Automatic Purgers in Refrigeration Systems PDF
Automatic Purgers in Refrigeration Systems PDF
Automatic Purgers in Refrigeration Systems PDF
Automatic Purgers in
Refrigeration Systems
By Douglas T. Reindl, Ph.D., P.E., and James L. Denkmann pressure, any nitrogen present would have
Member ASHRAE Member ASHRAE to be cooled to 264°F (164°C) in order
A
to liquefy. As a result, any nitrogen that
purger is an essential component for the proper and efficient opera- may accumulate in a refrigeration system
always will remain in a gaseous state. Lets
tion of an industrial refrigeration system. A purger gathers, separates take a closer look to see how non-
and expels non-condensable gases from the system. Successfully condensables infiltrate into, or accumulate
within, ammonia refrigeration systems.
purging non-condensables from a refrigeration system leads to increased re- Air is the most abundant non-condens-
frigeration capacity, improved system efficiency, and enhanced system safety. able gas impacting industrial refrigeration
systems. Air can infiltrate into systems
In this article, we review the types of non- ness of a refrigeration system is dependent during continuous operation and as a re-
condensable gases (NCG) that can accu- on the ability for the phase-change pro- sult of system servicing. Most low-tem-
mulate in systems, consequences of NCG, cesses to proceed unimpeded. perature refrigeration systems (i.e., work-
purger operation, application consider- ing temperatures below 28°F [33°C])
ations and factors that influence purger per- Non-Condensable Gases have a significant proportion of the sys-
formance. Our emphasis is on vapor com- In the context of vapor compression- tem piping, valves, and vessels operating
pression-based industrial refrigeration sys- based ammonia refrigeration systems, we with working pressures below atmospheric
tems that use anhydrous ammonia as the want only pure refrigerant (anhydrous am- pressure. Any pathways for leaks will re-
refrigerant because this choice covers the monia) present in our systems. Unfortu- sult in air infiltrating into the system rather
majority of industrial systems in use today. nately, refrigeration systems can and will than the refrigerant leaking out. Pathways
accumulate foul substances. Apart for air leakage during operation include:
Background from water, the foul substances, gaseous valve stem packings, bonnet gaskets,
Most industrial refrigeration systems in nature, are commonly referred to as compressor shaft seals, non-welded con-
currently in use are based on the vapor non-condensable gases (NCG). Foul gas nections, and control transducers.
compression cycle. Vapor compression re- is another term used to describe a gas- Another pathway for air entry into sys-
frigeration systems function through a con- eous refrigerant stream that contains NCG. tems occurs as a result of inadequate
tinuous closed cycle whereby a volatile Non-condensable gases eventually will evacuation after system servicing. For ex-
working fluid (refrigerant) undergoes a se- accumulate in all ammonia vapor-compres- ample, if a portion of the system is opened
ries of phase changes, which leads to the sion refrigeration systems if adequate to clean a strainer or replace a component,
ability for providing a useful refrigeration means are not provided for their removal. air will occupy that part of the system im-
effect. In the condenser, heat is rejected In some cases (i.e., newly built high-suc- mediately after reassembly. Ideally, the ser-
from the system converting hot gaseous tion temperature systems with screw com- vice technician will evacuate the air from
refrigerant at high pressure to pure liquid- pressors), it may be many years before that part of the system prior to bringing it
phase refrigerant also at high pressure. The abnormal operation becomes evident. back into service. Unfortunately, this is sel-
high-pressure liquid is subsequently Non-condensable gas constituents com- dom done. The net result is that the refrig-
throttled to lower pressures to be available monly include air, nitrogen, hydrogen, and eration system ingests a large gulp of air
for absorbing heat into the system through hydrocarbons. The nomenclature non- when brought back into service and the
the evaporator as part of a refrigeration pro- condensable means that these gases will
cess. In the evaporator, low-pressure liq- not liquefy at the temperatures and pres- About the Authors
uid refrigerant boils as a result of heat sures present in condensers consistent Douglas T. Reindl, Ph.D., P.E., is
added from a space or a process load. The with industrial refrigeration systems. For associate professor and director of the
low-pressure vapor refrigerant generated example, anhydrous ammonia will change Industrial Refrigeration Consortium at
is then raised in pressure by the compres- phase from gas to liquid if heat is removed the University of Wisconsin, Madison,
sor and directed to the condenser to reject while at a temperature of 95°F (35°C) and a Wis. James L. Denkmann is presi-
heat from the system again. The effective- pressure of 196 psia (1349 kPa). At the same dent of DTS, Chicago.
Refrigeration
trapped air must be removed by purging. Gas Mol. Weight Density, lb/ft3 (kg/m3)
Hydrogen 2 0.057 (0.91)
Secondary types of NCG include hydrogen and nitrogen. Am m o n i a 17 0.52 (8.3)
Hydrogen and nitrogen gases accumulate as a result of the Nitrogen 28 0.79 (12.7)
refrigerant (NH3) dissociating (breaking-down) over time. The Ai r 29 0.82 (13.1)
two most important factors that influence the breakdown of Oil Decomposition 1544 0.452.03 (7.132.6)
ammonia into its constituent parts are temperature and pres- R-22 86 2.75 (43.9)
sure. At higher temperatures, ammonia is more prone to irre- Table 1: Gas properties including common NCG and indus-
versibly breaking down into nitrogen and hydrogen. Older sys- trial refrigerants for reference.
tems (>25 years) and those with reciprocating compressors
appear to experience an accelerated rate of breakdown. How- side environment. The heat rejection capacity of any given
ever, the gross quantity of NCG generated by this mechanism is evaporative condenser is dependent upon:
relatively small. Even small dissociation rates lead to the accu- Outside air wet-bulb temperature (lower wet-bulb tempera-
mulation of large quantities of hydrogen and nitrogen over time tures translate into greater heat-rejection capacity);
if they are not removed from the system on a regular basis. Refrigerant saturated condensing temperature (higher satu-
Tertiary sources of NCG arise from the breakdown of lubri- ration temperatures translate into increased heat rejection ca-
cating oils. Most industrial refrigeration systems use mineral- pacity at the condenser);
based lubricating oils. As a result, the oil will breakdown and Wet operation (water flow over the outside surface of the
liberate a complex series of hydrocarbon gases. Some of the condenser tubes greatly enhances heat-rejection capacity); and
gases will have lower molecular weights when compared with Airflow rate (increased airflow rate will increase heat-rejec-
ammonia (e.g., CH4) while others will be heavier (e.g., C8H18). tion rates).
Table 1 lists each of the gases potentially present in a non- One of the places where NCG accumulate is in the lower
condensable gas mixture, along with their molecular weights portions of evaporative condenser heat exchange coils. This is
and densities at a design condensing pressure for many ammo- because the refrigerant has been liquefied at that point and the
nia refrigeration systems (196 psia [1349 kPa]). Refrigerant R-22 NCG are prevented from flowing further downstream (due to P-
is also shown for reference. traps located at the drop leg for each condenser outlet) or up-
stream (due to convective forces as a result of the continual
Consequences of Non-Condensable Gases flow of gas into the condenser).
The total heat rejection requirement for a vapor compression Since the NCG remain in their gaseous state, they will occupy a
system is the sum of the gross refrigeration effect plus the relatively large volume of the evaporative condensers heat ex-
aggregate work input to the system by the compressors. Indus- changer. Their presence interferes with the condensers ability to
trial refrigeration systems commonly use evaporative condens- change the phase of the gaseous refrigerant to a liquid. With the
ers as the means of rejecting heat from the system to the out- heat transfer capacity of the evaporative condenser diminished