Liquid Recirculation Systems Part II

In the first part of the series on liquid recirculation systems, we discussed the basic
system operation and fundamentals. In the concluding discussion we will cover
some of the more subtle points found in these systems.

Pump Effect
In Figure 6, an example is shown of a typical overfed evaporator (pressure losses are
not included). The operating conditions are 33-psig suction with a liquid supply
pressure of 45-psig. The liquid is pumped from a low-pressure receiver operating at
20F (33 psig).

If you examine the saturation temperature of the 45-psig liquid, you will find that
this is 30F. In other words, we have 30F-20F = 10 of liquid subcooling at the
entrance of the hand expansion valve (HEV). In order for the liquid to boil in the
evaporator at 33 psig, the liquid supply pressure at the HEV outlet should be reduced
by 45 psig-33 psig, or 12 psi.

If the HEV is adjusted to produce a 12 psi pressure drop, then the liquid entering the
evaporator will begin to boil. If the pressure drop of the HEV is less than 12 psi, the
liquid entering the evaporator is subcooled. In order for the subcooled liquid to
provide a useful cooling benefit it must absorb heat without boiling. This can cause a
slight reduction in coil capacity. So another way of looking at this is; too much
subcooling can decrease the total evaporator capacity.

If the HEV is properly set, the head generated by the pump is completely dissipated
at the HEV outlet; therefore, the pump contribution stops at the HEV. Downstream
of this point in the system, gravity and compressor suction take over.

Figure 6

Liquid Supply at 20F

Pump Discharge
Pressure = 45 psig

Suction Line at
20F (33 psig)

One way to view this is as a push-pull system. The refrigerant pump pushes the
liquid up to the pressure reduction stage (HEV) of the system. After the head
(pressure) is decreased across the hand expansion valve, the compressor and/or
gravity must provide the energy to move the vapor and liquid in the wet suction line.
The pump cannot continue to provide motive force to the liquid since the pump head
has been dissipated at the hand expansion valve.
Compressor Effect
For the age-old question of, Where does the compressor start and where does the
pump stop? We offer these guidelines:

The compressor effect occurs after the hand expansion valve, if a back
pressure regulator (BPR) is not used to control the coil evaporating pressure.
Or, at the BPR outlet, if BPRs are used.

A recirculation system has two considerations for proper operation, pressure and
thermal lift. The pressure lift is the required head to overcome the elevation
changes, pipe friction loss, and the liquid feed valve train pressure losses.

The thermal lift is a requirement whenever back pressure regulators are used on a
coil to control the evaporating pressure/temperature. Thermal lift is the difference in
the saturation temperatures between, the coil evaporating pressure plus the
pressure loss of the regulator, minus the compressor suction pressure. The
difference between these pressures must be added to the pump friction head in order
to supply liquid refrigerant into the coil.

Either the compressor provides the motive force to return the vapor back to the low-
pressure receiver after the BPR, or gravity. The recirculated liquid is assisted by
gravity, where such consideration has been given; otherwise, the drag force created
by the vapor movement by the compressor suction returns the two-phase mixture to
the low-pressure receiver.

Additional compressor performance penalties will occur if liquid must be returned

thru, vertical elevation changes by pressure drop alone. You would normally perform
this by using dual vertical risers, or use gravity drainage of the liquid back to the
low-pressure receiver and lift the vapor portion only. The static effects of vapor are
drastically smaller than liquid lifts.

Use of Back Pressure Regulators (BPR) on Recirculation Systems

Notice in Figure 7 the example has a BPR added to increase the coil evaporating
pressure from 33 psig to 58 psig to hold the coil temperature at 40F. The important
question here is; how do you get liquid at 45 psig to enter a coil operating at 58
psig. The answer is, the coil will not work.

Figure 7

Liquid Supply at 20F

Pump Discharge
Pressure = 45 psig

BPR set at
58 psig (40F)

Suction Line at
20F (33 psig)
If you add BPRs on liquid overfeed systems, you need to add the additional pressure
requirement to the pump head when selecting the pump. The additional pressure is
the difference in the desired controlled evaporating pressure minus the low-pressure
receiver vapor pressure.

Figure 8 below illustrates the differences to make this evaporator work. Notice that
the pump discharge pressure is increased to 59 psig. Now the liquid supply pressure
is high enough to allow liquid to flow into the coil. Of course, the supply pressure
would have to high enough to overcome all of the valve train pressure losses too, but
these have been deleted to explain the system operation.

Figure 8

Liquid Supply at 20F

Pump Discharge
Pressure = 59 psig

BPR set at
58 psig (40F)

Suction Line at
20F (33 psig)

If the pump is incapable of delivering sufficient pressure (head), liquid will not flow
into the coil. If you increase the pump head capability too much, you can generate
subcooling in the liquid, which leads to a condition known as brining. The extent of
the subcooling, or excess head may be adjusted out by increasing the pressure drop
across the HEV, if the pump head is not too high.

In some cases such as the one above, the liquid supply at 20F is subcooled by 20
(40F-20F = 20). Since the liquid is colder than the desired coil temperature, not
only do we loose capacity, but also the coil may just simply frost over.

Brining
Brining is an older term used to depict a condition of operation with sub-cooled
liquid. This condition occurs when the liquid does not undergo a phase change in the
evaporator and operates as sensible heat transfer.

In essence, if the equivalent saturated temperature of the pumped liquid feed is

greater than the actual, liquid supply temperature, the liquid is subcooled. If the
pump head (pressure) is not dissipated by the HEV (HEV outlet pressure = saturated
evaporating pressure) the liquid retains some subcooling. This may occur if the HEV
is too far open (less pressure reduction).

Instead of a overfeed rate of 3:1 for normal operating conditions at full load, the
overfeed rate would be greater, perhaps 3:0.5 or 3:0. This indicates an under-
performing evaporator. At full load, the evaporator is not producing the rated
capacity and very little, if any, vapor.
When this condition is encountered, you will find a coil with a lack of capacity due to
a difference in fundamental heat transfer. If the liquid refrigerant temperature is
lower than the coil evaporating temperature, the liquid must absorb heat until it
reaches the bubble point for that pressure before it can flash. This is a sensible heat
transfer function and much less, efficient use of coil surface area is a result.

A similar condition can occur if the liquid feed supply temperature is at a lower
temperature than the equivalent saturated evaporating temperature. At 40F,
liquid being feed into a coil controlled by a BPR at 15F the liquid must first absorb
heat until the liquid temperature is at 15F before boiling is initiated.

Ideally, we want a phase change to occur so that each pound of refrigerant picks up
more heat for the same surface area.

For this to occur we must ensure that the components of the liquid recirculation
system are properly designed, selected, and adjusted properly.

Gravity Drainage
Gravity drainage provides the most efficient means of returning liquid back to low-
pressure receiver. This method does not require any additional penalty except for
friction losses. Gravity is free, If it is used it properly. Liquid will fall if allowed to
and vapor will rise of its own accord. Attempting to carry liquid up requires
additional energy, which must be supplied by the refrigeration compressor unless a
pump is used for this purpose.

Suction Risers
Suction risers carrying a two-phase mixture exhibit a greater pressure loss when
required to transport liquid refrigerant due to higher required vapor velocities. If the
overfed liquid is not carried up and returned to the low-pressure receiver, the liquid
will stack-up in the vertical wet suction line and impose a static head on the
evaporating pressure which increase the overall coil temperature. The net result is a
loss of coil capacity due to lower temperature differences (TD).

In some cases where significant load changes occur, a dual suction riser should be
used to accommodate liquid return at part load. The smaller riser is selected upon
the minimum velocity to carry liquid in an annular flow regime up the pipe. At light
loads the larger diameter pipe traps liquid and the vapor flows thru the smaller bore
pipe. As the load increases, the gas velocity increases Through the smaller riser
until the liquid seal in the trap blows out. The vapor velocity continues to increase
through both risers until the gas velocity in both risers is equal.

Float Column
The float column is a pipe equalized to the vapor space and the liquid within the low-
pressure receiver vessel. This column provides a relatively quiet chamber for
measuring the liquid level changes within the vessel. Mechanical float switches or
electronic capacitance probes can be attached for measuring liquid levels.

When float switches are provided you will normally find three separate floats;
1. Low-level shutdown to protect the pump from cavitation.
2. Operating level controlling a solenoid valve.
3. High-level shutdown to protect the compressor from flooding.
Capacitance probes provide the same functionality but with easily adjustable control
levels, where the levels with mechanical floats require physical relocation of the
floats on the column.

Figure 9

The float column will normally be provided with a drain connection and valve on the
bottom of the pipe chamber for oil or refrigerant draining.

The chamber equalizing lines connected to the vessel will be provided with a valve in
each line (lower & upper) for service. To assist in tuning the system response at
startup it is recommended that a hand expansion valve be used in the top vapor line
to provide a dampening effect during load changes in the vessel. This dampening
slows the response in the float column due to sudden boiling of liquid, which can
artificially actuate float switches.

When the compressor capacity increases, the liquid in the vessel begins to boil. If
the load rate of the compressor is too fast, the resulting violent boiling can
temporarily increase the liquid level in the vessel and chamber, which may result in
nuisance trips of the high-level shutdown safety control. Adjustment of the hand
expansion valve can reduce the effect when this occurs, by reducing the volume of
vapor that can be equalized to the vessel.
Oil Recovery
An oil recovery vessel is required on ammonia systems to reclaim oil that separates
in the low-pressure receiver. Refrigeration oil has a higher density than liquid
ammonia and will settle to the bottom of the vessel interior surface. The oil pot will
be connected to the bottom of the low-pressure receiver and to the vapor space.

Oil and liquid refrigerant flow into the oil pot and the vapor in the oil pot is displaced
upwards to the vessel vapor space allowing flow. This process continues until a
system operator recognizes the need to drain the oil pot. This is a relatively
straightforward process of identifying. On systems with evaporating temperatures
below 32F, the oil pot will have a frost line above the oil level in the pot.

The oil draining process should always be manned and operated in a slow and
deliberate manner to prevent the loss of any residual vapor or liquid ammonia in the
oil pot. The use of clear plastic tubing facilitates the observation of the fluid flow
being drained. When the tube appears dark, oil is present. If the tube has a clear or
creamy appearance, ammonia is present and the drain valve should be carefully
closed to prevent ammonia from escaping.

Recommended Practices for Recirculation Systems

Use low-speed pumps; lower speeds for a given flow rate will require a larger
pump. The larger pump will have a larger impeller and greater impeller eye
diameter, which reduces NPSHR.
When selecting the pump, select the smallest impeller trim (impeller
diameter) for a pump volute that meets the operating requirements. If
higher flow rates are required later, a larger impeller diameter can be added
without changing entire pump.
Base NPSHR on largest impeller trim requirements for the pump volute
selected. Larger impellers have larger inlets, hence less NPSHR.
Select pump motor size on the requirements of the largest impeller trim to
prevent overloading of the motor.
Limit pressure reductions in low-pressure to 1 psi per minute. Set the
compressor loading time at a low value to accomplish this.
Ensure that the vessel volume has sufficient liquid storage volume to
accommodate surge requirements (defrost), and adequate volume for run
down (re-filling the coils after defrost) without dropping the liquid level to the
pump cutout float switch.
Size the liquid make-up valve train to meet the capacity during the on
duration and for the available pressure drop (liquid make-up feed pressure
low-pressure receiver vapor pressure)
Install pump suction piping correctly.
Use low-pressure drop valves in pump suction piping.
Do not oversize piping (larger piping has greater surface area to pick-
up heat).
Provide sufficient pipe lengths from change in directions (allows fluid
flow to stabilize). Minimum of 10 12 pipe diameters.
Do not use pump suction line strainers. If strainers are required, pipe
them into a bypass arrangement off the pump discharge line where
the pressure drop can be accommodated.
 At start-up, make sure the pump by-pass valve and discharge valve are set
properly to ensure that the pump operates at the desired point on the pump
curve.
Do not provide too much pump head.
Be conservative in NPSHA calculations and installation details.
Select low speed pumps.
Do not use backpressure regulators on liquid recirculation systems, or use
them with care if necessary.

Conclusions
We have explored the fundamental operation of liquid recirculation systems in this
series of discussions and noted several areas that always seem to be present in our
systems.

By careful examination of system pressures and saturation temperatures, you can

quickly determine the area of the problem before adjusting valves, pumps, and other
corrective actions.

The best way of fixing the problem is to first understand the nature of the beast, and
then housebreak it, before it becomes a problem.