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Prepared by
Cascade Energy Engineering, Inc.
6½ N. Second Ave, Suite 310
Walla Walla, Washington 99362
www.cascadeenergy.com
Primary Authors
Marcus Wilcox, Rob Morton, Josh Bachman, Dan Brown: Cascade Energy Engineering
Technical Illustration
Elaine Giraud: SeeFigureOne
Technical Reviewers
Greg Jourdan: Wenatchee Valley College
Anthony Radspieler and Steve Greenberg: Lawrence Berkeley National Laboratory
Doug Reindl: Industrial Refrigeration Consortium
Michael Steur: Hixson, Inc.
Copyright
© 2007 Northwest Energy Efficiency Alliance, Inc. All rights reserved. Northwest Energy Efficiency Alliance grants permission to
reproduce this material in whole or in part only for information or education purposes.
ISBN: 0-9721077-9-7
Disclaimer
This Guide was prepared by Cascade Energy Engineering for the Northwest Energy Efficiency Alliance. Neither the Northwest
Energy Efficiency Alliance nor any of its contractors, subcontractors, or employees, makes any warranty, expressed or implied, or
assumes any legal liability of responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or
process disclosed within this Guide. This Guide and any examples described herein are intended to be general information and
guidelines concerning the subject matter, and are not recommendations with respect to any specific project or application.
Introduction
Courtesy of Frick
Background
This Guide identifies and discusses best practices for making industrial refrigeration systems both energy-
efficient and productive. The highest levels of efficiency in these systems are achieved through a
combination of design, construction, commissioning, operation, and maintenance coupled with a robust
energy management program. This Guide provides insights into approaches to industrial refrigeration
systems that cost less to operate, are reliable, can maintain accurate and consistent temperatures in
refrigerated spaces, help ensure that processing equipment operates consistently, and can meet varying
production needs.
This Guide was developed with the support of the Northwest Energy Efficiency Alliance (NEEA). NEEA
is funded by, and works in alliance with, local utilities to encourage the development and adoption of
energy-efficient products and services. NEEA’s mission is to make the Northwest more energy efficient
for the benefit of electric ratepayers.
NEEA’s industrial initiative focuses on helping Northwest industry gain a competitive advantage via the
adoption of energy efficient business practices. The industrial initiative works alongside local utilities and
with regional industry associations to provide expert support, resources and services to give companies
tools and training to make energy efficiency a core business value.
Goals
Ultimately, market transformation for energy efficiency in industrial refrigeration is achieved by changing
the business practices of food processing companies, cold-storage and refrigerated warehouses, and the
trade allies that support and serve them. Design standards and operation-and-maintenance practices that
increase and maintain energy efficiency can also be adopted by users of industrial refrigeration and their
engineering consultants and contractors.
In this context, the goals of this Best Practices Guide are:
! To identify opportunities to increase electrical energy efficiency in industrial refrigeration
systems The Guide specifically focuses on energy savings measured in kilowatt-hours (kWh). It is
Attribute Criteria
Size: 100 tons or larger
Refrigerant: Ammonia (R-717) in the vast majority of cases, with some R-22 applications
System Type: Centralized and built-up, as opposed to commercial refrigeration equipment, which is
simpler, more modular, and distributed
Load Temperatures: -60°F to 55°F with normally at least one load below 40°F
Function: Primarily storage and processing of food products
Industrial refrigeration systems are distinct from two related system types, which are not covered in this
Guide:
! Commercial refrigeration systems (such as those in grocery stores) which tend to be smaller, simpler,
and more modular.
! Large HVAC systems that cool spaces occupied by people and equipment, and that maintain space
temperatures higher than 55°F.
Although most of this Best Practices Guide will be of interest to all readers, some sections will be of
particular interest to specific audiences. The chapters of the Guide and how each audience may find them
valuable are outlined below. We hope that you will find useful information on best practices for your
refrigeration system for energy efficiency, to control operating costs, and to realize productivity benefits—
fundamentally, to improve your bottom line.
Chapter 2: Best Practices
Overview, beginning on
page 5, includes an overview of
design, operation, and
maintenance best practices, an
outline of the major categories
of improvement, and a guide on
how to obtain best practices in
industrial refrigeration systems.
Chapter 3: Refrigeration
System Basics, beginning on
page 10, reviews refrigeration
basics and, if needed, will help
familiarize you with industrial Figure 1: Suggested road map to this Guide for various audiences
refrigeration concepts and
equipment. Regardless of your level of familiarity with refrigeration systems and related components, this
chapter will be a very useful reference.
Design
! Designing the facility to reduce loads
! Selecting energy-efficient equipment and controls
! Integrating that equipment into a system that is optimized for efficiency at both peak and typical loads
Operation
! Trained and certified operators with a conceptual knowledge of energy-efficient practices and an
understanding of refrigeration cycles
! Scheduled or regular review and documentation of key set points and operational strategies required
for energy-efficient operation
! Using a control system to review operations to confirm efficient operation and to automate complex
control strategies
! Observing equipment and gauge readings to confirm efficient operation
Maintenance
! Trained and certified maintenance staff and contractors
! Preventive maintenance practices
! Routine calibration of sensors, controls, and actuators that indicate system performance
! Routine cleaning and maintenance of evaporators, condensers and heat exchangers
Commissioning
! Implementing commissioning for new construction, for major retrofits, or periodically for all systems
to ensure that the system, equipment, and controls meet process and energy-efficiency objectives
Life-Cycle Costs
Best practices encompass much more than just energy performance. In the broadest sense, best practices
could be defined as follows:
Design, operational, and maintenance practices that help minimize life-cycle costs to the system
owner are based upon factors that include:
! Initial capital investment
! The expected life of the equipment
! The reliability of the equipment
! Life-cycle cost of energy
! Life-cycle cost of equipment maintenance
Ideally, all of these costs and their interactions would be well understood, and selecting the “best
practices” for a given situation would be straightforward. Real situations, however, are more complicated
and have more unknowns, but we contend that in most cases, a system that is designed, operated, and
maintained in an energy-efficient manner will typically have low life-cycle costs.
There is no single set of best practices that is ideal for every situation. We do not suggest that every
conceivable energy-efficient option should be integrated into every system. The optimum design for a
system that operates continuously at a relatively high load will be different than the design for a system
with a short season with highly variable loads. Instead, we believe that it is warranted to consider a range
of energy-efficiency choices when designing a new refrigeration system or modifying an existing system.
Existing system constraints, energy rates, and utility or government incentives can all significantly influence
which best practices are economically viable for a specific system.
System Commissioning
" Develop and execute a commissioning plan to assure that the system, equipment, and controls meet
their process and energy-efficiency objectives.
" Think of commissioning as a way to ensure that you are getting what you are paying for in your
refrigeration system project, not as an additional cost without benefit.
Introduction
In this chapter, we explain the basic vapor refrigeration cycle and describe the equipment typically used in
industrial refrigeration systems. We discuss the various features and characteristics of this energy-using
equipment and review system-control and variable-frequency drive (VFD) technology.
If you are already familiar with industrial refrigeration, this chapter can serve as a refresher or as
background reference information. If you are unfamiliar with refrigeration, this chapter will introduce and
explain critical basic concepts and terms that underlie best practices for energy efficiency. In any case, this
chapter can serve as the basis of a common understanding of industrial refrigeration among the parties of
various duties, responsibilities, and expertise—managers, maintenance staff, system operators, vendors,
contractors, and so on.
Purpose of Refrigeration
The purpose of refrigeration is to remove heat from some medium—
a fluid or solid—and transfer or reject that heat elsewhere. In most
systems, heat is removed from the air (for example, a refrigerated
warehouse), water or glycol (for example, a water chiller), or a food
product (for example, ice cream), and transferred outdoors to the
ambient environment. Although industrial refrigeration is also used in
the chemical industry and in unique applications such as cooling the
concrete during dam construction, the fundamental purpose and
operation is the same.
Refrigerants
Figure 2: Refrigeration transfers
A refrigerant is a chemical compound that undergoes a phase change heat from a medium to the
from liquid to gas and back as part of the refrigeration cycle. ambient environment
Refrigerant selection is a complicated topic that goes beyond the
scope of this guide. Three refrigerants are noteworthy for industrial
refrigeration.
! Ammonia is by far the most common refrigerant in industrial For food processing and
refrigeration systems. It is inexpensive, energy-efficient, and has storage, ammonia is the most
no ozone depletion potential.
! R-22 (also known as Hydrochlorofluorocarbon-22 or HCFC-22)
efficient refrigerant.
is the next most common choice. It is occasionally used in
industrial refrigerant systems and is used commonly in smaller
packaged refrigeration system. R-22 is slated for gradual phase-out in the United States under an
international treaty called the Montreal Protocol due to its ozone depletion potential.
! Carbon dioxide (CO2) has been used in a few prototype low temperature hybrid refrigeration systems
in recent years. These system use CO2 as the low temperature refrigerant in conjunction with
ammonia on the high temperature side of the system.
All of these refrigerants work in the same general way. When a liquid refrigerant is heated (absorbs heat), it
boils and turns into gas. When a gas refrigerant (vapor) is cooled, it condenses into a liquid and releases
heat. The engineering terms for these processes are “evaporation” and “condensation.” A refrigerant
Evaporation
Imagine we have a cold liquid refrigerant, such as ammonia, at 0 psig
(atmospheric pressure) and -28°F. The liquid ammonia is located in
an evaporator coil. Air that is warmer than the refrigerant, at say
-10°F, is blown across the evaporator by fans. When that air passes
over the fins on the evaporator, it is cooled by the -28°F ammonia
inside the evaporator. As the ammonia absorbs heat from the air
stream, it boils (at a constant pressure and temperature) and the air
exits the evaporator at a colder temperature than it entered, say
-20°F.
The processes within the evaporator in any particular application are
essentially the same. Instead of air blowing over a coil, water could be Figure 3: The basic refrigeration
flowing through the tubes of a heat exchanger, or a food product cycle
such as ice cream could be opposite a heat-exchange surface from the
ammonia. In any case, the result is refrigerant that has absorbed heat, boiled, and made something else
colder, thus achieving the refrigeration effect the system was designed for.
We now have a volume of ammonia that is still at -28°F and 0 psig, but is now a vapor. So that it can do
more refrigeration, we must return it to a cold, low-pressure condition. To do this, we first need to raise
the temperature of the refrigerant so we can get rid of the heat outside, where the temperature is likely
much higher than -28°F.
Compression
This is where compression comes in. A compressor is a piece of equipment that simply compresses the
refrigerant vapor, raising its pressure and therefore its temperature. In our example, the compressor would
receive the boiled ammonia vapor at -28°F, 0 psig ($ in Figure 3), and compress it to an elevated pressure
and temperature, say 85°F and 150 psig (% in Figure 3). (In reality, the discharge temperature is
superheated, but we have used saturated conditions for the sake of simplicity.) This achieves our goal of a
high-temperature refrigerant that can now reject heat to the cooler ambient environment. We now need a
piece of equipment that can reject that heat from the refrigeration system.
Condensing
The high-pressure, high-temperature refrigerant vapor now enters a piece of equipment called a condenser,
which, like an evaporator, is a bundle of tubes that looks like a car radiator. The refrigerant vapor at 85°F
and 150 psig enters the condenser (%in Figure 3). Fans blow cooler ambient air at, say 70°F, across the
condenser. Within the condenser, the warm refrigerant vapor heats the air. The air leaves the condenser at
Expansion
When a liquid refrigerant at high pressure passes through a restriction such as a narrowed tube or a barely
open valve, the liquid loses pressure. That loss of pressure causes a small portion of the liquid to vaporize.
That vaporization absorbs energy from the remaining liquid refrigerant, causing it to cool down. This
process is called expansion, and in industrial refrigeration systems it is
achieved using an expansion valve.
In our example, our 85°F, 150 psig liquid enters an expansion valve, Two-stage refrigeration is more
and its pressure drops to 0 psig. The liquid refrigerant temperature
drops to -28°F, and we find ourselves back where we started. Our
efficient than single-stage in
cold liquid refrigerant is again ready to do more refrigeration (# in low-temperature applications.
Figure 3).
Two-Stage Cycle
In applications where a very low temperature (for example, less than -25°F for ammonia) is required, two-
stage refrigeration systems are often used. A two-stage system (Figure 4) is essentially two standard cycles
stacked on top of each other (with an “intercooler” in between). The first stage of compression is
performed by a “first-stage,” “low-stage,” or “booster” compressor, and the second stage is performed by
a “second-stage” or “high-stage” compressor.
The booster compressor discharges “superheated”
refrigerant vapor—that is, vapor that is above the
saturation temperature (the threshold boiling
temperature) of the refrigerant. To improve
efficiency (and to utilize a slightly smaller high
stage compressor), most two-stage systems cool
this superheated vapor back down to saturation
prior to the vapor prior to entering the high stage
compressor. This is where the intercooler comes
in. The booster compressor discharges its
superheated vapor at the bottom of a vessel—the
intercooler—filled with liquid ammonia. The gas
bubbles up through this liquid, is cooled back to
saturation, and is then drawn into the high-stage
compressor. Figure 4: Thermodynamic process associated with
The intercooler often has a second thermodynamic two-stage compression
purpose. Two stage compression often
incorporates “subcooling” of the liquid refrigerant that is destined for serving low temperature
refrigeration loads. One simple type of liquid subcooler in a two-stage system consists of a piping coil
within the intercooler vessel. High pressure liquid refrigerant flows through this coil on its way to low
temperature loads flows. This coil is essentially bathed in the colder refrigerant of the intercooler. As the
high pressure liquid refrigerant cools off while flowing through coil, it transfers heat to the liquid
refrigerant in the intercooler. This heat transfer causes some refrigerant to boil off in the intercooler. The
subcooling improves energy efficiency, as a fraction of the gas compression load is shifted from two-stage
compression to high stage compression.
Expansion can also be performed in two stages.
The following sections discuss these in greater detail and address issues of performance ratings, capacity
control, and design and selection.
Evaporators
Introduction
All cooling within the refrigeration cycle occurs in a piece of equipment called an evaporator. There are
two primary types of evaporators:
! Refrigerant-to-air coils
! Heat exchangers Refrigerant-to-air coils are the
most common type used in
There are two main types of heat exchangers:
evaporators.
! Refrigerant-to-secondary fluid
! Direct-contact
Refrigerant-to-Air Coils
Overview
The most common evaporator configuration is the refrigerant-to-air coil (also called an evaporator fan
coil), in which the cooled refrigerant is passed through tubes, and air is drawn over the tubes to refrigerate
it. The tubes typically have attached fins to improve heat transfer. Figure 5 shows an example.
Evaporator coils are used to cool air within a closed space. Examples include a freezer or cooler, a blast
freezer, a spiral freezer (Figure 6, left), a freeze tunnel (Figure 6, right), or an industrial air-conditioning
system.
Axial Fans
Most evaporator coils use axial fans that either
push or pull air through the coil. In larger
evaporator coil applications, the fan motors are
standard NEMA frame units and are normally
mounted to a rigid mounting plate with four bolts
in the motor base. In smaller applications with
fractional horsepower motors, there is often a
belly-band mount, in which the fan shroud wraps
around the body of a footless (often special OEM)
motor, and is cinched around the motor body.
This is important because these special motors are
often inefficient and create challenges with VFD
installations.
Larger evaporator coils are usually equipped with Figure 8: Evaporator coils in a penthouse
cast aluminum fan blades, while smaller coils are
equipped with simple stamped-steel propellers attached to a hub.
Two-Speed
Evaporator fan motors can have two speeds, allowing full- and
(typically) half-speed operation.
Variable Speed
Evaporator fans can be managed with variable-frequency drives
(VFDs) to control fan speed continuously (rather than in steps). A
detailed discussion of VFD technology is presented in Variable
Frequency Drives (VFDs) beginning on page 42. Courtesy of Vilter
Refrigerant Transport
There are three major methods of supplying liquid refrigerant to evaporator coils:
! Recirculated or overfeed
! Flooded
! Direct expansion Virtually all ammonia
Normally, the capacity of evaporator coils is controlled by controlling evaporators are either
the flow or pressure of the liquid refrigerant to achieve temperature recirculated or flooded.
control.
Direct expansion is rare,
The following sections describe each method and explain how
evaporator capacity is controlled in each. although it sometimes limits
system efficiency.
Flooded
In a flooded system, low-pressure, low-temperature liquid refrigerant
is held in an adjacent vessel called an accumulator. The accumulator
is physically located above the coil, and refrigerant simply flows to
the coil due to gravity. As the refrigerant boils, the vapor bubbles rise
through the coil to the top of the accumulator, where the vapor is
drawn away by the compressors.
In a flooded system, a pressure regulator is located on the
accumulator. The refrigerant pressure (and hence temperature) is
varied in the accumulator by throttling the gas returning in the
suction line of the compressors. When the regulator is wide open, the Figure 11: Flooded evaporator
refrigerant essentially sees the full suction pressure of the
compressors and the refrigerant is at low temperature, thus maximizing capacity. As the regulator closes,
the pressure rises in the coil, with a commensurate increase in boiling temperature and decrease in
temperature difference between refrigerant and entering air.
Direct Expansion
In a direct expansion (or DX) system, high-
pressure liquid refrigerant is piped from the high-
pressure receiver to the evaporator coil. A thermal-
expansion valve meters refrigerant flow to
maintain a target superheat for refrigerant leaving
the evaporator coil. Direct expansion evaporators
are designed to evaporate all of the liquid
refrigerant that is fed to the coil. When operating
properly, a DX coil will evaporate refrigerant in
Figure 12: Direct expansion refrigerant transport
about 70% of the coil. The last 30% of the
refrigerant circuit has little heat transfer associated
with it as the refrigerant is being superheated in this section. Since 30% of the coil is lost to effective heat
transfer, DX coils are less efficient on a fan power per ton basis relative to liquid overfeed and flooded
coils. Refrigerant flow control is often challenging for direct expansion evaporators. Too much flow leads
to liquid return in the suction line (which can damage compressors or create other problems for the
system). Too little flow lessens refrigeration capacity and reduces evaporator efficiency.
A high pressure differential is often required across conventional thermal expansion valve. Insufficient
pressure differential can lead to some of the problems with under- and over-feeding the evaporator coils.
Types of Defrost
There are four common methods of frost removal and a fifth hybrid
method.
Hot-Gas Defrost
In a hot-gas defrost system, high-pressure, high-temperature,
refrigerant vapor is discharged from the compressor and routed to
and passed through the evaporator coil. The gas is often managed by
a pressure regulator at the coil outlet, maintaining a pressure of 65 to
95 psig within the coil. In addition, there may be a master pressure
regulator on the main hot-gas line that reduces pressure to about
100 psig. Any liquid or vapor refrigerant leaving the coil is typically
returned in the coil suction line.
Figure 13: Frosted evaporator
Water Defrost coil
In a water defrost system, warm water (typically 40 to 80°F) is
sprayed over the coil surface. Although well or city water is sometimes used directly, there is usually a tank
or pit where defrost water is stored. In a few cases, the water is heated by steam or electric resistance, but
normally, it is heated using heat recovered from the refrigeration system. In most cases, a remote
condenser sump serves double-duty as a defrost water tank, and water is heated during condenser
operation.
Air Defrost
Hot-gas and water defrost are
Air defrost is used in spaces where the refrigerant is below freezing
and the air temperature is above freezing. The flow of liquid most common.
refrigerant is interrupted, and the fans continue to operate, blowing
air over the coil surface to melt the ice.
Hot-gas defrost is often done
too frequently for too long,
Electric Defrost
wasting energy.
Electric-resistance defrost is fairly uncommon in industrial
refrigeration systems. Resistance elements are located on the
evaporator coil, in contact with the metal. The elements heat the coil
to melt accumulated ice. The size of the elements ranges typically from 10 to 40 kW per coil.
Hybrid Defrost
Although uncommon, some systems use a simultaneous combination of hot-gas and water defrost. A
typical application would be a freeze tunnel where completely eliminating all frost quickly is critical to
productivity.
Heat Exchangers
The second major category of evaporators is the heat exchanger. There are two main categories of heat-
exchange methods and several types of heat exchangers that are appropriate for each:
Heat-Exchange Methods
Direct-Contact Freezers
In this method, refrigerant is used to cool a food product such as juice or milk. This is usually done with a
plate-and-frame, shell and tube, or other specialty heat exchanger. Also, scraped-surface exchangers are
used for high-viscosity or hardening products such as puree, ice cream, or flake ice. In other systems,
refrigerant cools a plate or surface that is directly opposite a hardening product such as cartons of ice
cream or fish fillets. This is usually done with a plate freezer. Also, batch ice-cube makers rely on contact
between a refrigerated surface and freezing water.
Courtesy of Mueller
Figure 15: Heat exchangers: Shell-and-tube, inside (left top) and outside (left bottom); Plate-and-frame
(center); Falling-film (right)
Plate Freezers
A plate freezer (Figure 16, right)
is commonly used to harden or
freeze food products such as Courtesy of Cherry-Burrell (left) and APV (right)
cartons of ice cream or fish
fillets. The product is placed on Figure 16: Scraped-surface heat exchanger (left) and plate freezer
a flat horizontal surface with (right)
refrigerant or a secondary
coolant directly on the other side.
falls into totes or a storage Figure 17: Flake ice maker and cutaway view
room for later use.
Crushed, tube, or cube is usually made with specialized machines that manufacture ice in batches. Tube ice
machines use hot gas refrigerant to harvest the ice. The batch operation can result in a highly variable
refrigeration load.
In the past, ice was manufactured manually in large blocks. Water was
poured into large metal tubs which were then immersed in a brine
solution. The blocks were then placed in storage or ground into
smaller material. These systems were labor-intensive and very few
remain in use.
Compressors
Introduction
The purpose of a compressor is to increase the pressure and
temperature of refrigerant vapor returning from the evaporators.
There are three primary types of compressors:
! Reciprocating
! Rotary screw
! Rotary vane
Reciprocating Compressors
Applications
Reciprocating compressors are widely used in either low- or high-temperature applications. They can
accommodate compression ratios up to 8:1 with ammonia, and can be installed as boosters, high-stage,
high-suction, and single-stage. Their maximum size is about 300 horsepower.
Capacity Control
Most, but not all reciprocating compressors have
capacity control. For those with capacity control,
Figure 20: Cut-away view of compressor
cylinder unloading is the universal method. The
inlet valve is held open (either by oil pressure or discharge-gas pressure), preventing the cylinder from
compressing. Although the piston still draws suction gas on its downward stroke, it simply pushes the gas
back into the suction line during the upward stroke. Most compressors have simple unloading stages (such
as an 8-cylinder machine unloading to 75%, 50%, and 25% capacity).
In general, electric solenoids
Sample Reciprocating Compressor Part Load
activate unloaders. The electric
solenoids can be managed by 100%
50%
Cylinder unloading is an
40%
efficient form of capacity
30%
control, with a nearly
proportional reduction in 20%
Cylinder Unloading
capacity and power (see 10%
Ideal
Figure 21). 0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Capacity
Cooling
Usually, reciprocating Figure 21: Reciprocating compressor part-load curves
compressors are cooled by
circulating water through the heads and cylinder jackets. Some compressors have external oil coolers that
are water-cooled. Water is often supplied from an adjacent condenser sump, although it is not uncommon
to simply use a once-through supply of city or well water that is sent to the drain (which can be costly in
terms of water use and possibly sewer charges).
Control
As mentioned before, reciprocating compressors are often provided with simple pressure switches for
cylinder unloading and safety cut-outs. Microprocessor-based controls are rarely provided for reciprocating
compressor packages.
Advantages Disadvantages
Low Cost Frequent Maintenance
Simple Maintenance High Maintenance Cost
Efficient Unloading Limited Capacity/Size
Compact Discrete Unloading
Many Moving Parts,
Limited Pressure Differential
Twin Screw
A twin screw has a male and female rotor which
rotate and mesh together (see Figure 22).
Refrigerant vapor is drawn into the space between
the rotors, and as the rotors turn and mesh, the
vapor is trapped. As the rotors continue to rotate,
the vapor is compressed and pushed to the
opposite end of the compressor. The vapor is then Courtesy of Frick
opened to the discharge port, and pushed from the
compressor. Figure 23: Screw compressor package
The screw compressor package relies on oil to seal the rotors during compression. In addition, oil is
pumped through bearings for lubrication. After compression, the refrigerant vapor and oil are mixed and
must be separated. The compressor and driving motor are commonly mounted on top of an oil separator,
as shown in Figure 23. The oil separator has coalescing elements that trap the entrained oil from the
refrigerant vapor stream.
Single Screw
The single-screw design is
relatively new and has a single
rotor and two gate rotors, one
on each side (see Figure 24).
The center female rotor is
driven by the motor and the
two male gate rotors mesh with,
and turn alongside, the female
rotor. The resulting
compression is similar to that of
a twin screw. Courtesy of Vilter (right)
Figure 26: Diagram of slide valve unloading (left) and Photograph of slide valve (right)
50%
30% of capacity. The slide valve
is usually moved by oil pressure 40%
Capacity
Slide valve unloading is a
moderately efficient form of
capacity control, although the Figure 27: Screw compressor part-load performance curves for various
efficiency of a machine degrades capacity-control methods
when highly unloaded,
particularly in applications with a high pressure ratio. Fully unloaded power varies from 30% to 50% or
more.
Cooling
Screw compressors use oil for lubrication and cooling during the compression process, so heat must be
removed from the oil continuously. There are several methods of cooling screw compressors, including:
! Liquid injection
! Thermosiphon
! Water or glycol cooling
! Direct cooling
Liquid injection cooling imposes a small capacity penalty, and can impose a power penalty of 1% to 10%
or more. The power penalty results from the need to recompress the refrigerant that was injected into the
compression process. In general, the power penalty increases with pressure ratio, and is greatest in single-
stage applications with a low suction pressure.
An additional disadvantage of liquid injection is the need to elevate condensing pressure to ensure
adequate pressure to inject properly. Older designs had a minimum pressure requirement of 100 to
125 psig, although modern designs with electronic expansion valves are capable of operating at lower
pressures.
In a small number of applications, the injection occurs in the compressor discharge line. This eliminates
the power penalty, but requires a booster pump. A small liquid pump boosts liquid pressure sufficiently to
Thermosiphon Cooling
Thermosiphon oil cooling (Figure 30) is a passive
method of cooling compressor oil. A shell-and-
tube (or small plate-and-frame) heat exchanger is
mounted on the side of the compressor package,
angled slightly from the horizontal. High-pressure
liquid ammonia is piped from a pilot vessel
(usually either a separate vessel located in the
ceiling of the engine room, or the upper portion of
a vertical high-pressure receiver with a catch basin)
to one side of the exchanger, and the hot
compressor oil is passed through the other side of
the exchanger. The warm oil causes the liquid
ammonia to boil, cooling the oil. The ammonia
vapor from this process floats upward and is piped
back to the condenser.
There are three advantages to the thermosiphon Courtesy of Vilter
system. First, there is no capacity or power penalty.
Second, there is no artificial lower limit to Figure 29: Discharge injection system showing pump
discharge pressure. And third, all heat rejected (arrow)
from the oil is routed directly to the condenser,
which provides energy savings with booster compressors in a two-stage system (discussed in Multistage
Compression beginning on page 71).
Thermosiphon cooling is not cheap: about $10,000 to $25,000 more per machine than injection cooling. In
addition, the heat exchanger requires adequate space next to the compressor package.
Discharge
steps or continuously), or can be set manually 120
Pressure
100 Overcompression
shape of the discharge port is changed by moving
End of Compression
80
a slide stop, a block of metal adjacent to the slide
valve. 60
40
Undercompression
Compressor Control
Virtually all new screw compressors are controlled by a
microprocessor panel mounted on the compressor package (see
Figure 33). Microprocessor panels allow the operator easily operate
the compressor in local, remote, or manual mode. They incorporate
many safety and protection features. They allow for easy calibration.
Advantages Disadvantages
Long maintenance intervals High initial cost
Available in large capacity Factory-level service requirements
Slide valve with infinite control Inefficient unloading
Few moving parts Large package size
Configuration
Figure 34 shows an external view of a rotary vane
compressor. Figure 34: Rotary vane compressor
The center shaft is offset, and flat blades called
“vanes” are located in slots of the rotor. As the compressor turns, the vanes are thrust outward and slide
along the case. Gas is drawn in one side of the compressor, and discharged at the other side. Figure 35
shows an internal view.
The compressors can move a tremendous flow of refrigerant, although they have limited pressure ranges.
In addition, the compressors are frail and the vanes are highly susceptible to shearing when liquid
accidentally enters the compressor. In addition, these compressors are very loud.
Cooling
In many rotary vane booster applications, no
cooling is required because of the very low
operating suction temperature. However, water
cooling is used when needed. Figure 35: Rotary vane compressor—internal view
Control
Virtually all applications are operated manually or with simple pressure switches or a computer-control
system.
Advantages Disadvantages
High-volume capacity No or limited capacity control
Compact Susceptible to vane damage
Noisy
Performance Ratings
Full-Load Ratings
All compressors are rated for capacity and power at various suction and discharge pressures and
temperatures. Ratings are often available as a table, performance curves, or through factory-provided
software.
Capacity is rated in tons of refrigeration (TR), where 1 TR = 12,000 BTU/hour. Power is universally rated
in brake horsepower (BHP), the input power required at the shaft. Table 6 shows sample ratings.
These rules will be used in later sections to improve compressor and system efficiency (see Increasing
Suction Pressure, page 46 and Reducing Discharge Pressure, page 49).
Part-Load Ratings
Traditionally, full-load ratings have been the focus for designing and assessing the overall performance of
compressors. Only recently has part-load performance become prominent, particularly in response to
increased energy awareness. Unfortunately, part-load ratings for compressors are developed and presented
less consistently than full-load ratings, making it difficult to compare the part-load performance of
equipment from different manufacturers.
Historically, only general part-load ratings were published. That is, performance at specific operating
conditions was not rated. In addition, manufacturers would “take liberties” with performance curves, for
example, claiming reduced discharge pressure when unloaded to mask inefficiency. It was difficult to
accurately assess compressor performance at reduced load.
However, most manufacturers now offer rating software that allows detailed part-load curves to be
developed, and variable speed performance to be documented.
There are only two absolute rules that can be taken from any set of part-load compressor ratings:
! Compressor efficiency degrades as the compressor operates at decreasing percentages of full load.
! Speed control provides the best part-load performance for screw compressors.
These rules will be used in later sections to improve compressor and system efficiency (see Improving
Compressor Part-Load Performance, page 59).
Common Configurations
There are three common configurations of evaporative condensers:
! Forced-draft with axial fans
! Induced-draft with axial fans
! Forced-draft with centrifugal fans
Courtesy Imeco (left), Evapco (center), and Baltimore Air Coil (right)
Figure 37: Forced-draft, axial fan condenser (left); Induced-draft, axial fan condenser (center); Forced-draft,
centrifugal fan condenser (right)
Capacity Control
Condenser capacity is managed by interrupting or varying the water and/or air flow.
Capacity Ratings
Full Load
All evaporative condensers are rated at nominal conditions (in thousands of Btu/hr, or MBH), and are
corrected based on condensing temperature and entering wet-bulb temperature. These correction factors
are virtually universal across all manufacturers and models.
Part Load
Condenser manufacturers do not provide part-load performance data in standard published literature.
However, there are experimental or theoretical formulas that can be applied to rated capacity at reduced air
or water flow. To be conservative, you can assume that capacity decreases proportionally with air flow. In
reality, performance is slightly better due to more effective heat transfer.
Dry Operation
If a condenser must be operated without water (conditions below freezing), the fans can be operated
alone. In this situation, heat transfer is very poor. Condenser manufacturers provide ratings for dry
operation, but, as discussed in Wet vs. Dry Operation (page 64), dry operation is very inefficient and
should be avoided unless absolutely necessary under frigid conditions.
Introduction
Some important components of an industrial refrigeration system do not use energy directly but
nonetheless affect the overall energy efficiency of the system. Examples include vessels, valves, heat
exchangers, purgers, and other miscellaneous equipment. It is important to be familiar with these
components and their role in system efficiency.
Vessels
Low-Pressure Receivers
A low-pressure receiver (LPR) is an insulated tank
that holds low-pressure, low-temperature liquid
ammonia to be sent to evaporators (Figure 38).
The liquid is pumped to the coils, and some of it
(typically 1/4 to 1/3) boils in the evaporator coil.
The mixture of vapor and liquid returns to the
LPR where the gas rises to the top and is drawn
away by the compressor suction. Since only some
of the refrigerant is boiled in the evaporator, this
system is often called “overfeed” or “liquid Figure 38: Low-pressure receiver (LPR) with
recirculation.” insulation and liquid pump
We address the LPR and its piping and valves in Chapter 4:Best Practices for Equipment, Systems, and
Controls because overfeed rates and other related issues can affect efficiency.
High-Pressure Receivers
A high-pressure receiver (HPR) is an uninsulated
tank that holds the high-pressure liquid draining
from the condensers (Figure 40). Virtually all
refrigeration systems have some kind of HPR. It is
usually located in the engine room, but it is
sometimes located on the roof immediately below
the condensers, or outdoors adjacent to the engine
room. These vessels can be horizontal or vertical
designs.
Controlled-Pressure Receivers
Some systems use a gas-pressure recirculation
design, where compressor discharge gas is used to
move liquid refrigerant throughout the coils and Figure 40: High-pressure receiver (HPR)
between vessels. In lieu of a high-pressure receiver,
these systems use a controlled-pressure receiver (CPR). In a system with a standard HPR, the pressure
inside the vessel floats with system condensing pressure. With a CPR, pressure in the vessel is held at a
constant level, typically 65 to 100 psig. Gas-pressure systems are often inefficient for several reasons:
! CPR often presents a bottleneck to reducing condensing pressure.
! In the course of managing liquid refrigerant and controlling vessel pressure, a significant volume of
refrigerant vapor is regulated or transferred from the condensing pressure to the low side of the
system. This gas must be recompressed and represents a “false” load on the system.
Figure 42: Hand expansion valve (left); Thermal expansion valve (center); Electronic expansion valve (right)
Pressure Regulators
Pressure regulators maintain a
steady pressure at their inlet or
outlet (Figure 43). Examples
include a suction-pressure
regulator on a flooded
evaporator coil, or a hot-gas-
defrost regulator. Pressure
regulators are common in
industrial refrigeration systems.
They can either be manual (set
to maintain a fixed pressure),
dual-pressure (with high and
low settings), or motorized Courtesy of Hansen
Purgers
Systems operating with negative suction pressures (below atmospheric pressure) tend to draw air into the
system. Left unresolved, the added air results in increased condensing pressures. We discuss the benefits of
purgers (Figure 44) in Purgers on page 75.
Underfloor Heating
Virtually all systems with freezers (below 32°F) need underfloor
heating to prevent the floor from frost heaving. There are three
common types of underfloor heating:
! Glycol
! Air
! Electric
can put too much heat under the floor, and can use inefficient forms
Figure 44: Automatic purger
of heating (for example, electric resistance).
Controls
Introduction
All industrial refrigeration systems must be controlled to keep temperatures, pressures, and other critical
variables within suitable ranges. Refrigeration controls affect production, safety, and efficiency. The basic
features of most computer-control systems are:
! Evaporator liquid solenoid and pressure regulator control
! Evaporator fan on/off control
! Evaporator defrost control
! Compressor on/off and unloading control
! Condenser pump and fan on/off control
In the simplest sense, evaporators are controlled in response to zone temperature, compressors are
controlled in response to suction pressure, and condensers are controlled in response to condensing
pressure.
In addition to these basic functions, refrigeration control systems can also provide additional advanced
functions including:
! Advanced compressor sequencing
! Advanced condenser control algorithms
! Advanced demand defrost initiation and termination control
! Two-speed motor and variable frequency drive control
! Underfloor heating system monitoring and control
! Recording of system variables (trending)
! System alarms
! Remote control
The presence of advanced control features depends on the control system capabilities and the customer’s
needs.
There are four basic categories of control systems:
! Manual control
! Electro-mechanical control
! Simple programmable logic controllers (PLC)
! Computer control
Electro-Mechanical Controls
Electro-mechanical controls use simple pneumatic or electronic circuitry to manage refrigeration
equipment.
Electro-mechanical controls are still relatively common, particularly for small systems where computer
control is not cost-effective, and with equipment such as reciprocating compressors where pressure
switches are often integrated with the equipment by the manufacturer.
Pressure Switches
Simple pressure switches are most often used to unload the cylinders in reciprocating compressors and to
control the cycling of condenser pumps and fans. There are two common types of pressure switches:
! Spring-loaded
! Mercury
Thermostats
A thermostat senses temperature changes and activates a switch that
controls a piece of equipment. In refrigeration systems, they are most
often used to control evaporator coils and associated liquid solenoids
and fans. Figure 46 shows a sample application.
Simple Programmable
Logic Control (PLC)
Small systems can be controlled Figure 47: Electro-mechanical control system
using simple programmable
logic controllers, or PLCs (Figure 48). These types of controllers perform the same basic functions as
electro-mechanical controls, using solid-state hardware in lieu of pneumatic, thermostatic, and electrical
(relay) controls. Common PLCs include the Honeywell Universal Digital Controller (UDC) series and the
Allen-Bradley SLC 500. UDC controllers are used for simple applications, such as taking a temperature-
probe input and outputting a control signal to a pressure regulator. These units can perform simple math
and can have multiple inputs and outputs. They are self-tuning, and have push-button set point
adjustments.
A PLC system like the SLC 500 is capable of more advanced control.
This type of PLC is mounted on a rack panel, and can be expanded
to meet a variety of input and output requirements. The system can
be tied into a central interface computer or process display, and can
provide trending and other advanced features.
Computer Control
Introduction
Computer-control systems for refrigeration first became available in the late 1980s and early 1990s. These
systems were a remarkable leap forward in control, trending, alarms, and other operations. Since these
early systems, the capabilities of computer-based controls have expanded dramatically, with easy-to-use
graphical interfaces, remote access, and advanced features.
Control Software
In the earliest systems, computer control depended on Unix, DOS, Assembly Language, C++, and other
low-level languages. These systems were usually proprietary, and have mostly given way to systems with
modern, open software platforms such as Wonderware, Intellution, Allen Bradley, GE, Think-N-Do, and
others. However, there are still many systems that use proprietary or low-level software for control.
Advanced features, brought about by Microsoft Windows and its graphical user interface, networking, and
the Internet, have expanded the abilities of control software. In general, there has been an evolution away
from proprietary and low-level software toward open architectures that require less arcane coding.
Introduction
Until the early 1990s, the use of variable frequency drives (VFDs) in industrial refrigeration was rare.
Throughout the 1990s, VFDs began to appear as a standard factory-offered option for other equipment
such as centrifugal water chillers. In the early 2000s, even rotary-screw air compressors offered VFD
options. Only relatively recently have manufacturers of industrial refrigeration equipment embraced VFD
technology. Now, virtually all prominent manufacturers of screw compressors for industrial refrigeration
offer VFD control as a factory option. It is also possible to retrofit VFDs on many existing compressor
systems. In addition, all prominent condenser manufacturers now discuss fan VFD control in marketing
literature. And VFD control of evaporator fans, although common in the Pacific Northwest, has become
more widely embraced nationally by refrigeration design firms and their customers.
Standard Motors
Whether driving fans, pumps, or compressors, virtually all industrial refrigeration motors are three-phase
induction units that operate at fixed speeds of 900, 1200, 1800, or 3600 rpm. Motor speeds for typical
equipment are:
Evaporator Fans: 1200 or 1800 rpm
Compressors – Reciprocating: 1200 rpm (direct) or 1800 rpm (belt)
Compressors – Rotary Screw: 3600 rpm
Compressors – Rotary Vane: 900 or 1200 rpm
Condenser Fans: 1800 rpm
The operating speed of the motor is determined by the frequency of the line current (in North America, 60
Hertz, or 60 cycles per second), and the winding configuration (number of poles) of the motor. When
running unloaded a motor turns at its nameplate-listed speed, slowing a few percent as load is placed on
the shaft. Equipment run by motors at a single, fixed speed meet peak loads requirements, but do not
accommodate part-load conditions well, which account for most operating hours.
1600 600
1200 400
800
200
400
Voltage
0
Amps
0
-200
-400
-400
-800
-1200 -600
-1600 -800
0 500 1000 1500 2000 2500 0 500 1000 1500 2000 2500
70%
0%
30 Hz, the load would require 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
VFD Issues
! Size of VFD
! Need for bypass feature
! Input reactor or harmonic filtering
! Output reactor or dV/dt filtering
! Grouping of multiple motors
! Setup of internal parameters
! Temperature of environment
! Need for external cooling
! Cleanliness of environment
Motor Issues
! Cooling at reduced speed
! Insulation dielectric capabilities
! Current in bearings
Driven-Equipment Issues
! Minimum and maximum allowed speeds
! Resonant frequencies
In the Best Practices chapters, we address these issues and the proper application of VFDs to evaporator
fans, screw compressors, and condenser fans; we identify inappropriate refrigeration applications such as
reciprocating compressors and condenser pumps; and we discuss proper control algorithms.
Introduction
This chapter covers engineering opportunities to improve refrigeration system design, select efficient
components, and control the system optimally. The chapter methodically addresses the “Big Picture”
efficiency categories introduced in Chapter 2: Best Practices Overview:
! Reducing Lift (below)
! Improving Part-Load Performance (page 55)
! Upgrading Equipment (page 65)
! Improving System Design (page 71)
! Reducing Refrigeration Loads (page 75)
At the end of this chapter, we highlight the importance of computer controls (page 79) and provide three
checklists (page 79) pertaining to evaporators, compressors, and condensers that help tie together these
concepts.
Reducing Lift
Introduction
“Lift” in a refrigeration system is the difference between suction pressure and discharge pressure at the
compressor. Reducing lift by raising suction pressure or lowering discharge pressure improves compressor
efficiency. Three general rules apply to lift:
! Increasing suction pressure increases compressor capacity.
! Reducing discharge pressure decreases power.
! Increasing suction or reducing discharge pressure reduces BHP/TR (brake horsepower per ton
refrigeration) and thereby increases efficiency.
This section presents methods for reducing lift, discusses some of the barriers to doing so, and presents
the potential energy savings. Note that suction and discharge pressure are often referred to as
temperatures, as there is a direct, proportional and consistent relationship between the pressure and
temperature of saturated ammonia vapor. This section will sometimes use one or the other description.
Table 7 describes the relationship between pressure and temperature for ammonia.
Energy savings from increased suction are seen at the compressor. When you increase the capacity of the
compressor, it will operate at a lower fraction of its full-load capacity when meeting a given cooling load.
Hence, the part-load performance characteristics of the compressor ultimately dictate the magnitude of the
energy savings. In the same way, an increase in suction may actually allow a compressor to be turned off,
or a large compressor to be shut down in favor of a smaller one. So although the 2% rule of thumb is
good for estimating, a complete analysis of compressor operation would be needed to determine savings
precisely.
Best Practices:
Regulating Suction Pressure Suction Pressure
Suction pressure is maintained by compressor set
points. Regulating suction can be as simple as ! Suction pressure should be held where
adjusting the set point in a computer-control compressor power and evaporator fan power
system. With other control systems, you may need
to adjust a micro-processor panel on a screw are at a “combined minimum.”
compressor or a pressure switch on a reciprocating ! When no fan savings are possible, set suction
compressor.
pressure as high as possible.
! A small increase in suction pressure will often
Selecting Larger Evaporator Coils
let the operator shut off a compressor. This
The cooling capacity of an evaporator is directly
proportional to the difference between the strategy should be pursued aggressively—
temperature of the air entering the coil and the particularly for systems with screw
temperature of the refrigerant within the coil. This
difference in temperature is called the temperature compressors.
difference, or TD. Evaporator coil capacity is also
proportional to the area of the heat-exchange
surface of the coil. So by using a larger evaporator coil (one with more surface area), you can reduce the
TD and still maintain cooling capacity. This lets you increase suction pressure while providing the same
amount of cooling in the space.
Typically, evaporator coils are selected based on their capacity at a TD of 12 to 15°F. By using a larger coil
that allows a TD of 10°F or even 8°F you can increase suction temperature. For example, reducing coil
TD from 15°F to 10°F will allow a 5°F increase in suction temperature and reduce compressor energy
consumption about 10%:
(15°F – 10°F) ! 2%/°F = 10% savings
You can also increase the number of evaporator coils to increase the area of the heat-exchange surface,
and achieve similar savings.
There may be system- or equipment-related ! Avoid having loads with different temperature
barriers to raising suction pressure. For example,
higher suction pressure causes the refrigerant flow requirements on the same suction system. In
rate and resultant velocity to increase in the oil particular, do not let a small, lower
separator of a screw compressor. If the separator
cannot handle the increased velocity, it may not
temperature load dictate the suction pressure
completely remove the oil from the refrigerant. In for a larger, higher temperature load.
addition, raising suction often increases the shaft
! Serve each load with the highest possible
horsepower of the compressor (even though
higher capacity improves overall efficiency), and suction system, even if it means additional
may overload the motor. In this case, current- compressors, piping, and complexity.
limiting would be required to unload the
compressor. In both new and retrofit applications, ! Additional suction systems can mean more
you should review the performance of the oil simultaneously unloaded compressors.
separator and the sizing of the motor before
increasing suction pressure. Improving compressor part-load efficiency must
also be addressed.
Balancing Compressor Savings and
Fan Energy
In some applications, a conflict can arise between increasing suction pressure to reduce compressor
energy, and maintaining an adequate coil temperature difference so that fan cycling or VFD control will be
effective. The optimal balance will be unique for each application, and is particularly sensitive to the ratio
of compressor and fan power and the non-linear nature of fan VFD energy savings.
In some cases, the evaporator fan horsepower is low enough that operating the compressor at the highest
possible suction pressure and operating the evaporator fans at full capacity is the most efficient strategy. In
other cases, the combination of a large fan horsepower and VFD control might make fan savings a higher
priority than compressor savings. The problem gets even more complicated with multiple refrigerated
spaces and different process loads all on a common compressor. In such cases, detailed energy analysis is
the only way to assess the optimal operating strategy. However, in all cases, the goal is the lowest total
system energy use.
It is important that the issue of “minimum ! All Systems: Operate at the lowest possible
allowable condensing pressure” and “approach” be
clarified. This is a common misconception when condensing pressure.
discussing reduced discharge pressure. ! New Construction: In the Pacific Northwest, use
a target condensing pressure of 90 psig.
Reducing Condenser Approach ! Retrofit projects: Every system is different. 90
Reducing condenser approach is another way to to 110 psig should be possible in most systems.
reduce condensing pressure. The effect of
increased condenser capacity on energy Never let a small or low-cost barrier dictate
consumption depends on outdoor conditions minimum pressure.
which vary by season and geographical location.
Whenever the refrigeration system operates above Benefits Beyond Energy
the minimum allowable condensing pressure set ! Lower pressure puts less stress on equipment,
point, condensing temperature will float above the
ambient wet-bulb temperature. Additional particularly reciprocating compressors.
condenser capacity will reduce the approach to ! Lower condensing pressure increase both
wet-bulb temperature, and hence the condensing
pressure. This will reduce compressor energy use. compressor capacity and system capacity.
If the system operates at the minimum allowable ! Lower condensing pressure requires more
condensing pressure, then additional condenser attention to maintenance and operation, but
capacity does not affect pressure and compressor
power. However, the condenser system will be this attention often helps identify and
allowed to operate at reduced capacity (for ultimately fix underperforming components.
example, with slower fan speeds under VFD
control). In this situation, the condenser will use
less energy.
The economic return on increased condenser capacity can be assessed incrementally. That is, a baseline
condenser designed for a 20°F approach can be compared to a condenser designed for an 18, 16, 14, or
even 12°F approach. At some point, the incremental return on investment will diminish, particularly when
the additional structural, piping, electrical, and water-treatment costs are considered.
In selecting incrementally larger condensers, it is better to rely on more surface area than on higher air
velocity, air-pressure drop, and fan power.
In the field, many condensers underperform relative to their design ratings. That is, they do not attain the
condenser approach that is expected based upon condenser rating, heat rejection load, saturated
condensing temperature, and ambient wet-bulb temperature. Many factors contribute to this
underperformance, including:
! Humid micro-climate brought on by condenser placement, spacing, or proximity to steam or other
humidity sources (for example, boiler stack)
! Inadequate piping that, among other things, can create pressure drop, causing the effective loss of
condensation surface area, and contribute to problems with non-condensable gases
! Inadequate maintenance that impedes condenser performance because of, for example, tube scaling,
unaddressed non-condensable gas, poor spray water dispersion, belt slippage, inadequate water
pressure, and blocked or clogged drift eliminators
The minimum allowable condensing pressure is ! In the Pacific Northwest, select a condenser
the lowest pressure at which the refrigeration
system will function properly. Compressor with a 15°F or lower approach to design wet-
limitations, liquid transfer issues, defrost, and bulb temperature.
many other factors affect the minimum allowable
! To do this, select a condenser with larger
pressure and must be considered when pursuing
strategies to reduce discharge pressure. surface area, not higher fan power.
Systems in cool, dry climates may operate for
thousands of hours per year at minimum Benefits Beyond Energy
condensing pressure, while systems in warm,
humid climates or with limited condenser capacity Oversized condensers provide:
may operate for only a few hours per year at
minimum pressure. In any case, there will be times ! Flexibility for the future and help maximize
during the year when it is impossible to achieve the
minimum pressure set point, such as in the heat of production
summer. ! A safety margin that helps avoid production
For industrial ammonia refrigeration systems, a slow-downs under peak loads.
minimum pressure of 80 to 90 psig is a relatively
aggressive target for energy efficiency. The number
of hours per year when condensing pressure can
fall this low will determine how aggressively this target range should be pursued.
To illustrate, we will compare systems in Seattle, WA and Miami, FL. To assess the opportunity to operate
at reduced condensing pressure, we must look at weather data for each location. Table 8 shows the
number of hours per year that fall within 5-degree ranges of dry-bulb temperature and the mean coincident
wet-bulb temperature for each dry-bulb range.
Since evaporative condenser performance is dictated by the condensing temperature relative to the
ambient wet-bulb temperature, the distribution of wet-bulb temperature is the key factor. The table shows
that the average wet-bulb temperature for Miami is almost 25°F higher (70.2°F – 46.3°F) than that for
Seattle.
Now, consider a system with a condenser designed for a 15°F approach (ambient wet-bulb temperature
minus refrigerant temperature). With a target minimum condensing pressure of 90 psig (at which ammonia
is 58°F), we need to determine how many hours per year the system would operate at this pressure.
In both Seattle and Miami, these conditions correspond to the dry-bulb temperature ranges from 44#F and
below. In Seattle, there are 2,907 hours—about one-third of the year—when the system could operate at
90 psig. In Miami, however, there are only 24 hours—about 0.3% of the year—when the system could
operate at 90 psig.
As this example shows, trying to reduce minimum condensing pressure to this 90-psig target will be a
more fruitful exercise in Seattle than in Miami.
Note that a constant 15°F approach to ambient wet bulb was assumed, regardless of actual wet-bulb
temperature. In reality, the necessary approach increases in cool weather since the psychrometric
properties of cooler air reduce the air’s ability to evaporate water. In this case, the same condenser may
require 20°F or 25°F approach during the winter to reject the same amount of heat. The constant
approach was used to simplify this example.
Introduction
In the simplest and least efficient scenario, evaporator fans operate non-stop at full speed except during
defrost. All evaporator capacity control (and hence, space temperature management) is achieved by
controlling the refrigerant with liquid solenoids (in recirculated or direct-expansion systems) or pressure
regulators (in flooded systems). Energy use of the evaporator fan is constant ultimately ending up as a heat
load on the refrigeration system. Because of this, any reduction in fan energy use through improved part-
load operation has the added benefit of reducing space refrigeration load. This can be done with fan
cycling, two-speed fans, or with VFDs.
Two-Speed Fans
Two-speed fans can operate at three conditions—off, half speed, and full speed—and require special two-
speed starters. They offer a level of control between fan cycling and VFD control. At half speed, fan
power obeys the affinity (or cubic) laws and draw about 1/8 the power needed to run at full speed while
still moving about one-half the air.
Computer-control systems can optimize operation to prioritize half-speed operation, particularly with
multiple coils serving a single zone or room. For example, with two evaporators in a room, it is better to
operate both fans at half speed than to turn one off and operate the other at full speed.
In addition, liquid solenoids should be kept on, and suction-pressure regulators at 100% capacity as long as
possible when running fans at half speed, as the evaporators are ideally four times more efficient (1/2
capacity for 1/8 power) than at full speed. As much heat as possible should be removed during half-speed
operation before switching to full speed.
1 Field measurements, which include motor and VFD losses, indicate that the “real-life” affinity-law exponent is
about 2.7 (instead of the theoretical 3.0). That is, fan power= (fraction of speed)2.7.
Some of the key design and implementation issues for a successful installation are discussed below.
Multiple / Small Motors A VFD can drive from two to more than thirty motors. In applications with
many small (<1 hp) motors, the total impedance seen by the VFD output circuitry can be very high.
Harmonics and Input Reactors To limit harmonic feedback into the system and to protect the input
circuitry of the VFD, a 3% input reactor should be considered for all VFD applications. Some VFDs offer
built-in reactors or harmonic filters.
Wiring Practices Carefully review the input and output wiring guidelines from the VFD manufacturer.
Unfortunately, some manufacturers have extremely stringent guidelines, including no mixing on any input
or output leads in a common conduit or gutter. This may be possible in new construction projects,
although it adds cost. For retrofit projects, the wiring layout is pre-determined. Consult with the
manufacturer for the best compromise between optimal wiring practices and practical considerations of
cost and existing layout.
Motor Protection with Output dV/dt Filters Because of the square-pulse waveform of the drive
voltage output and the fast switching of VFD transistors, the VFD and the motors it controls exhibit a
reflected-wave phenomena. This reflected wave can have voltage spikes above the rated capacity of the
motor insulation system. The increased potential between motor windings results in corona that can break
down winding insulation. Over time (anywhere from hours to years), the breakdown will result in a ground
fault within the motor. For evaporator fans, an output reactor or dV/dt filter should always be installed to
reduce or eliminate this danger. Again, consult the VFD manufacturer.
Inverter-Rated Motors Standard motors operating on 480 volts have winding insulation rated for 1200
volts. Most motor manufacturers now offer inverter-rated motors that have insulation that complies with
the NEMA MG1-Part 31 standard of 1600 volts. In new installations, you should specify motors for
evaporator coils that meet this standard. Note that simply specifying “premium” or “inverter-rated”
motors may be insufficient; be sure to specify the MG1 Part 31 standard.
Custom and 56-Frame Motors Some evaporators use small 56-frame motors from 1/3 to 1.5 hp. These
1200- and 1800-rpm motors are very frail, and their windings may fail even with proper dV/dt filtering. In
some cases, a retrofit with inverter-rated replacements may be required. One complication is the belly-
band design, where the fan shroud wraps around and cinches down on the motor body. These motors are
Introduction
The efficiency of all industrial refrigeration compressors degrades as they operate at a fraction of full
capacity. Figure 58 shows the relationship of power input and part-load fraction for a screw compressor.
In general, the following
Sample Screw Compressor Part Load
strategies improve the efficiency
of the compressor system: 100%
80%
50%
These criteria can help you configure equipment and select control algorithms to operate your
compressors efficiently.
Stage Number
Unit
1 2 3 4 5 6 7
100 hp ' ' ' '
200 hp ' ' ' '
400 hp ' ' ' '
Power
50%
systems with a computer
40%
control system, the control
system asks for a change in 30%
Capacity
Proper Screw
Compressor VFD Figure 60: Comparison of constant speed and variable speed part load
power
Implementation
Some important design and installation issues are summarized below.
Factory Option Most major screw-compressor manufacturers now offer VFD control as a factory-
provided option. Some manufacturers are experimenting with increasing maximum speed and reducing
minimum speed for increased flexibility. A factory-configured VFD has been optimized for efficiency and
equipment longevity.
Retrofit vs. New Construction VFD control can be retrofitted to existing compressors, but is most
cost-effective in new construction where the additional cost is only the incremental cost of the VFD
control above that of a basic solid-state starter. It is very important to consult the compressor
manufacturer in any retrofit application.
Inverter-Rated Motors Due to the limited speed reduction (2:1), virtually all existing ODP (open drip-
proof) and TEFC (totally enclosed fan-cooled) motors can be used for VFD control of screw
compressors. To be safe, contact the motor or compressor manufacturer for written authorization to
operate at 2:1 speed reduction with a constant-torque load. If the motor normally operates into the service
factor, note that motors are often down-rated from 1.15 to 1.0 service factor with VFD control. One
manufacturer currently offers 5:1 speed reduction, which requires a blower-cooled motor and utilizes a
liquid-cooled VFD.
Introduction
In the simplest configuration, the capacity of evaporative condensers is controlled by using simple pressure
switches or computers to cycle the pumps and fans of this equipment. This section discusses ways to
improve fan control and control-system algorithms.
Two-Speed Fans
Manufacturers have offered two-speed fans for condensers for some time. One variation is a half-speed
pony motor driving the same shaft. In either configuration, the fans can be operated at full or half speed,
adding an additional discrete operating point that is highly efficient due to the affinity laws. Because of the
advantages of VFDs, the use of two-speed motors with new condensers is uncommon and will likely
disappear.
Best Practices:
Upgrading Equipment Evaporator Selection
Table 10: List of coils with a capacity of about 50 TR at 10°F temperature difference
Surface Air
Capacity Fan Total Efficiency
Option area Velocity
(TR) Configuration BHP (TR/BHP)
(sq ft) (fpm)
#1 52.3 15,627 595 4 ! 2 hp 8 6.54
#2 48.7 11,313 647 4 ! 2 hp 8 6.09
#3 49.8 14,650 615 4 ! 2 hp 8 6.23
#4 49.5 12,503 632 4 ! 2 hp 8 6.19
#5 51.1 12,067 625 4 ! 2 hp 8 6.39
#6 47.5 11,722 655 4 ! 2 hp 8 5.94
#7 47.6 15,627 595 4 ! 2 hp 8 5.95
#8 51.5 11,722 733 5 ! 2 hp 10 5.15
#9 52.8 11,313 725 5 ! 2 hp 10 5.28
#10 54.3 14,650 682 5 ! 2 hp 10 5.43
TR/HP
DX coils are derated since some 5.5
Efficient Fan Blades Figure 61: Graph of coil efficiency versus face velocity
Some evaporator coils, particularly those with small (less than 1 hp) fans, may have stamped-steel fan
blades of an older, inefficient design. Modern alternatives provide the same fan performance (in terms of
air flow and pressure) but require less shaft power.
In Figure 62, the fan blade on the right is the
original four-blade version provided with the coil.
The fan blade on the left performs nearly
identically, but uses about 1/3 less shaft power. (In
this example, the fan blade was teamed with a
premium-efficiency motor and VFD control for a
package upgrade.) Purchased in bulk, the new fans
cost about $10 to $15 each. (It is important to get
a fan-performance curve for the existing fan blade.
If none is available, a testing lab can generate one.)
Penthouse Applications
Figure 62: Newer efficient fan-blade design (left)
Locating evaporator coils in a penthouse (Figure 8, and older less efficient design (right)
page 14) offers many advantages, including
simplified maintenance. However, a penthouse design can be energy intensive for several reasons,
including:
! Additional nozzles or ductwork increases pressure drop and fan power.
! The coils are centrally-located, requiring additional air flow and velocity for proper air movement.
! The coils may discharge air perpendicular to aisles, requiring higher air velocity for air movement.
For these reasons, you should evaluate penthouse designs by comparing them to ceiling-hung evaporators
based upon all quantifiable life-cycle costs. If you implement a penthouse design, use fan-control strategies
(for example, VFD control, simultaneous speed control) to minimize energy use.
Screw Economizers
Screw compressors used in
BHP/TR vs Pressure Ratio
applications with low suction
pressure can benefit 2.6
Ammonia Charge
This chart shows that condenser
efficiency is highest at the left 100
When low-efficiency condensers are installed, the reason is usually that they cost less. The condenser cost
(in $/MBH) is the lowest at the greatest capacity for a given tube bundle size range (that is, at the right end
of the bands on the graph). Increased air flow is a relatively low-cost method of adding capacity, albeit at
the expense of efficiency.
It is important to compare condenser models or manufacturers at the same wet-bulb and condensing
temperatures. Some manufacturers use different nominal conditions, making direct comparison difficult.
Condensers can be installed with either integral ! Avoid creating a warm humid “microclimate”
(built-in) sump pumps, or they can be piped to a
large remote sump tank, often located in the near condensers (confined spaces, inadequate
engine room. Integral sumps are the most efficient spacing, and proximity to steam or humid
design, because pump head and the associated
power are minimized.
exhaust sources).
! Use integral sumps instead of remote sumps in
Remote sumps are popular for water treatment,
freeze protection, and pump backup. temperate climates.
Unfortunately, pump head in remote sumps is ! Install an automatic non-condensable gas
commonly doubled or tripled, and requires a
proportional increase in pump size. In addition, purger for systems that operate under vacuum.
these pumps are often selected with excess flow ! Use modern high-performance spray nozzles.
capability, and a discharge butterfly valve is
frequently throttled to maintain the target 2–4 psig
of water pressure at the spray header, further
reducing efficiency.
Unfortunately, it is often difficult to convince a refrigeration designer or operator that integral sumps are
worth the inconvenience, particularly for water treatment or freeze protection. Creative solutions such as
hybrid integral/remote sump design can often be implemented. Also, using computer control to
automatically operate condensers dry during freezing weather can help.
Premium-Efficiency Motors
All major pieces of refrigeration equipment can be ordered with premium-efficiency motors. Most
evaporator and condenser manufacturers offer two or three brands of motors, each available with a
premium-efficiency line. You can ask manufacturers about their current products, and select the motor
with the highest efficiency.
Compressors are treated somewhat differently. Most motor manufacturers offer a premium-efficiency
series through the largest NEMA frame size (400 to 450 hp). Anything above this size is considered
custom and often built to order. Premium-efficiency motors cost more, so you should specify them with
care; the energy savings from the increased efficiency may not outweigh the higher initial equipment cost.
Efficiency (%)
92
improved efficiency through a higher loaded rpm. 90
In some fan and pump applications this may 88
law. 84
ODP-Highest Available
82
ODP-EPACT
80
Liquid Subcooling
Liquid subcooling is a process of cooling liquid refrigerant below the
saturated condensing temperature for the purposes of increased
capacity and efficiency. Whenever multistaging or economizers are
applied, subcooled liquid is available. Serving loads with subcooled
liquid increases efficiency by reducing the total amount of refrigerant
that must be supplied and compressed from evaporator loads. Hence,
additional stages of subcooling, and using subcooled liquid whenever
possible are two methods of increasing efficiency.
In the previous example of five suction levels, the +35°F system
could serve liquid to the +5°F system. The +5°F system could then
serve the -65°F, -45°F, and -35°F systems. These lowest suctions
would benefit from two stages of subcooling, substantially increasing
efficiency. Figure 69: Two-stage system
In applications with single-stage economized screw compressors, the with multiple temperature levels
economizer port on an unloaded screw compressor will become
inactive as the compressor slide valve unloads (for example, at 70% capacity). Unless there are other
operating economized compressors or a stand-alone subcooling system, efficiency will suffer due to
diminished or eliminated liquid subcooling.
Hot-Gas Defrost
In the Reducing Lift section of this chapter (page 46), we addressed the importance of avoiding high
condensing pressures for defrost. Four other basic tenets apply to energy-efficient defrost:
1 Use free sources of heat for defrost (hot gas or water). Avoid any form of electric resistance heating.
2 Only defrost when needed.
3 Only defrost for as long as needed.
4 Return hot gas defrost to the highest available suction system.
Hot-gas defrost can have a significant effect on system efficiency. Proper initiation, gas management, and
termination are all key to efficient hot gas defrost.
2 Detailed explanations of these systems are beyond the scope of this guide.
Heat Recovery
Heat recovery, particularly for food processing facilities, is popular. Many systems use hot compressor
discharge gas for underfloor heating (using glycol), boiler makeup water, or plant cleanup water. The
greatest opportunity to recover heat is through a desuperheater, where water can be heated as high as 100
to 120°F in a circulating loop. Unfortunately, about 10% or less of total compressor heat rejection is
superheat, so the total heat (Btus) available for recovery is limited.
If a condensing heat exchanger is installed, water temperature is limited to the condensing temperature
which, at 90 psig for ammonia, is only 58°F. Although most of the total rejected compressor heat is
released in condensing, the quality of the heat recovery is limited by saturated condensing temperature. In
this case, the water could not be heated higher than the 58°F temperature of the condensing ammonia.
The economics of heat recovery often depend on the relative costs of electricity and natural gas or other
fossil fuels. In some situations, it may be cost-effective to operate at elevated discharge pressure to
increase heat recovery. In most cases, however, the energy cost savings from reduced condensing pressure
outweighs the savings afforded by increasing heat recovery. In addition, any analysis should include the
effect on compressor energy of the pressure drop on the ammonia side of the heat exchanger.
In some multicompressor applications, one or more compressors can be operated at increased discharge
pressure to act as heat pumps. An example would be a large vegetable processor that uses steam or other
Building Upgrades
Insulation
Increasing the insulation levels in the roof, walls, floors, piping, and vessels saves energy by reducing heat
flow into the refrigerated space or refrigerant piping. Increasing insulation is possible in both new
construction and retrofits, but is usually more cost-effective in new construction where the installation cost
includes only the incremental cost of higher insulation compared to a less efficient alternative. (In some
Figure 70: Strip curtain (left), fast-folding door (center), and vestibule-style door (right) for infiltration
control
3 These heaters use more energy than is wasted from infiltration through a fully open doorway.
Process Upgrades
Clearly, any system improvement that reduces process refrigeration loads will be beneficial. The following
are some commonly encountered scenarios in food processing.
Best Practices:
Transfer Loads to Higher Suctions Multistage Cooling
Though it doesn’t actually reduce the refrigeration
load, you can cool or freeze a product in stages ! Remove heat from products in stages, using
with multiple suction systems. Consider cooling a higher suction pressure systems first, and lower
product in scraped-surface heat exchangers (such
as vegetable puree in a Contherm or Votator) suction systems for final heat removal.
before freezing. The heat exchangers often operate
at a higher suction pressure than a freezer.
Removing additional heat in the heat exchangers will ultimately reduce loads on the more costly freezer
suction, saving energy. Again, you should assess the cost-effectiveness of installing or expanding heat
exchangers to reduce freezer load.
Chapter 3: Refrigeration System Basics outlines various control system types. We recommend that you
refer to that chapter to review the options. Although there are several variations on computer control, we
generally recommend that the control solution have these three attributes:
It is designed and built by a firm that specializes in industrial refrigeration control. These
systems consistently have the highest level of functionality. Their designers have typically already
encountered and addressed many issues that are specific to industrial refrigeration. Control systems put
together by generalists can work just as well, but the design process will likely be less efficient. If you use a
generalist, make sure a knowledgeable refrigeration consultant, either in-house or contracted, is on the
team.
It is designed and built by a control-system firms that is willing to customize the system for the
specific application. Every system is different and although most control solutions have already been
developed, there are almost always some control issues that are unique to a given project.
It has extensive trend-logging capabilities Extensive trend-logging, including the ability to export
data, are valuable for commissioning, O&M, and evaluating capital projects.
Efficiency Checklist
In this chapter, we have separated best practices into the several categories (listed under Energy
Efficiency—“The Big Picture” on page 6). However, most of these practices and the systems they affect
are interactive, so treating them separately may result in missed opportunities or in solutions that are less
than optimal. To foster a comprehensive approach, the following tables pull together all of the major
concepts related to compressors, evaporators, and condensers from the preceding sections. The tables also
preview the effects of proper maintenance procedures, which are addressed in the next chapter.
Introduction
This chapter discusses best practices for achieving energy efficiency through the operation, maintenance,
and commissioning of refrigeration systems.
Operation and maintenance (O&M) can be defined as maintaining originally-specified equipment
performance through proper service at the specified intervals. Even the most efficient system design and
equipment can be rendered inefficient by inadequate O&M. It is important that proper O&M practices be
followed throughout the life of the system.
Commissioning can be defined as the inspection, review and adjustment of set points, control strategies,
and equipment features, to ensure that the system achieves the design intent and meets original
specifications in a way that maximizes performance and efficiency. Systems should be commissioned when
they are built (or modified) and should be periodically recommissioned.
Performing Periodic Calibration Calibration is primarily associated with maintaining process or space
temperatures at targeted levels. However, instrumentation and controls that are out of calibration can
negatively affect energy performance. Poorly calibrated pressure gauges, temperature sensors, and slide
valves can lead to:
! Overly conservative settings that compensate for the unknown.
! Faulty interpretation of problems with the system.
Tracking Equipment and System Performance Best practices include establishing habits and
procedures that allow the emerging problems to be identified and fixed before they impact process or
energy performance. This includes maintaining daily engine room logs, trend-logging control points with a
computer-control system, and comparing performance over time.
Seeking Optimization The operators that attain the highest levels of efficiency make regular
adjustments to control system settings and adjustments to equipment. These adjustments are followed by
observation or measurement to see how the system responds.
Being Well-trained Knowledgeable maintenance staff and operators have a better understanding of all
of the items on this list. They also have a better conceptual understanding of the overall performance
goals. Plus, training often is used to satisfy PSM requirements as per federally mandated OSHA standards.
The following sections address some key O&M issues for evaporators, compressors, and condensers that
affect energy performance.
Evaporators
Clean Coils Clean evaporator coils regularly.
Pressure washing can remove dirt that accumulates
on evaporator fins and tubes. This is especially
true in dirty or dusty environments.
Fix Leaking Valves Rebuild liquid and gas valves
when leaking or other improper operation is
detected. For example, a leaking hot-gas defrost
valve will impart false refrigeration loads by leaking
gas into the suction line.
Calibrate Temperature Probes and Sensors
Calibrate temperature probes and sensors regularly
using a consistent and traceable standard (for
example, an ice bath).
Replace Failed Motors Failed evaporator
motors lessen total coil airflow (cfm) and capacity.
The failed motor also creates an alternate path for
air to flow back through the fan shroud on the
front of the evaporator Figure 72: Dirty evaporator coil
Check Air Temperature Drop Track or check air temperature drop across the evaporator coils. This
technique helps identify evaporators that are underperforming. Underperforming coils should be debugged
to identify and address the underlying problem. For example, a typical evaporator coil in a freezer
application should provide approximately ½ degree reduction in air temperature per degree temperature
difference (entering air minus refrigerant temperature).
Compressors
Calibrate Slide Valves on Rotary Screw Compressors Rotary or linear potentiometers are often used
to measure slide valve position (and for variable VI, the slide stop position) on a screw compressor
(Figure 73). The potentiometers eventually drift or wear, preventing the compressor from properly
determining slide valve position. Where slide valve position is used for sequencing or other advanced
control, accurate slide position is important.
Calibrate Pressure Transducers All screw compressors have built-in pressure transducers for
information, control, and safeties. Errors in these pressure readings can result in poor control of suction
pressure, and possibly operating at a lower suction pressure than desired.
Condensers
Clean Water-Spray Nozzles and Strainers Figure 73: Slide valve potentiometer
Proper flow and water distribution to condenser
tube bundles is critical. Check for spray pattern and clean nozzles and strainers as needed to ensure full
flow and wetting of coil surface (Figure 74).
Clean Condensers Remove build-up of solids Best Practices:
and other foreign material from all condenser Condenser Maintenance
surfaces. In particular, a clean tube bundle is
critical to maximum heat transfer. Also, pressure-
wash drift eliminators regularly, as they accumulate
Stay on top of the three big threats to condenser
solids that can reduce air flow. performance with proper maintenance at correct
Maintain Belt Drives Adjust and replace fan intervals:
belts as necessary. A slipping belt is not only ! Non-condensable gases.
inefficient, but results in less air flow and heat
transfer in the condenser. ! Scale on the condenser tube bundle.
Evaporators
Coil Overfeed Rates Adjust overfeed or recirculated evaporator coils for the specified overfeed rates.
Proper overfeed rates are typically 3:1 to 4:1 (rates that maximize overall heat transfer). This adjustment is
particularly critical in gas pressure recirculation systems where excessive overfeed rates can reduce system
efficiency.
Evaporator Pressure Regulators In some flooded or recirculated systems, evaporator coil pressure
regulators are manually set to limit refrigerant pressure and temperature within the coil. This means that
with the regulator operating at 100% capacity, the refrigerant pressure within the coil is well above the
compressor suction pressure. These limitations are appropriate to avoid excessive temperature differences
that cause evaporators to frost rapidly. However, excessively high regulator settings limit the capacity of
the evaporator coil, and limit savings from evaporator fan cycling or VFD control. Adjusting the pressure
regulator for maximum capacity will increase capacity and maximize efficiency.
Defrost Regulators Defrost regulators that are set too high can limit the minimum condensing pressure
of the refrigeration system. Defrost regulators that are set too low can result in ineffective defrosts. Most
efficient systems use a regulator setting in the 70 to 75 psig range.
Compressors
Adjust Economizers for Effectiveness On economized rotary screw compressors, the economizer port
should always be enabled when it is necessary for liquid subcooling of low temperature loads. Loss of
subcooling can reduce compressor efficiency by 5% to 10% or more. In addition, most economizer ports
are equipped with pressure regulators to maintain pressure in the subcooler or economizer vessel. Adjust
these regulators for the optimal intermediate pressure. Avoid part-load operation on economized screw
compressors that are necessary to serve a liquid subcooling load. The economizer is typically disabled or
ineffective below about 70% capacity.
Manually Adjust VI Properly For compressors with manually adjusted internal volume ratio, review
factory recommendations for proper setting at the given operating pressures. Improper VI adjustment can
reduce compressor efficiency, particularly after adjusting system pressures, or reassigning the compressor
to an alternative duty.
Investigate Current-Limiting Virtually all screw compressors implement a current-limiting feature into
the microprocessor panel. If motor load exceeds the nameplate capacity or the service factor, the
compressor can limit further loading or actually be forced to unload. This occurs most often when a motor
is undersized or a compressor is operating at elevated suction or discharge pressure relative to design
conditions. Since operating unloaded is inefficient, you may need to reassign the compressor or replace the
Condensers
Review Purger Operation Inspect automatic system purgers for proper operation and capacity. If a
system has increased in size and capacity over time, a purger may not be capable of handling all non-
condensable load. Make sure that the foul-gas piping from the condenser circuits to the purger does not
trap liquid.
Refrigeration Loads
Optimize Door Heating Adjust door and air curtain controls to minimize heating while maintaining
door functionality. Electric resistance heating, blowers, and even ammonia hot gas are often employed
with doors and air curtains. Several door controls have features that allows heating to be cycled rather than
operated continuously or only cycle on heating for a period after the door has been opened.
Minimize Door Cycle Times and False Openings Adjust closing delay timers to minimize open time
for doors that automatically close. Tune door motions sensors to eliminate “false openings” caused by
cross traffic or activity by the door that is not passing through the doorway.
Optimize Underfloor Heating The underfloor heating system should use the lowest possible air or
glycol temperature required to prevent frost heaving. Due to the slow thermal response of the slab and
underfloor system, you should experiment slowly and carefully.
Minimize Pressure Differences Between Rooms Exhaust systems, make-up air units, and positive
pressure requirements can all have create pressure differentials that force high levels of infiltration into a
refrigerated spaces. Commissioning can sometimes mitigate these effects while meeting plant
requirements.
Controls
Optimize Suction Pressure Set Point In some systems it is best to raise the set-point as high as
possible. In other systems, it is best to balance pick a set point that best balance compressor energy use
with evaporator fan energy. As part of the commissioning process, keen attention should be focused on
the limiting refrigeration load to make sure that it is performing consistent with its design rating.
Compressor Sequencing Carefully review and optimize compressor sequencing set points, including
order and criteria for starting and stopping compressors. Simultaneously unloading multiple screw
Introduction
This chapter explains the benefit of incorporating a robust energy management strategy and provides a
variety of resources and approaches that can help you understand and control your refrigeration system
energy costs. An effective refrigeration energy management strategy strives to raise awareness of energy
use and operating costs. All plant staff should have full knowledge of the costs of running the refrigeration
system—from plant engineers, process operators, to maintenance staff. Owners and plant management
also need to see energy costs as a variable rather than a fixed expense. We believe that if you are aware of
your energy use, the related energy costs, and the options available to control them, you are more likely to
select efficient choices that minimize life-cycle cost and maximize profits.
This section includes the following:
! Examples of energy management strategies utilized at industrial facilities and key elements of
successful programs.
! An overview of Key Performance Indicators (KPIs) that can be employed on an industrial
refrigeration system to measure system performance and ensure that efficiency improvements are
sustained and improved over time.
! A self-assessment questionnaire that allows you to consider how all aspects of your refrigeration
system can influence operating costs. This includes equipment choices, control methods, system
design, operation and maintenance, and management techniques.
! An overview of life-cycle cost analysis.
! An example of how to estimate the annual energy cost of your refrigeration system.
! An overview of the techniques and benefits of refrigeration energy-efficiency studies.
! A discussion of energy-accounting practices and their benefits.
! A reference section that includes a variety of sources for information on industrial refrigeration
engineering and operation.
Clearly, a Strategic Energy Management program presents the best opportunity to fully optimize energy
efficiency. An energy management program is most effective when it is appropriately scaled to meet the
needs of a facility. In general, the greater energy costs are and the greater percentage of total operating
costs energy represents, the greater opportunity for a comprehensive energy management program.
Score
2 The controls for our system allow space temperatures to pull down below the required temperature by
more than 2°F.
Points
Yes ............................................................................................................................................ 0
No ............................................................................................................................................. 1
Score
3 Which of the following descriptions best describes your system:
Points
We maintain our suction pressure below its design suction level to be
conservative and run all evaporator fans at full speed.................................................. 0
We maintain our suction pressure at its design suction pressure and
run all fan evaporator fans at full speed. ........................................................................ 1
We allow our suction pressure to float above the design suction
pressure while running all evaporator fans .................................................................... 2
We operate at the highest allowable suction pressure that still allows
some fan cycling or fan-speed reduction........................................................................ 3
Score
4 A small but colder load on our refrigeration system determines the suction pressure we run, while a
larger load on the same system could handle a higher suction pressure. (An example is an ice cream
room on the same suction as a main freezer.)
Points
Yes ............................................................................................................................................ 0
No ............................................................................................................................................. 1
Score
Score
Section Score
Score
7 Our peak summer condensing pressure is about:
Points
above 180 psig ........................................................................................................................ 0
170–180 psig ........................................................................................................................... 1
160–170 psig ........................................................................................................................... 2
150–160 psig ........................................................................................................................... 3
below 150 psig ........................................................................................................................ 4
Score
8 We have direct expansion (DX) evaporators or other DX loads in our system.
Points
Yes ............................................................................................................................................ 0
No ............................................................................................................................................. 1
Score
9 Our high-stage or single-stage compressors are forced to unload (current-limit) in the summer to
avoid overloading the motors because of high condensing pressures.
Points
Sometimes ............................................................................................................................... 0
Never ........................................................................................................................................ 2
Score
Section Score
4 Questions in this section are geared toward the Pacific Northwest region of the United States.
Score
Section Score
Score
Score
Section Score
Score
14 We operate our condenser fans first and our pumps second.
Points
Yes ............................................................................................................................................ 0
No ............................................................................................................................................. 2
Score
Score
Section Score
Score
17 Our screw compressors are cooled with liquid injection.
Points
Yes ............................................................................................................................................ 0
No ............................................................................................................................................. 3
Score
18 Our system has no suction systems below -10°F saturated suction temperature that are not either
single-stage economized or two-stage.
Points
True .......................................................................................................................................... 0
False .......................................................................................................................................... 3
Score
19 Our system has no suction systems below -30°F saturated suction temperature that are not served
with a two-stage system.
Points
True .......................................................................................................................................... 0
False .......................................................................................................................................... 3
Score
20 We have refrigeration computer-control system.
Points
False .......................................................................................................................................... 0
True .......................................................................................................................................... 3
Score
Section Score
Score
Section Score
Score
23 We measure the liquid ammonia temperature returning from our condenser. It is normally within 2°F
of the saturation temperature corresponding to the discharge pressure.
Points
False .......................................................................................................................................... 0
True .......................................................................................................................................... 2
Score
24 We check, clean, and replace condenser nozzles, water distribution trays, and strainers such that the
system is clog-free and our water spray coverage is complete.
Points
False .......................................................................................................................................... 0
True .......................................................................................................................................... 2
Score
25 We calibrate temperature sensors, pressure sensors, and slide valves at least once a year.
Points
False .......................................................................................................................................... 0
True .......................................................................................................................................... 2
Score
Score
27 We practice preventive maintenance on our compressors including regularly scheduled oil changes,
filter changes, oil analysis, vibration analysis, and clearance checks.
Points
False .......................................................................................................................................... 0
True .......................................................................................................................................... 2
Score
28 We routinely inspect our hot gas solenoid valves to confirm that no gas is leaking through to the
suction system.
Points
False .......................................................................................................................................... 0
True .......................................................................................................................................... 2
Score
29 Which of the following statements best describes how you manually record and track variables that
have a significant energy or process impacts (examples include space or process temperatures, system
pressures, compressor motor current, slide valve positions, compressor hour meter readings, etc.).
Points
We don't formally track these variables................................................................................ 0
We manually record engine room and space temperature logs on at
least a daily basis. This technique allows us to recognize problems
early, but we seldom refer back to previous logs for comparison. ............................. 1
We record engine room logs on at least a daily basis. We use this for
early recognition of problems and we periodically compare
performance over time to identify emerging problems................................................ 2
Score
30 Which of the following best describes our use of our computer-control system for control?
Points
We either don't have a computer-control system or we have
overridden and disabled most/all of its control functions. ......................................... 0
Our control system provides most/all of the control for our system,
but we largely rely on the original settings. .................................................................... 1
We consider the control system a tool for active use. We routinely
make control changes with a particular emphasis on minimizing
energy use. ......................................................................................................................... 2
Score
Score
Section Score
Score
Section Score
Score
34 We have installed electrical submetering of our refrigeration system and we use it as a tool to optimize
energy use and identify emerging trends.
Points
No ............................................................................................................................................. 0
Yes ............................................................................................................................................ 1
Score
Score
Section Score
Total 100
This self-assessment tool is intended to give you an initial idea of your refrigeration system’s energy
efficiency and potential. You’ve probably noted that more expensive or complex options are represented
by higher scores. In most circumstances, this also indicates greater energy efficiency. But there are many
operation-and-maintenance options for reducing energy costs with minimal investment.
This self-assessment tool was developed with a “typical” refrigeration system at a cold storage warehouse.
Remember that your refrigeration system is customized and unique to your situation. If you have
significant process loads for fluid cooling or freezing, or your system is older, some of the scoring choices
may not apply well to you.
Technically:
kW = motor shaft power x .746 / motor efficiency
but a decent approximation is:
kW = Motor Nameplate hp x typical motor amps / motor full load amps * 0.8
Average shaft power should address control type (constant, fan cycle, or speed control).
A lower level of efficiency is cost-effective when one or more of the above conditions are not met. In such
a scenario, an energy study is the best tool for addressing the specific case and helping define what is
economically feasible.
An energy study defines the capital costs and energy cost savings associated with various upgrades (in the
case of new construction) or retrofits (for existing systems). It also summarizes any utility incentives or tax
benefits that may be available, and provides the proper rigorous analysis and documentation required to
obtain them. If possible, the study should list or quantify non-energy benefits and/or costs. Financial
results are presented in terms of simple payback, return on investment, or annual net cash flow, depending
on the preferences of decision makers.
An energy study should be conducted by someone with expertise and experience in refrigeration and
energy analysis. A lack of refrigeration knowledge will result in missed opportunities and poor
recommendations. A lack of energy experience will miss the big picture in terms of energy baseline, utility
rate schedules, and incentives. Limited analytical experience will result in dubious savings estimates.
Some larger food-processing facilities have developed (or may want to develop) energy-study expertise in-
house. More commonly, energy studies are contracted out to energy-efficiency specialists. Often, energy-
efficiency programs of electric utilities will provide partial or full funding for these studies. However, even
if the customer pays for the study, this investment is small relative to the capital cost of the equipment and
the lifetime energy costs of the system. In other words, it is a “best practice” to invest in high-quality
decision-making information.
At a more detailed level, an energy study includes the following:
An engineering model of the energy use of the refrigeration system This model would represent
the loads, equipment, and control of the system. Such models can be constructed for both existing systems
and for proposed new construction.
! A baseline model is constructed that represents either “as-is” conditions (for an existing system) or a
“baseline design” model (for new construction).
! Modified versions of the model are created to represent alternate system configurations. The
difference in annual energy use between the baseline and alternate models represents potential energy
and cost savings.
! These models can be quite complex, due to a combination of factors including seasonal variations in
weather and production, interactions between energy-using equipment, nonlinear equipment part-
load, and control subtleties. To be an accurate representation, a comprehensive model should address
both full-load and part-load equipment operation and the full range of load levels and ambient
conditions. It is a mistake to concentrate strictly on worst-case design loads that occur for only a small
fraction of the time.
! For existing systems, we advocate monitoring the system for a representative period of time to
observe how the system actually operates. The monitored loads and equipment control are then
Estimates of the cost of efficiency upgrades These costs can be estimated based upon similar
projects, but a better approach is to obtain contractor costs based upon the specific case. It is an excellent
management practice to ask contractors for cost estimates for efficiency alternates as part of the bidding
process for new construction.
Design details The study should provide enough detail on specific design details, necessary set points,
and control algorithms to ensure that the energy-efficiency goals will be achieved.
Measurement and verification plans It is a good idea to describe how the system will be
commissioned and how savings will be verified at this early stage, particularly if incentives are at stake.
Table 12: Example summary of savings and cost from an energy study
1.90
2,500,000
1.85
2,000,000
1.80
kWh
1,500,000
kWh
1.75
1,000,000 2000
1.70
2001
2002
500,000 1.65
2003
- 1.60
- 2,000 4,000 6,000 8,000 10,000 12,000 45 50 55 60 65 70 75 80
Production (lb/month) Average Monthly Ambient Temperature (°F)
Figure 75: Examples of tracking energy use normalized to production (left) and temperature (right)
Energy accounting can help your facility staff understand how and where energy is used in your plant, and
can help motivate people to take actions that can significant reduce utility costs. To get the most benefit
from energy accounting, allocate sufficient staff resources to set up and maintain the system, and to
develop a system of communication with owners, managers, facilities staff, and others whose decisions
affect energy use.
Energy accounting can’t save energy on its own. But when used as a tool for energy management, it can
help you make changes in operation or equipment that will reduce energy costs. Energy accounting will
These two software tools can help you determine the economics of premium-efficiency vs. standard
motors. They also include other features, such as a database of plant motors, calculation of motor
operating costs, and tracking of motor maintenance.
! MotorMaster+:
www.oit.doe.gov/bestpractices/software_tools.shtml
! em2 Solutions, Electric Motor Management Software
www.em2solutions.com
Case Studies
This section contains short case studies that were selected to show how some of these Best Practices have
been implemented in the Pacific Northwest.
! Henningsen Cold Storage
! Oregon Freeze Dry
! SYSCO Food Services
! WestFarm Foods
Baseline
www.energy.state.or.us
350,000
Improved Electric Utility
300,000
Portland General Electric
Energy Use (kWh)
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Month
BEST PRACTICES IN INDUSTRIAL REFRIGERATION
Background
The engineering staff at Oregon Freeze Dry believes plant
energy use is their responsibility. In 2002, they decided to
look at the ammonia-based refrigeration system, one of their
most energy-intensive systems. They invited Al Leake of
Pacific Power to discuss energy-efficiency projects and
available incentives.
Pacific Power arranged for Cascade Energy Engineering to
perform an energy study to find specific ways to improve
the efficiency of the refrigeration system. Their report
suggested three efficiency measures: 1) installing variable- Features
frequency drives (VFDs) on four of the eight compressors;
2) adding a new suction line between two plants, and ! ABB variable frequency drives were installed on four
3) expanding computer screw compressors (two high stage and two booster
controls to manage the compressors). The remaining four compressors are now
VFDs. used for base loading and back-up.
The existing compressors ! A Techni-Systems computer-control system manages
inefficiently varied capacity which compressors run and at what speeds to meet the
with slide valves. The VFDs refrigeration load with maximum efficiency.
would instead allow the ! A 12-inch-diameter suction line supplements the old 8-
compressor motors to vary inch line.
speed to match refrigeration
loads. The existing
undersized suction line
created a large pressure drop
Replication
which required a lower (and
less efficient) system suction ! In industrial refrigeration systems, VFDs are often cost
pressure. effective for screw compressors, evaporator fans, and
condenser fans. Generally, VFDs are useful where
Oregon Freeze Dry
equipment operates for long hours in systems with
management reviewed the
variable loads or light loads.
report, found the financial
! If a compressor operates at or near full speed most of the
payback and incentives
time, adding an adjustable speed drive will not be cost
attractive, and approved the
effective.
installation.
! A VFD may not always be the best way to control
capacity. Sequencing of multiple compressors or the use
Benefits of a reciprocating
compressor for trim are
other possibilities.
! VFDs and control system efficiently vary the capacity of ! The use of VFDs is only
the refrigeration system with speed control rather than one way to save energy
with the less efficient slide valves. in industrial refrigeration
! Energy savings of 1,939,000 kilowatt hours/year (34 systems. Other ways
percent of base energy use) with no reductions in include refrigeration
production. computer control,
! Energy cost savings of $77,700/year. thermosiphon oil
! Reduced wear on motors and compressors due to soft cooling, high-speed
starts and fewer operating hours. energy efficiency doors,
! The VFDs and control system require minimal and bi-level lighting.
employee training.
BEST PRACTICES IN INDUSTRIAL REFRIGERATION CASE STUDY
SYSCO Food Services
Energy Management Strategy
To achieve their energy efficiency goals, SYSCO implemented an
energy management program at each facility:
! Energy Champion: An Energy Champion was assigned at
each facility. The Champion is accountable for achieving
SYSCO’s energy reduction goals and manages all energy
related aspects at the facility. The Champion also manages
key resources such as facility maintenance staff, vendors and
contractors, and the local utility in order to implement
energy efficiency improvements.
! Key Performance Indicators (KPIs): A website tool was
developed to track facility energy use and to establish KPIs
which track and benchmark improvements. KPIs include
tracking current facility energy use versus historic
performance and plant energy use per warehouse storage
volume.
The Program ! Commissioning: A rigorous commissioning was conducted
by Cascade Energy Engineering at each facility to identify
low- or no-cost opportunities to reduce energy use.
SYSCO has long been a market leader in the highly competitive ! Capital Projects: Each facility was tasked with identifying,
North American food-service distribution industry. At the heart prioritizing, and implementing capital projects to reduce
of the company are over eighty broadline distribution facilities energy use in an effort to meet SYSCO’s energy reduction
spread throughout the United States and Canada. These facilities goals.
provide ingredients needed to prepare meals as well as other ! Performance-Based Incentives: A system was put in place
services for restaurants, hotels, schools, cruise ships, and other to tie compensation of the energy champions and upper
food-service locations. management to achieving and sustaining SYSCO’s energy
efficiency goals.
In 2006, SYSCO established energy goals for each broadline
facility to reduce use by 10% in the first year and by 25% after In regards to establishing comprehensive energy KPIs, Richter
three years (by 2009). “Energy represented the next layer of our commented, “SYSCO has always been a data driven company.
operating costs that could be reduced,” noted Pete Richter, We recognize that extending this philosophy to energy is critical
SYSCO Corporate Project Manager. “We had some past towards achieving and sustaining success.”
experience implementing energy projects at a few of our
facilities. The ROI for these projects was always excellent. We
knew that a corporate-wide effort could yield tremendous cost
savings.”
25,000
20,000
15,000
10,000
5,000
0
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Month
BEST PRACTICES IN INDUSTRIAL REFRIGERATION
PROJECT SUMMARY
Changes Made
Refrigeration
! Increased suction-pressure setpoint of freezer
system
! Increased suction-pressure setpoint of cooler
system
! Lowered condensing pressure setpoint
! Improved sequencing order of condenser pump
and fan
! Optimized defrost frequency and time for each
evaporator zone
! Reduced heating intensity and duty cycles of cold-
storage door
! Tuned hot-gas defrost regulator East Wisconsin Commissioning
! Lowered temperature setpoint of underfloor
glycol heating
In April 2006, the SYSCO East Wisconsin facility was one of
Lighting the first broadline facilities commissioned. The purpose of the
! Reduced delay times of occupancy sensors on bi- commissioning was to identify low or no-cost opportunities to
level lighting reduce energy use through improvements in the refrigeration,
! Relocated poorly positioned occupancy sensors on lighting, HVAC, and battery charger systems. Potential capital
bi-level lighting upgrades to reduce facility energy use were also identified.
Energy Consultant
Cascade Energy Engineering, Inc.
(509) 529-8040
Marcus Wilcox, P.E.
marcus.wilcox@cascadeenergy.com
CASE STUDY
BEST PRACTICES IN INDUSTRIAL REFRIGERATION
WestFarm Foods
PROJECT SUMMARY
Benefits
! Reduced energy cost
! Increased system capacity
! Improved control
! Improved trending and alarming
! Reduced evaporator fan noise
! Reduced condenser fan noise
Financial Overview
Incremental Installation Cost
$310,000
Oregon Business Energy Tax Credit
The Project $108,000
Portland General Electric Incentive
$127,000
WestFarm Foods is one of the largest dairy manufacturers in
Energy Savings
the nation, with 1,200 employees at 11 processing plants in
Washington, Oregon, Idaho and California. In early 1996, 40% of base energy use
WestFarm Foods began planning for an expansion and 2,000,000 kWh/year
modernization of their Portland, Oregon creamery. Energy Cost Savings
WestFarm engineers were designing a new Extended Shelf
$75,000/year
Life (ESL) processing line and the associated cooler space. Resources
Increased loads from the ESL process and cooler would Project Owner
require adding a 350-hp compressor to supplement the
WestFarm Foods
existing 350-hp and 600-hp screw compressors. This in turn
(206) 281-3456
would require another condenser.
www.WestFarm.com
WestFarm and their Portland General Electric account
Energy Consultant
representative arranged for Cascade Energy Engineering to
perform a detailed energy study, starting with data logging Cascade Energy Engineering, Inc.
of the existing refrigeration system. The data collected (503) 287-8488
included suction pressure, condensing pressure, and Rob Morton, P.E.
compressor slide valve position. Hour meters recorded run rob.morton@cascadeenergy.com
time for the liquid solenoid valves and power measurements Business Energy Tax Credit
were made on the primary refrigeration compressor. Oregon Department of Energy
Data logging revealed three major issues with the existing 1-800-221-8035 (inside Oregon)
systems. First, compressors operated unloaded much of the (503) 378-4040
time because they were sequenced manually, not by www.energy.state.or.us
computer control, to meet the wide range of plant loads. Electric Utility
Second, the high minimum condensing pressure of 140 psig,
which was required to ensure proper liquid ammonia flow
Portland General Electric (Incentives are now
throughout the sprawling plant, resulted in increased available through the Energy Trust of Oregon)
compressor power, particularly during the winter. Third, 1 (866) 368-7878 (inside Oregon)
the evaporator coil liquid solenoids in the milk cooler were (503) 493-8888
off much of the time, resulting in excessive fan power. www.energytrust.org
BEST PRACTICES IN INDUSTRIAL REFRIGERATION
800
Day
and the new ESL cooler. The
computer reduces fan speed
whenever space temperature
is satisfied.
Results
A new high-pressure Implemented measures reduced annual energy consumption
ammonia receiver with a at the WestFarm facility by more than 2,000,000
booster pump was installed kWh—nearly 40% of the
to ensure adequate liquid total refrigeration energy
pressure to sensitive loads. use. Annual operating costs
This allowed the minimum were reduced by about
condensing pressure to be $75,000.
reduced from 140 psig to 90
psig. The entire package of
improvements cost $310,000.
A larger, more efficient Although this represented an
condenser was specified, and attractive 4.2-year payback,
all condenser fans were incentives from Portland
equipped with VFD control General Electric and a 35%
to manage condenser tax credit from the Oregon
capacity with speed rather Department of Energy
than cycling. reduced the final customer
payback to one year.
Industrial Refrigeration Best Practices Guide 123
Industrial Refrigeration Best Practices Guide
December 2007 (2nd revision)
ISBN: 0-9721077-9-7