Refrigeration and Air Conditioning Systems

Introduction

In this lecture, you will learn about the various types of refrigerants and their properties, the
operation of a vapour compression refrigeration cycle. You will learn to identify the major
components in a refrigeration system and the materials used in their construction. You will
learn the function of control devices and safety devices in refrigeration systems. You will learn
about a shipboard air conditioning system and typical operating parameters of such a system.

On completion of the lecture you should be able to describe the following with the aid of
sketches where necessary;
• The operation of refrigeration and air conditioning plants, including safety fittings and
materials used.
• State the various common types of refrigerants and their properties.
• Explain the operation of a vapour compression refrigeration system, stating typical
operating parameters of pressure and temperature.
• Identify the major components, safety devices, and fittings of a refrigeration plant and
explain their function.
• List the materials used in refrigeration plants and their components.
• Explain the operation of a shipboard air conditioning plant, stating common operating
parameters.

Common types of refrigerants and their properties

Refrigeration is a process of cooling by transferring heat. Heat is absorbed by the refrigerant

and transferred to a cooling medium. To provide an efficient cycle it is necessary to absorb
and reject heat in the form of latent heat. Therefore it is necessary to circulate a refrigerant
which can be evaporated and condensed at suitable temperatures.

The evaporating and condensing temperature of a refrigerant is directly related to the pressure.
The characteristics of the refrigerant will be governed by the upper and lower limits of these
temperatures. Below the lower limit (known as the triple point) the refrigerant will not
evaporate and above the upper limit (known as the critical point) the refrigerant will not
condense.

Desirable properties of a refrigerant:

• The triple point and the critical point should be well outside the working
temperature and pressure range.

• The latent heat capacity at the working temperature range should be as high as
possible.

• The pressure must be low at the condensing temperature of the refrigerant.

• The specific volume at the working pressures should be low.

 • Must have low Ozone Depleting Potential (ODP)

• Must have low Global warming Potential (GWP)

In addition to the above it is desirable that refrigerants are not toxic, irritants, inflammable or
corrosive.

The environmental impact of a refrigerant is now the primary concern and legislation
to curb or prohibit the use of refrigerants known to be damaging to the environment is
being enacted by the convention meetings of the Montreal Protocol.

Refrigerants can be categorised as primary refrigerants and secondary refrigerants.

Primary refrigerants

R12 (Freon 12) - Dichlorodifluoromethane (CCL2 F2)

Refrigerant 12 or Freon 12 is a refrigerant derived from methane. Freon 12 posses most of the
desirable properties for an ideal refrigerant but has a relatively low latent heat capacity. It is
not affected by contact with moisture and is readily miscible with lubricating oils preventing
filming of the heat transfer surfaces with oil. Freon 12 is very slightly toxic, stable, colourless,
odourless, non-irritant, and non-flammable. However, when it comes in contact with a naked
flame it decomposes to chlorine and phosgene, which are very toxic gasses.

ODP=1, GWP=10000

The high ODP of Freon 12 now renders it unacceptable as a refrigerant and is being replaced
by Freon 22.

R22 (Freon 22) - Chlorodifluoromethane (CHCIF2)

Freon 22 has similar qualities to freon 12 and is highly stable, non toxic and non flammable.
Freon 22 has a low evaporating temperature, hence allows it to be used for lower
temperatures. However the system pressures are higher than Freon 12 systems. The higher
pressures reduce the risk of drawing air into the system.

Initial problems were experienced with Freon 22 with respect to miscibility with existing
lubricants at lower temperatures. However with the introduction of synthetic lubricating oils
for very low temperatures, this problem has been overcome.

ODP=0.05, GP=1100

R502 - (C2CIF5)

Refrigerant 502 is a mixture of two refrigerants, 48.8% R22 and 51.2% R 115. It has similar
properties to R 22 and is used for medium to low evaporating temperatures, and is well suited
for use in hermetically sealed compressors.
ODP=0.6, GWP=25000
R717 – Ammonia

Ammonia is a good refrigerant, but it is explosive (HEL=27%, LEL=16%,) poisonous (toxic

TLV=1500 (damage to body tissue) >2500 (Death), and an irritant (very pungent odour). It is
corrosive to copper and its alloys, so all plant part have to be ferrous. Ammonia is soluble in
water. Due to the hazards associated with it ammonia is not widely used at sea. Where
Ammonia is used as a refrigerant, the plant must installed in a separate well-ventilated
compartment.

R744 - Carbon dioxide

When CO2 is used as a refrigerant the working pressures are very high and range between 20
– 70 bars. The critical temperature is also high (31C), hence causes problems in areas with
high seawater temperature. Poor miscibility with oil requires the system to have an oil drain
from the evaporator.

Can be dangerous if leakage occurs as CO2 displaces air and can cause asphyxiation.

R134a - (CH2FCF3) - Hydroflourocarbon

Refrigerant 134a has zero ODP, hence is extremely environment friendly. It is not as stable as
the chlorofluorocarbons and this causes it to breakdown before reaching the ozone layer. R
134A has similar thermodynamic properties to R 12 and is a non flammable, low toxicity
refrigerant. This refrigerant has been introduced as a replacement for ozone depleting gas in
refrigeration and air conditioning systems. (ODP=0, GWP=900)

Traditional mineral oils cannot be used with R 134A, hence synthetic ester or
polyalkyleneglycol (PAG) lubricants must be used.

Ozone Depletion Potential (ODP)

ODP is the Relative Ozone Depletion Potential. R11 was taken as the ‘standard’ and given the
arbitrary value of unity (1·0), thus other materials are compared to the ozone depletion
potential of R11.

Almost all R12 plants should now have been converted since R12 is very difficult to obtain.

R22 is being widely used as an interim measure until the new refrigerants become more readily
(and cheaply) available. Sometimes one of the various ‘blends’ is used instead of R22.

Summary of the 1987 Montreal protocol and the 1990 London and 1992 Copenhagen
amendments

Refrigerant 1987 Protocol 1992 Amendments

CFC – 11 Freeze at 1986 levels by 1989. Reduce by 75% by 1994

CFC – 12 Reduce by 20% by 01 July (from 1986 levels)
CFC – 113 1993 Total phase out by 1996
CFC – 114 Reduce by a further 30% by
 CFC – 115 01 July 1998

Other CFC s Not included in 1987 Reduce by 20% by 1993

protocol (from 1989 levels)
Reduce by 75% by 1994
Total phase out by 1996

HCFC s Not included in 1987 Freeze by 1996

protocol Reduce by 35% by 2004
Reduce by 65% by 2010
Reduce by 90% by 2015
Reduce by 99.5% by 2020
Total phase out by 2030

The above time table set by the Montreal protocol is for consumption of ozone depleting
refrigerants in developed countries. Consumption is defined as the quantities manufactured or
imported less those quantities exported in any given year. Percentage reductions relate to the
base year for the substance.

Secondary refrigerants

The main purpose of a secondary refrigerant is to reduce the amount of the primary
refrigerant in circulation in large refrigeration plants. A secondary refrigerant does not
undergo a change of state and is only a medium used for the transfer of heat. Two common
mediums used as secondary refrigerants are air and brine.

Brine is a solution of calcium chloride dissolved in water. The freezing point of brine is
directly related to the brine density and it is important to maintain the correct density in order
to ensure that the brine does not freeze. Typically brine density is measured in “Twaddell”
using a specially calibrated hydrometer. In order to achieve the lowest freezing point of -31C,
the brine density must be maintained at 50 Twaddle, equivalent to a specific gravity of 1.25.

Due to the limited heat absorption capacity of brine a large amount of brine has to be
circulated in the system resulting in a large network of piping. Brine is very corrosive and the
solution must be dosed with anti-corrosion chemicals and periodically tested for levels of
alkalinity.

The vapour compression refrigerating system

Before we discuss the operation of the refrigeration system in figure 1, let us revise the
definitions of some of the terms used in refrigeration.

Saturation Temperature The temperature at which a change of phase from liquid to

vapour will occur.
Under cooled Liquid that is below saturation temperature at that pressure.
Saturated Liquid The refrigerant is in a fully liquid state. Any heat added will
create some vapour.
Wet Vapour Both liquid and vapour are present as a mixture in the

Dry Saturated Vapour
Superheated Vapour
Refrigerating effect
vapour.
The refrigerant is fully vapour state. Any cooling will
condense some vapour into liquid.
Vapour at a higher temperature than its saturation
temperature.
Enthalpy absorbed by refrigerant

Coefficient of Enthalpy absorbed / Work input

performance (COP)

Figure 1 shows a typical refrigerant flow and pressure–enthalpy diagrams for the refrigerant R-
22.

In order to get the saturation temperatures at the operating pressures of the system,
thermodynamic tables for the particular refrigerant must be referred to.

It must be remembered that thermodynamic tables may use absolute temperatures and
pressures and the appropriate conversions must be carried out when analysing a refrigeration
system.

With reference to the system shown in figure 1 the typical pressure for the high pressure side
is 11.92 bar (1091.7 kPa absolute) and the pressure for the low pressure side is 1.32 bar (31.6
kPa absolute). 1 bar = 100 kPa

Gauge pressure = Absolute pressure + atmospheric pressure (approximately 1 bar)

2.1 Typical vapour-compression refrigeration system

From the thermodynamic tables for refrigerant 22, it can be ascertained that:

Saturation temperature @ 11.92 bar = 30C

Saturation temperature @ 1.32 bar = - 35C

The vapour compression refrigeration system can be considered as two sections.

• High pressure side

• Low pressure side

The high-pressure side of the refrigeration system consists of the section from the compressor
outlet to the inlet of the expansion valve. The compressor imparts energy to convert the low-
pressure vapour to a high-pressure superheated vapour.

Referring to our figure we can see that the temperature of the vapour is approximately 90C.
As the saturation temperature at the pressure is 30C, the amount of superheat in the vapour
leaving the compressor is 60C.
The high temperature vapour is then condensed to an under cooled liquid in the condenser.
The degree of under cooling will depend on the amount cooling water flow through the
condenser. As can be seen from the figure the temperature of the condensed liquid is 25C.
The saturation temperature at the condensing pressure (11.92 bars) is 30C. This means that
the refrigerant has been under cooled by 5C. The refrigerant then flows to the thermostatic
expansion valve.

The liquid refrigerant is then ‘throttled’ through the expansion valve. There is a pressure drop,
but no heat is transferred. However when the refrigerant flows through the expansion valve
slight evaporation of the liquid refrigerant takes place (flash off) which reduces the liquid
refrigerant temperature. The vapour immediately after the expansion valve will be a very ‘wet’
vapour (mostly liquid but with approximately 10% or so of vapour) at the saturation
temperature appropriate to the pressure. As the cold liquid flows through the evaporator it
absorbs heat and is converted into a vapour, it remains at saturation temperature until the last
section of the evaporator where it is slightly superheated to ensure that no liquid is returned to
the suction of the compressor. It is vital that the expansion valve functions such that the
temperature of the refrigerant leaving the evaporator is at a temperature of about 5°C - 10°C
above saturation temperature of the refrigerant at the evaporator pressure (1.32 bars). The
saturation temperature at 1.32 bars is -35°C. In figure 1(a) we can see that the temperature of
the refrigerant vapour is leaving the evaporator is -25°C. This means the vapour has 10°C
superheat.
Figure 1 Flow diagram & P-H diagram for a R 22 cycle
Typical shipboard domestic refrigeration system

Figure 2 Typical domestic refrigeration system

Figure 2 shows a typical shipboard domestic refrigeration system utilised for cooling three
cold rooms at three different temperatures.

Each room has a solenoid valve, which shuts off the flow of refrigerant to the room when the
set temperature on the thermostatic switch is reached. As the room temperature rises the
solenoid valve will open allowing refrigerant to flow to the expansion valve and then to the
evaporator. When all three rooms have reached the set temperatures all three solenoids will
isolate the rooms from the system and no refrigerant will return to the compressor. The Low-
pressure controller will then stop the compressor at a pre-set pressure. When the room
temperatures rise and the solenoid valves open, the pressure in the lines will increase and the
low-pressure controller will once again start the compressor. Thus depending on the room
thermostat setting the room will be maintained at a desired temperature.

Major components of a refrigeration system

Compressor plants

Typically three types of compressors are used in refrigeration plants. They are reciprocating,
centrifugal and rotary. Of these the reciprocating and rotary screw types are commonly found
in refrigeration and air conditioning plants on board ships.
Reciprocating compressors

The most common type of compressor is the reciprocating compressor. In a typical multi-
cylinder compressor the cylinders may be arranged in-line, radially or at an angle to each other
to form a “V” or “W” configuration.

Figure 3 Configurations of multiple-cylinder compressors

Figure 3 shows the piston,

cylinder and crankshaft
arrangements for 2, 4 and eight
cylinder compressors.

Figure 4 shows a direct drive V

/ W type compressor.

Figure 4 Reciprocating
compressor with V or W type
cylinder arrangement

Most compressor crankcase and

cylinder housings are cast iron.
The cylinder liners may also be
of high quality cast iron or an
aluminium alloy. The castings
are usually very dense to prevent
seepage of refrigerant. The
larger compressors have a water
jacket space surrounding the
cylinders for cooling.
Compressor pistons may also be of cast iron or of aluminium alloy. The pistons have grooves
machined in them for the piston rings. Typically a piston will have the two top grooves for
compression rings and one or two grooves for oil rings. The oil rings will be positioned above
and below the piston pin. The piston has a drilled and reamed hole to fit the piston pin for
fastening to the connecting rod. The piston pin is made of hardened high carbon steel.

The connecting rod may be cast iron, forged steel or aluminium and the crankshaft made of
steel or cast iron.

The suction and discharge valves are typically spring-loaded ring plate type or reed valves
clamped on valve plates.

Most cylinder heads have a spring-loaded safety head to prevent damage in case of
incompressible liquid slugs of refrigerant entering the cylinders.

Figure 5 Compressor cylinder head safety valve & unloading arrangement

Refrigeration compressors are generally provided with unloading mechanisms in order to

reduce the motor starting load (fig 5). Unloading is effected by holding the suction valve open
during starting or by opening a by-pass valve between the suction and discharge sides. The
unloading mechanism is actuated hydraulically or electrically by the use of a solenoid valve.
Cutting in or cutting out cylinder by means of the unloading mechanism controls the
compressor capacity.

Open type compressors are fitted with a shaft seal, which consists of a carbon rubbing ring,
bearing onto a seal. The seal is pressed onto the face of the rubbing ring by a spring, which is
attached to the bellows. The rubbing ring is sealed against the shaft by a neoprene ring. (fig 6).
The compressor crankcase is fitted with a heater to prevent the refrigerant from condensing in
the crankcase when the compressor is stopped. If refrigerant is allowed to condense in the
crankcase the oil will foam and carry over with the refrigerant on starting up of the
compressor. This can also cause liquid slugs of refrigerant and oil to enter the compressor
cylinders damaging the cylinder components.

Shaft seal

Figure 6 Compressor shaft seal

Screw compressors

Double screw compressors are commonly used in marine refrigeration plants. This type of
screw compressor consists of a male rotor and a female rotor with matched helical grooves.
The male rotor has four lobes that mesh with the six flutes on the female rotor. The gas is
sucked in from the inlet port as the rotors mesh and turn together. The gas is then
compressed and forced out axially through the outlet port.

Oil is constantly injected into the compressor in order to seal and lubricate the rotors. The oil
also cools the rotors and reduces the gas discharge temperature. Noise levels are also reduced
due to oil injection.

Capacity control in screw compressors is achieved by means of a regulating slide valve. When
the valve is open some of the gas from the inter-lobe spaces of the rotors return to the suction
inlet. The slide is actuated hydraulically and infinitely variable capacity control is possible.
Oil separators

Some oil is always carried over with the compressed gas and must be removed before the gas
enters the condenser and evaporator. Fouling of the internal surfaces of these heat exchangers
will impair heat transfer and reduce the efficiency of the system. A typical oil separator is
shown in figure.

Figure 7 Oil separator

With reference to figure 7, the oil separates out and collects at the bottom of the drain. At a
certain oil level the float opens the valve from the oil trap and the oil is returned to the
compressor crankcase due to the higher pressure in the oil trap (oil separator pressure is the
same as the compressor discharge pressure).

Condensers

The condenser extracts the heat from the installation and this includes the heat extracted from
the produce being refrigerated, heat flow through insulated surfaces, and heat introduced
through motors, fans and pumps.

The compressed vapour is condensed to a liquid in the condenser. The cooling medium
used in the condenser may be air or more commonly seawater. The change of state from
vapour to liquid takes place, as the cooling medium temperature is lower than the
saturation temperature of the refrigerant at the pressure.

The standard type of condenser used in marine refrigeration plants is the shell and tube
heat exchanger. A typical heat exchanger has a cylindrical steel shell. The tubes are
usually aluminium brass and are expanded into copper alloy clad mild steel tube plates.
Corrosion plugs are fitted to the end covers and the heat exchanger is designed to limit the
water velocity in order to reduce erosion.
An air purge connection is fitted at the top of the condenser to facilitate the purging of air.

Evaporators

In the evaporator the liquid refrigerant evaporates and provides the cooling effect. It is usually
located in the space to be cooled. A fan forces air over the evaporator tubes and the cooled air
is circulated around the space. The liquid refrigerant is completely turned into a gas and leaves
the evaporator with a degree of superheat.

Control and safety devices in refrigeration systems

Expansion valve

The main function of the expansion valve is to regulate the amount of refrigerant flow
through the evaporator. A correctly adjusted expansion valve would ensure an optimum
refrigerant flow through the evaporator at varying refrigerating loads and ensure a satisfactory
degree of superheat in the refrigerant vapour at the evaporator outlet.

The liquid refrigerant is throttled through the expansion valve. There is a pressure drop, but
no heat is transferred. A slight amount of liquid evaporates when flowing through the
expansion valve (approximately 10% flash off), which reduces the liquid refrigerant
temperature.

The pressure in the sensing bulb is always the saturation pressure corresponding to the
temperature of the liquid/vapour
contained in the bulb. [Consult the
Tables or Charts shown earlier for the
relationship between Temperature and
Pressure for liquid or vapour under
saturation conditions].

The degree of superheat is determined by

the spring compression. The degree of
superheat in the refrigerant vapour
leaving the evaporator can be adjusted by
altering the spring compression.
However, care should be taken to ensure
that the adjustments made suit all
operating conditions to ensure that an
adequate degree of superheat is obtained.

Figure 8 Automatic thermostatic expansion valve

Solenoid stop valve

A thermostatically operated solenoid valve is used where control of cut in and cut out
temperature is required in a refrigerated room or cabinet. The solenoid stop valve is generally
located in the liquid line and as close as possible to the evaporator.
Each room has a solenoid valve, which shuts off the flow of refrigerant to the room when the
set temperature on the thermostatic switch is reached. As the room temperature rises the
solenoid valve will open allowing refrigerant to flow to the expansion valve and then to the
evaporator.

The refrigerant solenoid valve is a simple stop valve which is closed by the action of a spring,
it will move to its fully open position when the activating coil is energised and remain open
until the coil is de-energised. This ensures that the valve is “fail safe” (it will move to a safe
position if there is an electrical fault or power failure).

Figure 9 Room solenoid valve

The solenoid valve will be activated by a thermostat having its temperature sensing element
located in the particular cold room controlled by that solenoid valve. It is usual to have two
adjustments available on the thermostat. These two adjustments will determine the cut in and
cut out temperatures for the refrigerated room.

Low pressure controller

The low-pressure controller stops the compressor when all the room solenoid valves have
shut. When the room temperatures rise and the solenoid valves open the pressure in the lines
will increase and the low-pressure controller will once again start the compressor. Thus
depending on the room thermostat setting the room will be maintained at a desired
temperature.

High-pressure cut-out

The high pressure cut out will stop the compressor in the event of an excessive pressure rise
in the condenser side of the compressor. Normally the high-pressure cut out has to be reset
manually. Excessive discharge pressure will expand the bellows and the lever that the switch
arm catch is attached to will swivel around its pivot point. The switch arm catch will slip off
the step and the switch arm will move down. The electrical contact will be broken and the
compressor will stop.
 Figure 10 High pressure cut out (Courtesy of Marine Auxiliary Machinery – HD
McGeorge)
Typical faults that would lead to a high discharge pressure include high cooling water
temperature or loss of cooling water to the condenser, air in the system or an excessive charge
of refrigerant in the system (overcharge).

Oil low-pressure cut out

All compressors in refrigeration systems will be fitted with a low oil pressure cut out device
which will stop the compressor in the event of loss of lubricating oil pressure. Low oil levels
in the compressor due to oil carry over with the refrigerant or failure of the lubricating oil
pump could be the cause of low oil pressure. The low oil pressure cut-out would be very
similar in design to the high pressure cut-out, but the pressure settings would obviously be
different.

Air conditioning systems

Air Conditioning

In different environments a human being will lose a certain amount of energy due to the
emission of specific heat by convection and radiation and by the emission of latent heat by
respiration. The quantity of heat emitted will depend on environmental conditions such as
temperature and humidity and the physical condition of the individual.

The human body temperature is naturally controlled within certain temperature limits.
However when the body is exposed to extreme environmental conditions discomfort and in
extreme cases thermal shock can result.
A typical air conditioning system of a vessel will be capable of heating, cooling and adjusting
the humidity of the atmosphere of the temperature controlled space.

Further an air conditioning system must ensure good ventilation, as this is vital for the health
and well being of the crew.
Humidity

Humidity is a measure of the amount of water vapour in the local atmosphere. It is usually
expressed in terms of “Relative Humidity” (R.H.), which is defined as:

Mass of water vapour in air

R.H. =  100
Mass of water vapour needed to saturate the air

The instrument used for measuring humidity is called a Hygrometer. Although there are
various types, the traditional method of measuring Relative Humidity is by means of a Wet
and Dry Bulb Thermometer. It consist of two thermometers, one totally exposed, while the
other has its bulb encased in moist wick.

In completely saturated air (ie. 100% R.H.), the two thermometer bulbs will register the same
temperature. However, in perfectly dry air, the evaporation of the water from the wet bulb
moist wick will further cool that thermometer, (ie. the wick absorbs heat from the
thermometer, due the latent heat of vaporisation). Thus, the Dry Bulb Thermometer will
register some 10 - 20 0C higher. In the ‘Comfort Zone’ the difference will be around 5 - 7 0C.

The psychometric
chart
Figure11
Psychometric chart

Consider the chart

shown in Figure 11,
called a “Psychometric
Chart”. It consists of
Humidity plotted
against Temperature.
Note the area described
as the Comfort Zone.
If the environment can
be maintained within
this comfort zone then
most people will feel
comfortable. Thus, this
range of temperatures
and humidity which forms the comfort zone is widely used by air conditioning engineers when
adjusting the controls of air conditioning systems.

Air Conditioning Systems

The basic cycle in an air conditioning unit is the same as that in a refrigerating system.
However, since very low temperatures are undesirable in the evaporator, the pressure ratio
between the high pressure and low pressure side is usually smaller. Air is blown (and
recirculated) past the evaporator and then into the space to be cooled.
 Single Air Duct System with reheating and humidity control

Figure 12 Typical air conditioning system with reheat and humidity control

Figure 12 shows a system where a typical refrigeration plant circulates refrigerant through an
evaporator situated before a large blower unit (fan). The evaporator temperature is controlled
by the thermostatic expansion valve setting which regulates the amount of refrigerant flow
through the evaporator. The blower circulates the air through a ducting network to individual
cabins. The system incorporates individually controlled hot water heaters, which can be used
to adjust the temperature of the air entering the cabin. With this system, the air leaving the
main unit will be set at a low enough temperature to satisfy those who prefer a cooler
environment. The ‘reheater’ can be used to raise the temperature by a few degrees by those
who prefer the environment to be a little warmer.

The humidity in the circulated air is controlled by the injection of a small quantity of steam. A
sensing element senses the humidity in the air and through a transmitter adjust the control
valve to increase or decrease the quantity of steam being injected.

In cold weather steam is circulated through the heating element before the blower, which
warms the circulating air. A temperature sensor, through a temperature transmitter adjusts the
control valve to regulate the amount of steam flowing through the heating coil.

By adjusting the position of the recirculating duct flap valve and the fresh air duct flap valve
the ratio of fresh air and recirculated air mixture can be varied. The amount of fresh air that
should be supplied varies according to the space conditions and is governed by factors such as
smoking, body odour and the capacity of the exhaust fans. Typically the regulatory bodies
recommend a minimum requirement of 7 litres/second of fresh air supply per person.
Maintenance requirements for air conditioning systems

Due to the presence of the Legionella bacteria associated with air conditioning systems of
large buildings it is assumed that this bacteria could also breed in air conditioning systems of
ships.

Regular inspections should be carried out with filters being cleaned and all drain lines cleared
to prevent stagnation of water. It is recommended that a 50ppm super-chlorinated solution be
used to sterilise filters and also to wash out cooler drain areas and lines.

Faults in refrigeration and air conditioning systems

1. Under-Charged

Should not occur in systems that employ a liquid receiver, since the level in the receiver can be
monitored. Some smaller systems use the capacity of the bottom of the condenser instead of
a liquid receiver and this is rarely fitted with a sight glass. Under charging is usually the result
of loss of refrigerant through leakage, but may result from incorrect charging after installation
or repair.

Symptoms

• Low compressor suction and discharge pressures.

• High degree of superheat at compressor suction (evaporator outlet).
• Large amount of bubbles in the liquid line sight glass, (this is usually the earliest
and most easily recognised symptom of undercharging).
• Compressor running for unusually extended periods.
• Reduced compressor load as indicated by ammeter, (if fitted).
• Cold room temperatures rising, (it may not be possible to maintain the cold
rooms at their required temperatures).

Remedies

• Make sure the cause of the symptoms is really a shortage of refrigerant.

• Carry out a leak test and seal any leaks.
• The system is then re-charged, by adding refrigerant slowly while the plant is
running. Usually liquid refrigerant is added to the high pressure side.
• Take care not to over charge the system.

2. Over-Charged

Usually the result of carelessness, particularly when adding liquid refrigerant into the high
pressure side. Most likely to occur in systems that do not have a liquid receiver and thus the
amount of refrigerant can not easily be monitored.
In systems having several cold rooms, the level of refrigerant in the liquid receiver can vary
considerably depending on how many evaporator coils are currently in use. This is due to the
amount of liquid contained in the various evaporator coils.

Symptoms

There will be no symptoms unless the system is so grossly overcharged that the condenser
becomes flooded with liquid refrigerant. Under these conditions the condenser effectively
loses some of its ability to condense the vapour entering from the compressor and the
condenser pressure (high side pressure) will rise. There will be a corresponding rise in the
temperature of the refrigerant leaving the condenser.

Remedies

The refrigerant is pumped to the condenser and the excess released into an empty refrigerant
cylinder. Note: the refrigerant should not be released to the atmosphere.

3. Air in System

This may occur due to faulty initial charging of the system. However, in most cases it is the
result of incorrect adjustment (or faulty operation) of the compressor suction pressure (LP)
switch, which allows a vacuum to be created in the low pressure side of the system.

Symptoms

• Since the air tends to collect in the condenser, the condenser pressure will be
abnormally high. However, the temperature of the liquid refrigerant leaving the
condenser will be normal. If the actual temperature of the liquid refrigerant
leaving the condenser is compared with the saturation temperature of the
refrigerant at the pressure occurring in the condenser, it will be found the actual
temperature is much lower than the saturation temperature.

• Small bubbles may be evident in the liquid line sight glass if some of the air is
getting carried along with the refrigerant. This is less likely to occur when a
liquid receiver is fitted.

Remedies

If the system has a significant amount air, it is usually purged using a special refrigerant and an
extractor pump to evacuate the system, thus preventing the refrigerant entering the
atmosphere. It is then tested for leaks and refilled. However, in an emergency and for small
quantities of air, the following can be carried out:

• With the cooling water on, pump all of the refrigerant to the condenser by
running the compressor.

• Isolate the compressor so that it cannot start.

• Wait 10-15 minutes for the refrigerant in the condenser to condense into liquid,
thus separating from the air.
 • The air can then be purged through the purge valve on top of the
condenser/receiver. Note: minimise the loss of refrigerant during purging.

• The system may have to be re-charged with refrigerant.

4. Moisture in System

Moisture may occur due to faulty initial charging or be drawn into the system with
air, if the suction line pressure is allowed to fall below atmospheric. Under normal
conditions very little moisture should be in the system.

Symptoms

• Any moisture in the system tends to freeze as the refrigerant temperature drops
rapidly through the expansion valve. This may cause the expansion valve to
become blocked, leading to loss of cooling effect in the evaporator and a low
suction line pressure. It will also cause high pressure on the condenser side and
the plant may shut down due to the activation of the high pressure cut out.

• Alternatively, the freezing of the moisture in the expansion valve may cause the
it to become jammed open, leading to excessive refrigerant flow, low
temperatures in the suction line (ice forming on outside of pipe), and possible
damage to the compressor due to liquid refrigerant being drawn into the
compressor.

• May cause corrosion in the system.

• Will accelerate the deterioration of the lubricant in the compressor and thus
cause excessive wear.

Remedies
Moisture is removed by the use of driers. These may be either a throw away unit or
recharged/reactivated with either silica gel or activated ammonia. Replace or reactivate the
drier as often as required until all of the moisture is removed.

5. Oil in System

• Even though the oil separator removes most of the oil from the refrigerant after
it leaves the compressor, there is always some oil carried over and mixed with
the refrigerant. Provided that the correct oil is being used, the oil will be
‘miscible’ (mixes readily) in the liquid refrigerant. Thus, it is carried round the
system and returned to the compressor suction without being deposited on the
inner surface of the evaporator coils. The miscibility of the oil in the liquid
refrigerant is the determining factor in the choice of an appropriate lubricating
oil for any particular refrigerant.

• The oil will deposit on the surfaces in the system, if an unsuitable oil has been
used, the oil has significantly deteriorated, the crankcase is overfilled, or the oil
separator is faulty.
Symptoms

• Loss of heat transfer in the condenser and evaporator.

• Abnormally high condenser pressures, (but the temperature of the liquid

refrigerant will be more or less at the corresponding saturation temperature).

• Loss of effectiveness of the evaporator, (it may be impossible to maintain the

cold room temperatures).
Remedies

• Check that the correct type of oil is being used.

• Check the oil level in the compressor crankcase, and reduce if needed.

• Check the operation of the oil separator, (this may require the plant to be
shutdown).

6. Choked Suction Strainer

Should only occur after major overhaul of the plant or if corrosion is occurring.
However, it can become blocked by ice, if moisture is present in the system.

Symptoms

• Low suction pressure.

• Reduced difference between condenser and evaporator pressures.

Remedies

• Clean or replace suction strainer.

• If occurring frequently, investigate and rectify cause.

7. Choked Liquid Line Strainer

Should only occur after major overhaul of the plant or if corrosion is occurring.

Symptoms

Low evaporator and suction pressures.

Choked strainers can give rise to symptoms indicating numerous other faults. Thus, strainers
should be kept clean at all times and should be checked first whenever operating problems are
encountered.
Remedies

• Clean or replace strainer.

• If occurring frequently, investigate and rectify cause.

8. Compressor “Short Cycles”

This simply means that the compressor starts runs for a short time then stops. It remains
stopped for a short time then starts again, repeatedly.

Causes
• Choked suction strainer.

• Faulty or badly adjusted Low Suction Pressure Cut-out Switch.

• Leaking Solenoid Operated Stop Valve(s).

9. Condenser Not Operating

This is usually due to a lack of cooling water to the condenser.

Symptoms

High refrigerant pressures and low temperature difference in cooling water to the condenser.

Remedies

Check for choked sea water passages in the condenser and clean. Check for pump failure and
rectify. For air-cooled condenser, clean condenser cooling fins, and cowlings.