Refrigeration System Operations and Maintenance

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Questions and Answers

What is the primary purpose of vibration absorbers in refrigeration systems?

  • To increase the pressure of the refrigerant
  • To reduce the transmission of vibration and noise (correct)
  • To cool the refrigerant before entering the evaporator
  • To enhance the efficiency of the compressor

Where should vibration absorbers be installed for maximum effectiveness?

  • Close to the condenser
  • As far from the compressor as possible
  • Near the evaporator
  • As close as possible to the compressor (correct)

What factors influence the type of piping and tubing material used in refrigeration systems?

  • The energy efficiency of the system
  • The brand of the compressor used
  • The size, refrigerant used, and application (correct)
  • The cosmetic design of the system

According to CSA Standard B52, what must piping, tubing, and related components comply with?

<p>Minimum requirements of the ASME Code B31.5 (B)</p> Signup and view all the answers

Which component is responsible for creating noise and vibration in refrigeration systems?

<p>The compressor (B)</p> Signup and view all the answers

Why might the noise in a refrigeration system become objectionable?

<p>Because of vibration transmission through rigid piping (D)</p> Signup and view all the answers

What does the exploded view of a liquid refrigerant distributor illustrate?

<p>The structure and components of a distributor (B)</p> Signup and view all the answers

In refrigeration systems, what component connects the refrigerant piping to the compressor?

<p>Vibration absorber (A)</p> Signup and view all the answers

What is the minimum operational time for the unit before starting the compressor?

<p>10 minutes (A)</p> Signup and view all the answers

If the compressor has a separate oil pump, what is the minimum operational time for this pump before starting the compressor?

<p>10 minutes (D)</p> Signup and view all the answers

What happens if the return chilled water temperature is at or above the cut-in setpoint?

<p>The control relay will start the condenser cooling water pump (B)</p> Signup and view all the answers

What is the primary function of the drying agent in the filter-drier?

<p>To remove moisture from the refrigerant (C)</p> Signup and view all the answers

What is the purpose of holding the inlet damper or vanes in a closed position during the starting sequence?

<p>To reduce starting torque and current draw (C)</p> Signup and view all the answers

After the compressor reaches normal speed, what controls the damper or vane operator?

<p>The thermostat sensing water temperature (A)</p> Signup and view all the answers

Under what condition should the filter-drier be replaced?

<p>When the desiccant reaches its moisture holding capacity (B)</p> Signup and view all the answers

What should be checked continually for the first 30 minutes after the compressor starts?

<p>Oil and refrigerant levels (B)</p> Signup and view all the answers

What change indicates the presence of moisture in the refrigerant?

<p>Change in color of a chemical dot in the sight glass (B)</p> Signup and view all the answers

Which type of desiccant is used to remove moisture through chemical action?

<p>Calcium sulphate (A)</p> Signup and view all the answers

What action is taken if all protective controls are energized during startup?

<p>Compressor motor will start (B)</p> Signup and view all the answers

What is the first step in the startup procedure after ensuring the unit is ready?

<p>Set the chiller demand limiter to its lowest setting (B)</p> Signup and view all the answers

Which of the following statements about the sight glass is true?

<p>It is used to observe liquid flow and detect bubbles indicating issues. (A)</p> Signup and view all the answers

Where is the ideal location for installing a sight glass to determine if the system is fully charged?

<p>At the receiver or liquid receiver outlet (B)</p> Signup and view all the answers

What does the presence of vapor bubbles in the sight glass indicate?

<p>There may be insufficient refrigerant or flow restrictions (D)</p> Signup and view all the answers

Which component changes color in the presence of moisture within the refrigerant system?

<p>Chemical dot in the moisture indicator (D)</p> Signup and view all the answers

What should be done first to initiate the refrigerant charging process?

<p>Turn on the condenser cooling water supply or start the condenser fan (A)</p> Signup and view all the answers

To charge an ammonia refrigeration system, how should gas be fed into the system?

<p>In gas form with the cylinder upright (B)</p> Signup and view all the answers

What pressure should the system reach for the compressor to start after charging?

<p>About 690 kPag (D)</p> Signup and view all the answers

What is indicated by frosting on the compressor suction line in small refrigeration systems?

<p>Overcharging of the system (C)</p> Signup and view all the answers

What should be monitored to determine if additional refrigerant is required?

<p>The flow of refrigerant through the sight glass (B)</p> Signup and view all the answers

What is the purpose of increasing the system load while charging refrigerant?

<p>To ensure enough refrigerant vaporizes in the evaporator (C)</p> Signup and view all the answers

When should the liquid shutoff valve be opened during the charging procedure?

<p>After the drum valve and charging valve are closed (A)</p> Signup and view all the answers

How can the correct amount of refrigerant to add to the system be determined?

<p>By weighing the refrigerant drum on a scale (A)</p> Signup and view all the answers

What can occur if liquid refrigerant is forced into the compressor?

<p>High suction and discharge pressures (B), Reduced compressor lifespan (D)</p> Signup and view all the answers

How should refrigerant generally be added to a compressor?

<p>In its vapour state through the suction line (D)</p> Signup and view all the answers

Which tool is commonly used to add oil to a refrigeration compressor?

<p>A hand pump (B)</p> Signup and view all the answers

What must be ensured when adding oil to a refrigeration compressor?

<p>The ventilation system is running at full capacity (D)</p> Signup and view all the answers

What should be checked before disconnecting the charging line from the refrigeration system?

<p>Only vapor should be in the line (A)</p> Signup and view all the answers

What is the typical normal oil level in the bull’s eye gauge glasses of a refrigeration compressor?

<p>About ½ full (B)</p> Signup and view all the answers

Why is adding oil to an in-service refrigeration compressor considered dangerous?

<p>Refrigerant is pressurized, toxic, and flammable (C)</p> Signup and view all the answers

What can gradually happen to the oil level in refrigeration compressors over time?

<p>It may run out due to oil passing along with refrigerant vapour (C)</p> Signup and view all the answers

What is the first step to take if the oil level is low?

<p>Return lube oil from the oil separators (A)</p> Signup and view all the answers

What is a required condition for adding oil while the compressor is in operation?

<p>The crankcase pressure should not exceed 690 kPag (A)</p> Signup and view all the answers

Which of the following precautions should be taken when adding oil?

<p>Preventing air and moisture from entering the system (A)</p> Signup and view all the answers

What is the purpose of bleeding off air before attaching the hose to the compressor oil charging valve?

<p>To prevent air from mixing with the oil (B)</p> Signup and view all the answers

What should be done after the oil charging is complete?

<p>Disconnect from the fill valve and return equipment (C)</p> Signup and view all the answers

What must be ensured before using the compressor suction to draw oil into the crankcase?

<p>It should be an approved plant procedure (B)</p> Signup and view all the answers

Which valve must be open while operating the hand pump to charge oil?

<p>The charging valve (D)</p> Signup and view all the answers

What does the figure showing the oil return system likely illustrate?

<p>Arrangement for returning oil to the crankcase (A)</p> Signup and view all the answers

Flashcards

Filter-Drier

A component in refrigeration systems that removes moisture from the refrigerant using a desiccant material.

Desiccant

A material that absorbs moisture from the surrounding environment, commonly found in filter-driers.

Adsorption

A method used by desiccants to remove moisture by attracting and holding water molecules onto its surface.

Chemical Reaction

A method used by desiccants to remove moisture by reacting chemically with water.

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Sight Glass

A visual device that shows the flow of refrigerant in a system.

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Moisture Indicator

A chemical indicator placed within the sight glass that changes color in the presence of moisture.

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Sight Glass with Moisture Indicator

A small housing with lenses that allows the observation of refrigerant flow. It can indicate both moisture and insufficient refrigerant.

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Replacing the Desiccant

The process of installing a new desiccant cartridge when the existing one has reached its capacity for absorbing moisture.

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Charging a Refrigeration System

The process of adding refrigerant to a refrigeration system to achieve the required operating pressure and refrigerant level.

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Liquid Charging Valve

A valve used to control the flow of liquid refrigerant into the system during charging.

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Drum Valve

A valve used to regulate the amount of refrigerant entering the system during charging.

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Low-Pressure Cutoff Switch

A pressure-sensitive switch that stops the compressor if the pressure in the system falls below a set point.

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Breaking a Vacuum

The process of breaking a vacuum by introducing refrigerant gas into a refrigeration system.

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Opening the Liquid Shutoff Valve

The process of opening the liquid line valve to allow refrigerant flow to the evaporator after the charging procedure is complete.

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Frost on Compressor Suction Line

The phenomenon of frost formation on the compressor suction line, indicating overcharging of the refrigeration system.

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Vibration Absorber

A component that absorbs vibrations and noise created by refrigeration system components, such as the compressor, evaporator, or condenser.

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Vibration Absorber Location

The connection points where vibration absorbers are typically installed in a refrigeration system, usually near the compressor and on both the suction and discharge lines.

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Manifold Distributor

A type of refrigerant distributor used in refrigeration systems, designed to evenly distribute liquid refrigerant to an evaporator.

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Refrigerant Piping and Tubing

The material used for piping and tubing in refrigeration systems, selected based on factors like size, refrigerant type, and application.

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CSA Standard B52, Mechanical Refrigeration Code

A standard that outlines minimum requirements for piping, tubing, valves, fittings, and related parts used in mechanical refrigeration systems.

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ASME Code B31.5: Refrigeration Piping and Heat Transfer Components

A code that sets forth specific requirements for refrigeration piping and heat transfer components, ensuring safety and functionality.

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Vibration Transmission

The transmission of vibrations and noise through rigidly connected piping in refrigeration systems.

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Noise and Vibration Reduction

The process of reducing noise and vibrations in refrigeration systems by installing vibration absorbers and ensuring proper piping and tubing selection.

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Oil Return

The process of returning oil from the oil separators back to the crankcase.

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Adding oil

When the compressor is operating, it is acceptable to add oil to the crankcase with a hand pump, provided that the crankcase pressure is not excessive and the compressor manufacturer permits it.

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Adding oil to a compressor

Refrigeration compressors are sealed units, preventing the escape of refrigerant. To add oil, specialized tools like hand pumps and pressure-rated hoses are needed.

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Why oil needs to be added?

If a refrigeration compressor is running out of oil, it needs additional lubrication. Oil can be added directly to the compressor crankcase, which is not straightforward due to the sealed nature of the system.

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Safety precautions

Before adding oil to a compressor, ensure the ventilation system is running at full capacity to prevent any accidental leaks of refrigerant and oil.

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Bull’s eye gauge glass

Bull’s eye gauge glasses are used to monitor the oil level in the compressor crankcase. A normal oil level is about half the glass.

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Adding oil safety

Adding oil to a running compressor, especially when the refrigerant is pressurized, toxic, and flammable, involves risks. Specific site procedures and personal protective equipment are crucial for safety.

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Potential hazards

Refrigerant leaks and oil spray are possible during the oil addition procedure because it involves accessing the compressor crankcase, which contains refrigerant vapor.

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Why compressors lose oil?

Compressor sumps gradually run out of lube oil because it passes through the discharge piping along with refrigerant vapor.

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Oil level monitoring

Regularly monitoring the oil level in the compressor crankcase is crucial to ensure proper lubrication.

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Pre-Startup Procedure

The process of starting the compressor and allowing it to run at low speed for a predetermined time to allow oil to circulate and reach a suitable temperature before full operation.

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Oil Pump Pre-Run

A safety feature that prevents the compressor from starting until the oil pump has been operational for a certain duration, ensuring adequate lubrication.

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Chiller Demand Limiter

A component that regulates the flow of chilled water to the evaporator, allowing for a precise adjustment of cooling capacity.

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Building Management Control System (BMCS)

A control system designed to monitor and manage building systems, including HVAC, lighting, and security.

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Cut-in Setpoint

The pressure at which the condenser cooling water pump is automatically activated, ensuring adequate heat dissipation.

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Thermostat

A device that measures the temperature of the chilled water leaving the evaporator, providing feedback for adjusting the chiller's operating parameters.

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Compressor Load-Up

The process of gradually increasing the compressor's load by opening the inlet damper or vanes, allowing the compressor to reach full operating capacity.

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Starting Torque

The amount of torque required to start the compressor, which is reduced by initiating the start sequence in an unloaded state.

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Study Notes

Learning Outcome

  • Describe the operating principles and maintenance of a refrigeration system.

Learning Objectives

  • Discuss refrigeration auxiliaries
  • Describe refrigeration system leak test procedures
  • Describe how a refrigeration system is dried and charged prior to start-up
  • List the steps for adding oil to an in-service refrigeration compressor
  • Describe the start-up and shut-down procedure for a compression refrigeration system
  • Describe operational log sheets and preventative maintenance procedures for refrigeration systems
  • Describe how a refrigeration system is purged of noncondensable gases
  • Discuss refrigeration condenser operation and maintenance requirements
  • Explain typical problems and resolutions related to refrigeration systems

Chapter Introduction

  • Power Engineers need to know refrigeration system layouts and types of equipment
  • Understanding components' functions are crucial for safe and economical operation
  • Professionals must be familiar with relevant codes and standards (e.g., CSA B52, ASME B31.5, IIAR)
  • Manufacturer's websites provide essential system-specific info for operation, maintenance, and troubleshooting

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