YOUR BASIC REFRIGERAION SYSTEM SVASD MAY 26, PDF Free Download

YOUR BASIC REFRIGERAION SYSTEM SVASD MAY 26, 2011

Today s Goal Is to Understand the basic function of a refrigeration system

Refrigeration The concept of refrigeration went unchanged for 2000+ years until mechanical refrigeration was invented 150+ years ago 3

Mechanical Refrigeration Since its invention, the process of mechanical refrigeration has remained relatively unchanged 4

Principles of Refrigeration and Refrigeration Systems Refrigeration systems do not add cold they remove and relocate heat Think of a train on a circular track with two stations. Little heat passengers are loaded at one station and unloaded at the other 5

Refrigeration Is the process of cooling or maintaining the temperature of a space or object, below that of the surrounding area.

Mechanical Refrigeration Is a series of steps that removes heat from a space or object, where it s not wanted, and transfers that heat to an area where we don t care or it causes no harm.

Principles of Refrigeration and Refrigeration Systems 10

Basic Theories Pressure / Temperature Relationship Types of Heat How Heat Movements Some Things We Should Know About Operating An Engine Room

Heat Heat is a form of energy and it s measured in BTU s or calories. BTU s - unit of measurement in the Fahrenheit scale Calories - unit of measurement in the Celsius scale Caspers unit of measurement in the Sonny Training scale

Heat Movement Heat will NOT move from one object to another if the temperature of the objects are the same. Heat will ALWAYS move from Hot atmosphere to a Cold atmosphere.

Types of Heat Sensible Heat - heat that causes a change in temperature is called sensible heat. This heat can be measured using a thermometer Latent Heat - heat that causes a change in state is called latent heat. This heat can not be measured with a thermometer, because a fluid or solid that is changing state does not change temperature. Latent heat is referred to as hidden heat.

Types of Heat cont. Latent heat of Vaporization -heat moving out of a liquid while a change of state is occurring. (steam) Latent heat of Fusion - heat moving out of a liquid while a change of state is occurring. (ice) Latent heat of Condensation -heat moving out of a vapor while a change of state is occurring. (discharge gas)

Heat is Heat is Heat BTU s Calories CASPERS

Heat Load - Out B.T.U's OUT SIDE SPACE (Ambient) (High Side) HP LIQ CONDENSER 2 HP VAP MAIN COMPRESSOR SUCTION 6 KING VALVE Head Pressure HP LIQ LP VAP HP VAP 1 SIDE PORT SUCTION RECEIVER 5 MECHANICAL ROOM (ENGINE-ROOM) FLASH COOLER LOW PRESSURE RECEIVER 8 COMPRESSOR LP VAP 7 INTERMEDIATE PRESSURE 9 AMMONIA PUMP EXPANSION VALVE Heat Load - In B.T.U's (Low Side) LP LIQ soleniod valve LP LIQ /VAP 3 EVAPORATOR 4 LP VAP /LIQ CONDITIONED SPACE (WAREHOUSE FREEZER OR COOLER) S-6 COMPONENTS HIGH SIDE / LOW SIDE SEPARATION AMMONIA STATE SUB-SPLITS INTERCOOLER VESSEL AMMONIA PUMP FLOW KING VALVE HEAT GAINS STATE CHANGES LOW PRESSURE VESSEL SHUT-OFF VALVES HIGH PRESSURE RECEIVER HEAT REMOVAL SOLENIOD VALVES PRESSURES / TEMPERATURES

Five Key Refrigeration System Components 1. Receiver 2. Expansion Valve 3. Evaporator 4. Compressor 5. Condenser 19

Components of a refrigeration system. Expansion Valve (metering device) Evaporator Compressor Condenser High Pressure Receiver

Your Basic Refrigeration Components 1. Expansion Valve (metering device) A place that provides a restriction. This is the point of Expansion. (A place where liquid ammonia changes its state from a liquid to a vapor with some liquid droplets.)

Five Key Refrigeration System Components 2. Expansion Valve A device used to reduce refrigerant pressure and the control flow rate 22

Refrigeration Components 2. Evaporator A place to absorb Heat / BTU s from the surroundings. Which sets up the rapid boiling of the liquid ammonia. This absorbed heat units are best known as BTU s (British Thermal Units).

Expansion Valve

Expansion Valve + 5ºF air 12# -5ºF Evaporator Coil

Evaporator Expansion Valve Liquid Evaporator Low Pressure Vapor

-5ºF Air

Refrigeration Components 3. Compressor A place to accept these evaporated vapors and to raise the pressure and temperature of those vapors. Heat of Compression (Sensible Heat)

Compressor Package

Five Key Refrigeration System Components 4. Compressor - Increases system pressure and pushes refrigerant through the circuit 30

Five Key Refrigeration System Components Screw Compressor 31

Five Key Refrigeration System Components 32

Five Key Refrigeration System Components Reciprocating (piston) Compressor 33

12# -5 Screw Compressor 42# 28 ºF 150# 164 ºF

Compressor Diagrams Vapor from Evaporator High Pressure gas to Condenser Comp.

Refrigeration Components 4. Condenser A place to reject the B.T.U. s from the vapor, and to allow the condensation of the refrigerant back into liquid State Conde Latent Heat of Condensation

Five Key Refrigeration System Components 5. Condenser - allows refrigerant to lose heat 37

High Pressure Vapors High Pressure Liquid

Evaporative Condenser

Condensers High Pressure Liquid Liquid Condenser Vapor High Pressure Vapor

Refrigeration Components 5. High Pressure Receiver A place to receive or store high pressure liquid ammonia Kind of like a gas tank.

Five Key Refrigeration System Components 1. Receiver - A reservoir for high-pressure liquid refrigerant 42

High Pressure Receiver

High and Low Side Receivers High Pressure Liquid High Pressure Receiver King Valve

Component Summary Expansion Valve Evaporator Compressor Condenser High Pressure Receiver King Valve

Manual King Valve Electrically controlled from remote location

Lets put a Refrigeration System together.

Low Side High Side Low Pressure Gas High Pressure Gas Compressor Condenser Evaporator Low Pressure Liquid Expansion Valve Receiver The Refrigeration Process High Pressure Liquid 49

Roof Top High Pressure Liquid Liquid Condenser Vapor High Pressure Vapor High Pressure Receiver Compressor Room Comp. King Valve Heat moves to cool Expansion Valve Cold Room Freezer Liquid Evaporator Vapor Low Pressure Vapor

Condenser High Pressure Receiver Comp. Expansion Valve Evaporator

On top of Building Condenser High Pressure Receiver Engine Room Comp. Expansion Valve Cooler / Freezer Evaporator

Roof High Pressure Liquid Liquid Condenser Vapor High Pressure Vapor High Pressure Receiver Engine Room Comp. King Valve CASPERS Expansion Valve Liquid Evaporator Vapor Freezer Low Pressure Vapor

1 PG&E Service Pole Across the street 2 Power Reduction Transformer Owned by PG&E 3 Engine Room Electrical Room 4 Comp.# 3 Comp.# 2 Comp.# 1 Main Plant Shut down on Electrical Room has 24/7 exhaust ventilation off

Low side receiver

Flash Cooler

Access Way to Evaporators

Access to the Evaporators

Refrigeration System Components

Evaporator Control

To Isolate Close AU3 1.3 liquid supply AU3 2.1 suction AU3 2 suction AU3 3 AU3 3.1 AU3 3.2 FAN FAN West Side AU 3W Evaporator (TY. Of Four) West Side Evaporator FAN AU3 2 NO SUCTION SHUT OFF VAVE Suction Return Line To Suction L.P.R. Return (V 2) in Line To engine L.P.R. room Returning from other evaporators evaporators 4 Liquid Supply Line From L.P.R. ammonia pump (PP 1) at L.P.R. in engine room AU3 1 NO ST STRAINER XV AU3 1.1 AUTO AU3 1.3 NO AU3 3.3 AU3 3.4 AU3 3.5 FAN East Side AU 3E Evaportors East (TY. Side Of Evaportors four) FAN (Continues to other evaporators evaporators) 4) FAN AU3 2.1 NO SUCTION SHUT OFF VALVE LIQUID FEED SHUT OFF FOR BOTH COILS This drawing typical of all four Evaporator platforms, Only the valve tagging numbers change

OUT SIDE SPACE Ambient Air CONDENSER 4 MAIN COMPRESSOR SUCTION MECHANICAL ROOM (ENGINE-ROOM) COMPRESSOR 3 EXPANSION VALVE EVAPORATOR 1 2 CONDITIONED SPACE (WAREHOUSE FREEZER OR COOLER) Refrigeration / Beer Box S-1 COMPONENTS FLOW

OUT SIDE SPACE Ambient Air CONDENSER 4 MAIN COMPRESSOR SUCTION 6 KING VALVE RECEIVER 5 MECHANICAL ROOM (ENGINE-ROOM) HIGH SIDE 3 COMPRESSOR LOW SIDE EXPANSION VALVE 1 EVAPORATOR 2 CONDITIONED SPACE (WAREHOUSE FREEZER OR COOLER) S-2 COMPONENTS FLOW HIGH SIDE / LOW SIDE SEPARATION KING VALVE HIGH PRESSURE RECEIVER

OUT SIDE SPACE HEAT OUT HIGH SIDE Liquid Side Ambient Air HP Vap HP Liq. CONDENSER 4 MAIN COMPRESSOR SUCTION 6 KING VALVE MECHANICAL ROOM (ENGINE-ROOM) LP Vap HPR RECEIVER 5 HP Vap 3 COMPRESSOR HEAT IN HP Liq. EXPANSION VALVE 1 LP Liq. EVAPORATOR LP Vap 2 LOW SIDE Vapor Side CONDITIONED SPACE (WAREHOUSE FREEZER OR COOLER) S-3 COMPONENTS HIGH SIDE / LOW SIDE SEPARATION AMMONIA STATE FLOW KING VALVE HEAT GAINS HIGH PRESSURE RECEIVER HEAT REMOVAL

HEAT OUT BTUs / HEAT OUT SIDE SPACE HP VAP (High Side) CONDENSER HP LIQ HP LIQ 4 MAIN COMPRESSOR SUCTION 6 KING VALVE HP VAP RECEIVER 5 MECHANICAL ROOM (ENGINE-ROOM) 3 COMPRESSOR LP VAP HEAT IN BTUs / HEAT HP LIQ EXPANSION VALVE LP VAP EVAPORATOR 1 LP LIQ CONDITIONED SPACE (WAREHOUSE FREEZER OR COOLER) 2 (Low Side) S-4 COMPONENTS HIGH SIDE / LOW SIDE SEPARATION AMMONIA STATE SUB-SPLITS FLOW KING VALVE HEAT GAINS STATE CHANGES HIGH PRESSURE RECEIVER HEAT REMOVAL

HEAT OUT BTUs / HEAT OUT SIDE SPACE HP VAP (High Side) HP LIQ CONDENSER 4 MAIN COMPRESSOR SUCTION LP VAP KING VALVE 6 RECEIVER MECHANICAL ROOM (ENGINE-ROOM) HP LIQ 5 Intercooler Low Pressure Receiver 8 HP VAP COMPRESSOR 3 LP VAP SIDE PORT SUCTION 7 INTERMEDIATE PRESSURE HEAT IN BTUs / HEAT (Low Side ) LP LIQ EXPANSION VALVE 1 LP LIQ / VAP EVAPORATOR 2 LP VAP / LIQ CONDITIONED SPACE (WAREHOUSE FREEZER OR COOLER) S-5 COMPONENTS HIGH SIDE / LOW SIDE SEPARATION AMMONIA STATE SUB-SPLITS INTERCOOLER VESSEL FLOW KING VALVE HEAT GAINS STATE CHANGES LOW PRESSURE VESSEL HIGH PRESSURE RECEIVER HEAT REMOVAL

Summary : The Interaction of the PSM Elements Employee Participation Process Safety Information Process Hazard Analysis Operating Procedures Training Contractors Pre-Start Up Review Mechanical Integrity Hot Works Permit Management of Chance Emergency Planning & Response Compliance Audits

Without an effective PMPRR or a PSM this is what can happen.

Thank You. That s all Folks Stop Them Small Stop Them All A.S.T.I. GO As You KNOW!