Retrofitting of

Refrigeration Trainer

Colon, Edcel P.
Francisco, Rome John S.
Mabbayad, Jeffrey B.
Viray, Maynard A.

Background of the Study

Refrigeration cycle in different forms finds applications in numerous
industrial and domestic situations throughout the world.
The components of a specific piece of refrigeration equipment have
been engineered
Issues arise from the use of inappropriate refrigeration equipment.
Retrofitting
Benefits of Retrofitting

Statement of the Problem

This study aims to provide mechanical engineering
students hands-on training of the principles and
systems of refrigeration, that is why we are proposing
for the retrofitting of the refrigeration trainer.

Objectives of the Study

General Objectives
To provide hands-on training to mechanical engineering
students

about

refrigeration

and

to

develop

troubleshooting skills.
To determine the components to be replaced or fixed in
the refrigeration trainer and make it functional.

Specific Objectives
To help the mechanical engineering students to
familiarize the parts and functions that the refrigeration
trainer.
To provide demonstration and better understanding on
the working principle of refrigeration cycle.
To develop fault finding techniques and assessment
procedures to build up diagnosis capability.

Assumption of the Study

The components to be replaced in the refrigeration
trainer are to be bought and some will be fabricated in
accordance

with

the

specifications

needed.

Other

components that dont need replacement are to be fixed

and adjusted.

Significance of the Study

The research study of retrofitting the refrigeration
trainer will provide hands-on training to mechanical
engineering students and better understanding of the
working principles of refrigeration. This will prepare
students to handle problems in refrigeration when
practicing the field Mechanical Engineering profession.

Scope and Delimitations

The scope of this study will be concentrated on
retrofitting of the refrigeration unit and to determine the
parts or components needed for replacement or to be
fixed.

Theoretical Framework
The concern of this research is to retrofit the
refrigeration trainer, to make it functional and operational
to provide hands-on training to mechanical engineering
students and understanding in the system of refrigeration.

Refrigeration Trainer

Retrofitting of the
trainer

Functional and
operational

Introduction of basic
refrigeration concepts

Provide hands-ontraining

Research Methodology
Retrofitting procedures are being followed in the Code of
Practice for Refrigeration and Air Conditioning Manual.
The retrofitting of the trainer is guided and supervise by a
refrigeration technician.

Research Methodology
3.1 Retrofitting Procedures
Record the system performance data
Pump down the system

Research Methodology
Recovered refrigerant must be stored
Knowing the recommended charge size
Ensure

the

prevention

of

refrigerant

emissions
Replace all equipment components and
accessories

Research Methodology
Charge the system with new and correct
amount of alternative refrigerant oil
Reinstall the compressor
Run the system while performing the oil
change procedure

Research Methodology
Leak test the system

Evacuate system to at least 1000 microns

Monitor

the

system

operation

performance
Check remaining content of mineral oil

and

Research Methodology
Follow the system and/or compressor
manufacturer recommendations
Label the system.

3.2 Leak Testing Methods

Method
Leak detection spray /
soapy water

Electronic leak
detector

Fluorescent additive
(injected into the
System with oil and
detected using
an ultra violet lamp)

Leak Points

1. Shut-off
And ball valves

2. Schrader
valves

3. Flare joints

4. Mechanical
joints and
flanges

Likely causes

Solutions

Wear of the packing gland between the

valve body and spindle shaft as it
Ensure that the gland is tightened.
becomes compacted with age and use. Wrap the valve with a damp rag while
Overheating during installation.
brazing.
Caps not fitted.

Valve cores damaged during brazing.

The cores not tightened correctly
during replacement.
Deterioration of internal seals over
time.
Caps not fitted or have no O-ring seal.

Remove the core when brazing the

fitting in; ensure the valve body has
cooled before replacing the core.
Use the correct tool to replace /
tighten the core.
Ensure the cap is fitted and has a seal
in place.

Loosening of the flare nut due to

thermal expansion / contraction due to a
wide temperature variation, especially
where those at the outlet of expansion
If possible, avoid using flare
valves.
connections.
Poor joint preparation.
Over tightening, leading to damage at
the copper flare face and the flare nut.
Under tightening of the flare.

Incorrectly prepared joint

Not replacing gaskets.
Uneven tightening of flanges.
Incorrect torque used for tightening
bolts.

Replace gaskets on flanges and

remove all the old gasket material
before applying the new one.
Tighten flanges down evenly applying
the opposites rule until the flange is
seated correctly.
Use a torque wrench to carry out the
final tensioning of flange bolts.

5. Pressure relief
valves and
fusible plugs

6. Shaft
seals

Fusible plugs wide temperature and /

or pressure variations weaken the bond
between the solder core and the plug.
PRVs - do not reseat when the pressure
drops after release and often leak across
the PRV seat during normal operation.

Lubrication failure.
Incorrect fitting of a new shaft seal.
Incorrect shaft alignment.
Excessive crankshaft end float or bearing
damage.

Fusible plugs
Where possible, avoid using fusible
plugs. If possible, replace them with a
PRV.
PRVs
Always leak test the outlet of PRVs.
If a PRV is leaking replace it with an
equivalent rated device.
Do not cap the PRV if it is leaking.

Leak testing of the shaft seal with the

compressor switched off.
Using the correct type of shaft seal
and following the proper procedure
when replacing the shaft seal.

7. Condensers
Shell and tube
condensers
Corrosion of the copper and mild steel if
the water circulating in the tubes is not
treated correctly. Leaks can be particularly
hard to locate, as they cannot be seen
refrigerant might be detected in the water,
but usually the leak is only detected by
carrying out a full pressure test of the
system.
Air-cooled
condensers
Corrosion due to aggressive air.
Impact damage due to foreign bodies in

Shell and tube condensers

Regular inspection to monitor
potential corrosion level.
Air cooled condensers
Always position condensers on a
level base.
Repair or replace out of balance fans.
Check the fin block for signs of oil.
When replacing a condenser, select it
carefully, especially if it is going into an
aggressive environment e.g. on the
coast.

8. Line tap
valves
Poor fitting of the line tap onto the
pipe, or being fitted to badly formed or
flattened pipe work.
Use of the wrong size line tap
Loosening of the line tap valve due to
movement and vibration.

9. Pressure
switches

Ensure the correct size of tap valve is

being used and read the instructions
for its installation.
Leak test any line taps found fitted
and replace them if possible.

Use flexible pressure couplers where

possible.
Vibration causing the pressure coupler
Make sure pressure couplers do not
to split or damage to the pressure
rub or chafe on other pipes or vibrating
switch.
surfaces.
The pressure coupler chafing.
Ensure the switch is correctly
supported / fixed.

10. O-rings
Check and change seals rather than
Wear, hardening or flattening,
re-using the existing ones, especially
especially when subjected to extremes during a refrigerant retrofit.
of temperature.
Oil seals before fitting them.
Leakage after retrofitting because of a Ensure the replacement seal is
different reaction to the new oil.
suitable for the system oil and
refrigerant.

11. Capillary
tubes

Chafing due to insecure fixing.

Leakage where a capillary tube
expansion device enters / exits the
suction line.

12. Return bends

on evaporators
and
condensers

Check capillary tubes are firmly

located and cannot chafe correct if
necessary.

Leak test return bends carefully,

especially if the atmosphere is
aggressive.
Corrosion due to chemical action on
If evaporators and condensers that
the return bends on coolers or air cooled are prone to leaks from return bends
condensers.
are to be replaced, specify materials
which are less susceptible to damage
such as coated or electro plated heat
fin blocks.

13. Condensate
tray pipe work
Corrosion of the discharge line
because of contact with air and water.

Always leak test in the vaporizer tray

and check the
condition of the pipe work. If it is
corroded, replace the pipe work
before it fails.
Where possible, replace the pipe
work with a plastic coated type as this
extends the life