FM Global

Property Loss Prevention Data Sheets 12-53

November 1991
Revised January 2000
Page 1 of 5

ABSORPTION REFRIGERATION SYSTEMS

Table of Contents
Page

1.0 SCOPE ................................................................................................................................................... 2

1.1 Changes ........................................................................................................................................... 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Equipment and Processes ............................................................................................................... 2
2.2 Operation and Maintenance ............................................................................................................. 2
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 3
3.1 Loss History ...................................................................................................................................... 3
3.2 Illustrative Losses ............................................................................................................................. 3
3.2.1 Absorption Refrigeration Systems, Case Study 1 ................................................................. 3
3.2.2 Absorption Refrigeration Systems, Case Study 2 ................................................................. 4
4.0 REFERENCES ........................................................................................................................................ 4
4.1 FM Global ........................................................................................................................................ 4
4.2 Others .............................................................................................................................................. 4
APPENDIX A GLOSSARY OF TERMS ........................................................................................................ 4
APPENDIX B DOCUMENT REVISION HISTORY ........................................................................................ 4
APPENDIX C PROTECTIVE DEVICES AND CONTROLS ......................................................................... 5

©1999 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
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photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
12-53 Absorption Refrigeration Systems
Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
The purpose of this data sheet is to provide loss prevention recommendations, support for those recommen-
dations and inspection guidelines, where applicable, to absorption type Water-Lithium Bromide (H2O-LiBr)
and Water-Ammonia (H2O-NH3) absorption systems. Such equipment is found in diverse occupancies, such
as office buildings, hospitals, laboratories, and chemical and food processing facilities.
The recommendations are applicable when the Loss Expectancy (LE) is such that they are economically
justified. Generally, this results in application of recommendations to units of 1500 tons (5280 kW) or larger.
While the focus of the data sheet is on the refrigeration aspects, the recommendations are applicable to
heating and cooling aspects as well.

1.1 Changes
January 2000. This revision of the document has been reorganized to provide a consistent format.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Equipment and Processes

2.1.1 For control and/or protection, absorption systems should be equipped with the following devices:

Device H2O-LiBr H2O-NH3

Chilled-Water Switch x x
Concentration Limiters x –
Cooling-Water Switch x –
Generator High-Temperature Limit Switch – x
Generator Shell Overpressure Protection x x
High Pressure Cut-out Switch x –
Liquid-Level Switches x x
Low Temperature Cut-out x x
Overflow Piping (‘‘J’’ Loop) x –
Sail Switch – x

2.1.2 Water-Lithium Bromide units should be provided with pressure relieving devices when leakage of inter-
nal chilled water piping could subject the shells, heat exchangers, and flat surfaces to pressures in excess
of that for which they were designed. Also, provide pressure relief for units using high pressure hot water for
the generator heat source. All appurtenances should have a design pressure rating at least equal to that
of the vessel to which they are attached.
Due to its high conductivity, lithium-salt solution should never come in contact with electrical equipment. There-
fore, any system safety/relief valves should be arranged to discharge to a safe location.

2.2 Operation and Maintenance

2.2.1 During idle periods, equipment should be properly prepared for lay-up in accordance with the manu-
facturer’s instructions. When freezing is possible, freeze protection should be provided in accordance with
Data Sheet 9-18/17-18, Prevention of Freeze-ups.
2.2.2 An absorption refrigeration system has no major moving parts, is relatively vibration-free and, in gen-
eral, requires less maintenance than other types of refrigerating systems. However, periodic maintenance
should be performed at least annually, by qualified service personnel. Maintenance should include visual
inspection, cleaning, testing of controls, testing of corrosion inhibitor limits, leak testing, and purging, in accor-
dance with established procedures and schedules, and manufacturer’s instructions.
All maintenance activity should be duly recorded and records should be reviewed to confirm that mainte-
nance activities are being executed as written in the program.

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Absorption Refrigeration Systems 12-53
FM Global Property Loss Prevention Data Sheets Page 3

2.2.3 Metallurgical analysis results reported by the American Society of Heating, Refrigerating and Air-
Conditioning Engineers, Inc. (ASHRAE) have shown that condenser and chiller tubes are subject to stress-
corrosion cracking, pitting and wall thinning because of their exposure to operating stresses and chemical
environments. To find these defects before tube leakage occurs, eddy current nondestructive testing (ET)
should be performed on the tubes on a three- to five-year frequency in accordance with the ASME Boiler and
Pressure Vessel Code, Section V, Articles 8 (Eddy Current Examination of Tubular Products) and 26 (Eddy
Current Standards). For further explanation of eddy current testing, refer to Data Sheet 17-1, Nondestruc-
tive Examination.
An acceptable alternative to ET examination would be to hydrostatically test individual tubes to determine
which tubes are on the verge of failure.
The three- to five-year frequency range is based on the degree of water treatment and analysis. Solict the
chiller and condenser manufacturer’s recommendations for specifications of pH levels and inhibitor concen-
trations. If the system cannot be operated consistently at these levels, more frequent ET may be required.
2.2.4 Analyze the system water annually to verify that it meets the manufacturer’s specifications. If annual
water analysis is not done, ET of the tubes should be performed on a three-year frequency. If annual water
analysis is done, and analysis is within the manufacturer’s limits, ET can be extended up to five years.
2.2.5 Maintain limit controls (temperature, flow and level) and protective devices (overpressure) in proper
working order. Check their ability to function under operating conditions, at least annually, in accordance with
manufacturer’s procedures.
To simplify maintenance activity, test these devices at the same time that the water is analyzed. All test data
should be logged and reviewed by personnel responsible for the safe operation of the system(s).

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 Loss History

Review of loss analysis data pertinent to absorption system losses over the period from 1985 to the present
indicates that roughly half of the incidents involved chiller freeze-ups that resulted in cracked or ruptured
tubes. The reasons noted were inadequate maintenance, failure to drain unit in preparation for winter lay-
up, lack of protective controls (low temperature cut-out and flow switches), controls improperly adjusted and
controls inoperative.
The second most frequently cited incident was tube cracking due to stress corrosion. Tubing in this type of ser-
vice is subject to flow induced vibration, mechanical and thermal stress, and corrosive pitting and thinning
due to normal operation in a chemical environment.
Loss history with larger absorption units has been favorable. Experience from smaller units is indicative of
the types of losses that can be incurred, regardless of size.
Loss history for absorption refrigeration, cooling and heating systems has not been significant over the past
10 years. However, with the recent changes in Environmental Protection Agency regulations to protect strato-
spheric ozone from chlorofluorocarbons (CFC’s), many air conditioning and refrigeration systems may con-
vert from CFC’s and new installations may select absorption systems as an alternative means for cooling. The
recommendations are provided for guidance in system maintenance.
Absorption cooling systems are a viable alternative for many air conditioning and some refrigeration sys-
tems and, as such, are likely to become an increasing exposure. At present, these systems are being built
predominantly in Japan. This may affect availability of parts Time Element [TE] exposure.

3.2 Illustrative Losses

3.2.1 Absorption Refrigeration Systems, Case Study 1

The outer shell of a 750 ton (2640 kW) absorption refrigeration unit used for air conditioning was overpres-
surized when five tubes in the absorber section of the system ruptured. The overpressurization distorted
the shell and broke a plastic sight glass on the purge system. Water-LiBr solution sprayed from the sight glass,

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12-53 Absorption Refrigeration Systems
Page 4 FM Global Property Loss Prevention Data Sheets

impinging on the main electrical switchgear causing severe arcing and subsequent damage to the switch-
gear and other associated electrical equipment. The unit was equipped with overpressure protection; how-
ever, the sight glass rating was less than 15 psig (100 kPa) (1 bar).
The incident occurred while plant personnel were filling the air conditioning system’s cooling water loop in
preparation for cooling season start-up. Following the incident, visual inspection revealed longitudinal crack-
ing in five absorber tubes. Cracking was further confirmed by eddy current testing.
Of importance was the fact that the tube walls showed no thinning in the vicinity of the cracks, indicating
that the cracking was not caused by ductile fracture due to overpressurization. Further investigation indi-
cated that the cracking was caused by stress corrosion.
Normal routine was to annually eddy current test the chiller tubing and to analyze the refrigerant solution,
prior to start-up. Tests had been performed in 1985, 1986 and 1987 with no reportable indications noted. No
explanation was given for the lack of testing in 1988 and 1989. Results of the earlier tests showed no signs
of tube wall thinning. Had eddy current testing and chemical analysis been done consistently, chemical
imbalance and/or the cracking would have been discovered and this incident would not have occurred.
In addition to the cracked tubes, distorted shell, and electrical equipment damage, the entire LiBr charge
was lost.

3.2.2 Absorption Refrigeration Systems, Case Study 2

Air conditioning for a 16-story office complex is provided by two Water-LiBr absorption units through a common
system.
Unit no. 1, rated at 270 tons (950 kW), is made up of two shell and tube assemblies; the absorber/
evaporator and the condenser/generator. Service for the units is provided by the manufacturer’s authorized
representative.
Just prior to unit start-up for the cooling season, the plant engineer observed water leaking from the solu-
tion pump. The service company was contacted to investigate. Investigation revealed that 42 out of 204 tubes
in the absorber/condenser were cracked. Several tubes were removed for analysis and it was determined
that the cracking was caused by stress corrosion. A consistently applied program of eddy current testing and
chemical analysis would have pointed out the existence of chemical imbalance and/or incipient crack
development.

4.0 REFERENCES

4.1 FM Global
Data Sheet 9-18/17-18, Prevention of Freeze-ups.
Data Sheet 17-1, Nondestructive Examination.

4.2 Others
ASME Boiler and Pressure Vessel Code, Section V, Article 8, Eddy Current Examination of Tubular Products.
ASME Boiler and Pressure Vessel Code, Section V, Article 26, Eddy Current Standards.

APPENDIX A GLOSSARY OF TERMS

Absorption refrigeration: [Mech Eng] refrigeration in which cooling is affected use of two or more sub-
stances in physical contact instead of one as in the compression system. Where two substances are used,
one is the absorbent and the other the refrigerant (i.e., water and ammonia or lithium bromide and water).

APPENDIX B DOCUMENT REVISION HISTORY

November, 1968
November, 1991
November, 1998

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Absorption Refrigeration Systems 12-53
FM Global Property Loss Prevention Data Sheets Page 5

APPENDIX C PROTECTIVE DEVICES AND CONTROLS

Some controls/devices keep the units operating within safe limits, while others stop the units before dam-
age occurs from a malfunction that would cause the safe limits to be exceeded. The following are typical
protective devices:
Chilled-Water Switch—This is a pressure- or flow-sensitive switch that will stop the unit if chilled water flow
is reduced below design limits. The switch resets itself when the proper chilled water flow is re-established.
Concentration Limiters—These are controls to limit the capacity of either or both the generator or absorber.
They respond to sensors that indicate limiting conditions of absorbent concentrations and reset when limit-
ing conditions no longer exist. Crystallization that is caused by high solution concentration and low cooling
water temperatures can be prevented by these devices.
Cooling-Water Switch—This is a pressure- or flow-sensitive switch that will stop the unit if the cooling water
supply fails. The switch resets itself when the cooling water supply is restored.
Generator High-Temperature Limit Switch—This is a temperature-sensitive switch that will stop the unit if
the generator (concentrator) operating temperature exceeds a safe limit. This is generally used only with
direct-fired LiBr units and all ammonia-water units.
High Pressure Cut-out Switch—This is a pressure-sensitive switch that will stop the unit if the high-side pres-
sure exceeds a safe limit. It is only required on ammonia-water units.
Liquid-Level Switches—These are float-type switches that will stop the unit if the refrigerant level in the evapo-
rator varies beyond preset limits. They are self-resetting.
Low Temperature Cut-out—This is a low-limit thermostat that will stop the unit when the evaporator tempera-
ture reaches the minimum safe value. When the refrigerant temperature warms to the cut-in point, the switch
resets itself to restart the machine.
Overflow Piping (‘‘J’’ Loop)—This device allows hot solution from the generator to overflow to the absorber
in the event another control fails. For Water-LiBr systems, it also prevents crystallization of the LiBr in the
economizer.
Pressure-Relief Devices—These devices, which may be either spring-loaded relief valves or rupture disks
or a combination of both, protect the refrigerant and absorbent-containing chambers against overpressure
conditions. They are mandatory only on ammonia-water units and must be sized, set and installed in accor-
dance with the ANSI safety code for mechanical refrigeration and local codes where applicable. On hot water,
high pressure steam, direct-fired and heat recovery units, a rupture disk may be placed in the generator
shell.
Sail Switch—These devices are frequently utilized in water-ammonia absorption systems to verify airflow
before allowing gas burner operation.
Other Controls—In addition to those described above, other controls are available to meet special
requirements.

FM Engr. Comm. Oct. 1991

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