e S TRANE Purge Systems Operation e@ Technical Training Student Handbook ST-MNLSPurge Systems Operation CONTENTS, INTRODUCTION 4 WHY PURGE SYSTEMS ARE NEEDED 4 HOW THE PURGE ELIMINATES AIR. WHEN TO PURGE A UNIT ..... oo HOW PURGE DESIGNS HAVE CHANGED . Bolt Drive Purge....... Cil-Less Purge Oit-Less Purge Purifier Purge HOW PURGE SYSTEMS WORK " Belt-Drive Purge Oi-Less Purge : Oil-Less Purge with UCP... - Purifier Purge” ......00000ce220005 SUMMARY pooaad 2 Ucr ‘This manual is a companion piece to the Trane seminar of the same name. ‘To order additional copies, contact: Service Literature Department The Trane Company 3600 Pammel Creek Road La Crosse, WI 54601 608-787-3684 Please specify the order number, ST-MNL-3. ‘The following support materials are also available through Trane Service Literature: PRG-OM-3A Operation and Maintenance Manual for Purifier Purge PRG-IN-1A Retrofit Installation of Purifier Purge The Trane Company, La Crosse, Wisconsin 54601-7599INTRODUCTION easy Figure 1 (Figure 1) In this section, we will introduce the operational aspects of the various purge systems utilized over the years by The Trane Company. WHY PURGE SYSTEMS ARE NEEDED er Cee Figure 2 (Figure 2) Why do we need purge systems? Because many centrifugal chillers operate in a vacuum, there is an opportunity for contaminates to get into the system from any leaks or minor servicing errors. These contaminates are classified ‘as noncondensables requiring a method for disposal. This is known as purging. ers as Figure 3 (Figure 3) The primary noncondensables requiring urge systems are air and moisture. While both air and moisture are collected by the purge systems, ‘only air can be removed automatically from the system by means of some form of bleed or relief valve. Moisture or water must be removed manually through a blow-down valve system or methods using water absorbing materials. Most Cen rere Figure 4 (Figure 4) All low pressure centrifugals operate completely or partially below atmospheric pressures. These machines use low pressure refrigerants such as R-113, R-11 or the new replacement refrigerant, R-123. Because the system operates below atmospheric pressure, there is the possibility for refrigerant contamination by way of leaks in the system. While some people may consider purge systems to be a nuisance, they actually play an important part in maintaining centrifugal chiller system integrityFigure 5 (Figure 5) This figure illustrates the difference between a low pressure and a high pressure system. It also may help you to understand why a purge system is used only on low pressure systems. In the example on the left, an operating high pressure system is represented using Refrigerant- 12. The high and low operating range for this refrigerant is indicated as positive pressures (PSI above atmospheric pressure). The example on the right with Refrigerant-11 is operating in a negative or partial vacuum measured in inches of mercury. Ifa leak were to occur with either of these systems, what would be the result? The high pressure refrigerant machine would probably lose all of its charge if the leak were not discovered in time. A leak of this type is hazardous to personnel and may result in injury. The low pressure machine would simply leak air into the machine. By simply monitoring the frequency of the purge relieving noncondensable geses, the operator ‘could spot the increasing leak rate in the low Pressure machine. The actual loss of refrigerant, then, depends only on the efficiency of the purge in separating air from refrigerant in the purge process, Since there is increased interest in reducing ‘atmospheric emissions of all refrigerants to an absolute minimum, the importance of an efficient leak prevention program will become paramount for all chiller systems, regardless of the type of refrigerant being used Pern emcees oer moe Figure 6 (Figure 6) Generally, we can isolate air and ‘moisture contamination to three areas: equipment leaks, poor service evacuation practices and contaminated refrigerants. All of these conditions can be improved by increased attention to the fundamentals of machine operation and maintenance, and a strong educational program, Improper or limited evacuation by service personnel is usually the result of haste in completing the job of restarting a machine after servicing. The service technician may opt for inadequate evacuation in the interest of time and the mistaken belief that the purge can handle all the air and moisture remaining in the chiller following major work.Pees ong Valea Figure 7 (Figure 7) Leaks can adversely affect the operating capacities and efficiencies of any air conditioning or refrigeration equipment. In large centrifugal chillers such as the Trane CenTraVac* chiller, the low pressure areas are most suspect when purge ‘operation rates increase, indicating an increase of noncondensable gas being relieved. Leaks are most likely to occur around the low pressure flanged or gasketed areas, tube and pipe fitting areas, and wherever contro! linkages must connect to the compressor inlet guide vanes. High pressure leaks are also possible past the ‘compressor’s first stage in the flange areas and at pressure taps. These leaks will occur when the chiller is running and will not be detected with the increased purging rate. It is useful, therefore, to monitor the machine room air for traces of refrigerant gas and periodically leak check these areas simply to minimize these types of refrigerant losses, HOW THE PURGE ELIMINATES AIR Pope ey Crees Uren Figure 8 (Figure 8) How the purge eliminates air from the chiller is the subject of the next area of discussion. Basie Separations Figure 9 (Figure 9) The first step to understand a purge system is to know how the noncondensables and refrigerant separate in a closed container. The container in Figure 9 shows the separation or stratification process of liquids and gases based on their different weights. Since air is the lightest of the components shown here, it will always rise to the top. Next in sequence is refrigerant vapor, water and finally refrigerant liquid, Because air is lightest, and is at the top of the container, it is a simple process to slowly release that air by means of a relief valve (provided that the container gases are not stirred or mixed in any way).Preece Tank Operate? Figure 10 (Figure 10) Using the basic separation process just covered, let's look at a typical purge condenser tank that is found on many chillers manufactured from the 1950's through the 1980's. First we will assume that noncondensables are not present. Refrigerant vapor comes from the chiller's condenser via a purge compressor and is directed to the purge condenser tank. The higher pressure {gas comes into contact with a coil which acts as a condenser. Using cool water flowing in the coil, the purge condenser transforms the refrigerant {2s to a liquid and it drops to the bottom of the tank. AA Tiquid level is maintained by a float-valve which meters the liquid back to the chiller’s evaporator. Since noncondensables did not enter the purge condenser tank with the refrigerant vapor, the pressure of the refrigerant in the purge tank will stay fairly close to the saturation temperature imposed by the cooling water in the coil. eee nae Figure 11 (Figure 11) This figure shows a system contaminated with air. The contaminated refrigerant and air mix is drawn from the unit condenser via the purge compressor and again is directed to the purge condenser tank. The gas mixture comes into contact with the purge condenser coil. With the mixture of gases, only the refrigerant portion will condense to a liquid. The remaining air becomes trapped within the purge condenser tank and will accumulate. Because pressures of dissimilar gases have an additive effect, the combined gas pressures reach the release pressure of the relief valve located on top of the purge drum, and the valve vents the air mixture. Because refrigerant vapor is present in the purge condenser tank when the relief valve is activated, some refrigerant can be lost with the air being vented. The efficiency of this method of purge depends, in part, on the condensing temperature in the purge drum. The temperature should be as low as possible to lower the distillation temperature of the refrigerant-air mixture. This will minimize the percentage of refrigerant vapor volume relative to the air volume in the drum while gases are being vented.WHEN TO PURGE A UNIT Figure 12 (Figure 12) Is it best to purge when the unit is operating or when the unit is shut down? It depends on where the purge pickup is located on the machine. Referring to Figure 12, note that the pickup is about halfway down the condenser tube bundle. With this form of pickup, an operating machine is more effectively purged than a machine that is standing idle. With the compressor forcing high velocity discharge gas into the top of the condenser shell air will be mixed with the refrigerant. A quiet zone is provided at the side of the condenser shell to help trap and hold air to be picked up by the purge compressor. With the unit off, there is @ Stratification of air to the top of the condenser. ‘The pickup becomes less effective because less air is actually exposed to the pickup point. Why is the pickup always located in the condenser and not in the evaporator? Air will always tend to be trapped in the condenser. With the unit running, the condenser has a liquid seal at the condenser discharge; air cannot travel past this point. With the chiller off, air in the machine will rise to the top of the condenser. Either way, the evaporator is not an effective source for the point of purge pickup. HOW PURGE DESIGNS HAVE CHANGED Why Did Trane Ch Figure 13 (Figure 13) Trane and other manufacturers of low pressure centrifugal chillers have all changed their design of purge units over time, In the centrifugal chillers of the 1930's, purging was often done by releasing the air-mixed refrigerant directly from the top of the condenser barrel. concerns about refrigerant losses; and owner ‘These were the priorities before the current concern af reducing refrigerant emissions to the lowest possible levels due to environmental concerns. The design requirements for purge effectiveness have changed!BELT DRIVE PURGE eon Figure 14 (Figure 14) The belt drive purge was the earliest purge design Trane used. One of the main reasons for using this purge system for so many years was ‘that its endurance record was well proven. It had an open drive type compressor supplied to Trane from several vendors. Other components were the oil separator, purge condenser tank and a fractional horsepower motor which drove the ‘compressor with a belt drive system. ‘The operation of this type of purge system can be controlled by the operator through the use of a three-position rocker switch. In the MANUAL position, the purge unit will run continuously with no respect to the operating mode of the chiller. Occasionally running the purge in the manual position was the preferred method of purging the chiller by many operators because it allowed them ‘to monitor the relief of noncondensables. In the OFF position, the purge unit is totally disabled. In the AUTO position, the purge unit would operate continuously when the chiller was on line and running. When the chiller shut down, ‘the purge system would be stopped. This purge design required careful operation and maintenance to keep the system running effectively. The oil separator, purge drum, float mechanisms, relief valve and purge tank al required cleaning and periodic service. The external components such as the motor and belt drive also had to be maintained. As with all open drive compressors, the seals often were subject to leaks and had to be inspected and serviced. OIL-LESS PURGE ee Conventional Cont Figure 15 {Figure 19) Shortly after the introduction of the Tiane three- stage CeriraVac chiller, the oil-less purge system was introduced. The main feature of this system was that the purge compressor did not utilize an oiMfilled crankcase, and because of this, it did not require a oil separator to recover oil ‘An advantage to this approach was lower maintenance. However this design did have a number of drawbacks. For example, continuous purging operations of long duration caused premature wearing of the purge compressor. The oil-less purge system again used a three-position rocker switch to control the purging of the chiller. In the MANUAL position, the purge system would run continuously with no respect to the chiller’s operation. In the manual position, it was imperative that chilled water be flowing through the purge condenser. This again was the preferred method of purging by many operators. In the OFF position, the purge system was totally disabled. In the AUTO position, the purge unit would operate for five minutes of each hour that the chiller is operating. This five minutes of purging was sufficient to remove noncondensables; however, the actual amount of noncondensables removed could not be determined in this mode of operation. This oil-ess purge unit, as well as preceding purge units, had no way of maintaining a record of the duration of operations or the number of purges. Without this information, it was difficult to determine both the condition of the system as well as the purge compressor overhaul needs.OIL-LESS PURGE WITH UCP Oit-Less Purge System reaver PURIFIER PURGE Figure 16 (Figure 16) The next step was to interface the oi less purge system with the new Trane three-stage CeniraVac unit control panel (UCP). This allowed for better control of the system. ‘The unit contro! panel (UCP) cil-less purge system again used a three-position rocker switch to control its operation. In the MANUAL position, the purge system operated continuously, regardless of the operating mode of the chiller. In the OFF position, the purge system was totally disabled, In the AUTO position, the purge operated five minutes out of each two hours of chiller operation (assuming that no significant purge gases were present). Although the basic oil-less purge system was the same, the method of control and recording capabilities were enhanced. This enhancement included the addition of a start counter to count the number of actual purge relief operations and an hour meter that would record the run hours, accumulated on the purge compressor. Another feature was the extended purge cycle, a slightly more flexible approach to purge. This feature increased purging time by an additional four minutes each time a call for relief was required. This increased the ability of the purge system to completely free its system of air and minimize the number of run hours accumulating on the purge compressor and extend the time between purge compressor overhauls. This unit also had a small purge tank and a solenoid valve controlled by the control panel instead of a relief valve. Figure 17 (Figure 17) In 1990, the Purifier Purge” system ‘was introduced. This style of purge also uses intelligent controls. In addition, it exhibits a whole new concept in purging methods. The net results ‘re more accurate and informative purging. ‘The features are numerous, the first being that the new system purges by monitoring a refrigerant ‘temperature instead of pressure. It does not need water connections for condensing purposes; therefore the purge system can be operated easily without the chiller running, and there is little chance of water contamination or accidental discharge of the refrigerant. This system dramatically reduces the amount of refrigerant emissions by about 90 percent. The purifier release of air to refrigerant ratio has been measured at .5 to 1 pound of refrigerant for each pound of air purged from the system. This ‘compares to a ratio of three to seven pounds of refrigerant to each pound of air in the old system. ‘There are similarities and differences in the ‘operation of this system. For example, when the three-position rocker switch is in the OFF position, the purge system is totally disabled, as with previous systems. ‘When the switch is in the AUTO position, the purge system will operate continuously with the chiller in a run mode. When the chiller shuts down, so does the purge system, When the switch is in the ON position, constant sampling is the result, regardless of the chiller’s, ‘operating mode and discharge noncondensables when needed. It also records minutes of relief operations.HOW PURGE SYSTEMS WORK ee eee Figure 18 (Figure 18) Now let's take a look at how these four purge systems work. BELT DRIVE PURGE Figure 19 (Figure 19) The belt drive purge system took refrigerant samples from the unit condenser via @ solenoid valve that had been energized to allow that sample to be compressed by the purge compressor and sent to the oil separator. Notice that the purge gas mix must be elevated to a higher pressure in order to develop sufficient pressure for this design of purge system to work. The oil separator is needed because the purge compressor has a crankcase filled with oil. The oil coming off the crankshaft lubricates the cylinder wall, As the piston comes down on an intake stroke of the compressor, some of the oil lubricating the cylinder wall slips past the piston rings. u The oil will leave the compressor by way of the discharge line on the compression stroke. This oil must be recovered and returned to the crankcase of the purge compressor by an oil separator. The oil separator must be kept warm through the use of heaters to insure the flashing of any refrigerant entrained with the oil ‘The higher temperature and pressure refrigerant vapor is then sent to the purge tank, where it's condensed to a liquid. The liquid refrigerant is then returned to the evaporator to do useful work OIL-LESS PURGE Figure 20 (Figure 20) The oil-less purge operation is very similar to the belt drive purge with one evident ‘exception and that is no requirement for an oil separator. All other purge functions are the same. It’s interesting to note that this compressor was originally designed to operate as an air compressor, but was redesigned to operate in a refrigerant atmosphere. Even though air compressor and refrigerant parts are interchangeable, parts designed for use in refrigerant atmosphere only should be used because of the difference in the life expectancy of the parts.OIL-LESS PURGE WITH UCP Pe rr aE ees forveerny Figure 23 (Figure 23) The initial big change we see is that a the purge pickup and purge liquid return are both ‘gure located in the unit condenser. This system has some advantages in that flow is established through migration of the refrigerant sample from. the unit condenser and returns by gravity flow. (Figure 21) The unit control panel controlled oil- less purge is the same as the earlier oll-less purge, xcept thatthe newer purge system operates on i ommand signals froma figher source and os So, the Purifier Purge system must be installed command signals from a ngher source ore onthe top of the condenser. The return flow an ered Gat te alle ry Wa cae = moisture content of the refrigerant is monitored by valve instead of the standard relief valve. melee ne This sample process is an improvement because it PURIFIER PURGE™ does not rely on elevated pressure for condensing or refrigerant return. It also reduces the possibility of leaks because fewer components and ‘connections are used, and the refrigerant sample @ is being taken from and returned to the same vossel. Seay eee Figure 22 (Figure 22) The Purifier Purge is a new and exciting concept. Its basic purpose is the same as that of all purge systems, but it performs in an entirely different manner. Figure 24 (Figure 24) The refrigerant vapor sample is brought into the bottom of the purge condenser. In the purge condenser there is @ vapor inlet and a liquid refrigerant return tube. There also are two filter drier cores installed end to end, the purpose of which is to remove any moisture that may be entrained with the refrigerant sample. 2‘The reftigerant vapor sample, having passed through the filter drier cores, will next encounter a serpentine coil, which acts as a heat exchanger. ‘The serpentine coil cools the refrigerant vapor and causes it to condense to a liquid and allows it to collect in the bottom of the purge tank. The liquid level rises in the bottom of the tank until it exceeds the height of the liquid refrigerant return tube and then returns the liquid to the unit condenser. ‘Any water present in the tank is prevented from returning to the unit condenser by a water separation tube that extends below the liquid level isolating the lighter water above the refrigerant, where it will be visible through the sight glass in the purge tank. This visible water line will serve as a cue that service is required and the filter drier cores should be replaced. re, Peon erst Figure 25 (Figure 25) in order for the purge condenser serpentine coil to act as a heat exchanger, a small refrigeration circuit is used. This refrigeration circuit is much like the one in a home refrigerator. Its purpose is to supply low temperature refrigerant, approximately 0 F, to the coil by way of an automatic expansion valve, The serpentine coil heat exchanger removes the heat from the refrigerant sample. The low temperature refrigerant supplied by the refrigeration unit now completes its circuit and returns at a higher temperature, sometimes as high as the chiller condensing temperature. 2 arene Figure 26 (Figure 26) What happens when air collects in the purge condenser tank? The diagram on the left shows a normal operating purge condenser. We know it’s operating because the temperature control is monitoring a return refrigerant ‘temperature of 22 F or greater. But the diagram on the right is a different story. As more air collects at the top of the tank, the air will begin to insulate the serpentine coil, preventing it from doing its job. AAs the volume of air increases in the tank, more and more of the serpentine coil surfaces become inefficient in absorbing heat. The temperature control monitors this condition and senses air is trapped in the purge tank because of the lower return refrigerant temperature.eect Figure 27 {Figure 27) Once the temperature control has sensed 18 F or below, indicating the presence of air in the purge tank, it will initiate and energize the purge solencids and the pump out compressor to remove the air. The temperature control will continue monitoring the returning refrigerant temperature from the serpentine coil and when it sees the temperature rise above 22 F, it will discontinue the purge relief cycle. It should be noted that there is a restricter located between the solenoid valves and the pump out ‘compressor. This restricter’s purpose is to slow down the discharge rate of the pump out ‘compressor to prevent excessive release of refrigerant vapor with the trapped ait. The slower release of air reduces turbulence inside the tank from the entering vapor. Also notice that there are two opposing solenoids installed in the pump out line. These solenoids provide a positive seal when they are de- energized to mir leak potential “ fo} Figure 28 (Figure 28). As discussed, three circuits are involved in the purge system. The refrigeration circuit supplies the low temperature refrigerant for condensing purposes to the purge serpentine coil ‘The purge pickup and return circuit to the unit condenser supplies the refrigerant sample for testing purposes. The solenoid valves and the pump out compressor reject air from the system.Figure 29 (Figure 29) There are several control schemes involved in the Purifier Purge control system. One of the control schemes relates only to a version which operates only by its own controls for use with older chillers. Another scheme involves the interfacing of the chiller’s microprocessor panel with the purge control system, allowing for a centralized control point. To get an explanation of the full sequence of ‘operation, refer to the applicable operators manual. Be sure to use the correct manual. This figure shows indicator lights and operational switches. The open solenoid and run pump out switch acts as a momentary service switch. This switch is meant to be used by service personnel 10 test for operation of the purge solenoid valves and the pump out compressor. ‘The ON, OFF/RESET, AUTO switch is used only with field retrofit of the newest version of the purifier purge system. The purpose of this switch is to reinitialize the internal purifier purge 24-hour smart timer. There are three i purge control panel: itor lights mounted on the Run: This light indicates that the purge system is ‘operating. It should be noted that the purifier purge runs continuously as long as the chiller is operating, Fault: This light will illuminate any time that the actual purge relief has exceeded the time value set in the 24-hour smart timer (factory set at 12 minutes). Bypass: This light is illuminated when the purge relief 24-hour fault timer has been bypassed intentionally. One reason for this intentional bypass may be because of a service requirement. The final switch, 24-hour bypass or normal, is a momentary switch and is used to reinitialize the 24-hour bypass fault timer for an additional 24 hours. Figure 30 (Figure 30) To get the maximum performance out of any purge system, certain maintenance requirements must be met. In the remainder of this manual, we will cover these necessary steps.Figure 31 Figure 32 (Figure 31) Performing regular, scheduled (Figure 32) The oil-less purge system maintenance maintenance will help assure proper operation of checks are basically the same, except those items the purge belt drive system. Here are suggested referring to the oil separator. The current service schedules: recommendation is to overhaul the oil-less purge compressor at 750 hours of accumulated run time. Daily: Check and log operating purge pressures. If Use only replacement parts which are suitable for the purge compressor has a sightglass, check for ‘operations in a refrigerant atmosphere. oil levels. Check the purge drum for proper level and any indication of moisture. Check the oll separator for proper operating temperature. Weekly: Operate the purge as required. Check the oil separator heaters for proper setpoints and. operating temperature. Monthly: Loak check all purge components, tines, connections and fittings. Check the purge drum water temperature. (It should be less than 80 F), Check the purge compressor oi! level. Quarterly: Lubricate purge motor bearings. ‘Semiannually: Check the purge belt drive for wear and proper tension. Clean all water strainers. Flush the oil separator with fresh oil. Annually: Check the purge relief for the correct ‘elief setting. Inspect, clean and recalibrate (if necessary) all safety and operating controls associated with the operation of the purge system, Figure 33 (Figure 33) The service requirements are basically the same for an oil-less purge system which uses unit control panel inputs. In addition, itis necessary to monitor the start counter and the run hour meter daily logs. Doing this will reveal any adverse operating conditions. Overhaul the purge condenser tank, disassemble, clean the tank, check the float and purge tank baffle. Change the purge compressor crankcase oil Check the purge compressor valves. Check purge compressor shaft seals. Clean the oil separator and recharge with fresh oil. Leak check all purge ‘system components, lines, connections and fittings, 6Figure 34 (Figure 34) The Purifier Purge” has similar checkout requirements for maintenance, although there are some differences we should discuss. Daily: Check and log the status lights of the purge control panel. Record the minute meter and note any changes in the accumulated time recorded. If the accumulated minutes setting has changed, be sure to take into consideration the operating schedule of the chiller. Make a visual inspection of the purge tank and liquid line sight glass and note any changes. Weekly: While the purge is operating, check the purge tank condensing activity at the sight glass. ‘A continuous flow of refrigerant droplets should be visible, Check the moisture indicator on the liquid return Tine. If the indicator shows the presence of moisture, itis time to replace the filter drier cores. Check the purge tank sight glass for the presence ‘of water. If water is present, there will be a visible line of separation between the water and the refrigerant. The presence of water in the purge tank indicates that service is required. See the appropriate operators manual for a description of the above mentioned conditions. Monthly/Semiannually: inspect the air-cooled condenser coil and clean as needed. A fouled coil will reduce purge efficiency and capacity. Annually: Perform a purge system control check as outlined in the operators manual. Perform purge tank service as described in the operators manual SUMMARY Figure 35 (Figure 35) To summarize, there are different types of purge systems. The new Purifier Purge” system, represents an opportunity for increased control over refrigeration emissions.