The Cold Front

Vol. 3 No. 3, 2003

INN THHIISS ISSSSUUEE LIQUID INJECTION VS.

• Liquid Injection vs. 1-6 THERMOSIPHON OIL COOLING
OF SCREW COMPRESSORS
Thermosiphon Oil Cooling
of Screw Compressors
• Upcoming Ammonia Classes 2 In this article we focus on the energy benefits associated
• Noteworthy 2 with thermosiphon oil cooling. We begin with a brief
introduction of the role of oil and oil cooling in today’s
• Join the IRC in 2004 6 screw compressor technologies and then proceed to a
case study on a recent conversion retrofit project.
• 2004 R&T Forum Advanced 7
Notice INTRODUCTION
Oil is an essential ingredient to make today’s screw
compressor technologies functional. Oil is primarily used
as a lubricant and sealant. Bearings and rotors ride on a
thin film of oil to minimize wear. Oil also serves as a
IRC Staff medium to seal the mating surfaces of rotors and the
enclosing housing to minimize internal leakage of the
vapor being compressed; thereby, maintaining high
Director compression efficiency.
Doug Reindl 608/265-3010
or 608/262-6381 Because industrial refrigeration compressors operate in
dreindl@wisc.edu an “oil-flooded” configuration, oil influences other aspects
of compressor operation. As oil circulates through
Jim Elleson 608/262-6940 compressors at a relatively high flow rate (of 10-20 gpm
jselleson@wisc.edu per 100 hp†), it absorbs some of the “heat of
Todd Jekel 608/265-3008 compression‡” resulting in lower compressor discharge
tbjekel@wisc.edu temperatures. One only has to consider the difference in
discharge temperatures between reciprocating (200-
Dan Dettmers 608/262-8221
220°F) and screws (140-180°F) to understand the heat
djdettme@wisc.edu sink action of oil. Finally, the movement of oil offers a
mechanism to flush contaminants from the mating
Toll-free 1-866-635-4721 surfaces within the compressor and remove them by
Phone 608/262-8220 filtration.
FAX 608/262-6209
Mail
1415 Engineering Drive
Room 2342 † Pillis, J.,W., 1998, Basics of Operation, Application &
Madison, WI 53706-1607 Troubleshooting of Screw Compressors, Frick.

e-mail info@irc.wisc.edu ‡ heat of compression is the rise in refrigerant vapor

Website www.irc.wisc.edu temperature experienced as it undergoes the compression
process

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In order to maintain acceptable oil
temperatures, the portion of the compressor’s U
“heat of compression” absorbed by the oil Uppccoom
miinngg AAm
mmmoonniiaa C
Coouurrsseess
needs to be removed in some way. This
function is provided by a screw compressor oil Introduction to Ammonia Refrigeration
cooling system. October 8-10, 2003 Madison, WI

DESCRIPTION Ammonia Refrigeration Piping

Oil cooling methods can be categorized as October 27-29, 2003 Madison, WI
either internal or external to the compressor.
Internal oil cooling is often called ‘liquid Intermediate Ammonia Refrigeration
injection’ since it utilizes liquid refrigerant for December 3-5, 2003 Madison, WI
direct oil cooling within the compressor.
External oil cooling relies on the use of a Process Safety Management Audits
secondary medium to cool oil outside of the January 6-8, 2004 Madison, WI
compressor. Let’s look at how each alternative
works. Ammonia Refrigeration: Uncovering
Liquid injection oil cooling (LIOC) and its
Opportunities for Energy Efficiency
variants rely on high pressure liquid refrigerant Improvements
fed into the compressor through a port drilled February 11-13, 2004 Madison, WI
into the housing in order to cool the oil. As the
liquid refrigerant enters the liquid injection port Introduction to Ammonia Refrigeration
within the compressor, it expands and cools. March 10-12, 2004 Madison, WI
The cool liquid refrigerant that remains after
expansion absorbs heat from the hot oil and Ammonia Refrigeration System Safety
partially-compressed refrigerant vapor. The April 14-16, 2004 Madison, WI
liquid refrigerant feed rate is modulated to
maintain the compressor discharge Design of Ammonia Refrigeration Systems
temperature at the required oil supply
for Peak Performance and Efficiency
temperature, generally 130°F. Valve types for
September 13-16, 2004 Madison, WI
metering in liquid injection arrangements
include thermal expansion, motor controlled
expansion, and temperature regulating valves. See www.irc.wisc.edu/education/ for more
The following are consequences associated information.
with liquid injection oil cooling arrangements:

Noteworthy
• Chris Meyer, Sargento Foods, and Todd Jekel, IRC, successfully completed
the requirements and obtained a Professional Engineer’s license in the State of
Wisconsin. Congratulations!
• Our new website (www.irc.wisc.edu) is up. Please browse and let us know what
you think.
• Send items of note for next newsletter to Todd Jekel, tbjekel@wisc.edu.

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 • Increased compressor power – Because
additional refrigerant is expanded and
evaporated into the machine during the
compression process, additional work is
required to compress the added
refrigerant mass.
• Reduced compressor capacity –
Compressor capacity is diminished in
two ways. First, liquid injection oil
cooling reduces the compressor’s
volumetric efficiency. Second, the high
stage load on a two stage system
increases when liquid injection is used
on booster compressors
The extent of these consequences depends on
the location of the liquid injection port within the
compression process. Injection port pressures
closer to the suction pressure (i.e. earlier in the
compression process) result in larger capacity
reductions and a higher horsepower penalty.
Figure 1 shows a booster compressor fitted with
LIOC.
The alternative to liquid injection oil cooling is to
use a heat exchanger, external to the
compressor, to cool the oil. Heat exchange
High-pressure
Figure 1: LIOC on screw compressor in booster duty.
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media include: water, secondary fluids (such as
ethylene glycol and water), and refrigerant.
Water and secondary fluid coolers rely on the
sensible (temperature-driven) heat exchange
between the cooling medium and oil. Another
approach to external oil cooling is “thermosiphon
oil cooling” (TSOC). Thermosiphon oil cooling is
accomplished by supplying high-pressure liquid
refrigerant from an elevated vessel
(thermosiphon pilot receiver) to one side of the
heat exchanger and hot oil to the other. The hot
oil causes the refrigerant to evaporate and
naturally rise back to the thermosiphon pilot
receiver. The vapor generated by the oil cooling
heat exchanger flows through the pilot receiver
and on to the condenser hot gas connection
where the condenser liquefies the vapor and
returns the liquid refrigerant to the pilot receiver.
In contrast to liquid injection, thermosiphon oil
cooling becomes a “load” on the condenser but
not on the compressor. Regardless of the fluid
that cools the oil, compressor performance is
identical because the oil cooling is external to
the compressor. Typical discharge
temperatures from compressors with external oil
cooling are in the range of 160-180°F. Figure 2
shows a booster compressor fitted with
Injection point
Thermal
expansion
valve
liquid piping
thermosiphon oil cooling.
COMPARISON
Liquid injection is the lowest capital cost option
for oil cooling; however, there are three primary
reasons to consider thermosiphon over liquid
injection:
1. reduced maintenance
2. reduced refrigeration energy use
3. increased high-stage compressor capacity
With regard to maintenance, thermosiphon oil
cooling is less stressful on the compressor;
thereby, prolonging the interval between
rebuilds. Anecdotal evidence from the field
suggests that liquid injection oil cooled screw
compressors have approximately half the run
hours between rebuilds as compared to
externally oil cooled machines. Energy benefits
can be broken down into three areas:
1. reduced compressor horsepower per
refrigeration load,
Vapor
refrigerant
return
piping
Figure 2: TSOC on a compressor in booster duty.
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2. reduced load on the high-stage of a two-
stage system, and
3. increased opportunity to float the
refrigeration system discharge pressure.
The first two items were mentioned in the
description of the methods above. Item 3 is an
often overlooked consideration that is important
in the context of achieving efficient systems and
can be considered a ‘synergistic’ efficiency
improvement. Liquid injection oil cooled
compressors often use thermal expansion
valves to modulate the feed of liquid refrigerant
to maintain oil temperature. Thermal expansion
valves require a minimum pressure difference
across the valve to properly control liquid
refrigerant feed. The pressure difference across
the valve is determined by the liquid injection
port position (i.e. pressure) within the
compressor and the high-pressure liquid feed
pressure. Therefore, the minimum pressure
difference across the thermal expansion valve
will constrain the extent to which the system’s
discharge pressure can be floated during off-
design loads and ambient conditions.
Liquid
refrigerant
supply
piping
Oil cooling
heat exchanger
CASE STUDY We’re Moving
The IRC recently completed a study of October 15-16, 2003
refrigeration system energy efficiency
improvements at a large food processing
plant. One of the opportunities investigated The IRC offices are moving back to the
was the conversion from liquid injection to engineering campus:
thermosiphon oil cooling. The refrigeration
system is configured with two-stages of Industrial Refrigeration Consortium
compression, three suction pressure levels, 1415 Engineering Drive, Room 2342
and two-stages of liquid expansion. Sum Madison, WI 53706-1607
total there are more than 10 screw
compressors of various sizes and duties with All other contact information for staff will
nameplate power totaling nearly 5,000 hp.
remain unchanged.
The plant manger requested an energy
analysis to quantify the energy cost benefit We anticipate this move, although a
of the proposed conversion. To complete disruption, will improve our ability to meet
such an analysis, both refrigeration loads our members’ needs.
and ambient conditions needed to be
determined. Refrigeration loads on each
condensing pressure set point was only done
suction pressure level were estimated and
when the dry-bulb temperature fell below 60°F.
divided into several bins over each day
throughout year to capture the various
With LIOC, the system required a wintertime
production schedules at the plant. Weather
minimum discharge head pressure of 140 psig
data was obtained from a Typical
(81°F saturated condensing) to maintain
Meteorological Year (TMY2) data set for a
adequate operation of the screw compressor
nearby location.
liquid injection oil cooling. The summer set
point of 160 psig was unchanged (although the
Gross validation of the model was
retirement of the liquid injection oil cooling
accomplished in two ways, first using the
feed line would allow the piping of a parallel
calculated estimates of design loads and
liquid feed to plant loads to relax that set point
design weather conditions to compute the
as well, without requiring a recertification of
design condensing pressure of the system,
the high-pressure receiver). Based on
and second by estimating the dry bulb
discussions with the operational staff, we
temperature at which the operational staff
estimated that the wintertime minimum
were required to valve out one of the three
discharge pressure could be safely reduced to
condensers.
120 psig (73°F saturated condensing)
immediately following the conversion to
The system model we developed included
thermosiphon oil cooling.
both the compressor efficiency effects and
the operational change (i.e. floating head
The resulting energy use and energy cost
pressure) were included. The ability to float
savings for the system were estimated to be
the head pressure below the current set
1,150,000 kWh and $53,000 per year,
points was only done in wintertime because
respectively. The demand savings are
it was determined that the liquid injection
approximately 170 kW on the yearly peak.
condensing pressure requirement only was
The energy savings represent an approximate
controlling during wintertime. The
9% reduction in compressor and condenser
summertime constraint was high-pressure
energy use. Note that 67% of the energy cost
liquid feed requirements due to the existence
savings is due to energy use reduction and
of direct expansion loads and the distance
33% is due to demand reduction.
over which the liquid was supplied. In the
Approximately 82% of the energy use savings
energy analysis, reducing the minimum

5
and 84% of the energy cost savings occur during production hours. A collateral benefit is that
the conversion freed up nearly 90 tons of high-stage load during peak production!

A key to the successful implementation of the oil cooling conversion was coordination with a
local contractor. Based on a quote the facility had in-hand for the conversion, the payback on
energy alone was approximately 4 years. The conversion was made more attractive because
the facility’s electric utility provided a rebate that reduced the payback period by nearly one year.
In addition, maintenance cost savings (although not quantified) will further reduced the payback
period. If you have questions or comments on this article please feel free to contact Todd Jekel
at tbjekel@wisc.edu.

COMING SOON
There are additional choices on liquid feed valves for liquid injection oil cooling. These valves
have relaxed pressure difference requirements and can allow floating head pressure. In a future
newsletter, we will analyze the energy implications of different options and estimate the cost of
operation.

PLLAANN FFO
ORR 2004!
Join the Industrial Refrigeration Consortium (IRC)
The IRC’s mission is to improve the safety, reliability, efficiency, and productivity of
industrial refrigeration systems. Our vision is to make continuous progress toward
improving the safety, productivity, and efficiency of the systems and technologies that
form the foundation of the industrial refrigeration industry.

Does your company have needs in the areas of education, technical assistance or
strategic planning for refrigeration? If so, please contact us to see how joining the IRC
can benefit you and your company. We can schedule and deliver a web-based
presentation on the benefits of IRC membership to you and other decision-makers in your
company.

Benefits include

• unbiased and authoritative information on industrial refrigeration

• applied research results to improve refrigeration system efficiency, productivity, and safety
• preferred access to refrigeration education programs to expand staff capabilities

In addition, IRC members have access to telephone hot-line support on technical,

operational and regulatory issues, internet-based information resources (including
access to IRC web courses), technical bulletins, safety updates, and specialized
publications, and refrigeration education for personnel at all levels.

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6
 2004 IRC Research & Technology Forum
January 14-15, 2004 Bradenton, FL

The Industrial Refrigeration Consortium is pleased to announce that the 4th Annual Research &
Technology Forum will be held on January 14-15, 2004 in Bradenton, FL. This event will feature
presentations by IRC staff, IRC member organizations, and industry experts.

Tropicana Products, Inc. has graciously agreed to host the 2004 R&T Forum at their Bradenton
Florida plant. A highlight of the event will feature an overview and tour of their new world class
North Compressor Room. Completed less then a year ago, this facility incorporates innovative
safety and operation features that define world-class standards in industrial refrigeration.

The 2004 IRC R&T forum will provide attendees an opportunity to receive information about
current refrigeration research, regulatory updates, emerging technologies, and refrigeration
education and to explore needs for future research in the area of industrial refrigeration. It also
provides you an opportunity to meet and exchange ideas with other industry experts. Topics
include:

• PSM – What’s the business case

• Standard Operating Procedures – lessons learned
• Variable frequency drive application considerations in industrial refrigeration
• IRC research update
o Benchmarking
o Mechanical integrity and non-destructive testing
o IRC Toolbox
• Underfloor heating problems and remediation

The forum is open to anyone interested in industrial refrigeration. IRC member registration is free
and there will be a nominal registration fee of $99 for non-IRC members to recover meeting costs.
Attendees receive a binder of all of the presentation materials. Visit our website
(www.irc.wisc.edu) to download registration materials. The registration deadline is December
24, 2003. Please note that for planning and security reasons no attendance is allowed
without pre-registration.

A block of rooms has been reserved at the Holiday Inn Riverfront in Bradenton at $94/night. For
reservations, call the hotel directly at (941) 747-3727 and ask for the Industrial Refrigeration
Consortium group rate.

IRC members should plan to arrive early for the IRC’s annual business meeting to be held the
morning of January 14, 2004.

Watch our website www.irc.wisc.edu for the agenda and registration materials. If you have any
questions regarding travel arrangements or presentation topics, please contact the IRC at 866-
635-4721 or info@irc.wisc.edu.