmorethanonerefrigerant

XIII. EstimatingDXEvaporatorRefrigerantChargeInventory

Inordertoproperlysizethevolumeofthesystemvessels(highpressurereceiverand
lowpressureaccumulator),anestimateoftherefrigerantchargeheldinthe
evaporatorsmustbemade.Designersnormallycalculatetheevaporatorchargeasa
percentageoftheevaporatorinternalvolumetimestheliquiddensityofammonia.

OneofthemainadvantagesofDXoperationisthesignificantlyreducedevaporator
ammoniachargecomparedtopumpedammonia.Manysystemdesignersestimate
evaporatorchargeforbottomfeedpumpedammoniaevaporatorstobeasmuchas
80%oftheinternalvolumetimestheliquiddensitytoaccountforlowloadandidle
conditions.DXammoniaevaporatorchargecanbeestimatedusingtwophasevoid
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fractionequations.Table11belowshowsDXammoniaevaporatorchargeasa
percentageofinternalvolume.

TABLE11
COLMACDXAMMONIACHARGEINVENTORY
SuctionPressure,psia ColmacDXAmmonia
(SaturationTemp,F) EvaporatorChargeInventory,
lbs/ft3ofInternalVolume
48.2(+20F) 1.01
30.4(0F) 0.83
18.3(20F) 0.63
10.4(40F) 0.52

Thissignificantlyreducedsystemchargenotonlyreducestherequiredsizeofthe
receiver(and/orothersystemvessels),italsogreatlyreducespumpouttimeforthe
evaporatorspriortodefrosting.Thisservestoshortentotaldefrosttimeandincrease
theeffectivenessofhotgasdefrosting,reducingenergyconsumptionandoperating
costs.

EXAMPLE:
AColmacDXammoniaevaporatoroperatingatasuctiontemperatureof20degFhas
aninternalvolumeof12ft3.WhatistheexpectedDXammoniaoperatingcharge?What
wouldtheoperatingchargebeforpumpedammoniaoperationusingthe80%rule?

Answer:
ColmacDXammoniacharge=12ft3x0.63=7.6lbs
Pumpedammoniacharge=12ft3x0.8x42.2lbs/ft3=405lbs

XIV. DXSequenceofOperations

FollowingareimportantsequenceofoperationsstepsspecifictoDXammoniasystems.
Othergeneralsystemstartupproceduresshouldcomplywithsafe,bestpractice,and
withestablishedstandardoperatingprocedures.

Startup:
o Runwithdefrostcondensatetosuctionreturnvalvesopen(closethe
condensatetoliquidlinereturnvalves)ateachevaporator.Thisputsalldefrost
condensateintosuctionaccumulatorsandactivelyflushesevaporatorsandthe
internaltubewickingstructurewithpureammonia.Sendsallwaterladen
ammoniatolowpressuresuctionaccumulator.
o Activelyrunthewaterstillandremovedistilledaquaammoniasolutionwhen
thestilltemperaturereaches110degF.Continuetooperatethestilluntilthe
systemiscompletelydriedout(stilltemperaturenevercomesupto110degF).
Afterstartupandpulldownstages,afterthesystemammoniachangeiscompletely
driedout:
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o Closethecondensatetosuctionreturnvalvesandopencondensatetoliquid
linereturnvalvesoneachevaporator.
o Disconnectpowertotheammoniastill.

XV. ColmacSmartHotGasDefrost
Theenergyefficiencyofhotgasdefrostingevaporatorsdependsonthefollowing
(Nelson2011(1)):

1. Minimizingconvectiveheatloss.
Uselowestpracticaldefrostregulatorsetting.75to90psig(50to60F)
shouldbeadequate.Note:Ifhigherpressuresareneeded,lookfor
problemselsewhere.
2. Shortendefrostduration.
UsetopfeedorDX(directexpansion)evaporatorfeedtoreducetime
requiredforpumpout.
Openthehotgassolenoidonlylongenoughtoclearcoil(68minutes).
Installaseparatehotgassolenoidanddefrostregulatorforpreand
postheatingofthepanloop.Alternately,installelectricresistance
drainpanheating.
3. Reducethenumberofdefrostsperday.
Reducethenumberofdefrostsperdaytomatchthefrostload.
Chooseevaporatorswithwidefinspacing(3fpiinsteadof4fpi)to
maximizefrostcarryingcapacity.
Mitigateinfiltrationofhumidairintotherefrigeratedspaceby:
Properdesignandoperationofdoorways,and
Keeploadingdocksatthelowestpracticaldewpoint
temperature.
CalculatingtheCostofDefrost

Asmentionedabovedefrostefficiencycanbesignificantlyimprovedbyreducingthe
amountofenergylosttotheroombyconvectionduringdefrost.Theoperatingcost
savingsduetoareductionindefrostdurationhasbeencalculatedandpresentedbelow
basedon:

1. Reducingdefrostdurationfrom30minutesto10minutes,and
2. Increasingfrostthicknessfrom1mmto2mm(reducingthenumberofdefrosts
perdaybyhalf).

Thecalculationsassume:

Evaporatorcapacity:100TR
Compressorruntime:16h/day
CostofElectricity:$0.10/kWh

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Table12showscalculatedcostsavingsforfourdifferentroomtemperatures.

TABLE12
CALCULATEDCOSTSAVINGS($/y/100TR)FOROPTIMIZEDVSCONVENTIONALDEFROST
Room Temp, C (F)

0 (+32) -18 (0) -23 (-10) -34 (-30)
SHR 0.66 0.89 0.93 0.97
System COP: 3.2 2.5 2.2 2
Frost Removed, kg/day: 2,778 899 572 245

Frost Removed, kg/y: 1,014,096 328,090 208,784 89,479
I. Baseline (30 min, 1 mm)
Defrost Efficiency, % 32% 18% 17% 14%
Defrost Convective Losses, %: 46% 61% 63% 65%
Defrost Convective Losses, kWh/y: 1,012,438 753,334 545,922 283,071
Baseline Cost of Defrost (Convective), $/y: $31,639 $30,133 $24,815 $14,154
II. Optimized (10 min, 2 mm)
Defrost Efficiency, % 61% 46% 43% 40%

Defrost Convective Losses, %: 15% 26% 27% 30%
Defrost Convective Losses, kWh/y: 168,740 125,556 90,987 47,178
Optimized Cost of Defrost (Convective), $/y: $5,273 $5,022 $4,136 $2,359
SmartHotGasDefrostPiping
Savings
Optimized vs Baseline, $/y: $26,366 $25,111 $20,679
$11,795

Conventionalammoniaevaporatorsaretypicallyarrangedforbottomfeedwiththehot
gaspanlooppipedinserieswiththecoil.TheColmacSmartHotGasDefrostsystem
(Nelson2011(2))resultsinthehighestpossibledefrostefficiencyandlowestoperating
costbyutilizingtopfeedDXcircuitingwiththehotgaspanlooppipedseparatelyfrom
thecoil.Thisresultsin:

Shorterpumpoutperiod
Defrostduration(timecoilhotgassolenoidisopen)ofonly68minutes

AtypicalColmacSmartHotGasDefrostcontrolvalvegroupisshowninFigure20below.

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FIGURE20
COLMACDXSMARTHOTGASDEFROSTCONTROLVALVEGROUP
HIGHPRESSURELIQUID(HPL)FEED

NOTES:
AND SERVICE VALVE B IS CLOSED DURING STARTUP AND
1. SERVICE VALVE A IS OPEN
COMMISSIONING TO ALLOW WATER LADEN DEFROST CONDENSATE TO PASS TO THE
IT IS SHOWN THAT ALL WATER HAS BEEN REMOVED
SUCTION ACCUMULATOR. AFTER
FROM THE SYSTEM (THE AMMONIA IS "DRY"), VALVE A IS CLOSED AND VALVE B OPENED TO
SEND DEFROST CONDENSATE TO THE LIQUID LINE.

GLOBE VALVE ANGLE VALVE

SOLENOID VALVE ELECTRONIC EXPANSION VALVE

STRAINER HAND EXPANSION VALVE
SUCTION STOP VALVE CHECK VALVE

TANK DISTRIBUTOR AUTO VENT

SIGHT GLASS

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Withaconventionalbottomfeedandhotgasdefrostpipingarrangement,hotgasisfirst
sentthroughthedrainpanloopandtheninseriesthroughthecoilblock.Thiscommonly
usedarrangementiseffectiveandsimple,however,itrequiresthatthehotgassolenoid
remainsopentokeepthedrainpanheatedlongenoughforallwatertocompletely
drainandexitthroughthedrainpiping.Convectiveheatlosstotheroomcontinuesafter
thecoilisclearoffrostwhilethepanisdraining.

Amoreefficientarrangementistocontrolhotgastothecoilblockandtothedrainpan
loopseparatelythroughtwoseparatelytimedhotgassolenoidvalves.Thisarrangement
shortenstheamountoftimehotgasisflowingthroughthecoilblock,minimizingthe
convectiveheatlossandmaximizingdefrostefficiency.

AproperlysizedcontrolvalvegroupfortheColmacSmartHotGasDefrostpiping
arrangementislessexpensivethanaconventionalbottomfeedhotgasdefrostpiping
arrangementwithdefrostregulator.
ColmacDXSmartHotGasDefrostSequenceofOperation

1. Defrostisinitiated.
2. LiquidLineSolenoid(LLS)closes
3. Pumpoutperiod(1520minutes)
4. Fan(s)stop
5. Panloopsolenoidenergizedfortimedpanpreheat(23minutes)
6. Coilhotgassolenoidandpilotsolenoid(closessuctionstopvalve)open
7. Timeddefrost(68minutes)
8. Coilhotgassolenoidcloses
9. Aftercoilpressureisequalizedtosuctionpressure(35minutes),SuctionStop
Valveopens
10. OpenLLS
11. Panloopsolenoiddeenergized
12. After5minutecooldowndelayfansrestart
DiversityandDefrostTiming

Aswithallhotgasdefrostsystems,thetwotoonerulemustbeobservedinthe
executionofdefrosts.Thatis,aminimumoftwoevaporatorsinthesametemperature
zonemustberunning(liquidlinesolenoidsopen)atthesametimeoneevaporatoris
defrosting.Thisstrategyisneededtoprovideenoughloadtobalanceevaporatingto
condensing(defrosting)capacityintherefrigerationsystem.

HotGasFlowrateandValveSelection

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Colmacprovidestoitsrepresentativesandselectedcustomersacalculationtoolfor
estimatinghotgasflowrategivenoperatingtemperaturesandevaporatordimensional
data.

ThecompleteColmacDXSmartHotGasDefrostevaporatorcontrolvalveisalsooffered
fromColmacasakitorfactorymountedontheevaporator.

XVI. DefrostWaterVolumeandDrainLineSizing
Followingisasimplemethodtocalculatetheamountofmoistureremovedbytheair
coolersfromairintherefrigeratedspacesinordertodetermine:

A) Totalseweragerequirementsforthefacility,and
B) Properdrainpipingsizestohandlepeakflowratesduringdefrost.

Thissectionwillpresenttwosimplecalculationmethodsfordeterminingthese
importantdesignparameters(Nelson2008).

DeterminingTotalVolumeofMoistureRemoved:
Inordertoestimatethevolumeofwatergeneratedfromdefrosting(orwetfin)air
coolers,thehoursperdaythecooler(s)operatealongwiththeSensibleHeatRatio
(SHR)mustbeknown.Assumingaroomrelativehumidityof90%,theSHRforanair
cooleroperatingatvarioustemperatureswillbeasshowninTable13below:
Table13
SHRfor90%rhAiratVariousTemperatures

RoomTemp,F AirSHR
45 0.59
32 0.70
10 0.85
10 0.93
30 0.98
Theamountofmoistureaccumulatedonthesurfacesoftheaircooler(s)thatwillbedrained
ascondensedwaterinhightemproomsorasmeltedfrostinmediumandlowtemprooms,
canbeestimatedusingthefollowingformula:
Gal / day 1.35t 1 SHRQ (9)

where:
t=OperatingTime,hours/day
SHR=AirSensibleHeatRatio
Q=SystemCoolingCapacity,tons(note:1ton=12,000Btuh)
1.35(constant)=12,000Btuh/ton/(8.33lbs/galx1,068Btu/lbs)
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8.33lbs/gal=liquiddensityofwater
1,068Btu/lbs=latentheatofvaporizationofwater

Example1:
RoomTemp:45F
OperatingTime:12hours/day
RoomSHR(fromTable1):0.59
SystemCoolingCapacity:50tons
CondensedWaterVolume=1.35x12x(1.59)x50=332gal/day
Example2:
RoomTemp:10F
OperatingTime:16hours/day
RoomSHR(fromTable1):0.93
SystemCoolingCapacity:100tons
DefrostWaterVolume=1.35x16x(10.93)x100=151gal/day

DeterminingPeakDefrostWaterFlowrate

Todeterminethepeakdefrostwaterflowrateleavingafrostedcoilsurface,firstcalculate
thevolumeofwateryieldedbyacoolingcoilduringdefrostusingthefollowingequation:
t fin

S fin
Vdef 0.0937
Asurf
(10)
2

:
where
Vdef
Asurf
S fin
t fin
Note:Thisequationassumesfrosthasaveragedensityof150kg/m3(Besant1999),approx.
1/6ththatofliquidwater.

Example1:
TotalSurfaceArea=4,500sqft
FinSpacing=4finsperinch
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FinThickness=0.012inches
FractionofFrostBlockage=0.5
VolumeofDefrostWater=0.0937x4,500x(1/40.012)/2x0.5=25gallons

Inordertothendeterminethepeakflowrate,anestimateofthelengthofdefrosttime
mustbemade.Forhotgasdefrosting,themajorityofdefrostwaterflowstothedrainina
relativelyshortperiodoftime.Toestimatepeakflowrateofdefrostwateranestimated
durationofdefrostof5minutescanreasonablybemade(Stoecker1983).

Tocalculatepeakflowrate,simplydividethevolumeofdefrostwaterbytheestimated
durationofdefrost.Fortheexample:

Estimatedpeakdefrostflowrate=25gal/5min=5gpm

Drainlinescannowbesizedbasedonthecalculatedpeakdefrostflowrate.Themaximum
peakflowrateforafacilitywillbethecombinedflowratesforthemaximumnumberof
coolingcoilsexpectedtodefrostsimultaneously.

Colmacprovidestoitsrepresentativesandselectedcustomersacalculationtoolfor
estimatingdefrostflowrategivenoperatingtemperaturesandevaporatordimensional
data.

SizingSlopingDrainLines

TheAmericanSocietyofPlumbingEngineers(ASPE)publishessizingmethodsforvertical
andslopingdrains(ASPE1999).ThefollowingtableistakenfromtheASPEDataBook
Volume2,page8.
Table14
ApproximateDischargeRatesandVelocitiesinSlopingDrains,n=0.015*
ActualInsideDiameter FullFlowDischargeRateandVelocity
ofPipe,inches Basedoninch/ftSlope
Discharge,gpm Velocity,fps
13/8 3.13 1.34
1 3.91 1.42
15/8 4.81 1.50
2 8.42 1.72

2 15.3 1.99

3 24.8 2.25

4 53.4 2.73

5 96.6 3.16

6 157 3.57

8 340 4.34
10 616 5.04
12 999 5.67
*n=Manningcoefficient,whichvarieswiththeroughnessofthepipe.
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Horizontaldrainlinesmustbepitchedatleastperfoottoinsurepositivedrainage.

Drainlinesrunningthroughfreezingspacesshouldbeactivelyheatedwithheattracecable
andthenwellinsulated.

Drainlinesshouldalsohaveptrapsinstalledjustoutsidetherefrigeratedspacetoprevent
backflowofwarmhumidambientairthroughthedrainlineintotherefrigeratedspace.

XVII. References

Briley,G.C.1984.Lubricant(Oil)Separation.InternationalInstituteofAmmonia
Refrigeration,Alexandria,VA.ProceedingsoftheIIAR1984AnnualMeeting,pp107F131F.

ClelandD.J.,OHaganA.N.2002.PerformanceofanAirCoolingCoilUnderFrosting
Conditions.AmericanSocietyofHeating,RefrigeratingandAirConditioningEngineers.
ASHRAETransactions2002V.109,Pt.1

Cleland,D.J.2012.TheEffectofWaterVapouronFoodRefrigerationSystems.The
InstituteofRefrigeration.London,UK.Proc.Inst.R.201112.5.

Davis,J.R.,1999,CorrosionofAluminumandAluminumAlloys,ASMInternaional,
MaterialsPark,OH.Chap2,pp38.

IIAR2004,AmmoniaRefrigerationPipingHandbook.InternationalInstituteofAmmonia
Refrigeration.Alexandria,VA.

IIAR2008,ANSI/IIAR22008Equipment,Design,andInstallationofClosedCircuitAmmonia
MechanicalRefrigeratingSystems,InternationalInstituteofAmmoniaRefrigeration.
Alexandria,VA.

Jensen,S.2013.Personalcorrespondence.

LaRocheIndustries,1987,AquaAmmoniaInformationManual,LaRocheIndustriesInc.
Concord,NC.

LaRocheIndustries,1998,MaterialSafetyDataSheet#4003(AmmoniumHydroxide),
LaRocheIndustriesInc.Concord,NC.

Nelson,B.I.,2008,DeterminingDefrostWaterVolume.TechnicalBulletin.ColmacCoil
Manufacturing,Inc.Colville,WA.

Nelson,B.I.,2010,ThermodynamicEffectsofWaterinAmmoniaonEvaporator
Performance,InternationalInstituteofAmmoniaRefrigeration,Alexandria,VA.
ProceedingsoftheIIAR2010AnnualMeeting,pp201236.
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Nelson,B.I.,2011,U.S.Patent7,958,738,DirectExpansionAmmoniaRefrigerationSystem
andaMethodofDirectExpansionAmmoniaRefrigeration.

Nelson,B.I.,2011(1),OptimizingHotGasDefrost.TechnicalBulletin.ColmacCoil
Manufacturing,Inc.Colville,WA.

Nelson,B.I.,2011(2),ColmacIntroducesDXAmmoniawithSmartHotGasSHGDefrost.
TechnicalBulletin.ColmacCoilManufacturing,Inc.Colville,WA.

Nelson,B.I.,2012(a),ComparingAirCoolerRatingsPart1:NotAllRatingMethodsare
CreatedEqual.TechnicalBulletin.ColmacCoilManufacturing,Inc.Colville,WA.

Nelson,B.I.,2012(b),ComparingAirCoolerRatingsPart2:WhyDTMRatingsCostYou
Money.TechnicalBulletin.ColmacCoilManufacturing,Inc.Colville,WA.

Smith,E.2010,TechnicalNote.InternationalInstituteofAmmoniaRefrigeration(IIAR).
Alexandria,VA.CondenserMagazineAugust2010.

Stoecker,W.F.1988,IndustrialRefrigerationHandbook,BusinessNewsPublishing
Company,Michigan.

TannerIndustries,2000,MaterialSafetyDataSheet(AmmoniumHydroxide),Tanner
Industries,Inc.Southampton,PA.

Welch,J.2013.Personalcorrespondence.

Wiencke,B.2002,SizingandDesignofGravityLiquidSeparatorsinIndustrial
Refrigeration,InternationalInstituteofAmmoniaRefrigeration,Alexandria,VA.
ProceedingsoftheIIAR2002AnnualMeeting,pp63133.

Wiencke,B.2012.Personalcorrespondence.

Wierbosch,M.andSandler,M.2010,BaseFluidEffectonPerformanceinanAmmonia
RefrigerationSystem.RMSupportBV.Henglelo,NL.

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XVIII. APPENDIXA
ThreeP&IDdiagramsareshownrepresenting:

FigureA1SingleStageSingleTemperatureLevel
FigureA2SingleStage(EconomizedScrew)MultipleTemperatureLevel
FigureA3TwoStageMultipleTemperatureLevel

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FIGUREA1
COLMACDXAMMONIA
SINGLESTAGESINGLETEMPERATURELEVEL

EXPANSION
TANK

EVAPORATIVE
CONDENSER

90 psig GLYCOL OIL
60F COOLING LOOP

e

SH P
LP

HLCO HIGH PRESSURE
RECEIVER
OPTIONAL SUBCOOLER
DX EVAPORATOR BPRV SUCTION
AIR DEFROST ACCUMULATOR
N.C.

75 psig
(50.3F SAT) e
(NOTE 1)
e
B T
FS SUBCOOLED
to 40F

OIL POT TRANSFER
(NOTE 1) T COMPRESSOR
HTR
SH P A 110F

WATER STILL
MOTOR
DX EVAPORATOR
HOT GAS COIL ONLY

COALESCING OIL
NOTES: SEPARATOR

1. SERVICE VALVE A IS OPEN AND SERVICE VALVE B IS CLOSED DURING STARTUP AND
SUCTION ACCUMULATOR. AFTER IT IS SHOWN THAT ALL WATER HAS BEEN REMOVED GLYCOL
OIL COOLER
SUBCOOLER SUCTION
SUBCOOLED REDUCED PRESSURE LIQUID

e
SOLENOID VALVE ELECTRONIC EXPANSION VALVE
PRV W/ ELECTRIC SHUT OFF
DRAIN VALVE 3-WAY VALVE

HAND EXPANSION VALVE
RELIEF VALVE GLOBE VALVE ANGLE VALVE

AUTO VENT CHECK VALVE STRAINER

PUMP TANK DISTRIBUTOR DOUBLE ACTING RELIEF VALVE

P PRESSURE GAUGE SIGHT GLASS LP LEVEL PROBE

SH SUPERHEAT TRANSDUCER T TEMPERATURE TRANSDUCER PRV

OIL LEVEL SENSOR

FIGUREA2
COLMACDXAMMONIA
SINGLESTAGE(ECONOMIZEDSCREW)MULTIPLETEMPERATURELEVEL

EXPANSION
90 psig TANK
60F
EVAPORATIVE
CONDENSER
GLYCOL OIL
COOLING LOOP
(NOTE 1)

e
B LP
HLCO MEDIUM
TEMPERATURE
SUCTION
ACCUMULATOR
HIGH PRESSURE
(NOTE 1) RECEIVER
SH
P
A
TRANS
SUBCOOLER
HOT GAS PAN LOOP

N.C.
DX EVAPORATOR
SMART HOT GAS COIL & PAN
MEDIUM TEMPERATURE
OIL POT 75 psig
(50.3F SAT) e

T
SUBCOOLED
to 40F

MOTOR
(NOTE 1)

e
B LP COMPRESSOR
HLCO

LOW
TEMPERATURE COALESCING OIL
SUCTION SEPARATOR
(NOTE 1) ACCUMULATOR
SH
P
A
GLYCOL
OIL COOLER
HOT GAS PAN LOOP

SUBCOOLER SUCTION
FS
DX EVAPORATOR
LOW TEMPERATURE TRANSFER
OIL POT
T
HTR
NOTES: 110F
WATER STILL
1. SERVICE VALVE A IS OPEN AND SERVICE VALVE B IS CLOSED DURING STARTUP AND
SUCTION ACCUMULATOR. AFTER IT IS SHOWN THAT ALL WATER HAS BEEN REMOVED

e

SOLENOID VALVE ELECTRONIC EXPANSION VALVE PRV W/ ELECTRIC SHUT OFF

DRAIN VALVE 3-WAY VALVE HAND EXPANSION VALVE
RELIEF VALVE
LIQUID DRAINER
CHECK VALVE STRAINER

AUTO VENT PIPE CAP (CLEANOUT) LP LEVEL PROBE

P PRESSURE GAUGE SIGHT GLASS T TEMPERATURE TRANSDUCER

SH SUPERHEAT TRANSDUCER OIL LEVEL SENSOR PRV

FIGUREA3
COLMACDXAMMONIA
TWOSTAGEMULTIPLETEMPERATURELEVEL

EXPANSION
90 psig TANK
60F
EVAPORATIVE
CONDENSER

GLYCOL OIL
COOLING LOOP
(NOTE 1) e
e
B LP
HLCO MEDIUM
TEMPERATURE HIGH PRESSURE
SUCTION RECEIVER
ACCUMULATOR
(NOTE 1)
SH SUBCOOLER
P
A
T
TRANS
HIGH STAGE
N.C.
COMPRESSOR
HOT GAS PAN LOOP

MOTOR 75 psig
DX EVAPORATOR (50.3F SAT) e
MEDIUM TEMPERATURE
OIL POT T
SUBCOOLED
to 40F
COALESCING OIL
SEPARATOR
GLYCOL
OIL COOLER

(NOTE 1)
e
B LP
HLCO
LOW
TEMPERATURE
SUCTION
(NOTE 1)
BOOSTER
ACCUMULATOR
SH COMPRESSOR
P
A
MOTOR
HOT GAS PAN LOOP

FS
DX EVAPORATOR
LOW TEMPERATURE TRANSFER
OIL POT COALESCING OIL
T SEPARATOR
HTR
NOTES: 110F
WATER STILL
1. SERVICE VALVE A IS OPEN AND SERVICE VALVE B IS CLOSED DURING STARTUP AND GLYCOL
OIL COOLER
SUCTION ACCUMULATOR. AFTER IT IS SHOWN THAT ALL WATER HAS BEEN REMOVED
SEND DEFROST COND ENSATE TO THE LIQUID LINE.

SUBCOOLER SUCTION
e
SOLENOID VALVE ELECTRONIC EXPANSION VALVE PRV W/ ELECTRIC SHUT OFF

DRAIN VALVE 3-WAY VALVE HAND EXPANSION VALVE
RELIEF VALVE
LIQUID DRAINER CHECK VALVE STRAINER
AUTO VENT PIPE CAP (CLEANOUT) LP LEVEL PROBE

P PRESSURE GAUGE SIGHT GLASS T TEMPERATURE TRANSDUCER
SH

SUPERHEAT TRANSDUCER OIL LEVEL SENSOR PRV

495 - Colmac DX Ammonia Piping Handbook 2nd Ed (Rev 0)

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P.O.

Box 571 | Colville, WA 99114 | USA

DT1 LMTD = 7.2 F DTM LMTD = 9.6 F

30 9.1 8.1 56.0

16 110.3 3.8 2.1 5.1 2.8 7.5 4.2

18 124.1 4.3 2.4 5.8 3.2 8.5 4.7

20 137.9 4.8 2.7 6.4 3.6 9.4 5.2

Room Temp, C (F)

Frost Removed, kg/day: 2,778 899 572 245

Defrost Efficiency, % 61% 46% 43% 40%

SUCTION STOP VALVE CHECK VALVE

Gal / day 1.35t 1 SHRQ (9)

SUBCOOLED REDUCED PRESSURE LIQUID

DRAIN VALVE 3-WAY VALVE

RELIEF VALVE GLOBE VALVE ANGLE VALVE

HOT GAS PAN LOOP

HOT GAS PAN LOOP

SUBCOOLED REDUCED PRESSURE LIQUID

PUMP TANK DISTRIBUTOR DOUBLE ACTING RELIEF VALVE

HOT GAS PAN LOOP

SUBCOOLED REDUCED PRESSURE LIQUID

LIQUID DRAINER CHECK VALVE STRAINER

PUMP TANK DISTRIBUTOR DOUBLE ACTING RELIEF VALVE

AUTO VENT PIPE CAP (CLEANOUT) LP LEVEL PROBE

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