Kngreddy Refrigeration and Air Conditioning System kngreddy

1. Describe with a line diagram its operation showing various pressures and
temperature of a Vapour Compression Cycle refrigeration system.

 The compressor sucks the vapour from the evaporator; the temperature and
pressure of the vapour are raised by compression.
 The compressed vapour flow through the oil separator gas discharge line in to the
condenser, where it is cooled with sea water as cooling medium.
 The vapour in the condenser first gives up its super heat and then cooled from the
discharge temperature to the saturation temp corresponding to condensing pressure
then gives up its latent heat as it condenses back to liquid.The liquid then flows from
the bottom of the receiver to complete the cycle.
 When the liquid temp is below the condensing temp it is said to be sub cooled.
 The liquid refrigerant stored at high pressure in the receiver. It flows through the
liquid line to the flow control valve (Thermostatic expansion valve)which regulates
the rate of flow to the evaporator to suit the evaporation and also the pressure of the
liquid is reduced to the evaporating pressure so that the temperature of the refrigerant
entering the evaporator is below that required in the refrigerated space.
 The liquid vapour refrigerant mixture then flows through the evaporator, extracts
heat from the refrigerated space and changes to a dry saturated vapour at approx the
same temp and pressure at which it left the flow control valve.
Kngreddy Refrigeration and Air Conditioning System kngreddy

2. Describe with a neat sketch a drier unit as fitted to a refrigeration system and why
is it required?

Filter driers:
The function of filter driers is to remove moisture from all refrigerant systems, with
the exception of those using ammonia (R717), which has a high tolerance for
moisture. Foreign particles, sediment, and the products of oil breakdown are also
filtered out. The filter driers are fitted in the liquid refrigerant line from the condenser
to prevent moisture and other contaminants entering and blocking the expansion valve.

1. Gauge connection. 2. Cover. 3. Joint. 4. Withdrawing handle. 5. Spring.

6. Distance piece. 7. Division plate. 8. Felt washers. 9. Gauze plates.
10. Casing 11. Inlet connection. 12. Oval flange. 13. Charging connection.
14. Center bolt 15. Drying agent.16. Retaining sleeve. 17. Outlet connection.

Refrigerant drier.

Filter driers contain a desiccant, which is a moisture absorbing substance which will
eventually become saturated with moisture and have to be replaced. Two widely used
desiccants are silica gel and molecular sieves. Where rechargeable units are fitted, the
desiccant can be removed and the drier refitted with a fresh charge. The commonest
drying agents used are silica gel and activated alumina, both of which can be
reactivated by heating to 140 deg.C for a number of hours.
Kngreddy Refrigeration and Air Conditioning System kngreddy

3.Sketch a thermostatic expansion control valve as fitted in a refrigeration system,

label the parts and state the location in the refrigeration system.

THERMOSTATIC EXPANSION VALVE:-

The expansion valve is fitted to the inlet of the evaporator after the drier unit. One
manually operated valves are fitted to either side of expansion valve and bypass line
provided used during pressure testing.

4. Describe with an aid of a sketch high pressure cut out fitted in refrigeration
system.

HP CUTOUT:-
 Used to protect against high discharge pressure which will overload the
compressor and may damage components.
 Set to stop the compressor motor at a pressure of about 90% of the maximum
working pressure of the system.

 The bellows connected by small bore pipe between compressor and condenser.Excess
Kngreddy Refrigeration and Air Conditioning System kngreddy

 pressure expands the bellow and moves the switch arm to activate electrically to trip the
compressor motor. The high pressure thus operated has to be manually reset after
rectifying the fault.


5a) Explain the term “Superheat” with reference to the thermostatic

Expansion valve and the term “under-cool” with reference to condenser.

Superheat
Superheat is referred to as the condition of gas at outlet of the evaporator and is
controlled by the thermostatic expansion valve.
The degree of superheat is set by the spring force at Factory. The sensing bulb senses
the gas temp at evaporator out let and controls the Qty of the refrigerant to maintain
the at degree of superheat.
• To ensure no liquid passes through to the compressor, the expansion valve is set
so that the gas at outlet from the evaporator has 2 to 3 degrees of superheat.

Undercool
 The hot and high pressure gas is fed from the discharge side of the compressor to
a
“Condenser” .
 The vapour in the condenser first gives up its super heat and then gives up its
latent heat from the discharge temperature to the saturation temp corresponding to
condensing pressure. The liquid then flows from the bottom of the receiver to
complete the cycle.
 When the liquid temp is below the condensing temp it is said to be sub cooled.
 If the liquid temperature is in sub cooled temp flash of gas Qty will he reduced
and refrigerating effect will be increased
5b) Explain the term entropy and enthalpy with respect to the refrigeration system.

Enthalpy
Enthalpy is the total amount of heat in one Lb. of a substance. It's units are therefore
BTU/Lb. The metric counter part is kJ/Kg. (kilo joules/kilogram)
Entropy
Entropy measures the energy dispersion in a system divided by temperature. This ratio
represents the tendency of energy to spread out, to diffuse, to become less concentrated in
one physical location or one energetic state. Entropy is measured in BTU per Lb. per degree
Kngreddy Refrigeration and Air Conditioning System kngreddy

change for a substance.

6. Explain the functions of the following with reference to the refrigeration system:-
a)Solenoid valve. b) High-pressure safety cut out. c) Oil pressure safety cut out.

Solenoid valves.
The solenoid valve is a servo-controlled electromagnetic valve, which provides
automatic opening and closing of liquid lines. It is fixed between the drier and
expansion valve and controlled by a thermostat.
When the coil energised, the pilot orifice is opened connecting the inlet and outlet due
to the diaphragm moving into open position (vice versa when the coil is de-energised).
The malfunction of this valve can occur due to burnt-out coil, a damaged diaphragm,
or blockage by dirt.

High pressure safety cut out: used to protect against high discharge pressure which
will overload the compressor and may damage components.
The control is set to stop the compressor motor at a pressure of about 90% of the
maximum working pressure of the system.

Oil pressure safety cut out : Used to protect against too low oil pressure in forced
lubrication system .It is a differential control using two bellows, one side represents low
side gas pressure and the other responds to the oil pressure. The oil pressure must
always be greater than the low side gas pressure for the oil to flow. If the oil pressure
falls below a minimum value the cut out controlol stops the compressor. The manual
reset of this safety cut out is required to put back the compressor to normal mode.

7.Describe the procedure of charging gas to a large refrigeration system after complete
overhaul of the compressor, assuming the condenser is empty.

The system have been opened to atmosphere during repair should be flushed through to
remove solid particles and evacuated to remove moisture or non condensable gases.
This is carried out on new system installations or when a plant has been discharged of
refrigerant prior to repair.
It involves the use of oxygen-free nitrogen (OFN) which is a high pressure gas.
This is used to obtain a higher pressure than that of the refrigerant in normal ambient
temperatures.
When an installation is completed and a pressure test is to be carried out.It is most
important to ensure that the compressor is isolated, irrespective of design, before
Kngreddy Refrigeration and Air Conditioning System kngreddy

pressurizing the system. This will also prevent rupture of the crankshaft seals in
compressors.
All pressure controls must be disconnected or by-passed.
The expansion valve is not capable of withstanding the test pressure must be removed
or by-passed.
The cylinder must be fitted with an approved regulator to control the test pressure.
When the system is pressurized, that pressure should be recorded leaving for few hours.
It could take a considerable time for a drop in the nitrogen pressure to become evident,
if a system has a small leak.

Drying by evacuation:
1.Connect a vacuum pump to system using a short length of large bore pipe and open
all valves in the system.

2.Evacuate the system to a pressure of 6mm hg.

3.Close the line between the system and vacuum pump. ( the pressure in the system
may not rise more than 2mm hg with in 5 mins. A rise in pressure indicates presence
of water and / or leak, where water is present, the system will be colder than
surrounding.)

4. Check for water and / or leaks carry out any repair and repeat evacuation procedure
until the pressure rise is less than 2mmHg.
When this is achieved the system is free of moisture and non condensable gases and
ready for refrigerant charging.

1.Low pressure side should be charged ONLY WITH GAS.

2.High pressure side should be charged ONLY WITH LIQUID REFRIGERANT.
CHARGING LIQUID BETWEEN CONDENSER OUTLET AND DRIER:-
1. Connect the Freon gas cylinder to the gas charging valve with a special flexible
hose(purge the air from the hose).
Kngreddy Refrigeration and Air Conditioning System kngreddy
2. Open the cylinder valve (to liquid side) and gas charging valve and run the
compressor.

3. The low pressure switch cuts in and the compressor starts on LP cut in.

4. Charge the liquid until the condenser level is normal and close Freon gas bottle
valve and gas charging valve.

5.The pumping down operation starts and compressor stops due to LP cut off.

6. Release the charging hose of pressure and remove from place.

Procedure for charging refrigerant in low pressure line:
CHARGING GAS THROUGH COMPRESSOR SUCTION VALVE:-

1. Connect the Freon gas cylinder to the gas charging valve with a special flexible
hose (purge the air from the hose).

2. Open the cylinder valve (to gas side) and gas charging valve and run the
compressor.

3. The low pressure switch cuts in and the compressor starts on LP cut in.

4. Charge the gas until the condenser liquid level is normal and close Freon gas bottle
valve and gas charging valve.

5.The pumping down operation starts and compressor stops due to LP cut off.

6. Release the charging hose of pressure and remove from place.

8.Explain with a neat sketch the drain system arranged in a cold room for draining
wash water and defrosted water.
Cold room

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Cold room Drain pipe overboard shipside

The drain pipe is designed with double bend as shown in the sketch above. The
defrosted drain water stagnates to form a water seal at the initial stage. The water
collected in excess due to defrosting, washing cold room would flow overboard and
Kngreddy Refrigeration and Air Conditioning System kngreddy

maintaining always some water in the bend. The purpose of this water is to act as a
“seal” avoiding outside air into the cold room effecting the temperature.

9.How will you know if the gas is leaking in the closed system of a refrigerated
compressor using F-12, Justify your answer.

The system under normal running condition is under pressure and the system can be
Leak tested by using simple soap solution test as a simple test. However leaks are
tested by using the electronic leak detector.

The detector contains an internal pump that draws air into a probe. If the gas is
present in the sample, the electrode sensing element generates a current and an
output signal is obtained.

In modern refrigerated cargo installations leak detector sensors are fitted in the holds
and machinery spaces activate audible and visual alarms located in the control room
in the event of refrigerant leakage.

10. How will you identify if the gas is leaking in a closed system of a refrigerated
compressor using F12 and how will you rectify it?

The easiest method of checking the leakage is by using soap solution.

After deducting the leak, if the pipe or valve connections are leaking, it should be
rectified by using proper gaskets/packing and tightening.

If the any hole identified on the pipe, then pumping down of gas to the condenser and
brazing of the holed portion to be carried out by isolating the system.

The repaired pipe is to be cooled and then re-start the system. After re-starting the
system the air in the system must be purged out from the condenser.

Leak detection equipments :-

Leak tested by using soap solution test as a simple test. However leaks are tested by
using the electronic leak detector. The detector contains an internal pump that draws
air into a probe. If the gas is present in the sample, the electrode sensing element
generates a current and an output signal is obtained.

11. Describe the procedure of charging gas to a large refrigeration system,

when condenser gas level is lower than normal.

TOPPING UP OF REFRIGERANT :-
1. Connect the Freon gas cylinder and gas charging valve with a special flexible hose-
purge the air from the hose. (If liquid is to be charged connect after the condenser and
if gas has to be charged connect to the suction side of the compressor.)
Kngreddy Refrigeration and Air Conditioning System kngreddy
2. Open the cylinder valve and gas charging valve and run the compressor.

3. Allow the liquid / gas to flow in to the system.

Check the liquid level in the condenser has reached to the normal level, then close
freon gas bottle valve and gas charging valve.

4.Release the charging hose of pressure and remove from place.

Precautions:
1. liquid refrigerant must never be charged directly into the compressor suction.

2. Properly tested charging hoses are used, and that non return valves are fitted when
charging into the high pressure side of the system.

12.Write short notes on maintenance of the following refrigeration system

quipments:- a)Condensers. b) Oil separators c)Filters and driers.

a)Maintenance of Shell and Tube Condenser:

In general the following work should be done at regular intervals.

1. To prevent fouling of water tubes with scale or marine growth, reducing the heat
transfer capacity of the condenser, the tubes should be cleaned by ‘tube brush’.
Alternatively, a ready mixed inhibitive scouring acid can be used, with subsequent
neutralization. Such agents must be suitable for use with the tube materials, and
applied in strict accordance with the chemical manufacturer’s instructions and
environmental protection.
2. The end cover should be inspected for wastage, caused by erosion and corrosion
especially the division plate. Zinc anodes to be renewed.

3. The tube ends on both sides of the end plate to be leak tested using soap solution
or any leak detector.

b) Oil separator:- Gas from the system to be pumped down to the condenser and the
circuit breaker of the compressor switched off with a sign board “men at work”. Close
the compressor and discharge valve. Release the pressure by slackening the drain plug
of the oil separator.

Open the float valve and take out the float out of the chamber carefully. Clean internal
thoroughly with a clean rag and blow dry air such that the partition mesh is cleaned.
Overhaul the oil return needle valve and fit back the float as original with new gaskets
and seal rings. After tightening all the fittings, open the compressor discharge valve
one turn and close back to pressurize the oil separator for leak test. Once leak test is
satisfactory, the suction and discharge valves of the compressor are fully opened and
the system set back to normal.

c)FILTERS AND DRIER:-

The filters are located one on the suction side of the compressor, one on the outlet
from the evaporator coil and one in each expansion valve. These filters are removed
Kngreddy Refrigeration and Air Conditioning System kngreddy
from location by shutting the inlet and outlet valves of the equipment. The filters are
cleaned using electro cleaner and later flushed with low pressure air. The filters are
fitted back to its original location by purging the air by opening the valves.

13.Explain the causes and rectification of the following defects, when observed
during the running of the refrigeration compressor:-
a) Too high delivery pressure.
b) Too high suction pressure.
c) Compressor starting and stopping too often on low-pressure switch.
Too high a delivery pressure. 1. Air or non-condensable gas 1. Purge the foul gas from the
in the system. condenser.
2. The cooling water is too 2. Inspect and clean the water
warm or an insufficient valve and water filter, and
quantity is passing through the make sure that the water valve
condenser. is opened wide enough.
3. Mud or scales block the 3. Clean the condenser tubes.
condenser tubes. 4. Drain off the excess R12 or
4. Too much liquid R12 or R22 in an empty cylinder.
R22 in the receiver and some
liquid in the condenser.

Too high a suction pressure. 1. Too much liquid refrigerant 1. Adjust the expansion valves
is being fed through the and check the sensing bulb.
expansion valve. 2. Remove the cylinder covers,
2. Leaky suction valves. check all the valves, repair or
renew and test.

Compressor starting and 1.The filters for liquid 1. Clean all filters.
stopping too often (on low refrigerants, suction strainers 2. Inspect and clean the valves
pressure switch). or filters for expansion valves or renew them if necessary.
blocked/chocked. 3. Renew the solenoid valve
2. The delivery valves of the
compressor leaking.
3. leaky solenoid Valve .

14. Explain the causes and rectification of the following defects, observed
during the running of the refrigeration compressor:-
a) Too low suction pressure.
b) Too low delivery pressure.
Kngreddy Refrigeration and Air Conditioning System kngreddy
c) Compressor stopping too often on high-pressure switch.

Too low delivery pressure. 1. Too much cooling 1. Regulate the water supply.
water to the condenser. 2. Reduce the water supply.
2. Cooling water is too cold. 3. Adjust the expansion valve
3.Liquid R12 or R22 is and check that the expansion
coming back from the valve bulb in contact with
evaporator. evaporator pipe and fastened
4. Leaky delivery valve. correctly.
4. Remove the cylinder cover,
inspect the valve plates and
piston rings; renew them if
necessary.
Too low a suction pressure. 1. Blockage in liquid pipe, 1. Evacuate; remove; inspect
expansion valve or suction and clean filters.
filters. 2. Charge with more R12 or
2. Too little refrigerant. R22.
3.Too much oil circulating in 3. Inspect to see whether oil
the system. has accumulated anywhere in
4. Incorrect adjustment of the the system.
expansion valves. 4. Set the expansion valves to
feed more refrigerant.
Compressor stopping too 1. Insufficient water flowing 1. Find out from cooling water
often (on high pressure through the condenser system the reason for
switch). (blocked condenser tubes). insufficient flow. Clean
2. High pressure switch set condenser tubes.
incorrectly. 2. Adjust the high pressure
3. The system is over charged switch to switch off at correct
with refrigerant. pressure.
3. Reduce the liquid
refrigerant from the system.

15.State how each of the following faults identified and rectified for a vapor compression
refrigeration machine.
a)Air in the system.
b)Moisture in the system.
c)Undercharge.
d)Overcharged.

a)Air in the System

Indication:
Kngreddy Refrigeration and Air Conditioning System kngreddy

• This may cause the refrigeration compressor to overheat, with a high discharge
pressure and normal condensing temperature.
• There are possibilities of small air bubbles in the liquid sight glass of the
condenser.
• Condensing pressure of the refrigerant in the condenser may be high.
• If there is excessive air, it may reduce the cooling capacity of the system making
the compressor to run for the extended period of time.
• It may cause the gauge pointer of the condenser to jump indefinitely.

Causes:
• During charging, air may enter in to the system.
• If Freon-12 is used, air may leak in to the suction line because of the working
pressure of the refrigerant is less than the atmospheric pressure.

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

b)Moisture in the System

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

c)Undercharging of Refrigeration System

Indication:
• Compressor is running hot and performance of the compressor falls off due to
high
superheat temperature at the suction side of compressor.
• Suction and discharge pressure of the compressor is low.
• Large vapor bubbles in the liquid sight glass.
• Low pressure gauge readings in the condenser.
• Ammeter reading for the compressor motor is lower than normal.
• Rise in room temperature which is to be cooled.
• Compressor is running for extended period of time.
Causes:
• Leakage of refrigerant at the shaft seal, flange couplings, valve gland etc.
• Expansion valve inlet filter may be blocked.
Kngreddy Refrigeration and Air Conditioning System kngreddy

• Partial blockage of refrigerant at the filter or drier may cause undercharging.

Action:
• Identify and rectify the leakage of refrigerant from the system.
• Clean the filter and drier.
• Charge the system if required with fresh refrigerant.

d)Overcharge of Refrigeration System

Indication:
• The liquid level in the condenser is too high (high condenser pressure gauge
reading). This will reduce the available condensing level, with corresponding increase
in the saturation temperature and pressure.
• High pressure switch of the refrigerant compressor activates and stops the
compressor.
• There is possibility of excessive liquid refrigerant getting to the evaporating,
giving icing at the compressor suction, and a pressure drop across the expansion valve.
The cold room temperature may rise, if the evaporator is flooded.
Causes:
• It may be due to the reason that excessive refrigerant has been charged in the
system.
• Air in the system may also cause over charging indication.
• It may also be due to the formation of ice on the regulator.
Action:
• Remove the refrigerant from the system. This is done by connecting a cold
cylinder to the liquid line charging valve, starting the compressor, and then operating
the charging valve.
• Purge the air from the system and maintain effective cooling.
• Remove ice from the expansion valve by using any of the defrosting methods.
16.Draw a block diagram of an automatic accommodation air conditioning unit and
label the parts and indicate the directions of airflow.
Typical system
Kngreddy Refrigeration and Air Conditioning System kngreddy

17.Draw a block diagram of an automatic accommodation air conditioning unit and

explain the reason for installing the dehumidification and humidification unit.

 Air conditioning is the control of humidity, temperature, cleanliness and air

motion. Winter conditioning relates to increasing temperature and humidity whilst
summer conditioning relates to decreasing temperature and increasing humidity.
 In summer when air temperature is lowered the humidity is increased to the level
more than the comfortable level. Hence in Air conditioning system air temperature is
lowered much lower than the comfortable level about 10 deg C and then reheated to
comfortable temp 17 deg c and humidity in the delivery duct.
 And when air is heated in winter the air becomes dry, and the humidity is
controlled by spraying and mixing wet Steam in the air path as shown in the diagram
Kngreddy Refrigeration and Air Conditioning System kngreddy

18.What are the readings taken and recorded of a domestic refrigeration system during
watch keeping on board a ship?

Watch keeping duties.

The following are the readings taken for a refrigeration system and recorded in the
Engine log book every four hours of watch keeping.

Item Check Procedure

1. Compressor……………………Check Suction, discharge, oil pressure, compressor oil level.

2. Compressors, fans, pumps…….Check no failure alarms in alarm condition.

3. Domestic refrigerant…………..Check temperatures.

Chambers.

4. Condenser and piping………….Check water pressure gauge that water flow satisfactory.
Check refrigerant liquid level. Examine for leaks.

5. Sight glass in refrigerant

liquid line………………….…Check that full flow of liquid.

6. Refrigeration blackboard……..Check any special instructions from Chief Engineer

The completion of the refrigerator Logbook should be the last task of a watch keeper
before going off duty, to ensure that he is leaving all temperatures in order.

19.Explain the following with reference to the refrigeration compressor:-

a) Sketch a mechanical shaft seal, method of lubrication and name its parts.
b) How is gas leakage deducted through shaft seal and what is its effect on
environment?
c) What factors can cause the shaft seal failure in service?
Kngreddy Refrigeration and Air Conditioning System kngreddy

ANS:- a)

The carbon seal acts as a fixed ring and its face is in contact with a soft bronze metal ring. A
metal ring firmly rotates along the shaft compressing a synthetic rubber ring against the
collar to form gas tight. The spring forces the fixed carbon ring against the stationary bronze
metal ring and prevents gas leakage. The synthetic rubber bellow rides on the shaft with
sufficient pressure to prevent leakage of gas along the shaft. This complete assembly is
forced with a strong spring to keep them in place during normal running. The complete shaft
seal is compressed with a seal mounting plate and bolted to the compressor housing with
proper gasket to prevent gas leakage.
Lubricating oil is fed to this packing, usually under pressure, to keep the shaft and packing
lubricated. The shaft normally moves forward and backward called “end clearance” of crank
shaft. The starting torque of the compressor is so high, which moves the shaft away from its
original position. This torque is balanced by the seal spring force to keep in equilibrium
position.

Ans b)The gas leak can be deducted by carrying out one of the following methods:-
Electronic leak detectors, Leak detector torch, Sulphur candles, Litmus paper and soap
solution.

Ans c) Moisture cause to form acids by reaction with the freon refrigerants. This acid
attacks the copper in the lines and deposits in other parts of the system. This can become
Kngreddy Refrigeration and Air Conditioning System kngreddy

particularly troublesome when it is deposited on the compressor mechanical seal faces

leading to damage and leakage. The air enters the system from the system valve glands
during pumping down operation or charging gas. This oxidizes the lubricant oil and
chemically reacts with the additives forming sludge in the presence of moisture affecting
the viscosity.
The belt is to be checked for tension and alignment of motor to compressor at regular
interval. If the belt tension is high or misalignment, it can cause the shaft seal breakage
due to high torque load transmitting to the shaft seal leading to failure.
If in-sufficient or contaminated lubricating oil supplied to shaft seal, the carbon seal
could be worn out due to abrasive wear damaging rotating seal face and causing loss of
refrigerant.

20. a) Draw a neat sketch of an oil separator fitted to an refrigeration compressor and name
its parts.
b) Why is oil separator required and how does it work?

Ans a)

ANS b)
Oil Seperator:-
The discharge from compressor carry some oil along with the compressed gas and this
must be removed.
The following are the reasons for fitting the oil separator:-
a) To prevent it entering and fouling the internal surfaces of the evaporator and condenser.
b) To separate oil from gas and return back to the crankcase, causing shortage of oil in the
crankcase.

Oil separators are placed in line between the compressor and condenser, and consist of a
pressure container with internal baffles and screens. The oil gas mixture enters the
Kngreddy Refrigeration and Air Conditioning System kngreddy

separator, where it is made to change direction. The heavier oil droplets tend to fall on the
mesh and slides down to the bottom and return back to the crankcase through the float
valve. The oil return may be float controlled or electric solenoid controlled needle valve
with a small bore capillary tube. With all of these methods a shut off valve is fitted
between separator and compressor to allow for maintenance.

21. a) Explain the properties of a refrigeration system lubricating oil.

b) How does the performance effect if lubricating oil of a refrigeration compressor
Deteriorate in service?
ANS a) Refrigeration oils should possess the following properties:
• Good chemical stability. There should be little or no chemical reaction with the
refrigerant or materials normally found in the system.
• Good thermal stability. They should not form hard carbon deposits at hot spots in
the compressor (such as valves or discharge ports).
• Low viscosity. This is the ability of oil to maintain good lubrication properties at
high temperatures and good fluidity at low temperatures, i.c. to provide a good
lubricating film at all times.
• Low wax content. Particularly important in the case of CFC and HCFC plants,
operating at low evaporating temperatures, as separation of wax particles from the
• refrigerant-oil mixture may cause problems by blocking expansion and regulating
valves.
• Low pour point. Ability of the oil to remain in a fluid state at the plant’s lowest
evaporating temperature. The pour point is particularly interesting in relation to
oils used in ammonia (R717) plants, as oils with a low pour point are easier to
drain from the plant’s low pressure side.
• Moisture free. Any moisture added with oil may cause corrosion, and in the case
of CFC and HCFC refrigerants would form as ice in a choked expansion or
regulating valve.
• When adding oil to a compressor, or doing an oil change, it is therefore important
that only the specified in the manufacturer’s operating manual is used. The oil
must be clean and have no moisture content. Oil should always be stored in
tightly sealed containers, in a warm place, to ensure it does not absorb moisture
from the atmosphere. It is important that the procedures given in the compressor-
operating manual for changing and topping-up the oil are strictly followed.

ANS b) Moisture cause two main problems. First, it can freeze to ice in the evaporator
and cause blockage. Second, it can form acids by reaction with the freon refrigerants.
This acid attacks the copper in the lines and deposits in other parts of the system. This
can become particularly troublesome when it is deposited on the compressor mechanical
seal faces leading to damage and leakage. Fine particles which could possible block the
expansion valve are removed. The system is installed with a drier to absorb any moisture
and also filter fine particles of debris in the gas using silica gel as an agent. If moisture
found on the higher side even after renewing silica gel a few times, then the gas has to be
renewed. The air enters the system from the system valve glands during pumping down
operation, charging gas and during standby mode. This oxidizes the lubricant oil and
chemically reacts with the additives forming sludge in the presence of moisture affecting
Kngreddy Refrigeration and Air Conditioning System kngreddy

the viscosity. The refrigerant is continuously filtered using gas filters at compressor
suction, expansion valve inlet and at the evaporator outlet. The contaminated gas will
foul the evaporator bringing the complete system to a halt.

22. Oxidation decomposes lubricating oil, explain briefly how does air
enters into the closed system of refrigeration compressor?

The air enters the system from the system valves glands during pumping down operation,
gas charging and during standby mode. This oxidizes the lubricant oil and chemically
reacts with the additives forming sludge in the presence of moisture affecting the
viscosity.

• In the refrigerant systems some oil always carried over from the compressor into the
condenser by the refrigerant gas, from where it is carried into the evaporator.

• The presence of oil in the circulating refrigerant reduces the heat transfer capacity
being greatest in the evaporator, since oil becomes more viscous and tends to congeal
at low temperature.

• To prevent oil related problems, the operation of the oil separator and the oil rectifier
(if fitted) should be checked regularly to ensure oil is being returned to the compressor
crankcase. The amount of oil added to the compressor crankcase should be strictly
monitored, a decreasing amount indicates that the oil is being trapped in the
evaporator or suction line.

• Oil and gas filters to be regularly cleaned and fresh oil to renew at regular intervals, to
avoid problems during normal running.

23. What action will you take if the moisture could not be removed from the
gas by renewing ‘silica gel’, due to contamination with excess moisture?

The following to be carried out in order to renew contaminated refrigerant in the

condenser:-
1. The pumping down of the gas to be carried out to collect the complete system gas to
the condenser and later close the condenser outlet valve.

2. Switch of the circuit breaker.

3. The empty freon gas cylinders must be cooled in a fish room to bring the temperature
approx. -18 deg.C.

4. The cooled cylinders are connected to the charging valve between condenser and drier
unit.
Kngreddy Refrigeration and Air Conditioning System kngreddy

5. Open the empty cylinder valve and condenser outlet valve, the liquefied gas from the
condenser is transferred to the bottle due to the differential pressure.

6. Renew bottles to collect all of the gas as a single bottle would not be enough.

7.The reason for more gas bottles is that temperature of bottles rise during collection
process equalizing the pressure of the condenser and bottle.

8. Renew silica gel on completion of removing entire contaminated refrigerant.

9. Charge fresh Freon gas to the system to normal condenser level.

10. It may be required to renew silica gel couple of times even after renewing the
refrigerant, due to left over moisture adhering to the walls of condenser.

24.What is humidity and how is it controlled on board ship?

 Air conditioning is the control of humidity, temperature, cleanliness and air
motion. Winter conditioning relates to increasing temperature and humidity whilst
summer conditioning relates to decreasing temperature and increasing humidity.

 In summer when air temperature is lowered the humidity is increased to the level
more than the comfortable level. Hence in Air conditioning system air temperature is
lowered much lower than the comfortable level about 10 deg C and then reheated to
comfortable temp 17 deg c and humidity either in the delivery duct or individual
re.heater fitted inside the cabin at delivery point.

 And when air is heated in winter the air becomes dry, and the humidity is
controlled by spraying and mixing wet Steam in the air path as shown in the diagram

25.What are the basic consideration taken into consideration in calculating

the capacity of air condition plant required for installation on a ship?

The basic principals of air conditioning

Air conditioning is the control of humidity, temperature, cleanliness and air motion.

All air conditioner units must have the five basic components to work:

1. The compressor (To maintain required flow of gas and maintain the necessary
superheat at the evaporator outlet).
Kngreddy Refrigeration and Air Conditioning System kngreddy

2. The condenser ( the cooling of refrigerant and maintain its temperature balance
between inlet and outlet).

3. The expansion device (to regulate the correct quantity flow of refrigerant to
evaporator and maintain superheat).

4. The evaporator (for keeping the required refrigerant flow for optimum enthalpy).

5. The capacity of the fan (to enable correct quantity of air and in addition change of
air in rooms to maintain optimum comfort level).

AIR CONDITION

The coefficient of performance calculated to determine the size of the evaporator and
the expansion valve. The air conditioner evaporator size is important.

The following are taken into calculation in addition to the above:-sensible heat, latent
heat and sub-cool. Humidifier is fitted to the system to regulate the moisture level of
the air outlet to the rooms. Change of air rate (cubic meters/hr) in each cabin to
measure to find the capacity of fan.

26.What is capacity control / un-loader in a refrigeration system and how is

the automatic operation controlled?

The Operation of refrigeration compressor is to balance the compressor capacity

against the refrigerant requirement.
1. Variable speed drives run induction motors at variable speeds down controlling the
capacity of a single compressor.

2. Vertical single-acting compressors use bypass system for capacity reduction. These
are operated either by hand or automatically by a solenoid valve.

3. Most modern multi-cylinder compressors control capacity with cylinder un-loaders.

When a reduction in capacity is required, the pumping action of one or more cylinders
is interrupted. This is accomplished by lifting the suction valve off its seat and holding
it open. With the suction valve open, no compression is possible. Only some of the
cylinders are capable of being unloaded, so there is always some pumping action
taking place. A lever that lifts or drops the valve is operated by a small control piston.
Some manufacturers use oil pressure, others use discharge gas pressure on this control
piston.
Kngreddy Refrigeration and Air Conditioning System kngreddy

A change in suction pressure operates a valve in the oil or gas line to the control
piston. Design is such that the cylinders that can be unloaded remain unloaded when
the compressor is idle. Thus, the compressor can be started at reduced load. As the
compressor comes up to speed, a change in oil or gas pressure activates the control
pistons to allow the suction valves to operate normally. All the capacity-reduction
methods reduce the power required to turn the compressor.

27.What are the factors taken into consideration for optimum comfort level in air
conditioning system?
The term comfort is not something that can be measured precisely. Attempts have
been made to convert this term into measurable parameters Whether a person feels
comfortable or not in a room depends upon many factors:-

Room design (daylight, colours, height, plant, wall temperatures).

Noise pollution (machinery, people, surroundings, air conditioning).

Room atmosphere (quality, hygiene, odour, air speed, temperature, humidity).

Air condition has an influence on the areas highlighted in bold print.

Depending upon the intensity of body activities and air pollution, 20-30 cubic meters
per hour fresh hour is necessary for the removal of carbon-dioxide and moisture

28. What are the dangers of gas to the crew and the environment, with respect to
International regulation?

The gas can cause cold burns if come in contact with the skin. The gas emits a
pungent smell causing breathing problems if the concentration is high. It can cause
blindness if comes in contact with eyes. The Freon gas has to be handled carefully in
order to avoid the danger of accidents.
• The release of CFC refrigerant in to the atmosphere is harmful to the environment.

• The CFCs released broken down to release chlorine atoms which destroy ozone, the
stratospheric gas which acts as a filter of ultra violet light from the sun.

• The increased UV light on earth as a result of ozone depletion will cause skin cancer,
interfere with immune system and harm aquatic system and crops.

• CFCs along with other “green house gases” inhibit the release of heat radiated from
the earth, contributing to global warming. If the global temp increase the mean sea
level will rise.
Kngreddy Refrigeration and Air Conditioning System kngreddy

• To protect the global environment, an international agreement, Montreal protocol

signed in 1987 controls the use and production of CFC refrigerant and other ozone
depleting substances throughout most of the world.

• It currently mandates that the production of the refrigerant R11, R12 and R502 is to be
phased out by1997.

• CFCs are characterized under the Montreal protocol according to the extent to which
they damage the ozone layer.

29.Draw a neat sketch of an oil separator and describe its functions.

0il Separators:
Some oil is always carried over with the compressed gas and must be removed. This
is:

a) To prevent it entering and fouling the internal surfaces of the evaporator and other
heat exchangers.

b) To ensure its return to the crankcase or reservoir, preventing failure through the
shortage of oil.
Oil separators are placed in the line between the compressor and condenser, and
consist of a vessel fitted with internal baffles and screens. The separation of oil is
mechanical, the slowing down and change of direction of the gas/oil stream throwing
out the oil. The oil separated from the gas collects in the bottom of the separator and is
returned to the crankcase or receiver through an automatic regulating needle valve of
float type.
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30.Explain the functions with a neat sketch the following with reference to the
refrigeration system:-
A) Thermostatic expansion valve. B) Compressor shaft seal.

Ans A) The expansion valve consists of a gun metal housing with both ends threads are
provided for inlet and outlet connections. A long capillary tube filled with same liquid
refrigerant with a bulb is connected to the top of the valve housing. A fine metallic
bellow fixed to the push pins at one end slides through the bores of the valve housing and
attached to a valve disc. This valve disc is fixed on a hollow metal chamber acts as a
retainer for the spring The spring tension is adjusted using a screw in order to adjust the
superheat. A balancing line from evaporator outlet is connected below the bellow. An
orifice plate is fixed in the centre of the housing for the purpose of gas expansion.

A)Thermostatic expansion valve:

Kngreddy Refrigeration and Air Conditioning System kngreddy

Expansion valve working procedure:-

Kngreddy Refrigeration and Air Conditioning System kngreddy

Three conditions present themselves in the operation of this valve: first, the balanced forces;
second, an increase in superheat; third, a decrease in superheat. The remote bulb and the power
element make up a closed system (power assembly), and the remote bulb and power element are
charged with the same refrigerant as that in the system. The remote bulb and Power element
pressure which corresponds to the saturation pressure of the refrigerant gas temperature leaving
the evaporator, moves the valve pin in the opening direction.

Opposed to this opening force on the underneath side of the diaphragm and acting in the closing
direction are two forces: (1) the force exerted by the evaporator pressure and (2) that exerted by
the superheat spring. In the first condition, the valve will assume a stable control position when
these three Forces are in balance (that is, when P1 = P2 + P3). In the next step, the temperature
of the refrigerant gas at the evaporator outlet (remote bulb location) increases above the
saturation temperature corresponding to the evaporator pressure as it becomes superheated. The
pressure thus generated in the remote bulb, due to this higher temperature, Increases above the
combined pressures of the evaporator pressure and the superheat spring (P1 greater than P2 + P3)
And causes the valve pin to move in an opening direction. Conversely, as the temperature of the
refrigerant gas leaving the evaporator decreases, the pressure in the remote bulb and Power
assembly also decreases and the combine evaporator and Spring pressure cause the valve pin to
move in a closing Direction (P1 less than P2 + P3).

COMPRESSOR SHAFT SEAL

The compressor shaft seal consists of a carbon seal acting as a fixed ring and its face is in
contact with a rotating soft bronze metal ring. A metal ring firmly rotates along the shaft
compressing a synthetic rubber ring against the shaft collar to form gas tight. The spring is
fixed with force the carbon ring against the metal ring and to prevent gas leak.

The synthetic rubber bellow rides on the shaft with sufficient pressure to prevent leakage of
gas along the shaft line. The complete shaft seal is compressed with a seal mounting plate
and bolted to the compressor housing with proper gasket to make gas tight.

Lubricating oil is fed to this shaft seal, usually under pressure to keep the shaft and packing
lubricated. The crank shaft normally has some “end clearance”. The starting torque of the
compressor can affect the shaft seal if the assembly is in correct or alignment problem
arises.

Shaft Seal Sketch.

Kngreddy Refrigeration and Air Conditioning System kngreddy

31.Describe the danger of “Contamination” with reference to sump oil in the

refrigerated compressor and its effect on the system?

• In the refrigerant systems some oil always carried over from the compressor into the
condenser by the refrigerant gas, from where it is carried into the evaporator.

• The presence of oil in the circulating refrigerant reduces the heat transfer capacity
being greatest in the evaporator, since oil becomes more viscous and tends to congeal
at low temperature.

• To prevent oil related problems, the operation of the oil separator and the oil rectifier
(if fitted) should be checked regularly to ensure oil is being returned to the compressor
lubricating system. The amount of oil added to the lubricating system should be
strictly monitored and excessive amount indicates that the oil is being trapped in the
evaporator or suction line.
Kngreddy Refrigeration and Air Conditioning System kngreddy

• Ammonia (R717) is not oil miscible, so in ammonia systems the oil carried over
compressor separates out and, as it is heavier than the liquid refrigerant, accumulates
at the bottom of the condenser and evaporator. These vessels are usually fitted with
drain points and should be kept drained of oil.

32.How is Freon gas effect the “ozone” and effect the climate?

a) Release of CFC refrigerants into the atmosphere is harmful to the environment.

CFCs released into the atmosphere are broken down by photolysis to release
chlorine atoms, which catalytically destroy ozone, the stratospheric gas that acts
as a filter of ultra violet light from the sun.

b) CFCS, along with other ‘greenhouse gases’, inhibit the release of heat radiated
from the earth, thereby contributing to global warming, leading to rapid rise in sea
level.

c) The increased UV light on earth as a result of ozone depletion will cause skin cancer,
interfere with immune system and harm aquatic system and crops.

UV light
ClF3 F3+Cl

Cl + Ozone(O3) ClO +O2

ClO + O Cl+O2

33. How does a port state control inspection carried out for a refrigeration
system?

The following are inspected by port state control:-

1) Official Engine log book readings of the refrigerant compressor readings entered
by all watch keepers every four hours.

2) All cold room temperature maintained during the entire voyage.

3) Any breakdown or maintenance carried out on the refrigeration system and

documentation of the same.

4) Internal inspection of all cold rooms and the arrangement made in storing food
items.
Kngreddy Refrigeration and Air Conditioning System kngreddy

5) Inspection of meat product temperature.

6) Any other defects related to hygiene, including expiry date of food products.

7) A visual inspection of the refrigeration system and its condition of its

components.

34. How is the reciprocating compressor lubricated?

Oil is supplied to the bearings and crankshaft seal by means of a gear pump
Drive taken from the crankshaft. The oil is filtered through the suction strainer
mounted inside the crankcase. A pressure gauge is provided for confirming the
lubricating pressure and sight glass are fitted for checking the crankcase oil level.
A protection device is fitted for oil failure is provided by a differential oil pressure
switch. Compressor oil loss result due to oil being carried into the system by the
refrigerant.

Oil pressure is about 2 bar above crankcase pressure. Cylinder walls are
splash lubricated. Oil and refrigerant are miscible (i.e. if they form a mutual
solution) but oil is separated and returned to the crankcase using an oil separator.

35.What are the uses of psychometric charts and when do you use them?

• A psychometric chart shows vertical lines representing dry bulb temperatures, and
dotted lines relative humidity. To obtain the relative humidity from a pair of wet
dry bulb temperatures is marked on the chart, and the line of relative humidity
passing through this point is the required relative humidity.

• The indicated area in this figure defines the so-called “comfort zone”, i.e. the
range of air conditions (in still air) in which most people feel comfortable when
sedentary. By “most people” is meant a very high proportion of people – tests in
controlled environment chambers have shown that people generally agree well
with one another as to what is comfortable.
Kngreddy Refrigeration and Air Conditioning System kngreddy

Psychrometric chart.

36.What are the major components of a reciprocating compressor and how does it work?

1. Crankshaft of spheroidal graphite cast iron.

2. The alloy pistons and cast iron liners.

3. Piston rings of cast iron.

4. Forged Connecting rods.

5. Cast iron Liners.

6. Crankcase comprise as a single piece cast iron.

7. Main bearings and crankshaft bearings.

8. Compressor Safety devices such as Oil pressure switch, High Pressure switch and
Low Pressure switch.
Kngreddy Refrigeration and Air Conditioning System kngreddy

Compressor working process

The pressure raised instantly from low pressure to high pressure by the compressor. This
process is carried out by stroke of the compressor. Both the suction and discharge valves
are held closed by a combination of spring pressure and vapor pressure. On the down
stroke, with both these valves closed, the pressure in the cylinder is lowered as the volume
increases. When the pressure in the cylinder becomes less than the pressure below the
suction valves, the differential pressure opens the valves. The vapor from evaporator flows
through the suction line into this constantly increasing volume.

At the bottom of the stroke (BDC) there is no pressure difference, and the springs close
the suction valve, trapping the cylinder full of vapor. On the upward stroke this vapor is
compressed from its low pressure to a pressure greater than the discharge pressure on top
of the discharge valve. This high pressure forces the discharge valve open. At this point,
compression stops and compressed vapor flow out through discharge valve. When the
piston reached top of the stroke (TDC), there is no differential pressure to hold the valve
open, so the spring closes it.

A small amount of high-pressure vapor is still trapped in the space between the piston top
and the valve plate. This space is referred to as the clearance volume. The vapor in the
clearance volume is called clearance vapor and must be re-expanded to a pressure slightly
lower than the suction pressure before the suction valve opens again.

37.Why is expansion valve used in the refrigeration or air conditioning system?

The purpose of this valve is to efficiently drop the pressure of the refrigerant.
• The thermostatic expansion valve is designed to provide an ample supply of liquid
refrigerant to dry expansion evaporators, ensuring high heat transfer under varying load
conditions, without allowing liquid to pass into the suction line and enter the compressor.

• The liquid refrigerant stored at high pressure in the receiver flows through the
Thermostatic expansion valve, which regulates the rate of flow to the evaporator to suit the
evaporation.

• The pressure of the liquid is reduced to the evaporating pressure so that the temperature
of the refrigerant entering the evaporator is below that required in the refrigerated space.

• The liquid vapour refrigerant mixture flows through the evaporator extracting heat from
the refrigerated space and changing to a dry saturated vapour at the same temperature and
pressure it left the thermostatic expansion valve.

38.What is called “coefficient of performance” in a refrigeration or air condition system?

The conventional way to express the effectiveness of refrigeration is Coefficient of

Performance (COP). This is the ratio of heat extraction to energy input. Both are expressed
Kngreddy Refrigeration and Air Conditioning System kngreddy

in the same units, normally kilowatt (kW). For a system in which the mass flow rate is
constant, COP becomes equal to the ratio of ratio of enthalpy change in the evaporator and
enthalpy increase during compression. i.e. dh1/dh2. On the pH chart, enthalpy is shown as
enthalpy per per unit mass, or specific enthalpy. The ratio dh1/dh2 is the rate of transfer of
energy in the evaporator divided by the rate of transfer of energy in the compressor.

39.Enumerate the standard maintenance carried out in a refrigeration or air condition

system?

The following standard maintenance are carried out:-

• Filters-Should be washed in 50ppm solution on a regular basis
• Plenum insulation-Insulation to be examined at re-fit and damaged areas resealed.
• Drier units are removed and renewed silica gel (content of moisture in the system).
• System gas side filters are removed and cleaned at regular intervals for free flow of
gas in the system.
• Condenser to be cleaned sea water side tubes get choked with the mug present in the
sea water affecting the discharge pressure and raising the gas temperature.
• Oil level and gas level to be maintained at all times and oil to be regular intervals to
avoid choking of evaporator coils.
• To carry out regular leakage check of gas in the system using leak detectors.

40.What are the properties of air for an effective air conditioning system?

Air conditioning is a mechanical process for controlling the humidity, temperature,

cleanliness, and circulation of air in buildings and rooms. Indoor air is conditioned and
regulated to maintain the temperature-humidity ratio that is most comfortable and
healthful. In the process, dust, soot, and pollen are filtered out.

41.What are the basic principles of air conditioning?

Air conditioning is the control of humidity, temperature, cleanliness and air motion.
Winter conditioning relates to increasing temperature and humidity, whilst summer
conditioning relates to decreasing temperature and increasing humidity. Air
conditioning implies to the total automatic control of internal environment primarily for
the comfort of humans. The term is used to control the temperature and moisture at the
outlet of central air conditioning unit to the rooms.

The external air volume flow per cubic metre per hour is calculated according to:-

• Number of people.

• Level of air pollution.

• Extract heat from air.

Kngreddy Refrigeration and Air Conditioning System kngreddy

Humidity is controlled by installing humidifier to supplement the required moisture to

the flow of air to the rooms. The percentage rating of water vapour per cubic meter of
air is important for human comforts.

42.What is called central air conditioning and how is it carried out?

• Central air conditioning is one in which large air condition refrigeration

machines are installed and their output are distributed about the ship by a variety of
means.

• The outside and re-circulated air (50% or above) is mixed in the inlet section of
the unit fitted with dampers. It is then filtered and passes through pre-heater and
humidifiers in winter (cold) condition, or through a gas cooler in summer (warm)
conditions. The fan distributes the conditioned air via a low velocity duct to cabin.

• One common large fan is used to circulate the conditioned air with one common
Freon coil and steam heater with a humidifier to all the cabins.

• All of the machines are arranged and fitted in one common room including
condenser and compressor.

43.What are the safety features incorporated in a vapor compression cycle.

The following are the safety features fitted in a vapor compression system.

• High-pressure safety cutout.

• Low-pressure safety cutout

• Oil pressure safety cutout

• Pressure relief devices on condenser

• Refrigeration compressor abnormal alarm and stop.

• Refrigeration compressor motor overload stop.

44.What is the term “defrosting” and how does it work?

Electric defrosting of a fish room:-

 The defrosting timer switch operates and shuts the solenoid valve of the fish
room.

 Automatic pumping down takes place and the compressor stops on LP cut off.
Kngreddy Refrigeration and Air Conditioning System kngreddy

 The evaporator fan stops and electric heater starts at the same time for about
15min.

 The electric heater switches off automatically and cools of the heater.(Hot air is
not cycled into the cold chamber).

 The evaporator fan starts after 10 min.

 The defrost moisture is drained out through a non-return drain pipe from the cold
chamber.

 The defrost cycle is thus completed with the solenoid valve of fish room opens
and compressor start back after defrost cycle.

45.What are the different types of Freon gas used for refrigeration system?

• Refrigerants RI 2, R22, R502 and R717 (ammonia), are the substances in general
use.

• The suitable alternative refrigerant for R12 and R502 currently limited to
R22,ammonia(R717) and R134a.R22 will continue to be the first choice for all new
marine installations.

• R134a has been developed as an alternative for R12, But it has a drawback in
being un suitable for use with mineral oil, and is expensive.

46.What is the use of the compressor in the vapour compression system?

The following are the reason for using the compressor in the vapour compression
system:-

 It removes the vapor from the evaporator and introduces vapor to the high-pressure
side of the systems.

 It maintains the low-side pressure at which the refrigerant evaporates, and the high-
side pressure at which it condenses.

 It supplies the pressure differences necessary to keep the system refrigerant flowing
through the system.
Kngreddy Refrigeration and Air Conditioning System kngreddy

47.How many gas filters are fitted in a refrigeration system and state the location of these
filters fitted in the system with three cold rooms?
b) How does the expansion valve work and control the superheat in the Evaporator?

ANS a)
The gas filters are fitted to filter the Solid particles which is formed by corrosion of
ferrous parts when exposed to oxygen and the non ferrous particles such as copper comes
out when lubricating oil mixes with moisture. There is one filter on the compressor
suction side, one on the return line to the compressor and one filter in each thermostatic
expansion valve inlet. Filter drier fitted on the liquid line before the solenoid Valve.

ANS b) Thermostatic expansion valve:

Kngreddy Refrigeration and Air Conditioning System kngreddy

The expansion valve consists of a gun metal housing with both ends threads are
provided for inlet and outlet connections. A long capillary tube filled with same liquid
refrigerant with a bulb is connected to the top of the valve housing. A fine metallic
bellow fixed to the push pins at one end slides through the bores of the valve housing
and attached to a valve disc. This valve disc is fixed on a hollow metal chamber acts as
a retainer for the spring The spring tension is adjusted using a screw in order to adjust
the superheat. A balancing line from evaporator outlet is connected below the bellow.
An orifice plate is fixed in the centre of the housing for the purpose of gas expansion.

Expansion valve working procedure:-

Three conditions present themselves in the operation of this valve: first, the balanced
forces; second, an increase in superheat; third, a decrease in superheat. The remote
bulb and the power element make up a closed system (power assembly), and the remote
bulb and power element are charged with the same refrigerant as that in the system.
The remote bulb and Power element pressure which corresponds to the saturation
pressure of the refrigerant gas temperature leaving the evaporator, moves the valve pin
in the opening direction.

Opposed to this opening force on the underneath side of the diaphragm and acting in
the closing direction are two forces: (1) the force exerted by the evaporator pressure
and (2) that exerted by the superheat spring. In the first condition, the valve will
assume a stable control position when these three Forces are in balance (that is, when
P1 = P2 + P3). In the next step, the temperature of the refrigerant gas at the evaporator
outlet (remote bulb location) increases above the saturation temperature corresponding
to the evaporator pressure as it becomes superheated. The pressure thus generated in
the remote bulb, due to this higher temperature, Increases above the combined
pressures of the evaporator pressure and the superheat spring (P1 greater than P2 + P3)
And causes the valve pin to move in an opening direction. Conversely, as the
temperature of the refrigerant gas leaving the evaporator decreases, the pressure in the
remote bulb and Power assembly also decreases and the combine evaporator and Spring
pressure cause the valve pin to move in a closing Direction (P1 less than P2 + P3).

48.What is the term “carry over” and what are the dangers of it in a refrigerated
system?
Kngreddy Refrigeration and Air Conditioning System kngreddy

 The vapour in the condenser gives up its super heat and then cooled from the
discharge temperature to the saturation temp corresponding to condensing pressure
then gives up its latent heat as it condenses back to liquid. This process will not take
place as the quantity of sea water flow decreases due to fouled condenser.
 The discharge temperature and pressure of gas from the compressor will be higher
than normal.
 This high discharge carries more quantity of oil to the oil separator and condenser.
 The oil “carry over” process to the condenser cannot be retrieved and would enter
into the evaporator.
 The oil in the evaporator affects heat transfer and does not allow normal flow of
gas.
 The desired room temperature cannot be maintained.
 The gas flow is restricted and blocked due to oil in the evaporator and complete
system stops normal functioning.

49.What are the min and max temperature of all the cold rooms on board ship?

The following are the temperatures of the cold rooms on board ship:-
Vegetable room +4 to +8
Meat room -12 to -15
Fish room -15 to -18

50.How do you identify the condenser is dirty and what action will you take?

 The condenser seawater side normally gets fouled. The heat transfer decreases
over a period of time.
 The discharge of gas to the condenser would not be cooled to form liquid thus
affecting the performance of the evaporator.
 The discharge temperature and pressure of gas from the compressor will be
higher.
 The high pressure switch prevents the compressor from normal running.

The following are carried out to clean the condenser:-

o The Sea water valves to the condenser isolated and both side end covers are
opened.
o The tubes of the condenser are to be cleaned manually using tube brush.
o Wash internal of tubes with pressurized water.
o Zinc anodes to be renewed.
o Check division plate of end cover and repair if corroded to avoid short cycling of
cooling water.
o Tube ends on both sides of the end plates to leak test.
o Upon completion end covers are fitted with new gaskets.

51.Explain the term “Liquid knock” in a refrigeration system.

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 The liquid refrigerant stored at high pressure in the receiver flows through the
Thermostatic expansion valve. It automatically adjusts the rate of flow to the
evaporator to suit the evaporation.

 The pressure of the liquid is reduced to the evaporating pressure so that the
temperature of the refrigerant entering the evaporator is below that required in the
refrigerated space.

 The liquid vapour refrigerant mixture then flows through the evaporator, extracts
heat from the refrigerated space and changes to a dry saturated vapour at approx the
same temp and pressure at which it left the flow control valve.

 The compressor sucks the vapour from the evaporator; the temperature and
pressure of the vapour are raised by compression.
 If more quantity of refrigerant flows than required by a faulty expansion valve,
the Freon sucked by the compressor will be liquid and ends up damaging the
complete compressor. This liquid entering the compressor is called “liquid knock”.

52.What are the two ways of charging gas to the refrigerated compressor?

Charging of refrigerant in the refrigerated system can be done on low pressure or high
pressure side.
1.Low pressure side should be charged ONLY WITH GAS.
2.High pressure side should be charged ONLY WITH LIQUID REFRIGERANT.

CHARGING LIQUID BETWEEN CONDENSER OUTLET AND DRIER:-

1. Connect the Freon gas cylinder to the gas charging valve with a special flexible
hose(purge the air from the hose).

2. Open the cylinder valve (to liquid side) and gas charging valve and run the
compressor.

3. The low pressure switch starts the compressor with LP cut in.

4. Charge the liquid until the condenser level is normal and close Freon gas bottle
valve and gas charging valve.

5. The pumping down operation starts and compressor stops due to LP cut off.

6. Release the charging hose pressure and remove from place.

Procedure for charging refrigerant at low pressure line:

CHARGING GAS THROUGH COMPRESSOR SUCTION VALVE:-

1. Connect the Freon gas cylinder to the gas charging valve with a special flexible
hose (purge the air from the hose).
Kngreddy Refrigeration and Air Conditioning System kngreddy

2. Open the cylinder valve (to gas side) and gas charging valve and run the
compressor.

3. The low pressure switch starts the compressor with LP cut in.

4. Charge the gas until the condenser liquid level is normal and close Freon gas bottle
valve and gas charging valve.

5. The pumping down operation starts and compressor stops due to LP cut off.

6. Release the charging hose pressure and remove from place.

53. What safety precaution will you take when working with a refrigerated compressor
during troubleshooting or repairs?

The following are carried out before Overhauling of compressor:-

• Pump down the entire gas to the condenser.

• Ensure that the entire system valves are shut and isolated.

• Isolate the compressor from its electric motor and switch off the circuit breaker.

• Place a safety board stating "MEN AT WORK." at the circuit breaker.

• Release the pressure on the compressor by slackening the oil filling plug with
great care due to high internal pressure.

• Correct tools to be used with proper torque while opening and tightening holding
bolts.

• Wear safety goggles and gloves.

54.How is the air cleaned in the air conditioned unit and how re-circulation controlled?
Kngreddy Refrigeration and Air Conditioning System kngreddy

The air filter material used is felt, it is soft and filters all dirt from the atmosphere. The
air conditioning system fan sucks the atmospheric air through this filter before
cooling. This filter is periodically removed and cleaned. The filter (felt) is fixed on to
the metal frame on the air intake side.
The re-circulation of air is normally carried out by allowing the same cold air from the
accommodation back to the inlet side of the air conditioning system . Small quantity of
fresh air is mixed to keep re-circulated fresh. The flaps located in the re-circulation
and fresh air trunking are operated to meet the comfort level of the crew.

55 . Describe the refrigerated ship refrigeration system and how does the cargo
temperature maintained.

The perishable cargo transporting long distance is always a complicated problem. The
cargo temperature has to be maintained through the voyage. A common agent of
decomposing of food stuff is heat and this can be removed by refrigeration.
Each cargo holds are well insulated with layers of insulation material. The floor is
double skinned to allow for even circulation of the cooling air. The air passages are
made to allow the cold air upwards through the cargo. The perishable cargo like fruits,
vegetables, fish and meat are carried in these cargo hold at temperatures -30 to +12
deg C. The most sensitive cargo is fresh bananas.
A reefer ship design carry large amount of pipelines with refrigerant, which lead to
each cargo hold. This refrigerant is the secondary cooling element and is brine. Each
Kngreddy Refrigeration and Air Conditioning System kngreddy

brine line feeds a bank of cooling coils which cools the forced air flow generated by
many number of cooling fans.
Reefer ship requires the following:-
1. Effective control systems to meet precision temperature requirement.
2. Higher capacity generators to meet the power needs.
3. Special monitoring equipment for safe monitoring of equipment and cargo.
4. Effective ventilation control system, high level of humidity needs to be maintained.
5. Extra hold bilge pumping requirements.
6. After loading, due to rapid drop in temperatures, condensation leads to large water
accumulation and requires to be controlled.
7.Modern reefer vessels also incorporate inert gas generators and systems thus
cooling and atmosphere control are both applied to the cargo.
The ripening of fresh fruits may cause lack of oxygen and produce unwanted gases.
The modern trend is to use inert gas generators called controlled atmosphere
transportation in the reefer world.
Controlled atmospheres are essentially those which deviate from the normal air
composition of 21% oxygen, 78% nitrogen and 300ppm of carbon dioxide. Other
gases are also present but negligible. The most common inert gas used is Nitrogen.
Special generators are employed to extract the atmospheric nitrogen (reducing oxygen
content). The resulting air mixture is then pumped into the cargo holds, purging the
existing mass of air. The atmosphere in the hold is controlled to preset levels
depending upon the cargo. Modern reefer ships can be monitored temperatures using
satellites and internet from shore to sea.