July 2007
Refrigerating Engineers & Technicians Association
HYDRAULIC SHOCK IN REFRIGERANT PIPING: CAUSES AND REMEDIES
— Steve Mesner and Joe Nelson, Parker Hannifin, Refrigerating Specialties Division
H
ydraulic shock is a common and
potentially dangerous phenom-
enon in a variety of piping systems.
Essentially, a sudden localized spike in
pressure, this shock occurs when a rapid
change in liquid flow velocity generates
a pressure wave within the liquid media.
Loud noises, movements in piping and even
the bursting of pipes or line components
can result from these pressure spikes.
The magnitude of the pressure wave
generated in a hydraulic shock event de-
pends on several factors. The change in
pressure is proportional to the fluid den-
sity, the change in velocity and the sonic
velocity of fluid in the pipe. As these fac-
tors go up, so does the potentially dam-
aging pressure in a hydraulic shock event.
Liquid Deceleration/Acceleration
The rapid closing or opening of liquid
valves is a common cause of hydraulic
shock. The action of the valve results in
a dramatic change in the velocity of the
liquid in the pipe in a very short period of
time. This particular variety of hydraulic
shock is known as sudden liquid decel-
eration or acceleration.
Sudden liquid deceleration typically oc-
curs in refrigeration systems at the instant
of closure of a liquid solenoid valve. Sole-
noid valves are fast acting controls capable
of quickly stopping all flow in a line.
Bringing the velocity of the refrigerant
in the liquid line to zero in this fashion
generates a pressure wave in the liquid
line upstream of the solenoid valve.
Sudden liquid acceleration can result
when a solenoid valve quickly opens, al-
lowing large amounts of liquid upstream
of the valve to start flowing. The sudden
momentum created by the moving liquid
can be enough to cause pipes to shake
violently. At times, it is a combination of
both liquid acceleration, and deceleration,
which can cause a shock event. In the case
of a liquid make-up solenoid, high pres-
sure liquid is held upstream of the valve
while there is little or no pressure on the
outlet side of the valve. When the valve
suddenly opens, the high pressure liquid
rushes through the valve; this sudden
change in velocity may be enough to start
pipes shaking. The problem is com-
pounded when the liquid encounters an
expansion valve or other feature down-
stream which again changes its velocity.
Vapor Propelled Liquid
A second common type of hydraulic
shock occurs when liquid collected in a
refrigerant line is propelled by vapor re-
frigerant in an intermittent flow regime
known as slug-flow. This phenomenon is
commonly referred to as vapor propelled
liquid slugs. Slug flow can only occur
when a portion of the line becomes com-
pletely filled with
liquid, at which time Figure 1
the slug of liquid
starts to move with
the vapor (figure 1).
The slugs of liquid
travel rapidly in the
line until they encounter a feature, such
as a valve, elbow or end cap, that will
cause a rapid change in direction. With
this change in velocity, or direction, there
is dramatic change in pressure, causing a
hydraulic shock event. While the volume
of liquid involved in this type of shock is
much less than that of a typical sudden
liquid deceleration/acceleration event, the
velocity of the liquid is often much
higher. The vapor refrigerant propelling
the liquid slugs often travels at a velocity
substantially higher than typical velocities
in liquid lines. The potentially higher ve-
locities can make these shocks particu-
larly destructive.
Vapor propelled liquid slugs might
occur under a number of circumstances
in refrigeration systems. One common
situation for a slug to be generated is with
the opening of a hot gas solenoid valve at
the onset of a defrost cycle. Hot gas lines
are often located in the refrigerated space
of a facility. The lower temperatures in
the refrigerated space cause the gas to con-
dense in these lines during the normal
refrigeration cycle. When the hot gas so-
lenoid opens, the condensed liquid, or
continued on page 2
 July 2007
HYDRAULIC SHOCK IN REFRIGERANT PIPING: CAUSES AND REMEDIES
YDRAULIC
Continued from page 1
slug, in this line can be propelled at high
velocity to the evaporator. Another com-
mon location for this phenomenon to
occur is on the outlet of a suction-stop
valve. Suction-stop valves are closed
during the defrosting of a hot gas defrost
evaporator. When these valves are re-opened
at the end of a defrost cycle there is poten-
tial for a vapor propelled liquid slug to
form, the condensed liquid is then propelled
by the defrost pressure. Typically this
occurs on lower temperature evaporators
where the difference between defrost pres-
sure and suction pressure is greater than
for high temperature evaporators.
Condensation Induced
A third type of hydraulic shock event
is caused by rapid condensation of vapor
in lines containing both liquid and vapor
refrigerant. Condensation induced hy-
draulic shock results from the introduc-
tion of a plug of high pressure vapor to
subcooled refrigerant liquid. When the
high pressure vapor is trapped in the cold
liquid space, rapid condensation occurs.
The pressure of the space once occupied
by the vapor rapidly drops as the refrig-
erant vapor condenses. The liquid refrig-
Figure 2
– 2 –
erant then accelerates towards this lower
pressure area, collapsing the void. This
fast moving liquid now can cause a hy-
draulic shock event when it encounters
the adjacent body of liquid refrigerant
(figure 2).
The circumstances under which conden-
sation induced hydraulic shock occur are
more difficult to define than those of sud-
den liquid deceleration and vapor propelled
liquid slugs. Anytime subcooled liquid and
high pressure vapor refrigerant are mixed,
there is a potential for this phenomenon
to occur. Some possible situations that
could induce this type of hydraulic shock
include: the pressurization of an accu-
mulator or trapped suction line during defrost
or when cold liquid refrigerant is pumped
into a higher pressure vapor line.
Hot Gas Defrost
Hot gas is the most commonly used
method for defrosting low-temperature
industrial refrigeration systems today. Yet,
it is this switching of an evaporator to a
condenser and back again that creates
prime conditions for the potential of va-
por propelled liquid slugs and condensa-
tion induced hydraulic shock events.
When these conditions exist, designers and
engineers must take special precautions
to reduce or eliminate the potentially
damaging effects of a shock event. Low
temperature (less than 0°F) liquid recir-
culation units are the most susceptible to
the hazards of a shock event. The higher
pressure and temperature difference in
these systems creates conditions and an
environment that make them more sus-
ceptible to shock.
Low temperature units are the most
susceptible to the hazards of shock for
several reasons. Because of the larger dif-
ferences in temperature, condensation is
more likely to form in hot gas lines. As
mentioned before, the subcooled liquid
will result in a higher intensity shock wave
should condensate-induced shock occur.
The large pressure differences between
the cold liquid refrigerant and the hot gas
required for defrost can result in critical
flow through control valves which can
cause a severe shock to coils, piping and
valves. Oftentimes, the low temperature
application puts system components near
their ductile brittle transition temperature.
This yields them more susceptible to fail-
ure from the impacts which can be caused
by a shock wave sent through the system
(IIAR 2000, Ammonia Refrigeration Pip-
ing Handbook, p. 3-18).
Recommendations
In most cases, because of the speed and
complexity of the flow patterns of a shock
wave, relief valves are left unaltered and
Continued on page 3
Continued from page 2
Figure 3
remain seated, leaving no signs the event
ever occurred. Fortunately, through care-
ful design and the proper application of
components, the damaging effects of sud-
den liquid deceleration/acceleration, va-
por propelled liquid slugs and condensa-
tion induced hydraulic shock can be
avoided. There are a variety of common
methods that system designers employ to
minimize or even eliminate the potential
for hydraulic shock in refrigeration
systems.
The application of valves with a slower
action eliminates the potential for sudden
liquid deceleration/acceleration in liquid
lines. Slow acting valves are often de-
fined as taking longer than a second to
fully open or close. There are many com-
mercially available valves such as motor
operated valves or solenoid type valves
with a dashpot design. These provide a
sufficiently slow closing or opening ac-
tion to avoid the shock caused by a sud-
den change in the liquid velocity. A re-
cent entry to the market is dual position
valves which can be staged on opening defrost temperatures are not only more piped in parallel are most commonly used
and closing. These valves can be opened efficient because they add less heat to the for this application (figure 3).
or closed to approximately 10% of full refrigerated area, but again they are less At the start of the defrost cycle, hot
capacity, allowing gas or liquid veloci- susceptible to condensation in the hot gas gas should be introduced to the coil
ties to change more slowly (offering us- lines. Likewise the pressure in hot gas slowly, through a smaller soft-start hot
ers complete control over valve func- headers should be maintained between gas valve. As the hot gas enters the cold
tions). Every refrigeration system is dif- 100 and 125 psig, not at condensing pres- coil it will condense. Eventually, as the
ferent, with its own characteristics; what sure. Maintaining the hot gas for defrost coil temperature starts to rise, condensa-
may be slow enough in one application any higher than this not only leads to more tion will slow and the pressure in the coil
may not be in another. Users are frequently condensation, but wastes energy. Even will start to rise. By introducing the hot
required to tweak the system for best per- with insulation and lower hot gas pres- gas in a slow controlled rate, the chances
formance. sures, some condensation can not be of pushing any remaining, or newly
avoided. Liquid drains should be installed formed, liquid from the coil at a high
The IIAR 2000, Ammonia Refrigeration at low points in hot gas lines; these allow
Piping Handbook, gives several recom- velocity is minimized. Typically the
the transfer of condensed liquid back to soft-gas cycle should be about five to 10
mendations for reducing the hazards of the low side of the system.
uncontrolled shock when going into and minutes depending on the size of the
out of hot gas defrost cycles. Hot gas lines The transition from refrigeration to valve and the hot gas pressure (IIAR 2000,
should be insulated and well-maintained to defrost and vice-versa should be done in Ammonia Refrigeration Piping Hand-
minimize condensation. This is especially a controlled manner. The IIAR 2000, book, p. 3-19). After the coil pressure has
important when hot gas lines are exposed Ammonia Refrigeration Piping Handbook, risen to the defrost pressure, the main hot
to ambient temperatures 10°F or more recommends slow acting or parallel equal- gas valve can be safely opened to supply
below the saturation temperature used for izing valves for the initiation and termi- full flow for the defrost cycle.
defrost. Operators should run defrost tem- nation of the defrost cycle. These valves Likewise, at the termination of the
peratures high enough to melt the frost, are commonly referred to as the soft-start defrost cycle, the high pressure saturated
but not in excess. Typically, 70 psig or 48°F hot gas valve and the suction stop equal- ammonia contained in the coil needs to
saturation is used for ammonia. Lower izing valve. Smaller, solenoid valves Continued on page 4
Continued from page 3
be released to the low side. This needs to
be done in a controlled manner in order
to avoid sending high pressure liquid and
gas through the suction line where it may
encounter elbows or abrupt changes in di-
rection. Typically, like the hot gas soft-
start valve, a smaller equalizing solenoid is
used to accomplish this (figure 1, page 1).
The smaller solenoid valve piped in par-
allel with the suction stop valve is opened
first to relieve the high coil pressure
safely. This prevents high pressure satu-
rated ammonia from moving at high ve-
locities through the suction line. A prop-
erly sized equalizing valve may take five
minutes or longer to equalize the coil
before the main suction stop valve can be
safely opened. It is important that both
the soft-start hot gas and suction stop
equalization solenoid valves are in good
operating condition and properly main-
tained. A failure of one, or both of these
valves, could go unnoticed as the system
will seem to operate normally. Yet all the
while, a potentially dangerous condition
for a shock event exists.
Another, more economical way to
achieve the desirable effects created by
using smaller redundant solenoid valves
for soft-start and coil equalization is with
a dual position valve. The staged open-
ing and closing action of these valves re-
sults in a controlled flow similar to that
of redundant parallel valves, but with a
lesser degree of complexity (figure 4).
One such type of valve on the market
today utilizes a two piston arrangement.
These valves are available in a solenoid
version for soft-gas or liquid applications,
and a suction stop version. Through the
sequencing of the two solenoids, pilot
flow, or hot gas (in the case of the suction
stop valve), will be directed to either one
or both of the pistons. Using the timer
settings on a standard defrost controller,
central computer or a delay relay, users
can hold the valve in any one of three
positions (closed, open or partially open
or closed). This gives users the ability to
fine tune the valve to best meet their
Figure 4
needs. Incorporating the equalizing fea-
ture directly into a single (dual position)
valve lowers the total number of valves
to be maintained, while reducing the
number of joints and potential leak paths.
When used in liquid applications the
staged opening and closing of the sole-
noid valve will reduce the effects of liq-
uid deceleration/acceleration. It should be
noted though, this valve is not intended
to act as a dual feed valve and should not
be used as such. As soon as applicable,
the valve should be fully opened to allow
full flow.
Controlling hydraulic shock events in
an industrial refrigeration system presents
designers and operators with unique safety
concerns which must be addressed. Un-
controlled hydraulic shock leads to pipes
shaking and banging, flanges loosening
and, in extreme cases, system rupture. But
with the proper design and maintenance
of the refrigeration system these concerns
can be reduced or eliminated.
The Technical Report is an official publication of
the Refrigerating Engineers & Technicians
Association (RETA). RETA is an international not-
for-profit association whose mission is to enhance the
professional development of industrial refrigeration
operating and technical engineers.
Editor • Rob Greer
Kemper Refrigeration
209.339.0234
rob@kemperrefrigeration.com
The information in this publication is based on the
collective experience of industry engineers and
technicians. Although the information is intended
to be comprehensive and thorough, it is subject to
change based on particular applications, field
experience, and technological developments. The
Refrigerating Engineers & Technicians Associa-
tion expressly disclaims any warranty of fitness
for a particular application, as well as all claims for
compensatory, consequential, or other damages arising
out of or related to the uses of this publication.
Copyright © 2007
Refrigerating Engineers & Technicians Association
Staff
Don Tragethon • don@reta.com
Jan Tragethon • jan@reta.com
Julie Mower-Payne • julie@reta.com
Susan Brown • susan@reta.com
Scott Henderson • scott@reta.com
Refrigerating Engineers & Technicians Association
PO Box 1819
Salinas, CA 93902
Tel: 831.455.8783 Fax: 831.455.7856
www.RETA.com