Created by Ankur Sharma, Gurudayal Srivastava, Vikram Singh, Sanket Tamhane

(1). Explain construction and working of ships refrigeration plant.

The refrigeration plants on merchant vessels play a vital part in carrying refrigerated cargo and provisions for the crew on board. In
reefer ships, the temperature of the perishable or temperature sensitive cargo such as food, chemical, or liquefied gas, is controlled
by the refrigeration plant of the ship. The same plant or a smaller unit can be used for maintaining the temperature of different
provision rooms carrying food stuffs for crew members.
The main purpose of ships refrigeration plant is to avoid any damage to the cargo or perishable material so that the cargo in
transported in good and healthy condition. Refrigeration prevents growth of micro-organisms, oxidation, fermentation and drying
out of cargo etc.
Main Components of Refrigeration plants
Any refrigeration unit works with different components inline to each other in series. The main components are:
1. Compressor: Reciprocating single or two stage compressor is commonly used for compressing and supplying the refrigerant to
the system.
2. Condenser: Shell and tube type condenser is used to cool down the refrigerant in the system.
3. Receiver: The cooled refrigerant is supplied to the receiver, which is also used to drain out the refrigerant from the system for
maintenance purpose.
4. Drier: The drier connected in the system consists of silica gel to remove any moisture from the refrigerant
5. Solenoids: Different solenoid valves are used to control the flow of refrigerant into the hold or room. Master solenoid is provided
in the main line and other solenoid is present in all individual cargo hold or rooms.
6. Expansion valve: An Expansion valve regulates the refrigerants to maintain the correct hold or room temperature.
7. Evaporator unit: The evaporator unit act as a heat exchanger to cool down the hold or room area by transferring heat to the
refrigerant.
8. Control unit: The control unit consist of different safety and operating circuits for safe operation of the refer plant.

Working of Ships Refrigeration Plant

The compressor acting as a circulation pump for refrigerant has two safety cut-outs- Low pressure (LP) and High Pressure (HP) cut
outs. When the pressure on the suction side drops below the set valve, the control unit stops the compressor and when the pressure
on the discharge side shoots up, the compressor trips.
LP or low pressure cut out is controlled automatically i.e. when the suction pressure drops, the compressor stops and when the
suction pressure rises again, the control system starts the compressor. HP or high pressure cut out is provided with manually re-set
The hot compressed liquid is passed to a receiver through a condenser to cool it down. The receiver can be used to collect the
refrigerant when any major repair work has to be performed.
The master solenoid is fitted after the receiver, which is controlled by the control unit. In case of sudden stoppage of compressor, the
master solenoid also closes, avoiding the flooding of evaporator with refrigerant liquid.
The room or hold solenoid and thermostatic valve regulate the flow of the refrigerant in to the room to maintain the temperature of
the room. For this, the expansion valve is controlled by a diaphragm movement due to the pressure variation which is operated by
the bulb sensor filled with expandable fluid fitted at the evaporator outlet.
The thermostatic expansion valve supplies the correct amount of refrigerants to evaporators where the refrigerants takes up the heat
from the room and boils off into vapours resulting in temperature drop for that room.
This is how temperature is maintained in the refrigeration plant of the ship.
(2) Safety devices on refrigeration system.
1. High Pressure Cut Out
High pressure can be caused in a refrigeration plant
due to various causes like over charge, loss of
cooling water, high ambient temperature, air, or
other incompressible gases in the system, and
obstruction in the discharge line of the compressor.
For protecting the compressor from high pressure
and subsequent failure, a high pressure cut out is
provided that take a pressure tapping from the
discharge line and when it detects an over pressure,
it stops the compressor. The HP cut out is not
resettable automatically but has to be reset
manually by the operator. This is because the high
pressure is a serious fault and the cause must be
investigated and corrected before the plant is
started again.

Operation of a High Pressure Cut Out

The high pressure cut out as shown in the diagram is of a simple construction. It has a bellows that is set against a spring. The nut at
the end of the spring is used to adjust the cut out pressure. When the high pressure gas enters the bellow, the bellow expands and
presses the spring. At the cut off pressure the movement of the bellow against the spring releases the catch and the contact is broken
and the compressor cuts off.
The switch arm can be pressed and the cut out reset after the cause of the over pressure has been found and rectified.
2. Low Pressure Cut Out
To protect the compressor against low pressure in the system and to avoid the ingress of air into the
system if a vacuum is generated in the lines a low pressure cut out is provided. Also when the
refrigerated compartments are cut off by the solenoids and there is no return gas, the low pressure
cut out is activated. When the solenoid of the refrigerated compartments open, the return gas comes
in the inlet of the compressor and the suction pressure rises, and then the low pressure switch cuts in
the compressor.

Unlike the high pressure cut out, the low pressure cut out is self-resettable and does not need to be reset manually.

3. Low Oil Pressure Cut Out

The oil is pumped under pressure by an attached oil pump that supplies oil to the bearings for lubrication. Any problem in the lube
oil pressure can jeopardize the bearings and therefore a tapping is taken from the pump outlet and fed to the oil pressure switch. Any
fall in the pressure will activate the cut out which will stop the compressor.

Oil differential cut out: This safety is again for compressor as it is the only machinery in the circuit having rotational parts
which requires continuous lubrication. In the event of low supply or no supply of lube oil to the bearing, the differential
pressure will increase and activates a trip signal to safeguard the bearing and crankshaft.

4. Oil Separator
As oil is miscible with the refrigerant and often goes out of the compressor with it, it can go to the evaporator where it can cause a
decrease in heat transfer. To avoid the oil from going to the evaporator where it can form a layer inside or cause obstruction an oil
separator is used. It basically consists of baffle plates that separate the oil from the refrigerant and feed it back to the compressor. A
float valve is provided so that short circuiting of the refrigerant should not take place.

Oil Separator Construction

5. Relief valves: Relief valves are fitted in discharge side of compressor and will lift and safeguard the compressor
in the event of over pressure. One relief valve is also fitted in the condenser refrigerant line to avoid damage to the
condenser if there is high pressure in the discharge line.

6. Solenoid valves: Master solenoid valve is fitted in the common or main line after the condenser discharge. It
closes when compressor stops or trips to avoid over flow of refrigerant in to evaporator. All holds or rooms are
fitted with individual solenoid valve which control the flow of refrigerant to that room.

7. Oil heater: Oil heater is provided for the compressor crank case oil and prevents compressor from getting
excessively cold which may effect the lubrication of the parts.
3. What is critical temperature ?
Critical temperature above which it is impossible to liquefy the refrigerant regardless of pressure.
It should be as high as possible and certainly above the maximum expected condenser temperature.
4(a). What is the primary refrigerant ?
It is a medium which is used in a vapour compression cycle to remove heat from a low temperature region and convey it to
a high temp: region .It undergoes change of physical state during its working cycles.

1) Mostly volatile liquid and employed inside direct expansion closed system.
2) Evaporate at low temperature and at reasonable pressure
3) Condense at SW temperature at reasonable pressure
4(b). What is secondary refrigerant ?
It is a substance which is transferred heat by conduction and convection. Brine is a secondary refrigerant .Its density 1250 kg /m2
1) It is a non volatile liquid during it working cycle and employed at large, complex installation, to avoid circulation of expansive
Primary Refrigerant in large quantities.
2) Cooled inside Refrigeration Machinery Room and pumped around the ship to batteries in each cargo space
5. What are the properties of an ideal refrigerant?
a. It should be environment friendly
b. It should have low critical pressure, high critical temperature.
c. It should have higher latent heat of evaporation.
d. It should have low specific volume.
e. It should not be fire hazard.
(Freon 11&12 are CFC and are banned now; Freon 22 are HCFC and can be utilized by 1st Jan 2020; and only HFC-133, HFC-134,
HFC-404 will be in use later)
6. Explain thermostatic expansion valve diagram?
Pressures Acting Inside the Thermostatic Expansion Valve or TEV
The working of the thermostatic expansion valve can be explained with the
help of the attached image of the valve. The valve comprises of external body
inside which various parts as shown in the figure are enclosed.
There are three pressures acting inside the thermostatic expansion valve. P1 is
the pressure at the top of the thermostatic expansion valve acting inside the
power element above the diaphragm. Due to this pressure the diaphragm tends
to move down due which the needle also moves down and the valve tends to
open. When the evaporator temperature becomes higher the gas in the feeler
bulb expands due to which the gas pressure inside the power element
increases. This causes the downward movement of the needle to open the
valve
The pressure P2 is the pressure acting on the lower side of the diaphragm due
to the refrigerant pressure inside the evaporator. This pressure tends to move
the diaphragm upwards and close the opening of the valve.
The pressure P3 is the spring pressure that tends to close the opening of the valve. This pressure remains constant.

The pressures P2 and P3 act against the pressure P1. The pressure P1 tends to open the valve while the
pressure P2 and P3 tend to close the thermostatic expansion valve. Thus if the valve has to open P1 should be
greater than combined forces of P2 and P3.

How Thermostatic Expansion Valve Works?

During the normal working of the refrigeration plant the thermostatic expansion valve remains opened in certain
position. When the refrigeration load increases, the temperature inside the evaporator also increases. In such cases
there is need of the more refrigerant to take care of the increased load. The increased temperature in the evaporator
is sensed by the feeler bulb of the thermostatic expansion valve. This leads to the expansion of the gas in the feeler
bulb and also in the power element of the TEV leading to the increase in pressure P1. Due to this the diaphragm of
the TEV moves down and tends to open the valve further to increase the flow of the refrigerant to the evaporator.
At the same time the pressure P2 below the diaphragm also increases due to superheating of the refrigerant inside
the evaporator. This pressure tends to close the valve. There is also spring pressure P3 below the diaphragm that
opposes the opening of the valve. If the increase in the refrigeration load is much higher the pressure P1 overcomes
pressure P2 and P3 leading to the further opening of the thermostatic expansion valve. This allows for the increased
flow of the refrigerant to the evaporator to take care of the extra load.

When the refrigeration load reduces, the magnitude of pressure P1 reduces and the combined pressures P2 and P3
overcome pressure P1 that allows for partial closing of the valve so the flow of the refrigerant to the evaporator
reduces. Thus the TEV maintains the flow of the refrigerant inside the evaporator as per the refrigeration or air
conditioning load. The TEV constantly modulates the flow to maintain the superheat for which it has been adjusted
by the spring.

7. Explain refrigeration cycle on P-H graph.

The stages in the cycle are as follows:
Stage 1 to 2: the superheated vapour is compressed.
Stage 2 to 3: the hot superheated vapour enters the
condenser where the first part of the process is
desuperheating.
Stage 3 to 4: the hot vapour is condensed back to a saturated
liquid.
Stage 4 to 5: the liquid is subcooled before it enters the
expansion valve (this may occur in the condenser, a second
heat exchanger or in the pipework connecting the condenser
with the expansion valve).
Stage 5 to 6: the high pressure liquid passes through an
expansion device.
Stage 6 to 7: low pressure liquid refrigerant in the
evaporator absorbs heat from the air or water being cooled
and evaporates to become dry saturated vapour.
Stage 7 to 1: the refrigerant vapour absorbs more heat while
in the evaporator and while in the pipework joining the
evaporator to the compressor, to become a superheated
vapour.
8. Explain HP cut out.
Already explained above.
9. How to charge gas in refrigeration system?
After leak test , evacuation, drying out.
*make sure vaccum exists &all stop valve in circuit are open.
*weigh bottle, check for proper refrigerant, connect charging line & purge. Close the receiver outlet valve and collect the gas in the
receiver.
* Open bottle stop valve open charging v/v slowly.
* Once all gas is collected in receiver then shut the compressor suction valve.
Check the liquid level; if it is below L/3, Charging is reqd.
Check the weight of the refrigerant bottle & keep it upright.
Connect the charging line to the connecting point and keep it loose.

Open the bottle valve slightly and purge the line into the collecting cylinder and then tighten the connection.

Open the charging valve and fully open the bottle valve.
Check the liquid level in the sight glass and make sure no air bubble present in the system.
Close the charging valve and the bottle valve.
Open the receiver outlet valve & start the compressor.
Carry out leak detection test.
Check the suction pressure & discharge pressure.
10. How to add oil in refrigeration compressor?
Method 1:
Mostly ships have hand p/p provided which develop more pressure than the inside pressure.
Method 2.:
Reduce the L.P Cut out setting. Dip the pipe inside the c/case of compressor. Run compressor, vaccum will develop. So, compressor
will start sucking the oil. Make sure the pipe is diped fully, because it has got chances of sucking air. If air gets in, then purge it in a
separate bottle after charging of oil gets completed.

11. EXPLAIN THE PROPERTY OF LUBRICANT USED IN REFRIGERATION SYSTEM?

1. Good immiscibility and insolubility to assist in good oil return to the compressor, where it belongs.
2. Chemical stability to resist chemical reaction with the refrigerant or other materials present in the system.
3. Thermal stability to eliminate excess deposits at compressor hot spots.
4. Low wax content to prevent separation of flocculent wax from the oil mixture at the low temperature points in the system.
5. Low pour point to prevent separated lubricant from congealing and restricting flow.
6. Proper viscosity, even when diluted with refrigerant, to ensure high film strength at elevated operating temperatures and still
provide good fluidity under coldest operating conditions.
8. No contamination to prevent scarring of bearing surfaces, plugging of lines or oil ports and general deterioration.

Some major compressor manufacturers prefer alkyl benzene refrigeration oil for some applications with HCFC refrigerant blends
such as R-22, R-123 and R-401A. However, alkyl benzene refrigeration oil with the proper viscosity can be used with most CFC
and HCFC refrigerants as well as hydrocarbons and ammonia in most refrigeration and air-conditioning applications.
The benefits of high-quality alkyl benzene lubricants are high miscibility, low foaming, excellent thermal stability, very low flock
points and good compatibility:
1. High miscibility: Miscibility is the ability of the refrigerant and lubricant to stay together as one homogeneous solution. Alkyl
benzene has excellent miscibility with CFC and HCFC refrigerants, resulting in the oil and refrigerant remaining as one mixture at a
wide range of temperatures and pressures.
2. Low foaming: The low foaming quality of alkyl benzene reduces carryover at compressor startup and subsequent oil loss from the
crankcase.
3. Excellent thermal stability: Alkyl benzene can enhance the life of refrigeration systems by providing better thermal stability in the
presence of CFC and HCFC refrigerants. It resists change under high temperatures, reducing problems with sludge, acids and
copper plating.
4. Very low flock points: The flock point is the highest temperature at which wax-like materials precipitate from the oil in the
refrigeration system. Because alkyl benzene is a synthetic lubricant, it contains little or no paraffin or wax, which can plug up parts
of a system. This can be very desirable in low-temperature applications.
5. Good compatibility: Alkyl benzene can be blended with mineral oil of the same viscosity. It will not affect motor insulation and is
compatible with most elastomers and additives often used to improve lubricity.
Preventing contamination problems is extremely critical in the refining and handling of all refrigeration oils. Great care must be
used to assure that refrigeration oil is free of moisture and other contaminants. Service technicians must ensure that oil remains
clean and dry.
12. DO WE CHECK IF TEMPERATURE OF ANY ONE ROOM IS NOT COMING DOWN?
1. IF ROOM DOOR IS NOT CLOSED PROPERLY.
2. PARTICULAR ROOMS INSULATION IS BAD.
3. PARTICULAR ROOMS FAN IS NOT RUNNING.
4. EVAPORATOR OF THAT ROOM IS FROSTED.
5. EXPANSION VALVE FOR THAT ROOM IS BLOCKED.
6. SOLENOID IS NOT WORKING FOR THAT ROOM.
13. WHAT ALL THINGS TO BE CHECK IF ALL ROOMS TEMPERATURE IS NOT COMING DOWN?
1. COMPRESSOR IS NOT RUNNING WELL.
2. PRESENCE OF MOISTURE IN SYSTEM & DRIER IS NOT WORKING PROPERLY DUE TO THIS EXPANSION VALVE
OF ALL ROOMS ARE GETTING BLOCKED.
3. LESS REFRIGERANT IN SYSTEM.
14. WHERE IS POSITION OF UNLOADER IN A/C & REF. COMPRESSOR?
IT IS LOCATED NEAR THE SUCTION VALVE OF COMPRESSOR.
15. Explain L.P. controller.
CONSTRUCTION:
1. THIS CONSISTS OF BELLOW WHICH MONITOR THE PRESSURE IN THE COMPRESSOR SUCTION.

2.

THE PUSH PIN OPERATES THE SWITCH THROUGH A CONTACT WHICH IS FLIPPED OPEN OR CLOSED
THROUGH A COILED SPRING PLATE. WITH THE CONTACTS OPEN THE SPRING IS COILED.
3. OUWARD MOVEMENT OF THE PIN COMPRESSES THE SPRING AND THIS THEN FLIPS THE CONTACT TO
CLOSE THE COMPRESSOR STARTING CIRCUIT.
OPERATION:
1. THIS STOPS THE COMPRESSOR WHEN LOW PRESSURE IS INDICATED ON SUCTION SIDE OF THE
COMPRESSOR.
2. WHEN THE PRESSURE IN THE COMPRESSOR SUCTION SIDE RISES AGAIN, IT RESTARTS THE
COMPRESSOR.
16. How to start refrigeration plant?
1. CHECK OIL LEVEL IN THE COMPRESSOR.
2. OPEN THE CONDENSER COOLING VALVES, CLOSE THE DRAIN COCK, START COOLING WATER PUMP AND
CLOSE AIR COCK AFTER PURGING OUT THE AIR.
3. OPEN ALL THE REFRIGERATION SYSTEM VALVES EXCEPT THE COMPRESSOR SUCTION VALVE. ENSURE
THAT COMPRESSOR DISCHARGE IS OPEN .
4. START FANS, BRINE PUMP etc.
5. CHECK POWER SUPPLY TO THE COMPRESSOR AND SOLENOID VALVES.
6. NOW OPEN THE SUCTION VALVE OF THE COMPRESSOR AND START THE COMPRESSOR.
7. OBSERVE THE SYSTEM FOR ANY ABNORMAL OPERATION FOR TEN MINUTES BEFORE PUTTING IT IN
AUTO-MODE
8. REFRIGERANT SYSTEM GENERALLY OPERATES AUTOMATICALLY ONCE STARTED. THE KING SOLENOID
VALVE OPENS ALLOWING THE REFRIGERANT TO FLOW TO THE BOXES. WHEN THE TEMP., IN THE BOX
RISES, IT ENERGISES THE BOX SOLENOID TO OPEN THE VALVE. THE REFRIGERANT THEN FLOWS
THROUGH THE EVAPORATOR. AS THE REFRIGERANT FLOWS THROUGH THE EVAPORATOR, COMPRSSOR
SUCTION PRESSURE BEGINS TO RISE. THIS SUCTION PRESSURE IS SENSED BY THE LPCO WHICH CUTSIN AT ITS HIGH PRESSURE SETTING AND STARTS THE COMPRESSOR.
9. WHEN INTENDED COLD TEMP., IS REACHED, THE BOX THERMOSTAT CLOSES THE SOLENOID VAVE.
COMPRESSOR CONTINUE RUNNING, UNLOADING THE CYLINDERS UNTIL THE SUCTION PRESSURE IS
LOW ENOUGH TO ACTUATE LPCO. WHEN SET PRESSURE IS REACHED LPCO SWITCH STOPS THE
COMPRESSOR.
Things to check during running of refrigeration plant:
1. ALL THE PARAMETERS SUCH AS PRESSURE, TEMP., OIL LEVEL IN THE COMPRESSOR, WATER FLOW IN
THE CONDENSER etc., SHOULD BE CHECKED AT REGULAR INTERVAL AND LOGGED IN.
2. THERMOSTATIC EXPANSION VALVE SHOULD BE CHECKED FOR PROPER OPERATION BY LOOKING AT
THE FROST DEPOSITION.
3. WHEN TWO COMPRESSORS ARE INSTALLED, THE COMPRESSOR OPERATION SHOULD BE CHANGED
OVER EVERY WEEK.
17. What are the tests for refrigerant leakage?
ELECTRONIC LEAKAGE DETECTOR:
1. FIRST VENTILATE COMPARTMENT THOROUGHLY FOR ACCURACY IN LEAKE DETECTION.
2. ADJUST THE SENSITIVITY OF INSTRUMENT ACCORDING TO THE MAKERS INSTRUCTIONS.
3. MOVE THE PROBE TIP OF THE INSTRUMENT SLOWLY ONE TO TWO INCHES PER SECOND IN THE
SUSPECTED AREA. PROBE DRAWS THE AIR AND FLASHING OF THE LIGHT SHOWS PRESENCE OF GAS IN
AIR
1.
2.

3.

HALIDE LEAK DETECTOR:

THIS CONSISTS OF A BURNER, NEEDLE VALVE, SUCTION TUBE AND A CHIMNEY WITH COPPER
REACTION PLATE.
THE EXPLODING TUBE OF THE DETECTOR IS
MOVED SLOWLY OVER THE SUSPECTED AREA AND
PRESENCE OF THE LEAKAGED REFRIGERANT IS
INDICATED BY CHANGE IN COLOUR OF THE
FLAME. SMALL LEAK GIVES GREENISH TINGE AND
A LARGE LEAK GIVES VIVID BLUE FLAME.
IF LEAK IS NOT FOUND WITH THIS METHOD, THEN
THE LEAK COULD BE INSIDE THE CONDENSER.
INVESTIGATE IT.

18. What is Defrosting and what are the methods?

DEFROSTING IS PROCESS OF REMOVING THE ICE FORMED ON THE SURFACE OF EVAPORATOR. FROST
HAMPERS THE HEAT TRANSFER EFFICIENCY OF EVAPORATOR.
WHEN FROST IS FORMED, THE REFRIGERANT ENTERING THE EVAPORATOR COILS DOES NOT
EVAPORATE COMPLETELY AND THERE IS DANGER OF UNEVAPORATED REFRIGERANT FLOODING BACK
TO THE COMPRESSOR, WHICH MAY CAUSE DAMAGE.
Methods of Defrosting:
HOT WATER SPRAY:
1. FOR THIS FIRST CLOSE THE STOP VALVE BEFORE THE EVAPORATOR.
2. SPRAY THE HOT WATER FROM ACCOMODATION WITH THE FLEXIBLE HOSE ON THE EVAPORATOR COILS
UNTIL ALL THE FROST MELTS.
3. WATER COLLECTED IN BILGES IS TO BE DRAINED BEFORE STARTING THE SYSTEM AGAIN.
ELECTRICAL HEATING:
1. ELECTRIC HEATING COILS ARE INSTALLED BETWEEN THE EVAPORATOR COILS.
2. THESE COILS HEAT THE ATMOSPHERE AROUND THE EVAPORATOR AND DEFROST IT.
3. ON COPLETION OF DEFROSTING ELECTRIC COILS ARE PUT-OFF AND WATER IS DRAINED FROM THE
COMPARTMENT BEFORE STARTING THE SYATEM AGAIN.
REFRIGERANT HOT GAS:
1.
IN THIS METHOD REFRIGERANT HOT GAS FROM THE COMPRESSOR IS DIRECTLY PASSED TO THE
EVAPORATOR COILS WITHOUT PASSING IT THROUGH THE CONDENSER AND EXPANSION VALVE.
2. ON COMPLETION OF DEFROSTING, GAS SUPPLY IS PUT-OFF AND WATER IS DRAINED FROM THE
COMPARTMENT BEFORE STARTING THE SYASTEM AGAIN.
19. Effect of sea water on refrigeration system?
20. Oil separator working in refrigeration cycle.

1.

2.

1.
2.
3.

4.

FUNCTION OF OIL SEPARATOR :

THE OIL WHICH IS USED TO
LUBRICATE CYLINDER LINERS MIX
WITH THE REFRIGERANT. THIS IS
REQUIRED TO BE SEPARATED AND
SENT BACK TO THE COMPRESSOR
BEFORE IT REACHES THE
CONDENSER.
BECAUSE THIS OIL MAY GET
COATED OVER THE HEAT
TRANSFER SURFACE OF
CONDENSER AND ALSO THE
EVAPORATOR etc., AND AFFECT THE
HEAT TRANSFER RATE.
OIL SEPARATOR IS ALSO
NECESSARY TO PREVENT ANY
DAMAGE TO THE COMPRESSOR
DUE TO OIL STARVATION, IF OIL
LEAVING THE COMPRESSOR ALONG
WITH REFRIGERANT IS NOT
REPLACED.
CONSTRUCTION & OPERATION OF OIL SEPARATOR:
THIS CONSISTS OF A VESSEL FITTED WITH BAFFLE AND DE-MISTER.
THE MIXTURE OF HIGH PRESSURE REFRIGERANT & THE OIL MIST IS MADE TO CHANGE ITS DIRECTION
OF FLOW.
FIRST ITS SPEED IS SLOWED DOWN BY FIRST MOVING DOWNWARDS THROUGH ANNULAR SPACE, THEN
THROUGH THE DE-MISTER AND THEN AGAIN UPWARDS THROUGH THE DE-MISTER MADE OF PAD OF
COPPER WOOL. AS IT PASSES THROUGH THE DE-MISTER ,TINY PARTICLE OF OIL STICK TO THE METAL
AND FORM DROPLETS OF OIL, WHICH DRIP DOWN TO THE BOTTOM OF HOUSING DUE TO GRAVITIONAL
FORCE.
OIL THUS COLLECTED FLOWS BACK TO COMPRESSOR

21. Troubleshooting of refrigeration system

Undercharging of Refrigeration System

Indication:
Compressor is running hot and performance of the compressor falls off due to high superheat temperature at the suction side of
compressor.
Suction and discharge pressure of the compressor is low.
Large vapor bubbles in the liquid sight glass.
Low gauge readings in the condenser.
Ammeter reading for the compressor motor is lower than normal.
Rise in room temperature which is to be cooled.
Compressor is running for extended period of time.
Causes:

Action:

Leakage of refrigerant at the shaft seal, flange couplings, valve gland etc.
Expansion valve may be blocked at the strainer.
Partial blockage of refrigerant at the filter or drier or evaporator may cause undercharging.

Identify and rectify the leakage of refrigerant from the system.

Clean the filter and drier.
Charge the system with fresh refrigerant as required.

Overcharge of Refrigeration System

Indication:

The liquid level in the condenser is too high (high condenser gauge reading). This will reduce the available condensing surface,
with corresponding increase in the saturation temperature and pressure.
High pressure switch of the refrigerant compressor activates and stops the compressor.
The suction and the discharge pressures are high.
Causes:
It may be due to the reason that excessive refrigerant has been charged in the system.
Air in the system may also cause over charging indication.
It may also be due to the formation office on the regulator.
Action:

Remove the refrigerant from the system. This is done by connecting a cylinder to the liquid line charging valve, starting the
compressor, and then operating the charging valve.
Purge the air from the system and maintain effective cooling.
Remove ice from the regulator by using any of the defrosting methods.

Moisture in the System

This normally comes with the ingress of air in the system. Moisture may freeze at the expansion valve, giving some of the
indication of under charging. It will contribute to the corrosion in the system. It may cause lubrication problems and breakdown of
the lubricating oil in the refrigerant compressor.
Action:

Renew silica gel in case of minor moisture.

Collect refrigerant and remove all air and moisture by vacuum pump if the amount is huge.

Air in the System

Indication:

This may cause the refrigeration compressor to overheat, with a high discharge pressure and normal condensing
temperature.

There are possibilities of small air bubbles in the liquid sight glass of the condenser.
Condensing pressure of the refrigerant in the condenser may be high.

If there is excessive air, it may reduce the cooling capacity of the system, making the compressor to run for the
extended period of time.

It may cause the gauge pointer of the condenser to jump indefinitely.

Causes:

During charging, air may enter in to the system.

If Freon-12 is used air may leaks in to the suction line because the working pressure of the Freon-12 refrigerant is less than the
atmospheric pressure.
Action:

Air in the system can be removed by collecting the system gas in the condenser, leaving the condenser cooling water on and
venting out the air from the top of the condenser because air will not be condensed in the condenser but remains on top of the
condenser above the liquid refrigerant.
Connect the collecting cylinder to the purging line of the condenser, open the valve, and collect air in the cylinder.
After purging the air from the system dont forget to shut the purging valve.
Check the level of the refrigerant in the system. If required, charge the system with fresh refrigerant.
Restart the compressor with all safety precautions.

Oil in the Refrigeration System

Indication:
Temperature is not dropping in the cold rooms as normal, due to fact that oil act as insulation in the evaporator.
It may cause excessive frost on the suction line.
Refrigerant compressor runs for the extended period of time.
Lubricating oil level in the compressor will drop.
Refrigerant level will fall if oil has caused blockage.
Causes:
This may happen if the oil separator is not working properly.
Oil may carry over from the compressor and may not come back to the compressor due to blockage in the system.
Defective piston rings or worn out liner of the compressor may cause the oil to carry over along with the refrigerant.
Compressor may take high capacity current during starting.
Action:

Check the oil separator for proper functioning.

Check the drier for proper cleaning and if its require cleaning clean it
Evaporator coil should be drained to remove any trace of oil.
If there is oil in the cooling coils, increase the condenser and evaporator temperature differentials and remove excess frost on
the suction pipe.
Heat pipes with blow torch.

Flooding of Refrigerant in the System

This is seen as liquid getting back to the suction of the refrigerant compressor. It may be due to a faulty or incorrectly adjusted
expansion valve and also due to solenoid valve leakage. It may also result from overcharging of the refrigeration system. Flooding
may lead to an iced up evaporator.
Short cycling:
REASONS: * L.P Cut out is defective.
* L.P Cut out setting not correct, too low difficult for Cut In.
* Lesser gas flow
* Less gas in system.
* Drier Choked.
* Expansion valve filter choked or Expansion valve Malfunction.
* Evaporator Choked.
* Compressor valves leaking.

Actions: a. Check L.P. cut out setting, cut out pressure OK.
b. Check flow of gas by seeing sight glass, which should show full flow of refrigerant.
c. If no full flow- either less gas or drier chocked, change the drier.
d. Check level in receiver, if low, then charges gas.
e. Expansion valve filter choked, then clean it.
f. Expansion valve malfunctioning- Change it.
g. Evaporator choked- Blow-thru evaporator with nitrogen.
23. What is Psychometric chart and its use?
Air condition is used for conditioning the air by altering its temperature and moisture content to suit the specific requirement.
Therefore it is necessary to air behaves when it is subjected to cooling, heating or humidifying process. The changes that can occur
in the air as it is subjected to these air conditioning process can be traced or analyzed by the use of Psychometric chart or table. The
chart shows relationship between dry bulb temp (Db), Wet bulb temperature(Wb), Relative humidity and dew point. If any two
factors are known the remaining two can be obtained by using the chart.

What is Psychrometric Chart?

Psychrometric charts are graphic representations of the psychrometric properties of air. By using psychrometric
charts HVAC engineers can graphically analyze different types of psychrometric processes and find solution to many
practical problems without having to carry out long and tedious mathematical calculations.
The psychrometric chart looks complicated with vast numbers of lines and curves in it, but is very easy to
understand if you know the basic properties of air. You will also understand its worth when you actually use it
considering the fact that you wont have to use any formulae to find the properties of air in different conditions, all
you will have to know is two parameters of air and the rest are easily found on the chart.

Various Lines and Curves in the Psychrometric Chart

All the properties of air indicated in the psychrometric chart are calculated at the standard atmospheric pressure. For
other pressures relevant corrections have to be applied. The psychrometric chart looks like a shoe.

1) Dry Bulb (DB) Temperature Lines:

The dry bulb temperature scale is shown along the base of the shoe shaped psychrometric chart forming the sole.
The DB temperature increases from the left to the right. The vertical lines shown in the chart are the constant DB
temperature lines and all the points located along a particular vertical line have same DB temperature.

2) Moisture Content:
Moisture content is the water vapor present in the air and is measured in gram per kg of dry air (gm/kg of dry air).
The moisture present within the air is indicated by the vertical scale located towards the extreme right. The
horizontal lines starting from this vertical scale are constant moisture lines.

3) Wet Bulb (WB) Temperature Lines:

The outermost curve along the left side indicates the Wet Bulb (WB) temperature scale. The constant WB
temperature lines are the diagonal lines extending from WB temperature curved scale downwards towards the right
hand side of the chart. All the points located along the constant WB temperature line have the same temperature.

4) Dew Point (DP) Temperature Lines:

Since the dew point temperature of the air depends on the moisture content of the air, constant moisture lines are
also constant DP temperature lines. The scale of the DP and WB temperature is the same, however, while the
constant WB temperature lines are diagonal lines extending downwards, the constant DP temperature lines are
horizontal lines. Thus the constant DP and WB temperature lines are different.