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In this edition of The Cold Front, we discuss both design and operating practices to effectively manage oil in
IRC Staff
Director
Doug Reindl 608/265-3010
or 608/262-6381
dreindl@wisc.edu In This Issue
Assistant Director • Standards Update 1-13
Todd Jekel 608/265-3008
tbjekel@wisc.edu • Upcoming Ammonia Classes 2
Research Staff • Noteworthy 2
Dan Dettmers 608/262-8221
djdettme@wisc.edu
John Davis
jgdavis@epd.engr.wisc.edu
practices aimed at ensuring safe, efficient, and reliable Principles and Practices of Mechanical
Integrity for Ammonia Refrigeration
ongoing system operation.
Systems
November 5-7, 2014 Madison, WI
Noteworthy
Noteworthy
•• Visit
Sendthe IRC of
items website to next
note for access presentations
newsletter made Jekel
to Todd , tbjekel@wisc.edu.
at the 2011 IRC Research
and Technology Forum.
• Mark your calendars now for the 2012 IRC Research and Technology
Forum – May 2-3, 2012 at the Pyle Center in Madison, WI.
• Send items of note for next newsletter to Todd Jekel, tbjekel@wisc.edu.
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Vol. 14 No. 3, 2014
in an industrial refrigeration system is used for compressors, it is also used as a lubricant in some other
subsystems such as bearings in open-drive liquid refrigerant pumps.
Because the volume flow rate of oil through screw compressor packages is relatively high, a specialty device
called an “oil separator” is used to remove oil from the compressor discharge gas stream. Most oil separators
use three principles for removing oil from the discharge gas: impingement separation, gravity separation &
filtration using coalescing elements. We go to great lengths to retain oil in compressors to avoid two (2) very
undesirable consequences when it escapes out to the refrigeration system. First, the loss of oil from a
compressor package will diminish the reservoir of oil available for continued use as a lubricant within the
compressor package. Second, the “lost” oil from the compressor package will migrate to other parts of the
refrigeration system to become a contaminant. Compared to a refrigerant such as ammonia, oil is an extremely
poor heat transfer fluid and any oil accumulation within heat exchangers will result in a marked loss of heat
transfer capability.
Figure 1 shows an illustration of a screw compressor package with its oil separator. The oil separator is a
large vessel that receives the discharge gas exiting the compressor. When the oil-laden discharge gas enters
the separator, the gas-oil stream is directed toward the vessel’s head. The momentum of larger oil droplets
causes them to impinge on the head where they are removed by impaction. The larger cross-section area of
the oil separator dramatically decreases the gas velocity and as the gas moves laterally through the separator,
Compressor
Motor
Discharge
vapor
Oil
intermediate size oil droplets simply fall to the bottom of the vessel by gravity. The very small droplets of oil
continue to be carried along by the refrigerant vapor flow where they proceed to flow through a second stage
of separation. In this stage, the refrigerant vapor-oil stream is forced through a series of “coalescing filter”
elements. The coalescing filters increase the surface area available to intercept the smaller misty droplets of
oil. Ideally what leaves the oil separator is high pressure ammonia vapor that is free of oil. Because no oil
separator is 100% effective, a small amount of oil will leave the oil separator and migrate out to the system.
The goal is to minimize, to the greatest extent possible, “oil carryover” from the oil separator.
The two (2) biggest factors that can lead to excessive oil carryover are (1) increased gas velocity through the oil
separator (both during steady operation and transient conditions) and (2) compromised function of the
coalescing filters. The velocity of gas through the oil separator is dependent on the mass flow rate of
refrigerant (capacity) through the compressor and the density of discharge gas. If the gas velocity through the
oil separator is higher than planned for in the original design, an increase in oil carry-over will occur. The
following are examples of changes that increase the refrigerant gas velocity through the oil separator:
• Operating with suction pressures higher than the limits identified in the original design
o Increasing suction pressure significantly increases compressor capacity and increase
compressor capacity results in higher mass flow rate and thus higher gas velocity
• Operating with discharge pressures lower than the limits identified in the original design
o Decreasing discharge pressure also increases compressor capacity but the capacity increase is
minor. The bigger effect is the decreased gas density in the oil separator causing increased gas
velocity.
• Operating with an excessive refrigerant flow rate for liquid-injection oil cooling (increases mass flow
rate in oil separator)
• Running the compressor at a higher shaft speed than the original design (i.e. increasing the capacity of
the compressor)
Table 1 below illustrates how changes in the discharge pressure and suction pressure impact the volume
flow rate of gas through the compressor’s oil separator. Because the cross-sectional area of the oil separator is
constant, the changes in volume flow translate directly to changes in the gas velocity. Higher velocity means
lower separation effectiveness. As the high-side pressure decreases from the design condition of 166 psig to
115 psig, the velocity of discharge gas through the oil separator at full-load condition will increase by 41%.
Approximately 5% of that increased gas velocity is attributable to the compressor’s increase in mass flow rate –
the majority of the increased gas velocity is due to the decrease in gas density at the lower discharge pressure.
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Table 1: Effect of changes in suction and discharge conditions on thermosiphon oil cooled compressor
performance.
Psuction Tsuction Pdischarge Tdischarge Capacity Mass flow Volume flow Volume flow
(psig) (°F) (psig) (°F) (tons) (lb/min) (CFM) (% change)
166 180 390.5 165.4 344.4 Baseline
25 11.7
115 172 412.1 166.8 485.4 +41%
30 17 115 167.2 463.7 187 538.6 +56%
In addition to the above-mentioned conditions, there are short-term transients that often cause excessive oil
carry-over. The most common condition is a rapid decrease in the compressor’s discharge pressure. When a
rapid drop in discharge pressure occurs, the density of refrigerant gas in the oil separator decreases which
results in a proportional increase in gas velocity. The increased gas velocity degrades the oil separator’s ability
to remove oil from the refrigerant and increased oil carryover results. Rapid decreases in discharge pressure on
the high-side can be caused by poor condenser capacity control during cool weather conditions (e.g. cycling
water pumps on and off for head pressure control) and high instantaneous hot gas demands for defrost (too
many evaporators simultaneously calling for hot gas or defrosting large evaporators without a soft-gas step that
gradually allows the pressure to build in the evaporator reducing the rapid in-rush of gas at the start of the
defrost cycle).
The intent of the discussion regarding oil separation thus far is to increase
your awareness of common factors that cause increased oil carryover. The
key is to avoid known conditions that can increase oil carryover and when
Figure 2: Coalescing filter element.
oil carryover is suspected take immediate steps to address the causes.
Preventing oil migration out of the compressor will minimize the adverse effects it can have on low-side
performance as well as the need to deal with oil that has left the compressor packages.
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Vol. 14 No. 3, 2014
Oil Management
We have already discussed the purpose of oil and the goal of preventing oil from leaving the compressor
package. How then do we deal with or manage oil that does manage to escape the compressor package(s) and
migrate out to other parts of the system? For the vast majority of industrial ammonia refrigeration systems, oil
management on the low-side of the system involves installing points in the system where it is intentionally
allowed to accumulate and then monitoring those points so the oil can be manually removed on an as-needed
basis. The subsystem designed to collect the oil is called an “oil pot.”
b. A vessel equipped with an oil drain valve in series with either a self-closing or manual quick-
closing emergency stop valve connected to the oil drain point, a vent line, a vent line isolation
valve, and an approved pressure relief device.
c. Piping which provides capability for isolation and refrigerant removal to another portion of
the system.
d. An oil drain valve in series with a self-closing or manual quick-closing emergency stop valve.
When draining to atmosphere, rigid piping routing the oil 2 to 4 ft [0.6 to 1.2 m] away from and
within sight of the valves shall be provided. Use of temporarily attached rigid piping and
emergency stop valves is permitted.
The “rigid piped oil return system” option identified in 14.2.3(a) typically consists of a central oil accumulator
vessel located in a machinery room (or outdoors) and a dedicated piping system designed to convey
accumulated oil from various points out in the system to a central “oil accumulator” vessel where it can be
safely removed from the system and subsequently recycled. In this design, the oil return process is
accomplished by operators actuating manual valves to allow oil to flow from the various drain points to the
accumulator.
Oil Pots
The majority of plants with industrial ammonia refrigeration systems utilize the option described in 14.2.3(b)
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where the “vessel” referred to is an “oil pot.” Figure 3 shows a schematic for an oil pot installation
connected to a recirculator package. The oil pot itself is a small vessel with its supply line piped from a low
point on the recirculator. Because oil is heavier than liquid ammonia, it will tend to collect in the low points of
a system. In this case, oil that finds its way into the recirculator will collect at the bottom of the vessel. With
the liquid refrigerant supply pipe to the pump physically stubbed higher into the bottom of the pressure vessel,
a small volume to collect oil in the main vessel is created. The liquid supply line to the oil pot is then connected
so that any accumulated oil along with liquid refrigerant will flow by gravity to the oil pot. Because the oil pot is
uninsulated, heat gain from the ambient environment causes the colder liquid refrigerant within the oil pot to
evaporate and return back to the pressure vessel through the oil pot’s vent line. The oil is nonvolatile at these
low temperatures and collects at the bottom of the oil pot. The intent of an oil pot is to provide a means of
isolation from the system so that oil can be safely drained.
Recirculator
Oil pot vent
Oil Pot
Figure 4 shows a more detailed schematic of the oil pot itself including its key valves. During normal
operation, the liquid drain valve (V-101) is open and liquid ammonia containing any accumulated oil flows from
the main vessel will flow to the oil pot. The liquid ammonia within the oil pot will absorb heat from the
surrounding environment and evaporate. The ammonia vapor produced during this evaporation process then
flows back to the vessel through the vent line because the vent valve (V-102) is normally open. The oil drain
valve (V-104) and the quick-close valve (V-105) are normally closed. Most oil pots have the vent pipe stubbed
down into the pot slightly. This arrangement creates a small vapor pocket in the top of the oil pot to minimize
the likelihood of liquid ammonia flowing out the relief valve (V-103) if it were to weep. Figure 5 shows a
photo of an oil pot installed on a low-temperature recirculator. The frosted portion of the oil pot’s surface is
the portion of the oil pot that contains low temperature liquid ammonia. The refrigerant vapor that collects at
the top of the pot is relatively poor at transferring heat so the rate of heat gain absorbed from ambient
environment is sufficient to prevent frost from forming on the top of the pot. The melted frost at the bottom
of the oil pot is due to the presence of collected oil. As oil continues to collect in the pot, the frost level will
progressively rise. It is desirable to drain oil prior to the pot completely filling so operators will use the
progressive disappearance of frost on the pot as a visual cue to schedule the pot for oil draining.
V-103
V-102 V-101
V-104
V-105
Refrigerant vapor
Refrigerant liquid
Oil
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Vapor ammonia
Liquid ammonia
Oil
Oil Draining
So it’s time to drain oil – what’s next? Prior to draining oil, the oil pot must be properly prepared prior to
executing the oil drain.
CAUTION: Read, learn, train, and follow your plant’s written operation/maintenance
procedures for oil draining on your specific process equipment!
Knowing that you will have plant-specific procedures for your oil draining, here we discuss key steps that
should be consistent with your established procedures. Let’s look at the steps involved and discuss why we
proceed in this fashion.
Referring to the valve nomenclature shown in Figure 4, the steps involved in oil draining are as follows:
This first step is intended to prepare the oil pot for draining by ensuring the liquid ammonia is
evaporated out of the oil pot. When we close the liquid supply (V-101) to the pot while leaving the
vapor vent valve (V-102) open, we are allowing ambient heat to evaporate the residual liquid
ammonia within the pot.
2. Wait
With the liquid supply valve closed, we let a sufficient time elapse to allow the ambient heat gain an
opportunity to fully evaporate the residual liquid ammonia resident in the oil pot. The complete
melting of frost from the outside of the oil pot gives us a visual indication that the residual liquid
ammonia has evaporated and vented back to the accumulator. Usually 24 hours is sufficient to
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Vol. 14 No. 3, 2014
Generally, plant procedures will prescribe the PPE operators are required to have accessible or donned
during oil draining. These may include chemical resistant gloves, apron, and safety glasses with face
shield (or full-face respirator). Some plants have developed safe work practices such as “line-break
permitting.” For these plants, oil draining likely falls within the scope and permits or other forms of
authorization would be required prior to oil draining. Once these details are addressed, the actual oil
drain process can proceed.
Figure 6: Operator with plant-required PPE donned performing an oil drain. Note the oil pot is not
frosted during the actual oil draining. Also note the second operator in the background behind the oil pot
serving as a backup.
4. Close vent line valve (V-102)
This step now fully isolates or segregates the oil pot from the system.
5. Position the drain receptacle to collect oil and carefully remove plug from oil drain line
The plug in the oil drain line is intended to prevent any spillage of oil while the pot is in its normal
service. Often there is some residual oil from the prior drain so proceed with caution and care in
removing the plug.
When the self-closing “deadman valve” is opened, there should not be any flow of oil from the pot
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because the oil drain shutoff valve has not yet been opened.
While manually holding the deadman valve open, the oil drain shut-off valve is now slowly opened to
initiate the flow of oil from the pot. The oil drain valve is used to manually regulate the rate of oil flow
from the pot to the receptacle - opening more to increase flow and closing more to decrease the rate of
oil flow. If there is an unexpected increase in oil flow i.e. it “spits”, the self-closing deadman valve can
be released; thereby, quickly stopping the oil drain flow. The oil flowing during the draining process
often appears brown in color and is a bit “frothy” as shown in Figure 7. As mentioned above, the
type of oils commonly used in ammonia refrigeration systems have low (but not zero) solubility with
ammonia.
Figure 7: Oil drained from pots is often chocolate in color and frothy.
As the oil level in the pot decreases, the pressure of the residual ammonia vapor in the pot will also
decrease. If the connected recirculator is operating at a pressure above atmospheric, the recirculator
can be used to build-up pressure in the oil pot. This is accomplished by closing down on the oil drain
valve (V-104) until it is just cracked open followed by releasing the self-closing deadman valve (V-105)
to fully stop the oil flow. The vent valve (V-102) can now be opened momentarily to allow vapor from
the recirculator to re-pressurize the pot. Re-close the vent-valve (V-102) and resume the oil draining by
re-opening the deadman valve (V-105) and regulating the flow with the oil drain valve (V-104).
The oil drain process is complete when the oil flow begins to be intermittent with vapor from the pot.
Carefully place the oil receptacle in a well-ventilated area to let any ammonia vapor absorbed in the oil
to off-gas.
8. Securely close the oil drain valve (V-104) while maintaining the self-closing “deadman” valve (V-105)
in the open position
The intent of maintaining the deadman valve (V-105) in the open position once the oil drain valve (V-
104) is closed is to enable any oil/vapor contained in the line between these two valves to flow out.
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11. Carefully crack open the deadman valve (V-105) once again to verify the oil drain valve (V-104) is
properly holding. If the oil drain valve is holding, then reinstall the cap or plug in the oil drain line. If
the oil drain valve does not appear to be holding, retighten the drain valve until secured. Crack open
the deadman valve (V-105) once more to release any residual oil and then reinstall the cap or plug in
the oil drain line.
Once the “swelling” of the oil has gone down following the off-gassing of ammonia, determine the
volume of oil drained. The location of oil removal, the quantity of oil removed, and the date oil was
drained should be noted in an oil log in accordance with Section 6.2 of IIAR Bulletin 110. Periodically,
the quantity of oil added to the system’s compressors should be compared with the oil drained to
ensure there is not a net accumulation of oil in the system.
The oil drained from points out in the system is not suitable for reuse in the compressors. This oil is not
only particulate-contaminated but will also contain water at concentration levels above thresholds
acceptable for the compressors. The drained oil should be properly recycled.
Do:
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• Fit your vessels or other equipment with provisions for oil draining in accordance with the
requirements of Section 14.2.3 from IIAR 2. Figure 8 shows both a high-side vessel (left) and a
low-side vessel (right) with inadequate provision for oil draining.
DON’T
CAUTION: DO NOT DRAIN OIL LIVE (i.e. not isolated from system pressures)!
References
IIAR 2, “Equipment, Design, and Installation of Closed-Circuit Ammonia Mechanical Refrigerating Systems”, with
Addendum B, International Institute of Ammonia Refrigeration, Alexandria, VA (2008).
IIAR 110, Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems”, International
Institute of Ammonia Refrigeration, Alexandria, VA (2008).
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