Refrigerant leaks and their detection

Leakage of refrigerant from a refrigeration system affects the performance of a sealed system (systems
with hermetic compressors) adversely.

● The running time of the system increases continuously.

● Both suction as well as discharge pressures reduce due to loss of refrigerant.

● Due to lower suction pressures, the lubricating oil return becomes difficult.
In addition to this possibility of oil leaking with refrigerant deprives the compressor of lubricating oil
and ultimately may lead to the damage of the compressor.

● If the suction pressure due to refrigerant leakage falls below atmospheric pressure, then there is a
possibility of air leaking into the system. This will bring moisture into the system and the presence of
moisture affects the system adversely.

● There will be less liquid and more flash gas, which has a negative effect on several components of
the system. For example, it is possible that instead of liquid, a mixture of liquid and vapour may enter
into the expansion valve leading to its malfunctioning, valve chattering and erosion due to higher
velocities etc.
Leak detection:
Two widely used leak detection methods are:

I. Halide leak detector

ii. Electronic leak detector

Halide Leak Detector

The halide leak detector works on the principle of change of colour of a flame in the presence of
refrigerants with chlorine as part of the components. Therefore CFCs and HCFCs can be easily detected
but HFCs cannot be detected using this method.

When such a refrigerant is sucked through a sampling tube and passed over a surface whose surface
temperature is high (around 500oC), then the refrigerant vapour breaks down and forms a foul smelling
gas known as phosgene (COCl2). When this gas is passed over a glowing copper (heated by the flame of
the torch itself) it forms copper chloride, which changes the colour of the flame from pale blue to
bright green.
The halide torch usually burns methyl alcohol, butane gas or acetylene and is similar in
construction to that of a blow lamp with a provision to draw the air for combustion through a
sampling tube. If the air consists of refrigerant (due to leakage) then it is detected by the
change in the colour of the flame.

Using halide leak detectors leaks as small as 1.5 to 2 oz. per year could be detected.

Not suitable to be used near gasoline or other flammables due to the open flame being
utilized. With better modern tools such as the electronic leak detectors being invented, this
method of detection is not favorable these days due to the many limitation and safety
factors.

The combustion of the flame and refrigerant also emit harmful chemicals.
Electronic leak detector

Based on the principle that when halogen vapour is heated,

positive ion concentration is increased and this increase is
suitably magnified to an audible or visual signal.

Thus the leak detector consists of a sampling tube through

which air around the refrigeration system is drawn by
means of a small fan.

The air sample is passed over a heated platinum element.

Under normal (clean air) conditions positive ion current
flows under a voltage of 240 V between the ion emitter and
collector (anode and cathode),

However, when a sample containing halogens is drawn into

the probe, an immediate increase in positive ions results
and this is magnified by the electrical circuit so that an
audible or visual signal is produced
Exact location of the leak can be determined as the strength of the signal increases as the
probe moved towards the leak and decreases when it is moved away from the leak.

In some leak detectors a reference leak is built for comparison and adjustment of sensitivity of
the detector. It is also possible to make compensation for background contamination.

Electronic leak detectors are highly sensitive and they can detect leaks as small as 0.25 to
0.50 oz. per year.

The operation is clean, quick and free from any fire hazard. However, it is important to maintain
the input voltage for good sensitivity of the detector. They are designed to detect refrigerant
leaks but should not be immersed in refrigerant streams, for example from the refrigerant
cylinder.
Charging the Refrigerant

Charging of refrigerant in the system is done in two ways:

i) Charging from suction line.

(ii) Charging from liquid line.

Suction line charging is done in the case of small units in which the amount of charge required is small.

For the purpose, the refrigerant cylinder is made to stand vertically on the ground so as to ensure that
only vapour enters the compressor.

The refrigerant cylinder is connected to the suction-side of the compressor either through the suction
service valve or through a separate 'charging line' in hermetically sealed units. After charging, the suction
service valve is closed, and the gas cylinder is disconnected. In the case of hermetically sealed units, the
charging line is 'pinched' with a `pinch-off tool', and then the pinch brazen or soldered.
To make sure that the correct weight of charge is made, many methods are used. In unitary equipment,
manufacturers charge a measured amount of refrigerant from experience. In the field it is ensured that
the required head pressure is reached.

Then the refrigerator is tested for pull-down period, or ice-making time, and so on.

Charing from the liquid line is done in large plants where the amount of charge required is large.
Charging refrigerant as vapour from suction line will take very long time.

For the purpose, the refrigerant cylinder is often kept at a height in a tilted position so that the liquid
enters the system. The pressure in the system in water-cooled units will be below pressure in gas
cylinder to enable liquid to flow in. Adequate charge is usually ensured by getting required operating
pressures in the system. Liquid refrigerant level can also be checked in the condenser or receiver
through a sight-glass.