Colmac DX Ammonia Piping Handbook 2nd Edition

P.O.
Box 571 | Colville, WA 99114 | USA

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
DXAMMONIAPIPINGHANDBOOK
2ndEdition
BruceI.Nelson,P.E.
TABLEOFCONTENTS
Background
SystemConfiguration
SystemStability
EvaporatorSelectionandOperation
DT1vsDTMRatings
SensibleHeatRatio,Roomrh%,andEvaporatorRatings
OptimizingSystemTD
EffectofTDonExpansionValveOperation
TypesofFrostandSelectionofFinSpacing
CondenserSelectionandOperation
Subcooling
PipingGeneral
LiquidLines
SuctionLines
HotGasLines
EffectsofWaterinAmmoniaandItsRemoval
Separation
DistillationandDisposalofAmmoniumHydroxide
LiquidTransfer
EffectsofOilonEvaporatorPerformanceandOilSeparation
EstimatingDXEvaporatorRefrigerantChargeInventory
ColmacSmartHotGasDefrost
CalculatingtheCostofDefrost
SmartHotGasSequenceofOperation
DefrostWaterVolumeandDrainLineSizing
References
APPENDIXADXAmmoniaP&ID
FigureA1SingleStage
FigureA2SingleStageEconomizedScrew
FigureA3TwoStage
Page
10
15
16
22
23
26
27
28
28
29
32
32
36
39
43
45
45
48
49
52
54
Page1of54
ENG00019544REVA2013ColmacCoilManufacturingInc.
P.O. Box 571 | Colville, WA 99114 | USA

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
I.
Background
Ammoniarefrigerationsystemshavetraditionallyemployedevaporatorssuppliedwith
liquidbyeithergravityflooding(withsurgedrums),orpumpedoverfeed(eitherwith
mechanicalpumpsordischargegasdrivenvessels).Bothofthesedesignstypicallyuse
bottomfeedcoilcircuitingwhichfeedsliquidammoniaatthelowestpointinthecoilcircuit
andcausestheammoniatoflowupwardandpercolatethroughthecoilinascending
passestotheoutletatthetopofthecircuit.Thesecoildesignsalsotypicallyuselarge
diametertubingwhichmeansrelativelylargecoilinternalvolume.Thiscombinationof
refrigerantfeed,circuiting,andtubediameter,resultsinthegreatestevaporatorcharge
inventorypossible.
Endusersofammoniarefrigerationsystemsareincreasinglyinterestedinreducingthe
chargeofammoniainevaporators(andintheoverallsystem)intheinterestofminimizing
therisktoworkersandproductsassociatedwithammonialeaks.Oneveryeffectivewayto
significantlyreduceevaporatorammoniachargeistodesignandoperatetheevaporator
usingdryexpansion(DX)circuitingandcontrols.UsingDXammoniacanreducethe
evaporatorchargebyasmuchas30to50timescomparedtobottomfeedfloodedor
pumpeddesigns.Themagnitudeofthisreductioninammoniachargemayalsomitigate
regulatoryrequirements(PSM,RMP),andpotentiallyreduceinsuranceriskandpremiums.
DXammoniahasbeenusedforsometimeinmediumandhightemperaturesystems
(suctiontemperaturesabove+20degreesF)withsomesuccess.However,inspiteofthe
chargereductionadvantagesmentionedabove,todateDXammoniahasnotbeenapplied
successfullyatfreezertemperatures.Atsuctiontemperaturesbelowabout+20F,the
followingparticularcharacteristicsofammoniaresultinextremelypoorperformanceof
evaporatorsunlessaddressedandmitigated:
1. Separationofliquidandvaporphases.Theveryhighratioofvaportoliquidspecific
volumeofammoniaatlowtemperaturescombinedwithitsveryhighlatentheatof
vaporizationcausesanunavoidableseparationofvaporandliquidphasesinside
evaporatortubes.Thisseparationofphasescausestheliquidammoniapresenttorun
alongtheverybottomofthetubesleavingthetopofthetubescompletelydry.The
resultisextremelypoorevaporatorperformanceandlowerthanexpectedsuction
temperaturesduringoperation.TosolvethisproblemColmachasdeveloped(and
patented)anenhancementtechnique,whichwhenappliedtotheinsideofevaporator
tubes,causestheliquidammoniapresenttocoattheentireinsidesurfaceofthetubes
bycapillaryaction.PerformancewithColmacenhancedtubetechnologyresultsinDX
ammoniaperformanceatlowtemperatureswhichisasgoodorbetterthan
performancewithbottomfeedpumpedammoniacircuiting.
2. Refrigerantdistributortechnology.Traditionallythedistributionofexpandedrefrigerant
tomultipleparallelevaporatorcircuitshasbeendoneusingarefrigerantdistributor
havingafixedorificeplate.Thisdesigndependsonarelativelylargepressuredrop
(approximately4045psi)acrossthefixedorificetothoroughlymixandequally
distributortheliquidandvaporphasesbeforetheyenterthedistributortubesand
evaporatorcircuits.Thisrelativelyhighpressuredropacrossthedistributorreducesthe
Page2of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
pressuredropavailablefortheexpansionvalve,andconsequentlylimitshowlow
condensingpressurecanbeallowedtofallduringperiodsoflowambienttemperature.
Theveryhighlatentheatofvaporizationofammoniaresultsinlowrefrigerantmass
flowrateandconsequentlyaverysmallorificediameterforagivencoolingload(the
orificecanbeassmallas1/16diameterinsomecases).Thissmallorificesizeisprone
tofoulingandbeingblockedbyevensmallsizedebris.Otherdisadvantagesofthis
distributordesigninclude:
a. Performanceisverysensitivetoliquidtemperature(subcooling)atthe
expansionvalve.
b. Operatingrangeissmall,atmost50%to125%ofratedcapacity.
c. Theorificeanddistributortubesrestricttheflowofhotgasduringahotgas
defrostcycle.
d. Themaximumnumberofparallelevaporatorcircuitsavailableinasingle
distributorislimitedtoonly15.
ToaddresstheseshortcomingsColmachasdevelopedanew(patentpending)
refrigerantdistributortechnology,theColmacTankDistributor,havingthefollowing
characteristics:
a. RefrigerantpressuredropacrosstheTankDistributorduringoperationisvery
low,only24psi.
b. AnyoilordebrisenteringtheTankDistributoriscapturedinadropleg(whichis
integraltothedesign)beforeitcanenterthecoilandfoultubesurfaces.
c. PerformanceoftheTankDistributoriscompletelyinsensitivetoliquid
temperature(subcooling).
d. Graduatedorificesineachdistributortubeallowequaldistributionof
refrigeranttoallcircuitsoveranextremelywideoperatingrangeof0%to700%
ofratedcapacity.
e. Graduatedorificesandlargediameterdistributortubesallowfullflow(minimal
restriction)ofhotgasduringhotgasdefrost.
f. ThenumberofparallelevaporatorcircuitspossibleinasingleTankDistributor
canbeashighas48.
3. Removalofwaterfromammonia.Asdescribedelsewhere(Nelson2010),evensmall
amountsofwater(13%)intheammoniawillsignificantlypenalizeDXammonia
evaporatorperformance.Watermustbeeffectivelyremovedduringoperation,
particularlyinfreezingsystemswhichoperateatsuctionpressuresbelowone
atmosphere(inavacuum).Currently,theonlyeffectivewaytoremovewaterfrom
ammoniaisinaheateddistillationvessel(anammoniastill).Thisverynegativeeffect
ofsmallamountsofwateronevaporatorperformancehasnotbeenfullyrecognizedin
thepast,butmustbeaddressedduringthedesignoftheDXammoniasystem.Colmac
hasdevelopedaneffectiveammoniadistillationvesseldesignandinstallationstrategy
whichisdescribedwithinthisHandbook.
Colmachasdeveloped,tested,andpatented(Nelson2011)anewLowTemperatureDX
Ammoniasystemwhichcorrectlyaddressesalloftheaboveissuespeculiartoammoniaasa
refrigerantthathaveheretoforepreventeditsuseatlowsuctiontemperatures.Itisnow
possibletosuccessfullyapplyDXammoniaatsuctiontemperaturesdownto50degreesF.
Page3of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
ThisPipingHandbookisintendedtoguidethereaderthroughtheprocessofsuccessfully
designingandimplementingDXAmmoniafrom+50Fto50Fandrealizingthebenefitsof:
Dramaticallyreducedammoniacharge
Simplifiedcontrols
Energyefficientdrysuctionline
Reducedlinesizes
Eliminationofammoniarecirculatorpumps
II.
SystemConfiguration
ColmacDXAmmoniacanbeappliedtoanytemperaturelevelandsystemconfiguration.
P&IDdiagramsforvarioustypicalsystemsareshowninAppendixA,simplifiedforpurposes
ofclarity.Selectionandsystempipingdetails(reliefvalves,purgers,isolationvalves,vessel
designs,etc)shouldfollowindustryguidelinesasfoundintheIIARAmmoniaPiping
Handbook(IIAR2004).Thediagramsarenotintendedtopresentanexhaustiverangeof
configurationseveryindustrialrefrigerationsystemwillhaveuniquefeaturesand
requirements.Thisinformationispresentedtoillustratethegeneralsystemfeatures
particulartoasuccessfulDXAmmoniadesign.
a. FigureA1SingleStageSingleTemperatureLevel
b. FigureA2SingleStage(EconomizedScrew)MultipleTemperatureLevel
c. FigureA3TwoStageMultipleTemperatureLevel
III.
SystemStability
Withliquidoverfeedandgravityfloodedsystems,liquidreturntotherecirculatorvesselor
thesurgedrumisnormalandexpectedthroughthewetsuctionline.Therecirculatorvessel
orsurgedrumeffectivelyseparatesreturningliquidfromvaporandinsuresthatthedry
suctionlinecarriesonlyvaporbacktothecompressor.
DXsystems,ontheotherhand,aredesignedtooperatewithadrysuctionlineandareby
definitionmoresensitivetoliquidfloodback.IndustrialDXsystemsshouldincorporatea
suctionaccumulatorvesseltopreventliquidsluggingofthecompressorduringafloodback
event,however,excessivefloodbackfromevaporatorscancausehighlevelalarmingand
systemshutdownuntiltheexcessliquidinthesuctionaccumulatorcanbetransferredback
tothehighpressuresideofthesystem.Stableandsmoothoperationofthesystemandthe
evaporatorexpansionvalve(s)iscriticaltoavoidingliquidfloodback.Instabilitiesand/or
rapidchangesindischargeandsuctionpressuresduringoperationarethetypicalcauseof
unstableoperationofexpansionvalvesandshouldbeconsideredcarefullybythesystem
designerandoperator(s).
Rapidchangesinsystemdischargepressurecancausesysteminstabilitiesinanumberof
ways.Asuddenreductionindischargepressurecanresultinundesirableflashingofliquid
refrigerantinliquidlinesandwillalsobeaccompaniedbyasympathetic,albeitsmaller,
reductioninsuctionpressure.Asuddenincreaseindischargepressurewillbeaccompanied
Page4of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
byasympathetic,albeitsmaller,increaseinsuctionpressure.Anincreaseinsuction
pressure,iflargeenoughandrapidenough,willsuppressboilingintheevaporatorswhich
candirectlyleadtoliquidfloodbackfromtheevaporatorstothesuctionaccumulator.
Rapidchangesindischargepressurearenormallycausedbyoneormoreofthefollowing
events:
a. Condenserfanscyclingonandoff,
b. Evaporativecondenserpumpscyclingonandoff,
c. Evaporator(s)initiatinghotgasdefrost,
d. Compressor(s)cyclingonandoff
**NOTE:Designthesystemtolimittherateofchangeincondensingtemperaturetono
morethan5degF/minute.
Rapidchangesinsystemsuctionpressurecanalsoresultinsysteminstabilityandpoor
performance.Itisasuddenincreaseinsuctionpressurethathasthehighestpotentialfor
liquidfloodbackfromDXevaporators.Thissuddenincreaseinsuctionpressureraisesthe
temperatureoftheevaporator,reducestheimposedload,andresultsinliquidrefrigerant
exitingtheevaporatorbeforetheexpansionvalvecanrespondandreducetheflowof
refrigerantenteringtheevaporatoraccordingly.
Rapidchangesinsuctionpressurearenormallycausedby:
a. Compressor(s)cyclingonandoff
b. Multipleliquidfeedsolenoidscyclingonandoff
c. Evaporatorfanscyclingonandoff
d. Evaporatorsstartingorfinishingdefrost
e. Suddenchangesinimposedloadonevaporators
**NOTE:Designthesystemtolimittherateofchangeinsuctiontemperaturetonomore
than2degF/minute.
Followingarerecommendedsystemdesignfeatureswhichwillservetomaximizesystem
pressurestabilityandminimizethepotentialforliquidfloodbackfromevaporators.
1. CondenserFans
a. UseofVFDfanspeedcontrolinsteadoffancyclingforcontrolofheadpressureis
recommended.
2. CondenserPumps
a. Itisalsorecommendedthatevaporativecondensersumpwaterpumpsbeoperated
continuouslyratherthancyclingonandoff,providedambientweatherconditions
allow.
3. CompressorCapacityControl
a. UseofVFDspeedcontrolforcapacitywherepossibleandappropriate.
Page5of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
4.
5.
6.
7.
b. Limitcapacityloading/unloadingsteps(on/off)tonomorethan10%oftotalsystem
capacity.
c. Limittherateofchangeofsuctiontemperature(speedofscrewcompressorslide
valvemovement)tonogreaterthan2degF/minute.
EvaporatorDefrost
a. Defrosttheminimumnumberofevaporatorsatonetime.
b. Useableedlinetoequalizepressureslowlyattheendofdefrost.
EvaporatorFans
a. FanspeedandcoolingcapacitycanbecontrolledbyVFD,howeverthefollowing
guidelinesmustbeobservedwhenappliedtoDXevapaorators:
o Rateofchangeinfanspeedmustbegradualandlimitedtoresultinno
morethan2degF/minutechangeinsuctiontemperature.
o Minimumfanspeedmustbesettoproducenolessthan250ft/minface
velocity.
b. Iffansaregoingtobecycledon/offforcapacitycontrol,nomorethan10%ofthe
totalnumberofevaporatorfansshouldbecycledonoroffatthesametime.
LiquidFeedSolenoids
a. Avoidcyclingmultipleliquidfeedsolenoidsallatthesametime.i.e.Liquidfeed
solenoidsshouldbecycledsequentially.
SuddenchangesinloadonEvaporators
a. Avoidlocatingevaporatordirectlyabovedoorways.
b. Mitigateintermittentprocessloadslocatedclosetoevaporators.
IV.
EvaporatorSelectionandOperation
1. DT1vsDTMratings
Asexplainedindetailelsewhere(Nelson2012(a))evaporatormanufacturerstypically
presenttheircapacityratingsusingoneoftwodefinitionsoftemperaturedifference,
DT1orDTM.SomemanufacturerspublishratingsbasedonbothDT1andDTMand
allowthedesignertochoosethepreferreddefinition:
DT1=AirOnTemperatureEvaporatorTemperature
DTM=Average(Room)AirTemperatureEvaporatorTemperature
Figure1belowgraphicallyillustratesthesetwodefinitionsoftemperaturedifferencefor
thesameevaporatorandtheireffectonLMTD(LogMeanTemperatureDifference),and
henceratedcapacity.Inthisexample,thesameevaporatorhavinga20degF
evaporatingtemperatureratedusingDTMproduces33.3%(DTMLMTDof9.6degF
versusDT1LMTDof7.2degF)morecapacitythanthesameevaporatorratedusing
DT1!
Page6of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Inshort,byusingtheDTMratingmethodamanufacturercanshowcoolingcapacities
thataremuchhigher(30to40%higher),andsoofferalowercostevaporatorwith
muchlesssurfaceareathanthemanufacturerusingtheDT1ratingmethod.
Unfortunately,onecannotgetsomethingfornothing.Eventhoughevaporators
selectedusingDTMratingswillbecheaperinitiallybecausetheyhavelesssurfacearea,
theywillcausethesystemtorunatalowersuctionpressurewithhigheroperatingcosts
thanevaporatorsselectedusingDT1ratings.Thisdifferenceinoperatingcostbetween
DTMandDT1evaporatorshasbeencalculatedandtheincrementalreturnon
investmentshowntodramaticallyfavorselectingevaporatorsusingDT1ratings(Nelson
2012(b)).Additionally,inthesamearticletheauthorshowsthatthebasicDTM
assumptionthattheaverageairtemperaturewithintheevaporatorequalstheaverage
roomtemperatureisafundamentallyflawedandfalseassumptionbecauseofair
entrainmentandmixingintheroom.
FIGURE1
TemperatureProfilesforDT1vsDTM
(a) DT1=10F(AirOn)TempDifference(b)DTM=10F(Average)TempDifference
DT1 LMTD = 7.2 F
DTM LMTD = 9.6 F
Inconclusion,ColmachighlyrecommendsthatevaporatorsbeselectedusingDT1ratings
ratherthanDTM.
2. SensibleHeatRatio,RoomRelativeHumidity(rh%),andEvaporatorRatings
Accuratepredictionoftherefrigerationload,bothsensibleandlatentcomponents,is
importanttoproperrefrigerationsystemequipmentselectionandsuccessfuloperation
Page7of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
(Nelson2012(a)).Varioustypesofsensiblecoolingloadsmustbeanticipatedand
includedinthecalculation,suchas:lighting,electricmotors,forklifts,product
cooling/freezing,transmissionofheatthroughwalls,ceilings,andfloors,andcoolingof
infiltrationair.Latentcoolingloadsarepresentwhenevermoistureisaddedtotheairin
therefrigeratedspace.Sourcesofintroducedmoisturetypicallyinclude:infiltrationair,
respiringfoodproducts,surfacemoistureonproducts,packagingandotherobjects
enteringthespace,residualwaterleftonfloorsafterwashdown(processrooms),
humanrespiration,andhumidificationequipment(abovefreezing).
Roomrelativehumidity(rh%),whichistheindicationofhownearlytheairinthe
refrigeratedspaceissaturatedwithwatervapor,willbetheequilibriumcondition
resultingfromthebalanceofmoistureintroducedintothespacewiththemoisture
removedfromspacebytheevaporatorcoils(Cleland2012).
Wheneverevaporatorsurfacesoperateattemperaturesbelowthedewpointoftheair
beingcooled,watervaporintheairstreamiscondensedtoliquid(attemperatures
above32F(0C))ordepositedtoformfrost(below32F(0C)).Thecoolingeffect
associatedwiththisdehumidificationoftheairstreamistermedlatentcooling.The
sumofthesensiblecoolingloadandlatentcoolingloadistermedthetotalload.The
ratioofthesensiblecoolingloaddividedbythetotalcoolingloadiscalledtheSensible
HeatRatio(SHR)anddefinestheslopeoftheairprocesslineonapsychrometricchart.
(1)
Refrigeratedspaceswithproductbeingtransferringinandoutthroughdoorwayswill
verytypicallyhavearelativehumidityinthe85to95%rangeduetoinfiltrationand
othersourcesofmoisture.Lowerroomrelativehumiditymaybefoundinsome
exceptionalcaseswheretrafficthroughdoorwaysisverylight,productistightly
packaged,dehumidificationequipmentisusedatdoorways,etc.Therelationship
betweenroomrelativehumidityandSHRisshowninTable1below:
TABLE1
SHRFORDT1=10degFATVARIOUSTEMPERATURESANDROOMRH%
SensibleHeatRatio,SHR
RoomTemperature,F(C)
65%rh
75%rh
85%rh
95%rh
45(7.2)
1.0
0.84
0.67
0.56
32(0)
0.98
0.84
0.73
0.64
10(12.2)
0.98
0.92
0.87
0.83
0(17.8)
0.98
0.95
0.92
0.89
10(23.3)
0.99
0.97
0.95
0.93
30(34.4)
0.99
0.99
0.98
0.97
TheroomrelativehumidityandresultingSHRcanhavealargeeffectonevaporator
coolingcapacity,especiallyathigherroomtemperatures.
Page8of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
CapacityFactor,Qtotal/Qsensonly
Usingacomputermodeldevelopedtoaccuratelycalculatefinefficiencyandsurface
effectivenessforbothsensibleandcombinedsensibleandlatentheattransfer,a
predictionoftheincreaseinevaporatorcoilperformanceasafunctionofSHRhasbeen
made(Nelson2012(a)).ResultsofthepredictedcapacityincreaseasafunctionofSHR
foranammoniarefrigerationevaporatorcoiloperatingoverawiderangeofroom
temperatures(+45Fto30F)andhavingtypicalfinspacingsandgeometrywithDT1=
10FareshowninFigure2below.
FIGURE2
TotalCoolingCapacityFactorvsSHR
1.5
1.45
1.4
1.35
1.3
1.25
1.2
1.15
1.1
1.05
0.6
0.65
0.7
0.75
0.8
0.85
0.9
0.95
1
SensibleHeatRatio,SHR
Tomakethingsabitmorecomplicated,someevaporatormanufacturersincludethe
effectofroomrh%intheirratings,othersdonot.AsshowninFigure2,thelowerthe
SHRthegreaterthetotalcoolingcapacityoftheevaporator.Amanufacturerwhoshows
theirevaporatorratingsasallsensible(SHR=1)willbemoreconservative(havemore
surfacearea)thanthemanufacturerwhoshowstheirratingsat85or95%rh.
Selectingevaporatorsusing85to95%rhratingswillresultinevaporatorshavingless
surfaceareaandlowerfirstcostcomparedtoevaporatorsselectedusingallsensible
ratings.Theriskinthisapproachisundersizingtheevaporatorsinthecasewherethe
actualoperatingroomrh%islessthantherh%usedduringtheselectionprocess.
Conclusion:Thelatentloadshouldalwaysbeestimatedandincludedinthetotal
calculatedrefrigerationload.Sizeevaporatorsforthedesigntotalcalculated
refrigerationloadattheestimatedroomrelativehumidity.Ifroomrelativehumidityis
difficulttoestimateorcannotbeestimated,thenaconservationapproachistoselect
evaporatorsbasedonalowroomrelativehumidity(i.e.65to75%rh)orusingsensible
onlyratings.
3. OptimizingSystemTD
Page9of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Theproductbeingstoredorprocessednormallydeterminestheroomairtemperature
inarefrigeratedfacility.Appropriatetemperaturesforstoringandprocessingvarious
foodsandfoodproductscanbefoundelsewhere(ASHRAE2009).
Oncetheroomtemperatureisdetermined,theevaporatortemperaturemustbe
decideduponbythedesigner.Compressorpowerandenergyconsumptionisastrong
functionofthesuctionpressureandtemperature.Thehigherthesuctionpressurethe
moreefficientlythecompressorwillrunandthelesspowerwillbeconsumed.Energy
efficiencycanbecharacterizedbyaratiotermedCoefficientofPerformance(COP),
definedas:
(2)
Inthecaseofarefrigerationcompressor,
(3)
,
Figure3belowshowstypicalammoniascrewcompressorCOPvsSST(SaturatedSuction
Temperature).Thefigureassumes2Stagecompressionisusedbelowasuction
temperatureof20degF.
FIGURE3
R717ScrewCompressorCOPvsSST
(SCT=85DegF)
8
CompressorCOP
1
50
40
30
20
10
10
20
30
40
SST,DegF
Page10of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
ItwouldappearfromFigure3thatasmallerTD(TD=RoomTemperatureEvaporator
Temperature)wouldalwaysbedesirablefromanenergyconsumptionstandpointsince
thesmallertheTD,thehighertheevaporator(SST)temperatureandcompressorCOP.
This,however,isnotthecase.
Heatistransferredfromtheroomviatheaircirculatedbytheevaporators.Thecooling
capacityofanevaporatorcanbecharacterizedbytheNTUeffectivenessequation.This
equationindicatesthatforaconstantcoolingcapacityandevaporatoreffectiveness(an
expressionofhowcloselytheleavingairtemperatureapproachestheevaporating
temperature),theflowrateoftheairwillbeinverselyproportionaltotheTD.
(4)

Where:

Evaporatoreffectivenessis,infact,verynearlyconstantoverthetypicalnarrow
operatingrangeofarefrigerationevaporator.Theeffectivenessequationshowsthatas
TDbecomessmaller,theairflowratemustbecomelargerinthesameproportionfora
givencoolingcapacity.
Fanpowercanbecalculatedusingasimpleequationasfollows:
(5)
Where:

Theairpressuredropthroughtheevaporatorcoil,andthereforefanpower,willbe
affectedby:
1. Thecoilfacevelocity,
2. Tubediameter,spacing,andpattern,
3. Numberofcoilrowsdeep,
4. Finspacingandpattern
5. Frostthickness
Page11of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
COP
TherelationshipsaboveindicatethatcompressorCOPwilldecreasewithincreasingTD
whileFanCOPwillincreasewithincreasingTD.Figure4showstheserelationshipsforan
exampleevaporatorcoilhaving8rowsdeepand3FPIfinspacing.
FIGURE4
COPvsTD
8Row3FPI,R717,AirOnTemp=10DegF
4
Fan(500FPM)x10^1
Fan(750FPM)x10^1
3
Fan(1000FPM)x10^1
2
Compressor
0
5
10
15
20
25
30
35
0
TD=AirOnTemp SuctionTemp,DegF
Figure4impliestherewillbesomemaximumcombinedCOPforcompressorandfans
whichwillrepresenttheoptimumoperatingTDintermsofenergyefficiency.This
combinedCOPisshownbelowinFigures5,6,and7,foratypicalammoniaevaporator
coilhavingthefollowingcharacteristics:
Tubing:7/8ODAluminum
TubePattern:2.25Staggered
Fins:ConfiguredAluminumPlateType
RowsDeep:8
FaceVelocity:500,750,and1000FPM
FinSpacing:2,3,and4FPI
AirOnTemperature:10degF
FrostThickness:0mm
Page12of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
FIGURE5
Compressor+FanCOPvsTD
2.4
2.2
2
1.8
1.6
500FPM
1.4
750FPM
1.2
1000FPM
1
0.8
0.6
0
10
15
20
25
30
35
FIGURE6
2.6
2.4
2.2
CombinedCOP
CombinedCOP
2
500FPM
1.8
750FPM
1.6
1000FPM
1.4
1.2
1
0
10
15
20
25
30
35
Page13of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
FIGURE7
2.6
2.4
2.2
CombinedCOP
2
500FPM
1.8
750FPM
1.6
1000FPM
1.4
1.2
1
0
10
15
20
25
30
35
ThefollowingisobservedfromFigures5through7:
a. CombinedCOPisaverystrongfunctionofcoilfacevelocity.COPat500FPMis
approximately10%higherthanCOPat750FPMand20%higherthanCOPat
1000FPM.
b. CombinedCOPincreasesasthedistancebetweenfinsisincreased.Coilswith
2FPIspacingwillhavehighercombinedCOPthancoilswith3FPI,whichwillhave
higherCOPthan4FPI.
c. Theoptimum(maximum)TDincreaseswithincreasingfacevelocity.
d. Inallcases,combinedCOPdecreasesveryrapidlybelowabout7degFTD.
InordertomakethefinaldecisionaboutselectingtheoptimumTD,thecostofpower
aswellasinstalledcostofthecompressor(s)andevaporatorsmustbeknown(or
estimated).Thesevariablescanthenbecombinedtocalculatetheincrementalreturn
oninvestmentcomparingdifferentevaporatordesigns(facevelocityandfinspacing)in
termsoffirstcostvsoperatingcost.
Sincethesecostsarehighlyvariable,thefinalreturnoninvestmentcalculationmustbe
madeonacasebycasebasisandpresentedtotheclientinawaywhichallowsthefinal
decisiontobemadegiventheprojectfinancialconstraintsandrequirements.
Page14of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Conclusions:
1. ForhighestsystemCOP/energyefficiency,selectevaporatorsforthelowestface
velocityandwidestfinspacingfinanciallypractical.Colmacrecommendsmaximum
facevelocityof600FPMandfinspacingof3FPIorwider(lowerFPI).
2. Forcoilfacevelocitiesbetween500and750FPMadesignTDbetween10degFand
15degFisrecommended.
3. FinaloptimizedevaporatordesignandTDmustbedeterminedbasedonspecific
projectfinancialconstraintsandacceptablereturnoninvestment.
4. EffectofTDonExpansionValve(EV)Operation
Withdirectexpansion(DX)evaporatorstheflowofrefrigeranttotheevaporatoris
meteredbyanautomaticexpansionvalveinresponsetoacontrolsignalmeasuredat
theevaporatoroutlet.Thecontrolsignalisnormallytheamountofsuperheatinthe
refrigerantsuctiongas.Thetheoreticalmaximumamountofsuctiongassuperheatthat
canbegeneratedisequaltotheoperatingTD(TD=AirOnTemperatureEvaporating
Temperature).
Theamountofsuperheatrequiredforstableoperation(modulation)oftheexpansion
valvevarieswiththetypeofvalveemployed.Twobasictypesofexpansionvalvesare
currentlyavailableonthemarket,Thermostatic(TEV)andElectronic(EEV).Bothuse
superheatinthesuctiongasasthecontrolsignal.
Thermostaticexpansionvalvesmeasureandmechanicallycalculatesuperheatbymeans
ofatemperaturesensingbulbandpressureequalizingline.Thesevalvesandtheir
operationaredescribedindetailbythevalvemanufacturers.Theadvantageofthistype
ofvalveistheirlowcostandcompactness.Withthistypeofvalve,temperaturesensing
isaccomplishedbyarefrigerantfilledbulbstrappedtotheoutsideofthecoilsuction
connection.Adisadvantageofthissystemistheadditionalsuperheatrequiredto
overcomethethermalresistanceofthepipewall.Thisadditionalsuperheatforcesthe
operatingTDtobeapproximately5degFgreaterthanforanelectronicexpansionvalve
thatusesatemperaturetransducertomeasuretemperaturedirectly.
Electronicexpansionvalvesoperatebasedonasignalreceivedfromasuperheat
controllerwhichreadssuctiongastemperatureandpressurefromacombinationof
sensors.Theexpansionvalveitselfmayoperatebasedonanopen/close(pulsing)
principleoronamotorizedpositioningprinciple.Advantagesofthistypeofvalve
includemoreaccurateandresponsivesensingofsuperheatwhichallowsstable
operationatsmallerTDthanthermostatictypevalves.PIDcontrolparameterscanalso
beadjustedinthecontrollertofinetuneoperationoverawiderangeofconditions.
Theprimarydisadvantageofelectronicexpansionvalvesisthehigherfirstcost
comparedtothermostaticvalves.This,however,ischangingasvalvemanufacturersare
findinglowercostsolutionsandbeginningtooffercostcompetitiveelectronicvalvesto
themarket.
Page15of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
MinimumrecommendedTDandsuperheatsettingsforbothtypesofexpansionvalves
areshowninTable2below:
TABLE2
MINIMUMRECOMMENDEDDXAMMONIATDANDSUPERHEATSETTING
ExpansionValveType MinimumRecommended RecommendedSuperheat

TD,degF
Setting,degF
Thermostatic
15
12
Electronic
12
10
Note:Colmacoffersfactorysuppliedandmountedexpansionvalvesandcontrollers,
boththermostaticandelectronictype.
5. TypesofFrostandSelectionofFinSpacing
Frostcanaccumulateonevaporatorcoilfinsbyoneoftwomechanisms:
1. Bydeposition,and/or
2. Asairborneicecrystals
Designingevaporatorstoproperlyhandlethesetwotypesoffrostisdescribedinthis
section.
1. Deposition:
Wheneverthetemperatureoftheevaporatorcoilsurfaceisbelowthedewpoint
temperatureoftheroomair,moisturewillcondenseandbedepositedonthesurface
eitherasliquidwater(abovefreezing)orasfrost(belowfreezing).Thismasstransfer
process,whenrelatedtotheformationoffrostiscalleddeposition,andisdrivenbythe
differenceinwatervaporpressurebetweentheairandthesurfaceofthecoil.The
amountofheatassociatedwiththismasstransferprocessistermedlatentheatandis
quantifiedbytheSHR(seepreviousdefinition).WhenevertheSHRislessthan1.0,the
depositionoffrostwilltakeplace.Therateatwhichfrostwillbedepositedonthecoil
surfacescaneasilybecalculatedasafunctionofthetotalcoolingload,theSHR,andthe
surfaceareaoftheevaporator.
Thesurfaceeffectivenessofarefrigerationevaporatorisrelativelyhigh(usuallygreater
than80%)duetothetypicallysmallTDandlowheatfluxcomparedtoairconditioning
andprocessevaporators.Thishighsurfaceeffectivenessresultsinamoreorless
constantsurfacetemperatureanduniformdepositionoffrostovertheentiresurfaceof
theevaporator.Thisassumptionofuniformfrostdepositionismadeinthefollowing
equation:
Page16of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Where:
(6)
/
,
/

, 10.4
304.8
, 1068
/ 3
, 2
EXAMPLE:
Anevaporatorhaving8rowsdeepandfinspacingof3FPIisoperatingwitha10degF
TD(DT1)ina+10degF/85%rhroom.Theevaporatorhasacoolingcapacityof240,000
Btu/h(20TR)andoutsidesurfaceareaof4100ft2.Whatwillbetherateoffrost
deposition?
Answer:
FromTable1theexpectedSHRatthisroomairtemperatureandrh%willbe0.87.
240,000 1 0.87

304.8 0.21
/
1068 10.4 4100
Asfrostisdepositedontheevaporatorcoilsurfacesthelocalairvelocitybetweenfins
willincreaseandresultinincreasedairpressuredropacrossthecoil.Theincreaseinair
pressuredropduetoaccumulationoffrostcanbeapproximatedbythefollowing
equation:
(7)

1
2
25.4
Where:

Page17of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Therateofblockageofthecoilwithfrostandassociatedpressuredropwillresultina
reductioninairflowandcoolingcapacity.Thisreductionincoolingcapacitywill
ultimatelydeterminedefrostfrequencyandefficiency,andoverallsystemenergy
efficiencyandpowerconsumption.
Coolingcapacityoftheevaporatorcanbecharacterizedasfunctionsoffacevelocity,
SHR,andfrostthickness.Knowinghowcapacitychangeswiththeseparameters,
combinedwiththerelationshipsshowninequations5,6,and7above,allowsthe
constructionofasimplemodelwhichwillpredictthechangeincoilcapacityovertime.
Simplifyingassumptionsinthemodelinclude:
o Frostisdepositeduniformlyoverthesurfaceofthecoil
o Frostdensityisuniformandofafixedvalue
o Suctiontemperatureremainsconstant
Normally,refrigerationloadsarecalculatedbasedon16to18hoursofruntimeperday.
Itisnotclearwhenorwhythisruleofthumbcameintopractice.Perhapsitisacorollary
tothe2to1ruleforhotgasdefrosting.Thatis,twocoilsmustbeinoperationwhile
thethirdcoilisinhotgasdefrostinordertoprovideasufficientquantityofhotgasfor
thedefrostcycle.Perhapsitissimplyanadditionalcatchallsafetyfactor.One
industryhistorianmentionedthatthe1618runhoursrulecamefromsplitsystem
applicationswherecapacitydropsoutduringdefrostcomparedtoacentralsystem
whichwouldrebalancetheTDontheremainingevaporators(Welch2013).Itmakesthe
mostsensetotheauthorthattheruntimeadjustmenttothedesignrefrigerationload
shouldbeusedtoaccountforthedegradationincoilperformanceovertimedueto
accumulationoffrost.
Inalargerefrigerationsystemhavingaconstantrefrigerationloadandcompressor
unloadingcapability,thecompressorswillunloadtomaintainaconstantsuction
temperatureasthecoilcapacityfallsoffduetofrosting.Asthecompressorsunloadto
maintainsystemsuctionpressure,theywillrunlongertomaintainroomtemperature.
Thisimpliesthatinordertomaintainroomtemperature,defrostingshouldbeinitiated
whenevaporatorcapacityfallstoalevelequaltothedesignruntimeratio(design
runtimedividedby24).Table3belowshowsthemaximumreductioninevaporator
capacityduetofrostingthatshouldbeallowedbeforedefrostisinitiated.Notethatthis
tableobviouslydoesnotapplytoevaporatorsoperatingabovefreezing.
TABLE3
MINIMUMEVAPORATORCAPACITYTOINITIATEDEFROSTATVARIOUSDESIGN
RUNTIMES
DesignRuntime,h/day
MinimumEvaporatorCapacityat
InitiationofDefrost
14
58%
16
67%
18
75%
20
83%
Page18of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
CoolingCapacity,%
CoolingCapacity,%
Theevaporatorperformancemodeldescribedabovewasusedtoexaminetheeffectof
finspacingandSHRonlossofcoolingcapacityduetofrostaccumulation.SeeFigures8,
9,10,and11below.
FromTable1itisclearthatthehighestfrostload(lowestSHR)willoccurinhigh
temperature(+32F)roomswithhighrelativehumidity.Thelowestfrostloads(highest
SHR)occuratfreezertemperatures,evenwhenrelativehumidityishigh.
FIGURE8
CapacityvsTimeforVariousFinSpacings
7/8StaggPattern,0.65SHR
100%
90%
80%
70%
60%
RBR(Stagg)8R2F
50%
RBR(Stagg)8R3F
40%
RBR(Stagg)8R4F
30%
20%
10%
0%
0
0.5
1
1.5
2
2.5
3
3.5
4
Time,h
FIGURE9
100%
90%
80%
70%
60%
RBR(Stagg)8R2F
50%
RBR(Stagg)8R3F
40%
RBR(Stagg)8R4F
30%
20%
10%
0%
0
1
2
3
4
5
6
7
Time,h
Page19of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
FIGURE10
100%
90%
80%
70%
CoolingCapacity,%
60%
RBR(Stagg)8R2F
50%
RBR(Stagg)8R3F
40%
RBR(Stagg)8R4F
30%
20%
10%
0%
0
10
12
Time,h
CoolingCapacity,%
FIGURE11
100%
90%
80%
70%
60%
RBR(Stagg)8R2F
50%
RBR(Stagg)8R3F
40%
RBR(Stagg)8R4F
30%
20%
10%
0%
0
5
10
15
20
25
30
35
40
Time,h
AnumberofobservationscanbemadewhenconsideringFigures811,Table1,and
Table3:
Page20of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
1. Therateatwhichfrostaccumulatesonanevaporatorincreasesastheroom
temperatureincreasesforagivenroomrelativehumidity.i.e.Frostonan
evaporatoroperatinginaroomat+32Fand85%rhwillaccumulatemuchfaster
thanonthesameevaporatoroperatingat10Fand85%rh.Thisisduetothehigher
watervaporpressureinairathighertemperaturesandtheresultinglowerSHR.
2. Foragivenreductioninevaporatorcapacity,widerfinspacingalwaysresultsin
longeractualruntimebetweendefrosts.
3. Asdesignruntimeisincreased,thenumberofdefrostsperdayrequiredincreases.
Inthecaseofveryhighfrostload(SHRlessthan0.75)usingdesignruntimegreater
than14h/daymayresultinaninabilityoftherefrigerationsystemtomaintainroom
temperature.
4. Figures8through11canbeusedtoestimatedefrostfrequencywhenroomSHR,
designruntime,andcoilfinspacingareknown.
Example:
Anevaporatorhasbeenselectedfora+10F/85%rhroombasedondesignruntime
of16h/day.Finspacingselectedis3FPI.Estimatethedefrostfrequencyusing
Tables1and3,andFigures8through11.
FromTable1:SHR=0.87
FromTable3:CoolingCapacityatTimeofDefrost=67%
FromFigure10:Timebetweendefrosts=5.2h
Therefore,estimateddefrostfrequency=24h/day/5.2h=5defrostsperday
Conclusion:Table4belowshowssuggestedmaximumfinspacing,designruntime,and
defrostfrequencyforvariousvaluesofSHR.Thistableisintendedtobeusedasageneral
guidelineinconjunctionwithTable1.Notethatroomrelativehumidity,andtherefore
SHR,willlikelychangethroughouttheyeardependingonlocationandclimate
conditions.Thisimpliesthatoptimumdefrostfrequencymaybedifferentinsummer
monthsvswintermonths.
TABLE4
SUGGESTEDFINSPACING,RUNTIME,ANDDEFROSTFREQUENCYVSSHR
SHR
SuggestedMaximum
FinSpacing,FPI
2
3
4
4
RecommendedMaximum
DesignRuntime,h/day
14
16
16
18
SuggestedDefrostFrequency,
No.Defrosts/day
9
8
6
2
0.65
0.75
0.85
0.95
Theabovediscussionandrecommendationsarebasedonfrostaccumulationby
depositionanddonotincludetheeffectsofairborneicecrystalsonfinspacingand
defrostfrequency.Theeffectsofairborneicecrystalsarediscussedinthefollowing
section.
2. AirBorneIceCrystals:
Page21of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Thistypeoffrostisformedquitedifferentlyfromthefrostformedbydepositionas
explainedabove.Itaccumulatesonevaporatorsurfacesbyadifferentmechanism,and
ismoredifficulttoquantifyandpredict.
Airborneicecrystalsasatypeoffrostthatcanbedepositedoncoilsurfaceshasbeen
recognizedanddiscussedforsometime(Cleland2002,Stoecker1988).Theseice
particulatesformwheninfiltrationairmixeswithrefrigeratedairtoproducea
supersaturatedcondition.Onapsychrometricchart,asupersaturatedconditionis
indicatedwhenthemixedairconditionfallstotheleftofthesaturation(100%rh)line
(thinkoffogthathasfrozeninmidair).
Ratherthanaccumulaterelativelyuniformlyovertheentirecoilsurfaceasisthecase
withfrostformedbydeposition,airborneicecrystalsaccumulateontheleadingedges
ofthecoilfinsandhavetheprimaryeffectofrestrictingairflow.Thistypeoffrostis
moredifficulttopredictsinceitsformationdependsonnotonlytheconditionoftheair
outsidetherefrigeratedspace,butalsoontheconditionofdoorwaysandhowtheyare
operated.
Whenevaporatorsarelocateddirectlyabovedoorwayswhereairborneicecrystalsare
formedthistypeoffrostcanaccumulateveryquicklyandhaveseriousconsequencesin
termsofdegradedperformanceandinabilitytodefrosteffectivelyduetoexcessive
accumulationofhoarfrostandice.Inoneparticularcaseobservedbytheauthor,two
identicalevaporatorswereinstalledinthesamerefrigeratedspace(a10degFfreezer)
alongthesamewall,onedirectlyoverthedoorwayandthesecondoffsetbetween
doorways.Theevaporatordirectlyoverthedoorwayhadchronicproblemswithrapid,
heavyaccumulationoffrost,andwithdefrostissuesrelatedtoaccumulationoficeon
theunitcabinetandinthedrainpan.Theevaporatorlocatedonly20feetawaybetween
doorways,operatedwithoutaccumulatingiceonthecabinetandorinthepanand
defrostednormallyandeffectively.Itisthereforerecommendedthatevaporatorsnotbe
locateddirectlyabovedoorwayswheneverpossible.
Ifitisknownthattheevaporatorwillbeexposedtothistypeoffrost,variablefin
spacingisrecommended.Thatis,afinspacingarrangementwhichhasfinsonthefirst
onetotworowsontheairenteringsideofthecoilspacedwiderthanintheremaining
rows.Typicalarrangementsare1/2fpi(finsperinch),1.5/3fpi,and2/4fpi.
V.
CondenserSelectionandOperation
Anumberofdifferenttypesofcondensersareavailableforusewithammonia.
WaterCooled
AirCooled
Evaporative
Hybrid(Adiabatic)AirEvaporative
Page22of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
VI.
Incertaincasesthetypeofcompressionequipment(screwvsreciprocating)selectedand
theexpectedmaximumambienttemperaturewilldeterminewhetherornotaircooled
condensingwillbepossible.Inothercasestheavailability(orunavailability)ofwatermay
requiretheuseofaircooledcondensing.ThegoodnewsisthatDXammoniaiscompatible
withalltypesofcondensingsystems!
Properselectionandoperationofammoniacondensingequipmentisoutlinedinthe
condensermanufacturersliterature.
Itisrecommendedthatthesystemdesignercarefullyconsiderthefollowingpointswhen
selecting/designingcondensingequipment:
Energyefficiency
Partloadoperation
Lowambientoperation
Internalvolumeandammoniacharge
Gasinletandliquidoutletpiping
Purgingofnoncondensiblegases
VFDcondenserfancontrol(highlyrecommended)
Subcooling
Refrigerantliquidleavingthecondenseristypicallyatornearsaturationtemperatureand
pressure.Iftheliquidhasnotbeensubcooledbeforeitenterstheliquidline,anydropin
pressure,and/oranyheatinput,willcausetheliquidtoboilandflashgaswillbeformed.
Becauseoftheverylargevolumeoccupiedbyvaporcomparedtoliquid,theflashgas
increasestherefrigerantvelocityandcausesanexcessivepressuredropintheliquidline,
Thisreducesthecapacityandinterfereswiththeoperationoftheexpansionvalve,and
consequentlywillreducesystemcapacity.Adequatesubcoolingoftheliquidwillpreventthe
formationofflashgasinliquidlines.
Subcoolingtheliquidafteritleavesthereceiveristhereforeanecessityforpropersystem
operation.Notethatanysubcoolingdonewithinthecondenserorbetweenthecondenser
andthereceiverwillbeeliminatedinthereceiverduetotheequalizerline.Theamountof
subcoolingrequiredcorrespondstotheliquidlinepressuredropandheatgain.Thepressure
dropisthesumof1)thelossinpressureduetoelevationgainintheliquidline,2)liquidline
pressuredropduetofriction,and3)pressuredropthroughserviceandcontrolvalves.
Table5showsthepressuredropinliquidlinesproducedbyelevationgainbetweenthe
receiverandevaporatorswithammonia.
Page23of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
TABLE5
PressureDropinAmmoniaLiquidLinesDuetoElevationGain
ElevationGain
PressureDrop
ft
m
psi
kPa
1
0.3
0.3
1.9
5
1.5
1.4
9.3
10
3.0
2.7
18.7
15
4.6
4.1
28.0
20
6.1
5.4
37.3
25
7.6
6.8
46.7
30
9.1
8.1
56.0
35
10.7
9.5
65.4
40
12.2
10.8
74.7
45
13.7
12.2
84.0
50
15.2
13.5
93.4
Oncethetotalliquidlinepressuredrop(thesumofelevationpressuredropplusfrictional
pressuredroppluspressuredropthroughvalves)iscalculated,therequiredamountof
subcoolingtopreventflashgasinthelinecanbedeterminedfromTable6.Notethatthe
amountofsubcoolingrequiredforagivenpressuredropincreasesascondensing
temperaturedecreases.
TABLE6
TotalLiquidLine
PressureDrop
psi
kPa
1
6.9
4
27.6
6
41.4
8
55.2
10
68.9
12
82.7
14
96.5
16
110.3
18
124.1
20
137.9
25
172.4
30
206.8
35
241.3
275.8
40
45
310.3
50
344.7
RequiredAmountofSubcooling(Ammonia)
120F(49C)SCT
95F(35C)SCT
65F(18C)SCT
degF
degC
degF
degC
degF
degC
0.2
0.1
0.3
0.2
0.5
0.3
1.0
0.5
1.3
0.7
1.9
1.0
1.4
0.8
1.9
1.1
2.8
1.6
1.9
1.1
2.6
1.4
3.8
2.1
2.4
1.3
3.2
1.8
4.7
2.6
2.9
1.6
3.8
2.1
5.6
3.1
3.4
1.9
4.5
2.5
6.6
3.7
3.8
2.1
5.1
2.8
7.5
4.2
4.3
2.4
5.8
3.2
8.5
4.7
4.8
2.7
6.4
3.6
9.4
5.2
6.0
3.3
8.0
4.4
11.8
6.5
7.2
4.0
9.6
5.3
14.1
7.8
8.4
4.7
11.2
6.2
16.5
9.2
9.6
5.3
12.8
7.1
18.8
10.5
10.8
6.0
14.4
8.0
21.2
11.8
12.0
6.7
16.0
8.9
23.5
13.1
Page24of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
AcommonlyusedmethodofsubcoolingliquidrefrigerantistermedMechanicalSubcooling.This
istheCOLMACRECOMMENDEDmethodofliquidsubcoolingandreferstousingaportionof
liquidrefrigerantfromtheuncooledliquidlinetoevaporateandcooltheremainingliquid.A
heatexchanger(typicallyaplatetypeexchanger)isinstalledintheliquidlineinsuchawayasto
cooltheliquidrefrigerantononesideoftheexchangerbyevaporatingarelativelysmallamount
oftherefrigerantontheothersideoftheexchanger.Theevaporatingsiderefrigerantis
meteredbyaTXVormotorizedvalveinresponsetoliquidlinetemperatureandtheevaporated
refrigerantthenreturnedtothesuctionline.Thismethodofsubcoolingproducespredictable
resultsunderallconditions,andisrequiredtoinsureproperoperationofColmacDXAmmonia
evaporatorcontrols.Withmechanicalsubcoolingthereisnonetlossofrefrigeratingeffector
systemenergyefficiency.
Alternatemethodsforsubcoolingrefrigerantliquidcanbeapplied,buthavevariousdrawbacks:
AmbientSubcooling.Thisinvolvesusingaseparatecircuitwithinthecondensertoroute
liquidrefrigerantfromthereceivertothesystemcausingtherefrigeranttoapproachthe
ambientairtemperature.Thisisarelativelysimpledesign,howevertheamountof
subcoolingwillbelimitedtothecondenserTD.Thismaynotbeasufficientamountof
subcoolingtoavoidformationofflashgasduringcertaintimesoftheyear.Therefore,this
methodofsubcoolingisNOTrecommended.
LiquidPumping.Herealiquidpumpisinstalledattheexitofthereceivertopressurizethe
liquidlinesufficientlytoovercomethetotalpressuredropduetofrictionandelevationgain.
Whileeffectiveateliminatingflashgasregardlessofoperatingconditions,thismethodadds
complexityandwillcausetheliquidlinetooperateatapressurewhichishigherthan
condensingpressure.Aswithambientsubcooling,thismethodisNOTrecommended.
NOTE:ReferringtoFiguresA1A3,liquidtemperatureleavingthemechanicalsubcoolerisshown
as40degF.Thisliquidtemperatureisconservativeandshouldpreventtheformationofflash
gasinliquidlinesinmostifnotallcases.
SubcoolerPiping:
Figure12belowillustratestypicalmechanicalsubcoolerheatexchangerpiping.
Page25of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
FIGURE12
SUBCOOLER KIT
SUCTION
HOT LIQUID IN
N.C.
SUBCOOLED LIQUID OUT
TEMPERATURE
TRANSDUCER
TEMPERATURE
CONTROLLER
SOLENOID VALVE
GLOBE VALVE
PRV VALVE
ANGLE VALVE
STRAINER
T TEMPERATURE GAUGE
Toinsureeffectiveliquidsubcooling,besuretoobservethefollowingrules:
1. Sizepipingandvalvesforthemaximumrefrigerantflowconditionanticipated,i.e.
lowestheadpressure/highestsuctionpressure.Thisconditiontypicallyoccursduring
wintermonths.
2. Alwaysinsulateliquidlinestopreventheatgainandlossofsubcooling.
3. Locatesubcoolerheatexchangerdownstreamofthereceiverattheentrancetothe
liquidline,NOTbetweenthecondenserandreceiver.SeeP&IDexamplesabove.
4. Usegoodpipingpractice,ascanbefoundintheIIARAmmoniaRefrigerationPiping
Handbook(IIAR2004).
MechanicalSubcoolerSelection:
ColmacofferspreengineeredMechanicalSubcoolerswhicharefactorypipedandpackaged
inafreestandingframe,andincludethefollowingcomponents:
Stainlesssteelplatetypesubcoolingheatexchanger
Electronicexpansionvalveandtemperaturecontroller
Service(isolation)valves
Pressurereducingvalveforcontrolledleavingliquidlinepressure
ULlistedandwiredcontrolpanel
SeeseparateEngineeringBulletinforsubcoolerselectionandspecificationdetails.
VII.
PipingGeneral
1. Cleanliness.Thesmallinternalpassagesfoundinexpansionvalves(andothercontrol
valves)inDXammoniasystemsareparticularlysensitivetofoulingandpluggingwith
Page26of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
VIII.
relativelysmallamountsofdirtanddebris.Forthisreason,particularcareneedstobe
takenduringtheinstallationofsystempipingtoinsurecleanlinessandtominimizethe
introductionofweldscaleanddust,andothertypesofdirtanddebris.
2. EvacuationPriortoChargingtheSystemwithAmmonia.BecausetheperformanceofDX
ammoniaevaporatorsisdramaticallyaffectedbyevensmallamountsofwater,itisvery
importanttofollowgoodpressuretestingandevacuationprocedurespriortocharging
thesystemwithammonia.Recommendedevacuationprocedurecanbefoundinthe
separateColmacEngineeringBulletinonthistopic.
LiquidLines
Industryacceptedmethodsandpracticeforpropersizingandarrangementofliquidlines
canbefoundintheIIARAmmoniaRefrigerationPipingHandbook(IIAR2004).Additionally,
followtheguidelinesexplainedbelow.
1. Designmassflowrate.Liquidlinesmustbesizedappropriatelyforthetypeofline
(condensertoreceiver,receivertoexpansionvalve,etc.)andtheexpectedmaximum
massflowratecondition.Themaximummassflowrateconditionwilloccurwhen
dischargepressureisatitsminimum,suctionpressureisatitsmaximum,and
compressorsarerunningfullyloaded.Typicallythiswouldoccurwithfloatinghead
pressuresystemsduringwintermonths.Designingliquidlinesforthehottestdayofthe
year(commonlytakenasthedesignpoint)willlikelyleadtoundersizedliquidlines
andhigherthanexpectedpressuredropwiththepotentialofformingflashgasinthe
liquidline.
2. Insulation.Insulationofliquidlinesdownstreamoftheliquidsubcoolerbecomes
criticallyimportantinDXammoniasystemstoavoidheatgainandthepotentialfor
developingflashgasintheliquidlineupstreamoftheexpansionvalves.Usegood
qualityinsulationsystemswithadequateinsulationvalueandprotectionagainst
physicalandweatherdamage.
3. TypeofExpansionValve.ThreetypesofexpansionvalvesarecommonlyusedinDX
systems:1)Thermostatic,2)Motorized,and3)PulsewidthModulating.Thermostatic
andmotorizedvalvesmodulateinresponsetotheimposedloadonthecoilandsoliquid
linesshouldbesizedforthemaximumexpecteddesignmassflowrate(seeparagraph
V.1.above).Pulsewidthmodulating(PWM)expansionvalves,ontheotherhand,
alternatebetweenwideopenandfullyclosedataratewhichcorrespondstotheduty
calledforbytheelectroniccontroller.Becausethemassflowrateofrefrigerantwillbe
determinedbythewideopencapacityofthePWMvalve,thelocalliquidlinefromthe
liquidsupplymaintotheindividualevaporatormustbesizedtohandlethemaximum
capacityofthevalve.WhenPWMvalvesareused,theliquidsupplymainlinemustbe
sizedtohandlethiswideopencapacitybyusingadiversityfactorbasedonthe
numberofevaporatorsexpectedtobeoperatingatthesametimedividedbythetotal
numberofevaporators.
4. PressureRegulatingValve.AsshowninFiguresA1A3,theliquidlinepressureleaving
thesubcoolerassemblyismaintainedat75psigbyapressureregulatingvalve.When
defrosthotgaspressureisregulatedtomaintain90psig(alsoshowninFiguresA1A3)
Page27of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
thispressuredifferentialallowsdefrostcondensateleavingtheevaporatorsduring
defrosttobefeddirectlybackintotheliquidlineandsenttootheroperating
evaporators.
5. Pipematerialspecifications.RefertotheIIARAmmoniaRefrigerationPipingHandbook
(IIAR2004)andANSI/IIARStandard22008(IIAR2008)fordetailedpipematerial
specificationrequirementsforammonialiquidpiping.
IX.
SuctionLines
X.
Unlikepumpedammoniasystems,nowetsuctionlinesareneededforDXammonia.
Althoughtheyshouldbepitchedandtrappedtoaccommodatetheoccasionalpresenceof
liquid,suctionlinepressuredropshouldbecalculatedtoreflectdryoperation.Refertothe
IIARAmmoniaRefrigerationPipingHandbook(IIAR2004)forpropersizingandarrangement
ofdrysuctionlines.Additionally,followtheguidelinesexplainedbelow.
1. Designmassflowrate.Aswithliquidlines,drysuctionlinesshouldbesizedforthe
expectedmaximummassflowratecondition.Again,themaximummassflowrate
conditionwilloccurwhendischargepressureisatitsminimum,suctionpressureisatits
maximum,andcompressorsarerunningfullyloaded.
2. Trappedverticalrisers.Suctionlineswithverticalupflow(suctionrisers)mustbe
installedwithaptrapatthebottom(entrance)oftheriseranddischargeintothetopof
theoverheadsuctionmainpipe.Whenvaryingloadsontheevaporatorareexpected,a
doubleriserdesignshouldbeused.RefertotheIIARAmmoniaRefrigerationPiping
Handbook(IIAR2004)forexamplesofdoublesuctionriserdesigns.
3. Pitchedsuctionlines.Suctionlinesmustbepitchedaminimumof1/8perfoottoward
thesuctionaccumulatortofacilitategooddrainageofanyliquidrefrigerantand/oroil
thatentersthesuctionline.
4. Pipematerialspecifications.Particularattentionmustbepaidtocarbonsteelpipe
materialspecificationsinlowtemperature(suctiontemperaturesbelow20degF),
whichmayrequireimpacttesting.RefertotheIIARAmmoniaRefrigerationPiping
Handbook(IIAR2004)andANSI/IIARStandard2(IIAR2008)fordetailedpipematerial
specificationsandrequirements.
HotGasLines
Industryacceptedmethodsandpracticeforpropersizingandarrangementofhotgaslines
canbefoundintheIIARAmmoniaRefrigerationPipingHandbook(IIAR2004).Additionally,
followtheguidelinesexplainedbelow.
1. Designmassflowrate.Hotgas(defrost)linesshouldbesizedforthemassflowrate
correspondingtothemaximumnumberandsizeofevaporatorsexpectedtodefrostat
thesametime.Conventionalwisdommaintainsthateachindividualevaporatorrequires
aflowofhotgasequalto2xtimestheflowrequiredduringcooling,andsothiswould
limitthenumberofevaporatorsbeingdefrostedatthesametimetoamaximumof1/3
thetotalnumberofevaporatorsinthefacility(thetwotoonerule).However,
evaporatorsequippedwithColmacSmartHotGascontrolscaneffectivelydefrostan
Page28of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
2.
3.
4.
5.
6.
evaporatorwithhotgasflowingtotheevaporatorforonly8to10minutes.Withan
effectivebuildingmanagementcontrolsystem,anddependingonthefrostloadand
frequencyofdefrosting,itispossibletolimittheamountofdefrosthotgasflowingat
anygiventimetoonlythatrequiredforthelargestsingleevaporatorinthefacility.This
approachobviouslyhasthepotentialtoreducethehotgaslineandPRVsizeandcost.
Expectedmassflowrateofhotgasfordefrostofagivensizedevaporatorcanbe
calculatedusingthemethoddescribedbelowintheHotGasDefrostsection.
Insulation.Insulationofhotgaslinesiscriticallyimportanttoinsurefastdefrosting.Use
goodqualityinsulationsystemswithadequateinsulationvalueandprotectionagainst
physicalandweatherdamage.
PressureRegulatingValve.AsshowninFiguresA1A3,thehotgaslinecomingfromthe
compressordischargelineismaintainedat90psigbyapressureregulatingvalve.When
defrosthotgaspressureisregulatedtomaintain90psigandtheliquidlineis
maintainedat75psig(alsoshowninFiguresA1A3)thispressuredifferentialallows
defrostcondensateleavingtheevaporatorsduringdefrosttobefeddirectlybackinto
theliquidlineandsenttootheroperatingevaporators.Maintainingthehotgasline
pressureatthereduced90psigalsominimizesheatlosstothesurroundingambient.
Pitchedhotgaslinesanddriplegs.Hotgaslinesmustbepitchedaminimumof1/8per
foottowardtheevaporatorstofacilitategooddrainageofanycondensedrefrigerant
(condensate)todriplegsinstalledaheadoftheevaporatorcontrolvalvegroup(s).
Liquiddrainers.Ashotgasfordefrosttravelsfromtheengineroomtotheevaporators
someofitsenergywillbereleasedtoheatupthepipingitself,andsomereleaseddue
toheatlossthroughinsulation.Condensatewillthereforeforminthehotgaspiping
whichmustthenbeeffectivelytrappedanddrainedbeforeitreachestheevaporators.
Unlessitiseffectivelyremoved,accumulatingcondensedliquidupstreamofhotgas
solenoidvalveswillcausecavitationontheseatsofthesolenoidvalveswhenthevalve
isclosed(Jensen2013).Condensatewillcollectindriplegs(describedabove)andmust
bereturnedtoeitheranearbysuctionline,oracondensatereturnline.Usealiquid
draineroranappropriatelysizedsteamtraptoallowonlyliquidtoleavethedripleg.
Usingliquiddrainersalsoeffectivelykeepshotgaslinescontinuallyheatedandreadyto
supplyfullflowofhotgastoevaporatorsimmediatelyondemandfordefrosting.
Pipematerialspecifications.RefertotheIIARAmmoniaRefrigerationPipingHandbook
(IIAR2004)andANSI/IIARStandard22008(IIAR2008)fordetailedpipematerial
specificationrequirementsforammoniahotgaspiping.
XI.
EffectsofWaterinAmmoniaandItsRemoval
Asexplainedindetailelsewhere(Nelson2010),thepresenceofevensmallamountsof
waterinammoniahasasignificantnegativeeffectonDXevaporatorperformance.
Unfortunately,waterisdifficulttoentirelykeepoutofindustrialammoniarefrigeration
systemsforanumberofreasons:Residualwaterinpressurevesselsleftfromhydrotesting,
incompleteevacuationofthesystempriortostartup,leaksinpartsofthesystemwhich
normallyoperateinavacuum,etc.
Thisresidualwatergoesintosolutionwiththeammoniaandincreasesandtheboilingpoint
(bubblepoint)temperature.Ataconcentrationof20%(bymass)waterinammonia,the
Page29of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
IncreaseinBubblePointTemperature,F
boilingpointrisestoapproximately10degFabovetheboilingpointofpureammoniaatthe
samepressure.SeeFigure13below.
Astheammoniawaterliquidenterstheevaporatorcircuititbeginstoboil.Becauseofthe
largedifferenceinvaporpressuresofammoniaandwater,onlyammoniavaporis
generatedduringtheevaporationprocess,leavingthewaterbehindintheremainingliquid.
Sotheevaporationprocessresultsinanincreaseinwaterconcentrationanda
correspondingincreaseintheboilingpointoftherefrigerantasitpassesthroughthecoil
circuit.Inthecaseofanevaporatoroperatingwitha10degFTD,therefrigerantwillstop
boilingoncethewaterconcentrationreachesabout20%sincetheboilingpointwillhave
risenby10degF.Thiscessationofboilingwilloccuratsomepointalongthelengthofthe
evaporatorcircuit,thepointatwhichboilingstopsdependingontheinitialconcentrationof
waterandsuctionpressure.Atthepointwheretheincreaseinthewaterconcentrationhas
causedanincreaseintheboilingpointequaltothecoilTD,liquidrefrigerantwillexitthe
evaporatorandenterthesuctionline.
Figure13belowshowstheincreaseinboilingpoint(bubblepoint)forvariousinitialwater
concentrationinammoniaatvariouspressures.
FIGURE13
IncreaseinBubblePointTemperaturevsComposition
AmmoniaWater
40
35
48.2 psia(3.3bar)
30.4psia(2.1bar)
18.3psia(1.3bar)
30
10.4psia(0.7bar)
25
20
15
10
0
0.1
0.2
0.3
0.4
0.5
Composition(MassFractionWater)
Anexampleoftheincreaseinbubblepointtemperatureoverthecircuitlengthofan
evaporator,representedbythechangeinvaporquality,isshowninFigure14belowforan
initialwaterconcentrationinammoniaof3%atapressureof10.4psia(40degFSST).In
Page30of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Increase in Tbub, F
thisexamplethebubblepoint(Tbub)hasincreasedby10degFatavaporqualityofapprox.
0.89.
FIGURE14
Incr in Bubble Point vs NH3 Vap Quality, 3.00% Water in NH3,
Tsat = -40.0F
50
45
40
35
30
25
20
15
10
0
0
0.2
0.4
0.6
0.8
1
NH3 Vapor Mass Fraction (Quality)
Thisincreaseinbubblepointsignificantlyreducesthemeantemperaturedifferenceand
thereforethecoolingcapacityoftheevaporatorisreducedasillustratedinFigure15.
FIGURE15
Page31of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Inadditiontotheperformancepenaltyseenwhenrelativelysmallamountsofwaterare
presentintheammonia,thisalsomeansthatthemassfraction(10.89)=0.11,or11%of
themassofrefrigerantexitingtheevaporatorasliquidwillhavetobecaptureddownstream
inthesuctionaccumulator.
Knowingthatammoniawaterliquidofapproximately20%waterconcentrationwill
unavoidablyleavetheevaporatorswheneverevensmallamountsofwaterarepresentin
theammoniaisimportantforthedesignertounderstand.Thesuctionaccumulatormust
thereforebeproperlydesignedtoperformthefollowingfunctions:
i. Separateliquidandvaporrefrigerantandallowonlyvaportoreturntothe
compressor,
ii. Captureanddistill(byheating)ammoniawaterliquidtoaconcentrationthat
cansafelyberemovedfromthesystemfordisposal.
iii. Transferexcesstrappedliquidtothehighpressurereceiver,orintothereduced
pressureliquidline.
1. Separation
Liquidvaporseparationinsuctionaccumulatorvesselsiswellunderstoodanddesign
methodswelldocumented.Refertorecognizedpublishedsizinganddesignmethods
(Stoecker1988,Wiencke2002).
Colmacoffersarangeofpreengineeredfactoryassembledsuctionaccumulator
packagesspecificallysuitedtooperationwithDXammonia.SeeseparateEngineering
Bulletinforselectionandspecificationdetails.
2. DistillationandDisposalofAmmoniaWaterSolution(AmmoniumHydroxide)
Distillation:
AmmoniaishighlysolubleinwaterduetothepolarityofNH3moleculesandtheir
abilitytoformverystronghydrogenbonds(Nelson2010).Thishighsolubilitymakes
ammoniawateragoodworkingfluidpairinabsorptionrefrigerationmachines,taking
advantageofthelargevaporpressuredifferencesbetweentheammoniavaporand
weaksolution.However,thissamebehaviormakeswaterremovalfromammonia
refrigerationsystemssomewhatchallenging.
Asmentionedabove,ammoniawatersolutionconcentratedtoapproximately20%
waterwillreturnfromevaporatorsviathesuctionlinetobetrappedinthesuction
accumulator.Thisaqueousammoniasolution,calledAmmoniumHydroxide,ata
concentrationof80%ammonia(20%water)wouldbeverydifficulttosafelyremove
fromthesystemfordisposal.Furtherdistillationofthesolutionisneededtobringthe
ammoniaconcentrationinthesolutiondowntothepracticalminimumbeforeitis
removed.
Page32of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
TheonlypracticalwaytodistilltheAmmoniumHydroxideisbyheatinginaseparate
distillationvessel,calledastill.AmmoniumHydroxidetrappedinthesuction
accumulatordrainsbygravityintothestillwhereitisheatedtoatemperature
correspondingtothepointonaPhaseEquilibriumdiagramwheretheslopeofthedew
pointlinechangesrapidlyfromnearlyverticaltomorenearlyflat.Thispointisshownon
Figure16asPointA.Belowthistemperature(between100and120degF),nearlypure
ammoniavaporwillleavethestillandtravelthroughtheventlinebacktothesuction
accumulatorwhereitwillthenbetakenbacktothecompressor.Abovethis
temperature,watervaporwillbegintoleavetheAmmoniumHydroxidesolutionand
exitthestillventlinewhereitwillgobackintosolutionwithanyammonialiquid
presentinthesuctionaccumulator.Basedonthis,theheatingelementinthestillmust
becontrolledtobringthesolutiontemperatureuptoamaximumof100to120degF,
atwhichpointitisreadytoberemovedsafelytoastoragecontainerforfurther
processingand/ordisposal.
FIGURE16
Figure16alsoshowsthatthemaximumwaterconcentrationintheAmmonium
Hydroxidesolutionheatedto100degFvarieswithsuctionpressure.Themaximum
waterconcentrationspossibleareshownasPointsB,C,D,andE,inFigure16,andare
listedinTable7below.Itisapparentfromthefigureandthetablethatthestillisableto
achievehigherwaterconcentrationsatlowersuctionpressures.
Page33of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
TABLE7
AMMONIAWATERCONCENTRATIONS@100degFvsSUCTIONPRESSURE
SuctionPressure,psia
WaterConcentration, AmmoniaConcentration,
(SaturationTemp,F)
%bymass
%bymass
48.2(+20F)
57.5
42.5
30.4(0F)
65.0
35.0
18.3(20F)
72.5
27.5
10.4(40F)
80.0
20.0
Usingtheaboveinformation,anestimatecannowbemadeofthevolumeof
AmmoniumHydroxidesolutionthatwillbegeneratedbythestillforagivensystem
ammoniachargehavingagiveninitialwatercontent.Table8belowshowsthe
expectedvolumeofAmmoniumHydroxidesolutionperpoundofinitialammonia
chargethatwillhavetoberemovedbythestill(anddisposedof)inorderto
completelyremovethewaterfromrefrigerationsystem.
TABLE8
EXPECTEDVOLUMEOFDISTILLEDSOLUTIONAMMONIUMHYDROXIDE@100F
(GALLONSperPOUNDINITIALAMMONIACHARGE)
InitialWater
SaturatedSuctionPressure,psia(SaturatedTemp,F)
Content,%
48.2(+20F)
30.4(0F)
18.3(20F)
10.4(40F)
0
0.00000
0.00000
0.00000
0.00000
1
0.00246
0.00211
0.00183
0.00161
3
0.00738
0.00633
0.00550
0.00484
5
0.01230
0.01055
0.00917
0.00807
10
0.02460
0.02109
0.01835
0.01614
20
0.04920
0.04218
0.03669
0.03229
EXAMPLE:
Asystemhasaninitialammoniachargeof5,000lbswith3%watercontent.Thestill
isinstalledonthe20degFsuctionaccumulator.Whatwillbethetotalvolumeof
distilledAmmoniumHydroxidesolutiondrainedfromthestill?
Answer:
FinalDistilledSolutionAmmoniaConcentrationforDisposal(fromTable7):27.5%
ExpectedVolumeofDistilledSolutionperPound(fromTable8):0.0055gal/lbs
TotalExpectedVolumeof27.5%AmmoniumHydroxideforDisposal:
5,000lbsx0.0055gal/lbs=27.5gallons
StorageandDisposal:
Page34of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
AmmoniumHydroxideislistedasahazardoussubstanceunderCWA(40CFR
1164.40CFR117.3ReportableQuantityCategoryC.1000lbs/454kg).Assuch,itis
importanttocomplywithalllocalandnationalregulationsforsafehandlingand
disposalofthesolutionremovedfromthesystemstill(Smith2010).
ItisinterestingtonotethatsuitablydilutedAmmoniumHydroxidemaybedisposed
ofonagriculturallandasfertilizer.However,thematerialshouldbekeptfrom
enteringstreamsandlakesasitisharmfultoaquaticlifeandcancause
environmentaldamage.
AmmoniumHydroxidewillreactexothermically(heatisgenerated)withacids,and
soneutralizingofthesolutionbyunqualifiedpersonnelisnotrecommended.
ItisimportanttopreventcontactoftheAmmoniumHydroxidesolutionwith
chemicalssuchasmercury,chlorine,iodine,bromine,silveroxide,and
hypochlorites,astheycanformexplosivecompounds.Contactwithchlorineforms
chloraminegaswhichisaprimaryskinirritantandsensitizer.
Figure16incombinationwithTable7canbeusedtopredictthetemperatureabove
whichammoniavaporwillbegeneratedwhenthedistilledsolutionisstoredinan
opencontainer.Thisvaporneutraltemperatureisfoundusingtheammonia
concentrationsshowninTable7forvarioussuctionpressures,intersectingalineof
constantbubblepointtemperature(Tbub)atatmosphericpressure(14.7psia)on
Figure16.Table9belowshowstheambient(storage)temperaturesbelowwhich
ammoniavaporwillnotbegeneratedfromtheAmmoniumHydroxidesolution
dischargedfromthestill.
TABLE9
RECOMMENDEDMAXIMUMAMMONIUMHYDROXIDESTORAGETEMPERATURES
SuctionPressure,psia AmmoniaConcentration, StorageTemperature,
(SuctionTemp,F)
%bymass
DegF
48.2(+20F)
42.5
42
30.4(0F)
35.0
64
18.3(20F)
27.5
90
10.4(40F)
20.0
108
AmmoniumHydroxidesolutionhasacorrosivereactionwiththefollowingmaterials
whichshouldnotbeusedtostorethedistilledAmmoniumHydroxidesolution
(LaRocheIndustries1987):
Galvanized(zinccoated)surfaces
Copper
Brassandbronzealloys
Certaintypesofelastomers
ThedistilledAmmoniumHydroxidesolutioncanbesafelystoredincontainersmade
ofthefollowingmaterials:
Page35of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Carbonsteel
Stainlesssteel
Aluminum
CastIron
Generallyspeaking,aluminumalloysarenotrecommendedforexposuretoaqueous
solutionshavingapHgreaterthan9.0duetoacceleratedcorrosionandmetalloss.
AmmoniumHydroxidehowever,eveninhighconcentrations,isanexceptiontothis
rule.(Davis1999).
Inconclusion,AmmoniumHydroxidesolutioncollectedfromthestillshouldbestored
inanappropriatelyconstructedcontainerlocatedinacoolspaceoutofdirect
sunlight.Itisrecommendedthatthedistilledsolutionbedisposedofusingalocal
qualifiedwastedisposalvendor.
MoredetailedhandlingandsafetyinformationcanbefoundonMSDSsheets
publishedbysuppliersofAmmoniumHydroxide(TannerIndustries2000,LaRoche
Industries1998).
3. LiquidTransfer
Liquidrefrigerantwillleavetheevaporator(s)andaccumulateinthesuction
accumulatorvesselduringoperationforanumberofreasons:
a. Liquidfloodbackduetowaterintheammonia(seeaboveexplanation),
b. Liquidfloodbackduetoarapidchangeinsystempressureand/orload,
c. Liquidcondensatefromhotgasdefrost.
Aliquidtransfersystemcapableofhandlingthetotalanticipatedvolumeofliquid
refrigerantreachingthesuctionaccumulatorvesselmustbeincludedinthesystem
design.Inordertoproperlysizethetransfersystem,estimatesoftheamountof
liquidreturningfromevaporatorsforthereasonsstatedabovemustbemade.
LiquidFloodbackDuetoWaterinAmmonia
i.
Theanticipatedvolumeofammoniawaterliquidleavingtheevaporator(s)basedon
anaverage20%waterconcentrationattheevaporatorexithasbeencalculatedand
showninTable10below.Multiplythevalueshowninthetablebythetotalcapacity
ofthesystemintons(TR)todeterminethevolumeofammoniawaterliquid
returningtothesuctionaccumulator.
Page36of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
TABLE10
VolumeofAmmoniaWaterLiquidLeavingDXEvaporators
WaterContentin
Ammonia,%
0.5
1.0
3.0
5.0
10.0
VolumetricFlowrateofAmmoniaWater
(20%waterconcentration)LeavingDX
Evaporators,ft3/h/TR
0.01
0.02
0.07
0.12
0.24
Example:
Ithasbeendeterminedthattheammoniafedtoevaporatorswithtotalcapacityof
200tons(TR)hasawatercontentof3%.Iftheevaporatorsareoperatedasdirect
expansion(DX),howmuchammoniawaterliquidisexpectedtoreturnfromthe
evaporatorstothesuctionaccumulator?
Answer:
VolumeofFloodbackDuetoWater=200TRx0.07ft3/h/TR=14ft3/h=1.8gal/min
Inaproperlydesignedandoperatedsystem,thistypeofliquidfloodbackshould
onlyoccurinitiallyduringstartupsincewaterinthesystemwillbecapturedinthe
stillandthenremoved.
LiquidFloodbackDuetoRapidChangesinPressureorLoad
ii.
Thistypeoffloodbackisdifficulttopredict,butfortunatelyis(orshouldbe)
relativelysmall.Aworstcaseruleofthumbmightbetoassumethatanaverage
10%ofthemassofrefrigerantleavesasliquidfrom25%oftheevaporators.Inthat
case,thetransfersystemwouldneedtohandleavolumeofliquidapproximatedby
thefollowingformula:
12,000

, 3/
0.10 0.25
(8)
Where:

,

,
/

, 3/
Example:
200TRofammoniaevaporatorcapacityat25degFsuctiontemperatureis
connectedtothesuctionaccumulator.Whatistheexpectedaveragevolumeof
liquidreturningtotheaccumulatorduetoliquidfloodback?
Page37of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Answer:
LatentHeatofVaporization,hfg=550Btu/lbm
ChangeinVaporQualityThroughtheEvaporator,dx=0.8
SpecificVolume(liquid),v=0.024ft3/lbm
,

0.024 0.10 0.25 3.3 3/
.
DefrostCondensatefromHotGasDefrost
iii.
0.4
Ifthereisanywaterpresentintheammoniaenteringtheevaporatorduringlow
temperatureoperation,itwillbeheldanddistilledintheporesoftheproprietary
wickingstructureontheIDoftheColmacevaporatortubes.Thislocaldistillation
processdegradestheperformanceoftheevaporatorbyreducingthelocalmean
temperaturedifference(MTD).Hotgasdefrostiscriticaltoremovingthiswater
richliquidfromthewickingstructure.Theammoniahotgascomingfromthe
highpressurereceiver(seeFiguresA1thruA3)isessentiallywaterfreeandoil
freeammonia.ThispureammoniavaporcondensesonthetubeID,dilutesthe
waterrichliquid,andsendsittoeithertheintercoolervesselorthelow
pressuresuctionaccumulatorwhereitcanbedistilledintheammoniastilland
removedfromthesystem.
Thisprocessofflushingtheevaporatorsandthesystemofwaterduringhotgas
defrostingshouldonlyhappeninitiallyduringthestartupphaseforsystemswhich
operatewithalowsuctionpressureaboveoneatmosphere(0psig)andthenonly
periodicallyforsystemswithalowsuctionpressureoperatinginavacuum(blast
freezing).Duringsystemstartup,avalveinthedefrostcondensatereturnlineon
eachevaporatorisopenedtoadmitthecondensatetothesuctionlineand
accumulator(seeFiguresA1throughA3).Intheaccumulatorthewaterladen
ammoniaiscapturedinthewaterstill,distilled,andremovedfromthesystem.
Afterthewaterintheinitialammoniachargehasbeencompletelyremoved(after
anumberofdefrostcycles)andtheammoniaisdry,thevalveinthecondensate
returnlinetosuctionisclosedandthevalveinthecondensatereturnlinetothe
liquidlineisopened.
Duringstartup,excessdefrostcondensatewhichisnotcapturedinthewaterstill
mustbetransferredtothehighpressuresideofthesystem.Thevolumeof
defrostcondensateleavingtheevaporatorscanbeestimatedusingthefollowing
formula:
, 3/
12,000
(9)
Where:

,
/
Page38of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
XII.
3/
0.15
Example:
200TRofammoniaevaporatorcapacityat+10degFroomtemperature/85%rhis
connectedtothesuctionaccumulator.Whatistheexpectedaveragevolumeof
defrostcondensate(liquid)returningtotheaccumulator?
Answer:
LatentHeatofVaporization,hfg=550Btu/lbm
SensibleHeatRatio(SHR)fromTable1=0.87
SpecificVolume(liquid),v=0.024ft3/lbm
DefrostEfficiency=0.15
200 12,000
1 0.87

, 3/
0.024
90.8 3/
11.3
/
550
0.15
Thesuctionaccumulator(s)andtheliquidtransfervesselmustthereforebe
designedtohandlethetotalamountofliquidreturningfromevaporatorsdueto
water+normalfloodback,+defrostcondensate.
AliquidtransfervesselisincorporatedintotheColmacPreEngineeredSuction
AccumulatorSkidpackage(seeseparateEngineeringBulletin).Thetransfervesselis
designedtohandleupto5%initialwatercontentinthesystemammoniacharge.
NotethatIndustrialRefrigerationgradeanhydrousammoniaiscertifiedtobe
99.95%pureammonia.
EffectsofOilonEvaporatorPerformanceandOilSeparation
ImmisciblelubricantsarerecommendedovermisciblelubricantsforlargeindustrialDX
ammoniarefrigerationsystemsforanumberofreasons:
o Lowercost
o Easeofseparation
o Relativeinsensitivitytocontaminants(water,dirt)
Eventhoughimmiscibleoilsarepreferredovermiscibletypesforthereasonsstated
above,anyoilreachingtheevaporatorcanpotentiallycoattheinsideofthetubesand
severelydegradeheattransferperformancedueto:
1. Addedresistancetoheattransferasexplainedbelowandshownin
Figure17,and
2. Foulingoftheproprietarywickingstructurepreventingliquidammonia
fromcoatingtheinsideofthetubesbycapillaryaction.
Evenathinlayerofoilcoatingtheinsideofevaporatortubesaddsresistancetoheat
flowasshownbelow.
Page39of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
CapacityReductionRatio
InsideFoulingFactor,ft2Rh/Btu
FIGURE17
InsideFoulingFactorvsOilFilmThickness
0.006
0.005
0.004
0.003
0.002
0.001
0
0.001
0.002
0.003
0.004
0.005
OilFilmThickness,inches
InatypicalDXammoniaevaporator,thisfoulingfactorcausesasignificantreductionin
coolingcapacityasisshownbelowinFigure18.
FIGURE18
CapacityReductionvsOilFilmThickness
AmmoniaEvaporator,15FSST,5FAirOn
0.95
0.9
0.85
0.8
0.75
0
0.0005
0.001
0.0015
0.002
0.0025
0.003
0.0035
0.004
OilFilmThickness,inches
Page40of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
ItisapparentfromFigures17and18abovethatitishighlydesirablefromanenergy
efficiencystandpointtopreventcompressorlubricatingoilfromreachingtheevaporators.
Toachievethis,thefollowingshouldbecarefullyconsideredandspecifiedinthesystem
design:
a. Typeofcompressorlubricatingoil
b. Compressoroilseparatordesignandefficiency
c. Oilcaptureandmanagementattheoutletofthecondenser
d. Oilcaptureinthesuctionaccumulator(s)
e. Oilcaptureattheevaporator
TypeofOil:
Dependingonthetypeofcompressorused(reciprocatingorrotaryscrew),varyingamounts
oflubricatingoilwillunavoidablybedischargedwiththeammoniavapor.Oilwillleavethe
compressorbothinliquiddropletformandasoilvapor.Theliquiddropletscanbecaptured
mechanicallyintheoilseparatorvesselbycontrollingvelocityandbyincorporating
coalescingelements.Theoilwhichiscombinedwiththeammoniainvaporformismore
difficulttocapture.Generallyspeaking,asvolatilityandsolubilityoftheoilincrease,
separationbecomesmoredifficult.Theamountofoilwhichisnotcapturedintheseparator
andreturnedtothecompressorisreferredtoasoilcarryover.
Alllubricatingoilsusedintheammoniarefrigerationindustryareblendsofabasefluid(s)
withadditives(Wierbosch2010).Thebasefluidcontrolsvolatilityandsolubiltyoftheoil.
Today,commonlyusedbasefluidsinclude:
Napthenic
SolventRefinedParaffinic
AlkylBenzene
2StageHydrocracked
PAO/AB
Thearomaticcontentofthebasefluidhasalargeeffectonvaporpressure(volatility)and
solubility.Thehigherthevaporpressureoftheoil,themoreoilvaporwillleavethe
compressorwiththeammoniainthedischargegas(Briley1984).Sincethisoilvaporis
difficulttocaptureintheseparator,itisdesirabletoselectanoilwhichhasthelowestvapor
pressurepossible.AlkylBenzeneandNaphthenicbaseshavethehighestaromaticcontent,
vaporpressure,andsolubility.2StageHydrocrackedbaseshavelowestaromaticcontent,
vaporpressure,andthelowestsolubility.
Itisthereforerecommendedthatammoniarefrigerationoilhavinga2StageHydrocracked
basefluidbeusedintheDXammoniacompressionsystemdesign.2StageHydrocracked
mineraloilmanufacturedbyCPI(CPI100968)isrecommendedforapplicationin
reciprocatingandscrewtypeammoniacompressorsfortemperaturesabove40.
Anotherfactoraffectingoilvaporpressureistheoiltemperature.Thehighertheoil
temperature,thehigherthevaporpressure.Reducingthedischargegas(andoilvapor)
Page41of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
temperaturebeforeitenterstheseparatorwillthereforereduceoveralloilcarryoverand
increasetheefficiencyoftheseparator.Forexample,desuperheatingthedischargegas
from80degCto35degCreducestheoilvaporpressure,andthereforecarryoverofoil
vapor,byapproximately85%(Wiencke2012).
OilSeparator;
ForsuccessfulDXammoniasystemoperation,anoilseparatorwithcoalescingelements
capableofguaranteeing57ppmcarryovershouldbespecifiedandinstalled.
Forreasonsmentionedabove,itisalsorecommendedthatthedischargegasbe
desuperheatedasmuchaspracticalpriortoenteringtheoilseparator.
NOTE:MeshPadoilseparatorsasfoundonolderscrewcompressorpackagesand
reciprocatingcompressorswillnothavetherequiredseparationefficiencyandarenot
recommended!
Oilcaptureandmanagementattheoutletofthecondenser;
Asmentionedabove,reducingthetemperatureofthedischargegasdowntothesaturated
condensingtemperature(i.e.fullydesuperheating)significantlyreducesthevaporpressure
oftheoilinthedischargegas.Thisreductionoftheoilvaporpressureincreasestheamount
ofoilavailableforcapture.
Consequently,mostoftheoilvaporwhichhasescapedtheoilseparatorvesselwillbe
condensedandheldintheliquidammonialeavingthecondenser.Itispossibletodesignthe
highpressurereceivertocollectandseparatethisoil,nowintheliquidphase,andthen
automaticallyreturnitautomaticallytothecompressors.Itisalsodesirabletotakethede
oiledammoniavaporfromthetopofthehighpressurereceiverratherthanusingoilladen
dischargegasforhotgasdefrost.ThesefeaturesareshowninFiguresA1thruA3inthe
appendix.
Oilcaptureinthesuctionaccumulator(s);
Properlydesignedsuctionaccumulatorsshouldincludeaccompanyingoilpotstocollectand
removeanysmallamountofoilthathasmadeitasfarastheevaporators.SeeFiguresA1
thruA3intheappendix.
OilCaptureattheEvaporator:
Asexplainedabove,itisimportanttopreventfoulingofevaporatortubeswithoil
particularlyatlowtemperatures.Tothisend,ColmachasdevelopedaproprietaryDX
ammoniadistributorwhicheffectivelyseparatesanyoilwhichhasescapedtheoilseparator
andhighpressurereceiverandpreventsitfromenteringtheevaporator.TheColmacTank
Distributor(patented)incorporatesadroplegintothebodyofthedistributortankwhich
Page42of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
servestocollectoilanddebriswhereitcanbeperiodicallydrainedandremovedfromthe
systemattheevaporator.
Figure19belowshowsacrosssectionoftheColmacTankDistributorwithitsintegraldrop
legfeatureforcapturingandremovingoil.
FIGURE19
COLMACTANKDISTRIBUTOR(CROSSSECTION)
Unlikeconventionalorificeplatetypedistributors,theColmacTankDistributoroperates
withverylowpressuredropandiswellsuitedtothefollowingapplications:
DXammoniautilizingmotorizedexpansionvalves
Floatingheadpressuresystems
Evaporatorsdesignedforoperationwithmorethanonerefrigerant
XIII.
EstimatingDXEvaporatorRefrigerantChargeInventory
Inordertoproperlysizethevolumeofthesystemvessels(highpressurereceiverand
lowpressureaccumulator),anestimateoftherefrigerantchargeheldinthe
evaporatorsmustbemade.Designersnormallycalculatetheevaporatorchargeasa
percentageoftheevaporatorinternalvolumetimestheliquiddensityofammonia.
OneofthemainadvantagesofDXoperationisthesignificantlyreducedevaporator
ammoniachargecomparedtopumpedammonia.Manysystemdesignersestimate
evaporatorchargeforbottomfeedpumpedammoniaevaporatorstobeasmuchas
80%oftheinternalvolumetimestheliquiddensitytoaccountforlowloadandidle
conditions.DXammoniaevaporatorchargecanbeestimatedusingtwophasevoid
Page43of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
XIV.
fractionequations.Table11belowshowsDXammoniaevaporatorchargeasa
percentageofinternalvolume.
TABLE11
COLMACDXAMMONIACHARGEINVENTORY
SuctionPressure,psia
ColmacDXAmmonia
(SaturationTemp,F)
EvaporatorChargeInventory,
lbs/ft3ofInternalVolume
48.2(+20F)
1.01
30.4(0F)
0.83
18.3(20F)
0.63
10.4(40F)
0.52
Thissignificantlyreducedsystemchargenotonlyreducestherequiredsizeofthe
receiver(and/orothersystemvessels),italsogreatlyreducespumpouttimeforthe
evaporatorspriortodefrosting.Thisservestoshortentotaldefrosttimeandincrease
theeffectivenessofhotgasdefrosting,reducingenergyconsumptionandoperating
costs.
EXAMPLE:
AColmacDXammoniaevaporatoroperatingatasuctiontemperatureof20degFhas
aninternalvolumeof12ft3.WhatistheexpectedDXammoniaoperatingcharge?What
wouldtheoperatingchargebeforpumpedammoniaoperationusingthe80%rule?
Answer:
ColmacDXammoniacharge=12ft3x0.63=7.6lbs
Pumpedammoniacharge=12ft3x0.8x42.2lbs/ft3=405lbs
DXSequenceofOperations
FollowingareimportantsequenceofoperationsstepsspecifictoDXammoniasystems.
Othergeneralsystemstartupproceduresshouldcomplywithsafe,bestpractice,and
withestablishedstandardoperatingprocedures.
Startup:
o Runwithdefrostcondensatetosuctionreturnvalvesopen(closethe
condensatetoliquidlinereturnvalves)ateachevaporator.Thisputsalldefrost
condensateintosuctionaccumulatorsandactivelyflushesevaporatorsandthe
internaltubewickingstructurewithpureammonia.Sendsallwaterladen
ammoniatolowpressuresuctionaccumulator.
o Activelyrunthewaterstillandremovedistilledaquaammoniasolutionwhen
thestilltemperaturereaches110degF.Continuetooperatethestilluntilthe
systemiscompletelydriedout(stilltemperaturenevercomesupto110degF).
Afterstartupandpulldownstages,afterthesystemammoniachangeiscompletely
driedout:
Page44of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
XV.
Closethecondensatetosuctionreturnvalvesandopencondensatetoliquid
linereturnvalvesoneachevaporator.
Disconnectpowertotheammoniastill.
ColmacSmartHotGasDefrost
Theenergyefficiencyofhotgasdefrostingevaporatorsdependsonthefollowing
(Nelson2011(1)):
1. Minimizingconvectiveheatloss.
Uselowestpracticaldefrostregulatorsetting.75to90psig(50to60F)
shouldbeadequate.Note:Ifhigherpressuresareneeded,lookfor
problemselsewhere.
2. Shortendefrostduration.
UsetopfeedorDX(directexpansion)evaporatorfeedtoreducetime
requiredforpumpout.
Openthehotgassolenoidonlylongenoughtoclearcoil(68minutes).
Installaseparatehotgassolenoidanddefrostregulatorforpreand
postheatingofthepanloop.Alternately,installelectricresistance
drainpanheating.
3. Reducethenumberofdefrostsperday.
Reducethenumberofdefrostsperdaytomatchthefrostload.
Chooseevaporatorswithwidefinspacing(3fpiinsteadof4fpi)to
maximizefrostcarryingcapacity.
Mitigateinfiltrationofhumidairintotherefrigeratedspaceby:
Properdesignandoperationofdoorways,and
Keeploadingdocksatthelowestpracticaldewpoint
temperature.
CalculatingtheCostofDefrost
Asmentionedabovedefrostefficiencycanbesignificantlyimprovedbyreducingthe
amountofenergylosttotheroombyconvectionduringdefrost.Theoperatingcost
savingsduetoareductionindefrostdurationhasbeencalculatedandpresentedbelow
basedon:
1. Reducingdefrostdurationfrom30minutesto10minutes,and
2. Increasingfrostthicknessfrom1mmto2mm(reducingthenumberofdefrosts
perdaybyhalf).
Thecalculationsassume:
Evaporatorcapacity:100TR
Compressorruntime:16h/day
CostofElectricity:$0.10/kWh
Page45of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Table12showscalculatedcostsavingsforfourdifferentroomtemperatures.
TABLE12
CALCULATEDCOSTSAVINGS($/y/100TR)FOROPTIMIZEDVSCONVENTIONALDEFROST
SHR
System COP:
Frost Removed, kg/day:
Frost Removed, kg/y:
I. Baseline (30 min, 1 mm)
Defrost Efficiency, %
Defrost Convective Losses, %:
Defrost Convective Losses, kWh/y:
Baseline Cost of Defrost (Convective), $/y:
II. Optimized (10 min, 2 mm)
Defrost Efficiency, %
Defrost Convective Losses, %:
Defrost Convective Losses, kWh/y:
Optimized Cost of Defrost (Convective), $/y:
Room Temp, C (F)

0 (+32)
-18 (0)
-23 (-10)
0.66
0.89
0.93
3.2
2.5
2.2
2,778
899
572
1,014,096 328,090 208,784
-34 (-30)
0.97
2
245
89,479
32%
18%
46%
61%
1,012,438 753,334
$31,639 $30,133
17%
63%
545,922
$24,815
14%
65%
283,071
$14,154
61%
15%
168,740
$5,273
46%
26%
125,556
$5,022
43%
27%
90,987
$4,136
40%
30%
47,178
$2,359
$26,366
$25,111
$20,679
$11,795
SmartHotGasDefrostPiping
Savings
Optimized vs Baseline, $/y:
Conventionalammoniaevaporatorsaretypicallyarrangedforbottomfeedwiththehot
gaspanlooppipedinserieswiththecoil.TheColmacSmartHotGasDefrostsystem
(Nelson2011(2))resultsinthehighestpossibledefrostefficiencyandlowestoperating
costbyutilizingtopfeedDXcircuitingwiththehotgaspanlooppipedseparatelyfrom
thecoil.Thisresultsin:
Shorterpumpoutperiod
Defrostduration(timecoilhotgassolenoidisopen)ofonly68minutes
AtypicalColmacSmartHotGasDefrostcontrolvalvegroupisshowninFigure20below.
Page46of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
FIGURE20
COLMACDXSMARTHOTGASDEFROSTCONTROLVALVEGROUP
HIGHPRESSURELIQUID(HPL)FEED
NOTES:
1. SERVICE VALVE A IS OPEN

AND SERVICE VALVE B IS CLOSED DURING STARTUP AND
COMMISSIONING TO ALLOW WATER LADEN DEFROST CONDENSATE TO PASS TO THE
SUCTION ACCUMULATOR. AFTER
IT IS SHOWN THAT ALL WATER HAS BEEN REMOVED
FROM THE SYSTEM (THE AMMONIA IS "DRY"), VALVE A IS CLOSED AND VALVE B OPENED TO
TO THE LIQUID LINE.
SEND DEFROST CONDENSATE
GLOBE VALVE
SOLENOID VALVE
STRAINER
SUCTION STOP VALVE
TANK DISTRIBUTOR
SIGHT GLASS
ANGLE VALVE
ELECTRONIC EXPANSION VALVE
HAND EXPANSION VALVE
CHECK VALVE
AUTO VENT
Page47of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Withaconventionalbottomfeedandhotgasdefrostpipingarrangement,hotgasisfirst
sentthroughthedrainpanloopandtheninseriesthroughthecoilblock.Thiscommonly
usedarrangementiseffectiveandsimple,however,itrequiresthatthehotgassolenoid
remainsopentokeepthedrainpanheatedlongenoughforallwatertocompletely
drainandexitthroughthedrainpiping.Convectiveheatlosstotheroomcontinuesafter
thecoilisclearoffrostwhilethepanisdraining.
Amoreefficientarrangementistocontrolhotgastothecoilblockandtothedrainpan
loopseparatelythroughtwoseparatelytimedhotgassolenoidvalves.Thisarrangement
shortenstheamountoftimehotgasisflowingthroughthecoilblock,minimizingthe
convectiveheatlossandmaximizingdefrostefficiency.
AproperlysizedcontrolvalvegroupfortheColmacSmartHotGasDefrostpiping
arrangementislessexpensivethanaconventionalbottomfeedhotgasdefrostpiping
arrangementwithdefrostregulator.
ColmacDXSmartHotGasDefrostSequenceofOperation
1. Defrostisinitiated.
2. LiquidLineSolenoid(LLS)closes
3. Pumpoutperiod(1520minutes)
4. Fan(s)stop
5. Panloopsolenoidenergizedfortimedpanpreheat(23minutes)
6. Coilhotgassolenoidandpilotsolenoid(closessuctionstopvalve)open
7. Timeddefrost(68minutes)
8. Coilhotgassolenoidcloses
9. Aftercoilpressureisequalizedtosuctionpressure(35minutes),SuctionStop
Valveopens
10. OpenLLS
11. Panloopsolenoiddeenergized
12. After5minutecooldowndelayfansrestart
DiversityandDefrostTiming
Aswithallhotgasdefrostsystems,thetwotoonerulemustbeobservedinthe
executionofdefrosts.Thatis,aminimumoftwoevaporatorsinthesametemperature
zonemustberunning(liquidlinesolenoidsopen)atthesametimeoneevaporatoris
defrosting.Thisstrategyisneededtoprovideenoughloadtobalanceevaporatingto
condensing(defrosting)capacityintherefrigerationsystem.
HotGasFlowrateandValveSelection
Page48of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
XVI.
Colmacprovidestoitsrepresentativesandselectedcustomersacalculationtoolfor
estimatinghotgasflowrategivenoperatingtemperaturesandevaporatordimensional
data.
ThecompleteColmacDXSmartHotGasDefrostevaporatorcontrolvalveisalsooffered
fromColmacasakitorfactorymountedontheevaporator.
DefrostWaterVolumeandDrainLineSizing
Followingisasimplemethodtocalculatetheamountofmoistureremovedbytheair
coolersfromairintherefrigeratedspacesinordertodetermine:
A) Totalseweragerequirementsforthefacility,and
B) Properdrainpipingsizestohandlepeakflowratesduringdefrost.
Thissectionwillpresenttwosimplecalculationmethodsfordeterminingthese
importantdesignparameters(Nelson2008).
DeterminingTotalVolumeofMoistureRemoved:
Inordertoestimatethevolumeofwatergeneratedfromdefrosting(orwetfin)air
coolers,thehoursperdaythecooler(s)operatealongwiththeSensibleHeatRatio
(SHR)mustbeknown.Assumingaroomrelativehumidityof90%,theSHRforanair
cooleroperatingatvarioustemperatureswillbeasshowninTable13below:
Table13
SHRfor90%rhAiratVariousTemperatures
RoomTemp,F
AirSHR
45
0.59
32
0.70
10
0.85
10
0.93
30
0.98
Theamountofmoistureaccumulatedonthesurfacesoftheaircooler(s)thatwillbedrained
ascondensedwaterinhightemproomsorasmeltedfrostinmediumandlowtemprooms,
canbeestimatedusingthefollowingformula:
Gal / day 1.35t 1 SHRQ
(9)
where:
t=OperatingTime,hours/day
SHR=AirSensibleHeatRatio
Q=SystemCoolingCapacity,tons(note:1ton=12,000Btuh)
1.35(constant)=12,000Btuh/ton/(8.33lbs/galx1,068Btu/lbs)
Page49of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
8.33lbs/gal=liquiddensityofwater
1,068Btu/lbs=latentheatofvaporizationofwater
Example1:
RoomTemp:45F
OperatingTime:12hours/day
RoomSHR(fromTable1):0.59
SystemCoolingCapacity:50tons
CondensedWaterVolume=1.35x12x(1.59)x50=332gal/day
Example2:
RoomTemp:10F
OperatingTime:16hours/day
RoomSHR(fromTable1):0.93
SystemCoolingCapacity:100tons
DefrostWaterVolume=1.35x16x(10.93)x100=151gal/day
DeterminingPeakDefrostWaterFlowrate
Todeterminethepeakdefrostwaterflowrateleavingafrostedcoilsurface,firstcalculate
thevolumeofwateryieldedbyacoolingcoilduringdefrostusingthefollowingequation:
t fin

S fin
0.0937
Asurf

2
Vdef
:
where
(10)
Vdef
Asurf
S fin
t fin
Note:Thisequationassumesfrosthasaveragedensityof150kg/m3(Besant1999),approx.
1/6ththatofliquidwater.
Example1:
TotalSurfaceArea=4,500sqft
FinSpacing=4finsperinch
Page50of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
FinThickness=0.012inches
FractionofFrostBlockage=0.5
VolumeofDefrostWater=0.0937x4,500x(1/40.012)/2x0.5=25gallons
Inordertothendeterminethepeakflowrate,anestimateofthelengthofdefrosttime
mustbemade.Forhotgasdefrosting,themajorityofdefrostwaterflowstothedrainina
relativelyshortperiodoftime.Toestimatepeakflowrateofdefrostwateranestimated
durationofdefrostof5minutescanreasonablybemade(Stoecker1983).
Tocalculatepeakflowrate,simplydividethevolumeofdefrostwaterbytheestimated
durationofdefrost.Fortheexample:
Estimatedpeakdefrostflowrate=25gal/5min=5gpm
Drainlinescannowbesizedbasedonthecalculatedpeakdefrostflowrate.Themaximum
peakflowrateforafacilitywillbethecombinedflowratesforthemaximumnumberof
coolingcoilsexpectedtodefrostsimultaneously.
Colmacprovidestoitsrepresentativesandselectedcustomersacalculationtoolfor
estimatingdefrostflowrategivenoperatingtemperaturesandevaporatordimensional
data.
SizingSlopingDrainLines
TheAmericanSocietyofPlumbingEngineers(ASPE)publishessizingmethodsforvertical
andslopingdrains(ASPE1999).ThefollowingtableistakenfromtheASPEDataBook
Volume2,page8.
Table14
ApproximateDischargeRatesandVelocitiesinSlopingDrains,n=0.015*
ActualInsideDiameter FullFlowDischargeRateandVelocity
ofPipe,inches
Basedoninch/ftSlope
Discharge,gpm
Velocity,fps
13/8
3.13
1.34
1
3.91
1.42
15/8
4.81
1.50
2
8.42
1.72
2
15.3
1.99
3
24.8
2.25
4
53.4
2.73
5
96.6
3.16
6
157
3.57
8
340
4.34
10
616
5.04
12
999
5.67
*n=Manningcoefficient,whichvarieswiththeroughnessofthepipe.
Page51of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Horizontaldrainlinesmustbepitchedatleastperfoottoinsurepositivedrainage.
Drainlinesrunningthroughfreezingspacesshouldbeactivelyheatedwithheattracecable
andthenwellinsulated.
Drainlinesshouldalsohaveptrapsinstalledjustoutsidetherefrigeratedspacetoprevent
backflowofwarmhumidambientairthroughthedrainlineintotherefrigeratedspace.
XVII.
References
Briley,G.C.1984.Lubricant(Oil)Separation.InternationalInstituteofAmmonia
Refrigeration,Alexandria,VA.ProceedingsoftheIIAR1984AnnualMeeting,pp107F131F.
ClelandD.J.,OHaganA.N.2002.PerformanceofanAirCoolingCoilUnderFrosting
Conditions.AmericanSocietyofHeating,RefrigeratingandAirConditioningEngineers.
ASHRAETransactions2002V.109,Pt.1
Cleland,D.J.2012.TheEffectofWaterVapouronFoodRefrigerationSystems.The
InstituteofRefrigeration.London,UK.Proc.Inst.R.201112.5.
Davis,J.R.,1999,CorrosionofAluminumandAluminumAlloys,ASMInternaional,
MaterialsPark,OH.Chap2,pp38.
IIAR2004,AmmoniaRefrigerationPipingHandbook.InternationalInstituteofAmmonia
Refrigeration.Alexandria,VA.
IIAR2008,ANSI/IIAR22008Equipment,Design,andInstallationofClosedCircuitAmmonia
MechanicalRefrigeratingSystems,InternationalInstituteofAmmoniaRefrigeration.
Alexandria,VA.
Jensen,S.2013.Personalcorrespondence.
LaRocheIndustries,1987,AquaAmmoniaInformationManual,LaRocheIndustriesInc.
Concord,NC.
LaRocheIndustries,1998,MaterialSafetyDataSheet#4003(AmmoniumHydroxide),
LaRocheIndustriesInc.Concord,NC.
Nelson,B.I.,2008,DeterminingDefrostWaterVolume.TechnicalBulletin.ColmacCoil
Manufacturing,Inc.Colville,WA.
Nelson,B.I.,2010,ThermodynamicEffectsofWaterinAmmoniaonEvaporator
Performance,InternationalInstituteofAmmoniaRefrigeration,Alexandria,VA.
ProceedingsoftheIIAR2010AnnualMeeting,pp201236.
Page52of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
Nelson,B.I.,2011,U.S.Patent7,958,738,DirectExpansionAmmoniaRefrigerationSystem
andaMethodofDirectExpansionAmmoniaRefrigeration.
Nelson,B.I.,2011(1),OptimizingHotGasDefrost.TechnicalBulletin.ColmacCoil
Manufacturing,Inc.Colville,WA.
Nelson,B.I.,2011(2),ColmacIntroducesDXAmmoniawithSmartHotGasSHGDefrost.
TechnicalBulletin.ColmacCoilManufacturing,Inc.Colville,WA.
Nelson,B.I.,2012(a),ComparingAirCoolerRatingsPart1:NotAllRatingMethodsare
CreatedEqual.TechnicalBulletin.ColmacCoilManufacturing,Inc.Colville,WA.
Nelson,B.I.,2012(b),ComparingAirCoolerRatingsPart2:WhyDTMRatingsCostYou
Money.TechnicalBulletin.ColmacCoilManufacturing,Inc.Colville,WA.
Smith,E.2010,TechnicalNote.InternationalInstituteofAmmoniaRefrigeration(IIAR).
Alexandria,VA.CondenserMagazineAugust2010.
Stoecker,W.F.1988,IndustrialRefrigerationHandbook,BusinessNewsPublishing
Company,Michigan.
TannerIndustries,2000,MaterialSafetyDataSheet(AmmoniumHydroxide),Tanner
Industries,Inc.Southampton,PA.
Welch,J.2013.Personalcorrespondence.
Wiencke,B.2002,SizingandDesignofGravityLiquidSeparatorsinIndustrial
Refrigeration,InternationalInstituteofAmmoniaRefrigeration,Alexandria,VA.
ProceedingsoftheIIAR2002AnnualMeeting,pp63133.
Wiencke,B.2012.Personalcorrespondence.
Wierbosch,M.andSandler,M.2010,BaseFluidEffectonPerformanceinanAmmonia
RefrigerationSystem.RMSupportBV.Henglelo,NL.
Page53of54

T: +1.509.684.2595 | F: +1.509.684.8331
www.colmaccoil.com
XVIII.
APPENDIXA
ThreeP&IDdiagramsareshownrepresenting:
FigureA1SingleStageSingleTemperatureLevel
FigureA2SingleStage(EconomizedScrew)MultipleTemperatureLevel
FigureA3TwoStageMultipleTemperatureLevel
Page54of54
SH
OPTIONAL
BPRV
(NOTE 1)
(NOTE 1)
1. SERVICE VALVE A IS OPEN AND SERVICE VALVE B IS CLOSED DURING STARTUP AND
SUCTION ACCUMULATOR. AFTER IT IS SHOWN THAT ALL WATER HAS BEEN REMOVED
SEND DEFROST CONDENSATE TO THE LIQUID LINE.
NOTES:
DX EVAPORATOR
HOT GAS COIL ONLY
DX EVAPORATOR
AIR DEFROST
SH
OIL LEVEL SENSOR
DOUBLE ACTING RELIEF VALVE
TANK DISTRIBUTOR
PUMP
TEMPERATURE TRANSDUCER
PRV
LP LEVEL PROBE
STRAINER
CHECK VALVE
AUTO VENT
SIGHT GLASS
ANGLE VALVE
GLOBE VALVE
RELIEF VALVE
PRESSURE GAUGE
GLYCOL
OIL COOLER
COALESCING OIL
SEPARATOR
COMPRESSOR
SUBCOOLED REDUCED PRESSURE LIQUID
SH SUPERHEAT TRANSDUCER
MOTOR
SUBCOOLER SUCTION
PRV W/ ELECTRIC SHUT OFF
TRANSFER
3-WAY VALVE
FS
WATER STILL
OIL POT
SUCTION
ACCUMULATOR
DRAIN VALVE
LP
SOLENOID VALVE
HTR
110F
HLCO
90 psig
60F
FIGUREA1
COLMACDXAMMONIA
SINGLESTAGESINGLETEMPERATURELEVEL
T
SUBCOOLED
to 40F
75 psig
(50.3F SAT)
N.C.
HIGH PRESSURE
RECEIVER
SUBCOOLER
EVAPORATIVE
CONDENSER
GLYCOL OIL
COOLING LOOP
EXPANSION
TANK
SH
(NOTE 1)
(NOTE 1)
(NOTE 1)
(NOTE 1)
SEND DEFROST CONDENSATE TO THE LIQUID LINE.
NOTES:
DX EVAPORATOR
SMART HOT GAS COIL & PAN
LOW TEMPERATURE
HOT GAS PAN LOOP
DX EVAPORATOR
MEDIUM TEMPERATURE
HOT GAS PAN LOOP
SH
HTR
110F
TRANS
LP
LP
SH
CHECK VALVE
TANK DISTRIBUTOR
PIPE CAP (CLEANOUT)
LIQUID DRAINER
PUMP
AUTO VENT
SUPERHEAT TRANSDUCER
OIL LEVEL SENSOR
SIGHT GLASS
GLOBE VALVE
RELIEF VALVE
PRESSURE GAUGE
3-WAY VALVE
TRANSFER
FS
LOW
TEMPERATURE
SUCTION
ACCUMULATOR
DRAIN VALVE
OIL POT
OIL POT
MEDIUM
TEMPERATURE
SUCTION
ACCUMULATOR
SOLENOID VALVE
WATER STILL
HLCO
HLCO
LP LEVEL PROBE
STRAINER
ANGLE VALVE
PRV
GLYCOL
OIL COOLER
COALESCING OIL
SEPARATOR
COMPRESSOR
SUBCOOLER SUCTION
MOTOR
90 psig
60F
FIGUREA2
COLMACDXAMMONIA
SINGLESTAGE(ECONOMIZEDSCREW)MULTIPLETEMPERATURELEVEL
T
SUBCOOLED
to 40F
75 psig
(50.3F SAT)
N.C.
HIGH PRESSURE
RECEIVER
SUBCOOLER
EVAPORATIVE
CONDENSER
GLYCOL OIL
COOLING LOOP
EXPANSION
TANK
SH
(NOTE 1)
(NOTE 1)
(NOTE 1)
(NOTE 1)
SEND DEFROST COND ENSATE TO THE LIQUID LINE.
NOTES:
DX EVAPORATOR
LOW TEMPERATURE
HOT GAS PAN LOOP
DX EVAPORATOR
MEDIUM TEMPERATURE
HOT GAS PAN LOOP
SH
HTR
110F
SH
TRANS
LP
LP
PIPE CAP (CLEANOUT)
AUTO VENT
STRAINER
TANK DISTRIBUTOR
PUMP
SUPERHEAT TRANSDUCER
OIL LEVEL SENSOR
SIGHT GLASS
ANGLE VALVE
CHECK VALVE
LIQUID DRAINER
PRESSURE GAUGE
GLOBE VALVE
RELIEF VALVE
SUBCOOLER SUCTION
GLYCOL
OIL COOLER
COALESCING OIL
SEPARATOR
PRV
BOOSTER
COMPRESSOR
GLYCOL
OIL COOLER
LP LEVEL PROBE
HIGH STAGE
COMPRESSOR
COALESCING OIL
SEPARATOR
3-WAY VALVE
TRANSFER
MOTOR
MOTOR
FS
LOW
TEMPERATURE
SUCTION
ACCUMULATOR
DRAIN VALVE
OIL POT
OIL POT
MEDIUM
TEMPERATURE
SUCTION
ACCUMULATOR
SOLENOID VALVE
WATER STILL
HLCO
HLCO
FIGUREA3
COLMACDXAMMONIA
TWOSTAGEMULTIPLETEMPERATURELEVEL
90 psig
60F
T
SUBCOOLED
to 40F
75 psig
(50.3F SAT)
N.C.
HIGH PRESSURE
RECEIVER
SUBCOOLER
EVAPORATIVE
CONDENSER
GLYCOL OIL
COOLING LOOP
EXPANSION
TANK

Colmac DX Ammonia Piping Handbook 2nd Edition

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Colmac DX Ammonia Piping Handbook 2nd Edition

Hochgeladen von

Copyright:

Verfügbare Formate

P.O.

Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

DT1 LMTD = 7.2 F

DTM LMTD = 9.6 F

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

ExpansionValveType MinimumRecommended RecommendedSuperheat

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

SUBCOOLED LIQUID OUT

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

Incr in Bubble Point vs NH3 Vap Quality, 3.00% Water in NH3,

NH3 Vapor Mass Fraction (Quality)

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

Room Temp, C (F)

P.O. Box 571 | Colville, WA 99114 | USA

1. SERVICE VALVE A IS OPEN

SUCTION STOP VALVE

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

Gal / day 1.35t 1 SHRQ

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA

P.O. Box 571 | Colville, WA 99114 | USA