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EBOOK Hướng dẫn Vận hành Lạnh cho Hệ thống Thương mại và Công nghiệp (Ashrae 2014) EBOOK Hướng dẫn Vận hành Lạnh cho Hệ thống Thương mại và Công nghiệp (Ashrae 2014) EBOOK Hướng dẫn Vận hành Lạnh cho Hệ thống Thương mại và Công nghiệp (Ashrae 2014) EBOOK Refrigeration Commissioning Guide for Commercial and Industrial Systems
The Essential Guide for Commissioning Refrigeration Systems Because deficiencies in system design found at start-up are not easily resolved, maintenance managers or operators may deal with unnecessary shortcomings and expenses over the life of the facility Commissioning helps project teams avoid these “surprises” by establishing a consistent, stepwise process that helps “get it right the first time.” The commissioning process starts with the initial planning and design and continues through construction, installation, start-up, and the first year of system operation Commissioning also sets the stage for ongoing servicing and maintenance of performance The result is refrigeration systems that are easier and less expensive to install and maintain, with lower energy costs, minimized liabilities from refrigeration system leaks, and reduced loss of refrigerated product due to system failures or unreliable performance Using this Guide will help achieve cost-effective and cost-efficient refrigeration systems for new projects, expansions, remodels, and existing systems that simply need a tune-up Refrigeration Commissioning Guide for Commercial and Industrial Systems The first of its kind, Refrigeration Commissioning Guide for Commercial and Industrial Systems provides guidance to owners and managers of commercial and industrial facilities that use refrigeration systems to help ensure that project requirements are met and owners’ expectations are achieved For commercial facility owners and managers, this means improved profitability through lower operating and service costs as well as reduced product loss Refrigeration Commissioning Guide for Commercial and Industrial Systems Commissioning Refrigeration Systems in ISBN 978-1-936504-53-4 ASHRAE 1791 Tullie Circle Atlanta, GA 30329-2305 ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 781936 50453 404-636-8400 (worldwide) www.ashrae.org Product code: 90315 12/13 • Food Retail and Convenience Stores • Small Retail Stores • Food and Beverage Facilities • Food Distribution Centers • Industrial Plant Applications RefCxGuide.book Page i Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page ii Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission This publication was developed under ASHRAE’s Special Publication procedures and is not a consensus document It was developed under the auspices of ASHRAE Special Project 137 and was supported with funding from U.S Department of Energy through National Renewable Energy Laboratory subcontract #AGN-1-11923 Cognizant Committee: Refrigeration Committee Refrigeration Commissioning Guide Project Committee Richard Royal—Chair Wal-Mart Stores, Inc Bryan Beitler Source Refrigeration and HVAC Doug Scott VaCom Technologies Jon Edmonds Edmonds Engineering Co Scott Smith Hillphoenix Timothy Gwyn DC Engineering, PC Paul Torcellini National Renewable Energy Laboratory Larry Meeker Target Robert Uhl Safeway, Inc Scott Moore PECI Jim Vannan Winn-Dixie Caleb Nelson CTA Lilas Pratt ASHRAE Staff Liaison Bert Etheredge ASHRAE Staff Support Updates/errata for this publication will be posted on the ASHRAE website at www.ashrae.org/publicationupdates ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page iii Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems 1791 Tullie Circle, NE Atlanta, GA 30329 www.ashrae.org ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page iv Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission ISBN 978-1-936504-53-4 © 2013 ASHRAE All rights reserved 1791 Tullie Circle, NE · Atlanta, GA 30329 · www.ashrae.org Cover design by Laura Haass ASHRAE is a registered trademark in the U.S Patent and Trademark Office, owned by the American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc ASHRAE has compiled this publication with care, but ASHRAE has not investigated, and ASHRAE expressly disclaims any duty to investigate, any product, service, process, procedure, design, or the like that may be described herein The appearance of any technical data or editorial material in this publication does not constitute endorsement, warranty, or guaranty by ASHRAE of any product, service, process, procedure, design, or the like ASHRAE does not warrant that the information in the publication is free of errors, and ASHRAE does not necessarily agree with any statement or opinion in this publication The entire risk of the use of any information in this publication is assumed by the user While supported by the U.S Department of Energy with the National Renewable Energy Laboratory, neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof The views and opinions of authors expressed herein not necessarily state or reflect those of the United States government or any agency thereof and shall not be used for advertising or product endorsement purposes Except for rights reserved by the U.S Government, no part of this book may be reproduced without permission in writing from ASHRAE, except by a reviewer who may quote brief passages or reproduce illustrations in a review with appropriate credit; nor may any part of this book be reproduced, stored in a retrieval system, or transmitted in any way or by any means—electronic, photocopying, recording, or other—without permission in writing from ASHRAE Requests for permission should be submitted at www.ashrae.org/permissions Library of Congress Cataloging-in-Publication Data Refrigeration commissioning guide for commercial and industrial systems pages cm Includes bibliographical references and index Summary: "Provides how-to guidance for commissioning custom-engineered refrigeration systems in commercial and industrial facilities to improve and supplement existing design, construction, and operational practices" Provided by publisher ISBN 978-1-936504-53-4 (softcover : alk paper) Refrigeration and refrigerating machinery Industrial applications Refrigerators Installation Commercial buildings-Equipment and supplies Installation Planning I American Society of Heating, Refrigerating and Air-Conditioning Engineers TP492.R3785 2013 621.5'6 dc23 2013041539 ASHRAE STAFF SPECIAL PUBLICATIONS Mark S Owen, Editor/Group Manager of Handbook and Special Publications PUBLISHING SERVICES PUBLISHER Cindy Sheffield Michaels, Managing Editor James Madison Walker, Associate Editor Roberta Hirschbuehler, Assistant Editor Sarah Boyle, Assistant Editor Michshell Phillips, Editorial Coordinator David Soltis, Group Manager of Publishing Services and Electronic Communications Jayne Jackson, Publication Traffic Administrator Tracy Becker, Graphics Specialist W Stephen Comstock ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page v Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Contents Preface The Business Case for Commissioning: A Message to Owners vii Acknowledgments ix Chapter Introduction The Need for Commissioning Purpose and Scope How to Use this Guide Chapter Commissioning during Planning and Design Introduction Forming the Commissioning Team 13 Developing the Owner’s Project Requirements (OPR) 15 Managing the Issues Log 24 Developing the Commissioning Plan 25 Developing the Basis of Design (BoD) 28 Requirements for Construction Documents (CDs) 32 Deliverables and Acceptance 34 Chapter Commissioning during Construction and Installation Introduction Installation Planning and Scope of Work Prefunctional Testing and Verification Construction and Installation Details Final Installation Commissioning and Review Chapter 37 41 45 50 55 Commissioning during Start-Up and First-Year Operation Introduction 57 Commissioning Activities 59 Start-Up Report and Handoff to Owner 63 Activities in the First Year 64 First-Year Final Report and Acceptance 68 ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page vi Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems Appendix A Roles and Responsibilities Matrix 73 Appendix B Example Commissioning Plan 77 Appendix C Example Acceptance Plan 85 Appendix D Technical Procedures 10 vi Verifying Control Functions 89 Verifying Refrigeration System Capacity 92 Evaluating Part-Load Operation 96 Checking Refrigerant Temperatures and Pressures and Evaluating Setpoints 98 Verifying Operation of Alarms 101 Evaluating Refrigerant Piping 104 Verifying Anti-Sweat Heater Control Operation 107 Verifying Defrost Adequacy and Defrost Control Operation 109 Minimizing Air Infiltration of Boxes and Cases 112 Evaluating the Use of Energy-Saving Features 113 Glossary 117 References 127 ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page vii Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Preface The Business Case for Commissioning: A Message to Owners Refrigeration Commissioning Guide for Commercial and Industrial Systems provides value to owners and managers of commercial and industrial facilities that use refrigeration systems by ensuring that project requirements are met and owners’ expectations are achieved Refrigeration systems account for a significant portion of commercial building energy use and are often the largest energy end use in food and beverage facilities A U.S Department of Energy (DOE) study estimates commercial refrigeration uses 1.23 quads (1.23 × 1015 Btu) (1.30 EJ) per year, which is approximately 7% of commercial building energy use Nearly 70% of this commercial refrigeration use consists of supermarkets and other customdesigned refrigeration systems (DOE 2009) Supermarkets are the largest example: a U.S Environmental Protection Agency (EPA) study estimates that supermarkets typically use approximately 3,000,000 kWh of electricity per year, with 60% of that energy use attributed to refrigeration (EPA 2007) Portland Energy Conservation, Inc (PECI) predicts that commissioning in existing grocery stores would result in 7% to 25% energy savings per year (PECI 2010) Based on these estimates, this commissioning guide, if widely adopted, would lead to substantial U.S national energy savings Custom refrigeration systems are complex and individually designed for each facility Deficiencies in the system design found at start-up are not easily resolved and, as a result, maintenance managers or operators deal with unnecessary shortcomings and expenses over the life of the facility The value of commissioning is to establish a consistent stepwise process that helps “get it right the first time,” resulting in refrigeration systems that “work right” and minimize maintenance and energy costs Thousands of refrigeration systems are installed every year in facilities ranging from convenience stores to large, sophisticated frozen food distribution centers Properly commissioned systems reduce energy costs, are easier to maintain, help minimize liabilities from refrigeration leaks, and reduce loss of product due to system failures or unreliable performance Commissioning of refrigeration systems is currently uncommon One reason is the belief that commissioning results in added cost and time without ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page viii Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems sufficient or measurable value Certainly, commissioning is an investment, but it provides significant financial value in several ways First, systems operate more reliably with lower maintenance cost and lower energy cost when commissioning is applied as described in this Guide Second, incorporating commissioning can reduce first cost through improved understanding of system performance and lead to better equipment design and installation methods Using this Guide will help achieve cost-effective and cost-efficient refrigeration systems for new projects, expansions, remodels, and existing systems that simply need a tune-up For commercial facility owners and managers, this means improved profitability through lower operating and service costs as well as reduced product loss For industrial plants, this means improved “up time” and improved labor productivity in addition to reduced operating cost The commissioning process is holistic and considers life-cycle performance, including the long-term operating (utilities and servicing) costs of the refrigeration system Commissioning is not another term for start-up The commissioning process starts with the initial planning and design and continues through construction, installation, start-up, and the first year of system operation Commissioning also sets the stage for ongoing servicing and maintenance of performance This Guide provides the process and methods to help achieve these desired results: expected performance and reliability with the lowest life-cycle cost viii ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page ix Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Acknowledgments Refrigeration Commissioning Guide for Commercial and Institutional Systems was developed to provide guidance to refrigeration system owners, project/design managers, and refrigeration system service providers This Guide is the result of the collaborative effort of dedicated professionals who unselfishly volunteered countless hours to give refrigeration system owners and the refrigeration industry consistent validation processes that can be used to bring order to the unorderly The primary authors were the members of ASHRAE Special Project Committee 137 and provided the expertise and experience necessary to develop the document They represented manufacturers, contractors, and end users of refrigeration systems The project would not have been possible without the financial support of the U.S Department of Energy (DOE) and National Renewable Energy Laboratory (NREL) as well as the invaluable support of ASHRAE In addition, DOE’s Better Buildings Alliance provided the project committee with the technical services of Rebecca Legett and Robert Zogg of Navigant Consulting, Inc I would also like to thank Paul Torcellini of NREL for his support and help with the development of the document I would also like to personally thank all the members of the project committee for their diligence, creativity, persistence, and willingness to take time to support the development and review of this Guide They worked extremely hard to put together practical and fundamental information covering the aspects of commissioning applicable to a holistic approach Their expertise and differing views greatly enriched this Guide The authors brought many decades of experience, success, and failure to the text to achieve a significant milestone for the refrigeration system owner and the refrigeration system industry I appreciate the patience of the committee members’ families during the development process, and I gratefully acknowledge the support of the committee members’ employers, including CTA; DC Engineering, PC; Edmonds Engineering Company; Hillphoenix; National Renewable Energy Laboratory; PECI; Safeway, Inc.; Source Refrigeration and HVAC; Target ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page 117 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Glossary The definitions provided in this Guide include terms that, while not necessarily used in this Guide, are commonly used in refrigeration commissioning practice azeotrope, azeotropic refrigerant A mixture of refrigerants whose vapor and liquid phases in equilibrium have identical compositions (the boiling point is constant) Figure G-1 is a refrigerant property diagram for single-component or azeotropic refrigerant blends, showing the effect of boiling point transition or “glide” as an aid to understanding this definition air curtain Device that produces steady airflow across the plane of an opening, intended to minimize heat transfer between two spaces air-cooled condenser A refrigerating system component, including condenser fans, that condenses refrigerant vapor by rejecting heat to air mechanically circulated over its heat transfer surface, causing a temperature rise in the air Graphic courtesy of NREL; credit Alfred Hicks Figure G-1 Refrigerant Property Diagram—Azeotropic ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page 118 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems alarm A device that detects a system occurrence or characteristic and provides an alert or notification The notification may take the form of a light, sound, email, or other form Types of alarms include anticipatory, energy, and safety or operation alarms anticipatory alarms Devices that provide notification of system conditions that, although not themselves harmful, could develop into harmful situations An example is an alarm that notifies the operator of an elevated rate of compressor cycling, which could indicate that compressor maintenance is required to prevent failure energy alarms Devices that provide notification of conditions that could result in high component or system energy use Examples include alarms that notify the operator of a walk-in box door left open, refrigerant suction pressure not within specification or, for water-cooled condensers, high condenser-water temperature safety or operation alarms Devices that provide notification of conditions that are likely to cause immediate harm to the system, system operators, or product being stored Examples include alarms that notify the operator of elevated case and cooler temperatures, refrigerant leakage, refrigerant head pressure outside safe operating ranges, or low levels of refrigerant oil analysis points Sets of conditions corresponding to different physical scenarios affecting both load and capacity, used to evaluate capacity control of the system anti-sweat heater Wire or other device that heats the frame or glass of a transparent door to reduce or eliminate condensation annual baseline log (ABL) The owner record of system operating control parameters and performance metrics approach (temperature) Temperature difference (TD) See also condenser temperature difference (TD) and evaporator temperature difference (TD) condenser approach temperature The difference between the condensing temperature (based on the refrigerant pressure entering the condenser) and the ambient air temperature entering the condenser design condenser approach temperature The approach temperature at which the condenser was designed to operate when operating at the design ambient air temperature and the design capacity balancing valve A device for maintaining a set flow of a fluid, often used in secondary refrigeration and water-cooled condensing systems Basis of Design (BoD) A document that records the concepts, calculations, decisions, and product selections used to meet the Owner’s Project Requirements (OPR) and to satisfy applicable regulatory requirements, standards, and guidelines The document includes both narrative descriptions and lists of individual items that support the design process ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 118 RefCxGuide.book Page 119 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Glossary bin analysis A simplified energy analysis method by which the hourly energy use is calculated for the average temperature within several sets of outdoor temperature ranges (bins) and multiplied by the annual (or monthly) hours in each range bubble-point temperature Refrigerant liquid’s saturation temperature at a specified pressure For a zeotropic refrigerant blend, the bubble point, which is colder than the dew point, is the temperature at a specified pressure where a liquid begins to evaporate (in an evaporator) as well as the temperature at a specified pressure where the refrigerant finishes condensing (in a condenser) capacity steps Discrete levels of capacity that the system is designed to maintain The number of steps is based on the number of compressors and unloaders (if used) and how they are staged carbon dioxide (CO2 ) A refrigerant used in primary and secondary systems As a refrigerant, an industrial grade or higher quality is often used Commissioning Plan A document that outlines the organization, schedule, allocation of resources, and documentation requirements of the commissioning process commissioning (Cx), commissioning process A quality-focused process for enhancing the delivery of a project The process focuses on verifying and documenting that the facility and all of its systems and assemblies are planned, designed, installed, tested, operated, and maintained to meet the Owner’s Project Requirements (OPR) commissioning authority (CxA) An entity identified by the owner who leads, plans, schedules, and coordinates the commissioning team to implement the commissioning process compressor staging System for operating only certain compressors at one time to maintain different system capacity steps condenser holdback valve The device that limits the minimum condensing pressure for the refrigeration system (flooding valve, low-ambient valve, drop-leg valve, drain-leg regulator) condenser temperature difference (TD) The difference between the saturated condensing temperature (SCT) and the entering air dry-bulb temperature for air-cooled condensers or entering air wet-bulb temperature for evaporative condensers control system The combination of components/hardware, field wiring, software, and programming that monitors the system via input signals and then governs the operation of the system via output signals compressor discharge pressure Pressure of refrigerant gas at the compressor outlet compressor discharge temperature Temperature of refrigerant gas at the compressor outlet continuously variable unloading Compressor capacity (CC) modulation achieved via digital output control that provides fine increments of capacity control over the range of maximum capacity down to full capacity ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 119 RefCxGuide.book Page 120 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems defrost demand defrost Defrost control strategy that does not initiate a defrost on a set schedule but initiates defrost automatically based on other system parameters electric defrost Defrost method that uses heated rods embedded in the evaporator coil to melt ice from the coil during defrost gas defrost Method of defrost that circulates discharge from the compressor rack or saturated gas from the receiver through the evaporator coil to melt ice on the coil off-time defrost Also called air defrost Defrost method used for units whose interior temperature is above freezing, which involves melting any ice from the evaporator coil by running the fans during the refrigeration system’s off cycle (i.e., when refrigerant is not circulating through the coil) reverse-cycle gas defrost Method of gas defrost piping that reverses the flow of refrigerant in the suction line to the evaporator coil three-pipe gas defrost Method of gas piping that uses a separate defrost gas supply line to the evaporator coil in addition to liquid and suction lines design ambient air temperature The highest outdoor air temperature at which the system is designed to meet the design load design capacity The maximum refrigerating capacity that the system is designed to supply when operating at the design ambient air temperature The design capacity typically exceeds the design load to accommodate losses in interconnecting piping and provide a safety factor design load The maximum refrigerating load that the system is designed to accommodate while maintaining the design setpoint temperatures in cases and coolers connected to the system design setpoint temperatures The maximum temperatures of the cases and coolers connected to the system that the system is designed to maintain while meeting the design load dew-point temperature Refrigerant vapor’s saturation temperature at a specified pressure For a zeotropic refrigerant blend, the dew point, which is warmer than the bubble point, is the temperature at a specified pressure where a liquid finishes evaporating (in an evaporator) as well as the temperature at a specified pressure where the refrigerant begins to condense (in a condenser) psychrometric dew point Temperature at or below which condensation forms on a surface discharge air temperature (DAT) evaporator discharge air temperature Temperature of air leaving a unit cooler ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 120 RefCxGuide.book Page 121 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Glossary refrigerated case discharge air temperature Temperature of air discharged from a refrigerated case discharge air grille direct expansion (DX) Evaporator arrangement whereby liquid refrigerant is fed through an expansion valve or metering device and is designed to evaporate completely before leaving the evaporator as vapor distributed refrigeration system A system wherein compressors and condensers are packaged with, or located near, the display cases or coolers that they service drip time Time between when defrost is terminated and when refrigeration restarts drop-leg pressure Pressure of refrigerant in the condenser drain line or the pipe between the condenser and the high-pressure receiver drop-leg temperature Temperature of refrigerant in the condenser drain line or the pipe between the condenser and the high-pressure receiver embedded controls Controls that the original equipment manufacturer (OEM) packages with the equipment at the factory evaporator return air temperature (RAT) Temperature of air returning to an evaporator from the refrigerated space evaporator temperature difference (TD) The difference between the saturated evaporator temperature (SET) and the return air dry-bulb temperature For zeotropic refrigerants, the average temperature difference is the difference between the average coil temperature and the return air dry-bulb temperature (Note: In an evaporator, the midpoint temperature does not represent the average coil temperature due to the reduction in refrigerant quality through the expansion valve.) evaporatively cooled condenser A self-contained refrigeration system component that condenses refrigerant vapor by rejecting heat to water and air, which are mechanically circulated over the condenser’s heat transfer surface, thereby causing evaporation of the water and an increase in enthalpy of the air fail-safe defrost termination time Time at which defrost will terminate if no other signal to terminate has been received failure detection and diagnostics (FDD) Automated means by which to sense actual or impending failures of equipment or components and alert the appropriate individuals Commonly called fault detection and diagnostics but rephrased here to avoid confusion with electrical faults In this context, the fault can be any equipment fault or failure, including, but not limited to, electrical faults fan delay Time between when the refrigeration restarts and the fans restart floating low-side pressure Means by which the low-side pressure is adjusted to operate the refrigeration system at the highest low-side pressure that adequately maintains the setpoint temperatures in cases and coolers Also known as floating suction pressure ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 121 RefCxGuide.book Page 122 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems floating high-side pressure Means by which the high-side pressure is adjusted to maintain a target temperature approach in the condenser This allows the refrigeration system to operate at higher efficiencies when the outdoor temperature is below the design outdoor temperature Also known as floating head-pressure control gasketing Flexible seal between two components of a box or case, such as between a door and a door frame glide The absolute value of the difference between the starting and ending temperatures of a phase-change process (condensation or evaporation) for a zeotropic refrigerant exclusive of any liquid subcooling or vapor superheating (AHRI 2008) glycol Propylene glycol, generally diluted with water to approximately 35% by volume, used as a secondary fluid heat reclaim The heat transfer subassembly to the refrigeration system that uses some/all of the heat available in the discharged refrigerant gas out of the compressor(s) input/output (I/O) The list of control input and output devices with descriptive naming used to connect the system hardware with the control system interval data Time-series energy data from a meter (typically electrical, but could be natural gas or water) Most often reported in 15 intervals Many electric utilities can provide these data to commercial customers upon request Alternatively, a utility customer may measure and record similar data to better understand energy-use characteristics and to help identify opportunities for improved energy efficiency issues log A formal and ongoing record of problems or concerns—and their resolution— that have been raised by members of the commissioning team during the course of the commissioning process leaving gas temperature (LGT) Temperature of refrigerant gas at the boundary of the refrigerated space, used to determine the productive refrigeration work accomplished by the refrigerant mass flow mechanical safeties Mechanically operated pressure switches and thermostats used for compressor safety protection, which may be in addition to electronic controls with safety functions midpoint temperature For zeotropic refrigerants, the average of the refrigerant’s bubble-point and dew-point temperatures at a specified pressure multiplex refrigeration system A system wherein compressors are located in a machine room remote from the display cases and coolers that they service net refrigeration effect (NRE) The refrigerating capacity available for space or process cooling equal to the mass flow of the refrigerant and the enthalpy difference at the boundary of the refrigerated space or cooling process operating parameters Control setpoints and schedules that govern the function of the unit or system ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 122 RefCxGuide.book Page 123 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Glossary overfeed ratio The mass ratio of liquid to vapor at the outlet of a liquid overfeed unit cooler This may also be referred to as overfeed rate Owner’s Project Requirements (OPR) A document that details the functional requirements of a project and the expectations of how it will be used and operated This includes project goals, measurable performance criteria, cost considerations, benchmarks, success criteria, and supporting information The term Project Intent is used by some owners for their commissioning process instead of Owner’s Project Requirements primary refrigerant Working fluid in a refrigerating cycle (as opposed to a secondary refrigerant) pulse-width modulation Method of heater control that “pulses” heaters on for a percentage of a specified cycle time (typically only a matter of seconds) pumpdown time Time between when the refrigeration is stopped and the defrost is initiated return gas temperature (RGT) Temperature of refrigerant gas at the compressor suction inlet saturated condensing temperature (SCT) For single-component and azeotrope refrigerants, the saturation temperature corresponding to the refrigerant pressure at the condenser entrance For zeotropic refrigerants, the arithmetic average of the dew-point and bubble-point temperatures (midpoint) corresponding to the refrigerant pressure at the condenser entrance (AHRI 2005) SCT is often referred to simply as condensing temperature saturated evaporator temperature (SET) Refrigerant temperature at the unit cooler inlet or outlet determined either by measuring the temperature at the outlet of the two-phase refrigerant flow (for a liquid overfeed unit cooler) or by measuring refrigerant pressure and determining the corresponding temperature from reference thermodynamic tables or equations for the refrigerant For zeotropic refrigerants, the corresponding temperature to a measured pressure is the refrigerant dew point (AHRI 2008) saturated suction temperature (SST) The equivalent saturation temperature of a refrigerant corresponding to the pressure at a specified location, such as at the compressor inlet, the suction manifold, or other suction location For zeotropic refrigerants, the compressor saturated suction temperature is normally defined as the dew-point temperature saturation temperature The equilibrium temperature of a pure refrigerant or an azeotropic refrigerant in a two-phase mixture of a vapor and liquid at a given pressure secondary fluid A fluid of known properties (e.g., water, steam, or brine) that is used as a cooling medium secondary refrigerant A volatile refrigerant (usually a single refrigerant or an azeotropic mixture) of known properties that is used as a cooling medium secondary refrigeration system The system and method of chilling and circulating a secondary fluid within a primary refrigeration system to transport the heat from the load to the primary refrigeration system The secondary fluid may also be a secondary refrigerant where some evaporation takes place at the load ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 123 RefCxGuide.book Page 124 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems self-contained refrigeration Refrigeration system that consists of the unit cooler and condensing unit connected by the manufacturer as one piece of equipment strip curtain Barrier made of plastic strips that spans a doorway to minimize air infiltration when the main door is open subcooling Cooling a refrigerant to a temperature below the saturation temperature for a given pressure Expressed as the temperature difference (TD) between the saturation temperature at that pressure and the liquid temperature at the same location For a zeotropic refrigerant, the bubble point is used as the saturation temperature subcooler A heat exchanger for cooling liquid refrigerant below its condensing temperature at a given pressure For a zeotropic refrigerant, the bubble point is used as the saturation temperature submittal The document exchanged from the equipment manufacturer or contractor to the design professional that illustrates equipment definitions, capacities, layouts, utility requirements, equipment weights, piping and instrumentation diagrams, etc suction pressure Pressure of refrigerant gas at the compressor suction header or compressor inlet suction temperature Temperature of suction refrigerant gas superheat The difference between the vapor temperature and the saturation (dew-point) temperature at a defined pressure It exists wherever in the system the temperature is higher than saturation (direct-expansion evaporator, suction line, compressor discharge, etc.) system energy baseline (SEB) Annualized electrical energy consumption calculation for the system based on the local weather data, system capacity, and operating control parameters test, adjust, and balance (TAB) The process of balancing/documenting pressures and flows through control valves of cooling coils and heat exchangers in hydronic systems, such as water-cooled condensers and secondary glycol refrigeration systems training plan A document that details the expectations, schedule, budget, and deliverables of commissioning process activities related to training of project operating and maintenance personnel and users trunk (loop) refrigeration system A variation of the multiplex system in which common liquid lines and suction lines (trunks) run refrigerant to the vicinity of each case or cooler supplied by the system Refrigerant lines (loops) branch off from these trunk lines to service each case or cooler unit cooler A factory-made cabinet incorporating a finned refrigerant-to-air heat exchanger and circulation fans, used in freezers or cooler walk-in boxes May also be called an evaporator coil or, in industrial applications, is often referred to as air unit unloader The solenoid-operated capacity control device that is attached to/within the compressor to reduce capacity in steps ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 124 RefCxGuide.book Page 125 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Glossary Graphic courtesy of NREL; credit Alfred Hicks Figure G-2 Refrigerant Property Diagram—Zeotropic variable capacity controller The device that regulates the refrigeration system’s compressor capacity (CC) control device(s) within the defined control limits walk-in box The enclosure of a walk-in cooler or freezer, comprising the walls, solid walkin doors, glass reach-in display doors, ceiling, and floor water-cooled condenser A condenser that removes the heat of the refrigerant by heat transfer fluid flowing inside heat exchanging surfaces zeotrope, zeotropic refrigerant Refrigerant blend comprising multiple components of different volatilities that, when used in refrigeration cycles, change volumetric composition and saturation temperatures as they evaporate (boil) or condense at constant pressure Figure G-2 is a refrigerant property diagram for zeotropic blends, showing the effect of boiling point transition or “glide” as an aid to understanding this definition ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 125 RefCxGuide.book Page 126 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page 127 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission References AHRI 2004 ANSI/AHRI Standard 540-2004: Performance Rating of Positive Displacement Condensing Units Arlington, VA: Air-Conditioning, Heating, and Refrigeration Institute AHRI 2005 ANSI/AHRI Standard 460-2005: Performance Rating of Remote Mechanical-Draft Air-Cooled Refrigerant Condensers Arlington, VA: Air-Conditioning, Heating, and Refrigeration Institute AHRI 2008 ANSI/AHRI Standard 420-2008: Performance Rating of ForcedCirculation Free-Delivery Unit Coolers for Refrigeration Arlington, VA: Air-Conditioning, Heating, and Refrigeration Institute ASHRAE 2005 ASHRAE Guideline 0-2005, The Commissioning Process Atlanta: ASHRAE ASHRAE 2007 ASHRAE Guideline 1.1-2007, HVAC&R Technical Requirements for the Commissioning Process Atlanta: ASHRAE ASHRAE 2010 ASHRAE Handbook—Refrigeration Atlanta: ASHRAE ASHRAE 2011 ANSI/ASHRAE/USGBC/IES Standard 189.1-2011, Standard for the Design of High-Performance Green Buildings Except LowRise Residential Buildings Atlanta: ASHRAE ASHRAE 2013a ASHRAE Handbook—Fundamentals Atlanta: ASHRAE ASHRAE 2013b ANSI/ASHRAE/IES Standard 90.1-2013, Energy Standard for Buildings Except Low-Rise Residential Buildings Atlanta: ASHRAE ASHRAE 2013c ANSI/ASHRAE Standard 147-2013, Reducing Release of Halogenated Refrigerants from Refrigerating and Air-Conditioning Equipment and Systems Atlanta: ASHRAE CA 2013a California Green Building Standards Code (CALGreen) Sacramento: State of California CA 2013b 2013 California Mechanical Code, California Code of Regulations Title 24, Part Sacramento: State of California CEC 2008 Reference Appendices for the 2008 Building Energy Efficiency Standards for Residential and Nonresidential Buildings Appendix NA-7: Acceptance Requirements for Nonresidential Buildings Sacramento, CA: California Energy Commission www.energy.ca.gov/2008publications/ CEC-400-2008-004/CEC-400-2008-004-CMF.PDF ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 RefCxGuide.book Page 128 Wednesday, December 4, 2013 9:55 AM © 2013 ASHRAE (www.ashrae.org) For personal use only Additional reproduction, distribution, or transmission in either print or digital form is not permitted without ASHRAE's prior written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems DOE 2009 Energy Savings Potential and R&D Opportunities for Commercial Refrigeration Washington, DC: U.S Department of Energy http:// apps1.eere.energy.gov/buildings/publications/pdfs/corporate/ commercial_refrig_report_10-09.pdf EPA 2007 Supermarket Energy Use Profile Washington, DC: U.S Environmental Protection Agency www.mgaeeip.com.au/uploads/1/8/9/6/189631 83/doe_supermarket_energy_use_profile.pdf EPA 2011a GreenChill Best Practices Guideline: Commercial Refrigeration Leak Prevention & Repairs EPA bulletin 430-b-11-001 Washington, DC: U.S Environmental Protection Agency www2.epa.gov/sites/production/ files/documents/leakpreventionrepairguidelines.pdf EPA 2011b GreenChill Best Practices Guideline: Ensuring Leak-Tight Installations of Commercial Refrigeration Equipment Washington, DC: U.S Environmental Protection Agency www2.epa.gov/sites/production/ files/documents/GChill_LeakTightEquipInstall.pdf Focus on Energy 2004 Anti-sweat heater controls: Technical data sheet Madison, WI: Focus on Energy ICC 2012a International Energy Conservation Code Washington, DC: International Code Council ICC 2012b International Green Construction CodeTM Washington, DC: International Code Council Maxson, S 1995 Oil pressure problems in refrigeration systems Tech·Topics 3(1) www.heatcraftrpd.com/res/pdfs/faqs/HRP_TechTopic_OilPressure Problems.pdf PECI 2010 Grocery Store Commissioning Presentation to the National Conference on Building Commissioning by Portland Energy Conservation, Inc www.bcxa.org/ncbc/2010/documents/presentations/ncbc-2010grocery_store_commissioning-moore.pdf Stoecker, W 1998 Industrial Refrigeration Handbook New York: McGrawHill Professional U.S Congress House Emergency Planning and Community Right-to-Know Act of 1986 HR 2005 99th Cong ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 128 AppendixA.fm Page 76 Wednesday, December 4, 2013 10:25 AM ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 Bookstore The ASHRAE Bookstore is a one-stop shop for all ASHRAE publications, including books, standards, guidelines, Handbook volumes, CDs, DVDs, and additional electronic resources These publications provide important information for engineers, architects, and others covering HVAC&R design and application as well as cutting-edge topics such as sustainability, building performance and commissioning, energy efficiency, and indoor air quality ASHRAE members are entitled to discounts on many ASHRAE publications Visit www.ashrae.org for more information on the many benefits ASHRAE membership has to offer Additional ASHRAE resources: • ANSI/ASHRAE/IES Standard 202-2013, Commissioning Process for Buildings and Systems • ASHRAE Guideline 0-2005, The Commissioning Process • ASHRAE Guideline 1.1-2007, HVAC&R Technical Requirements for the Commissioning Process • ASHRAE Handbook—Refrigeration (More than 750 pages covering equipment and systems for cooling, freezing, and storing food; industrial applications of refrigeration; and low-temperature refrigeration.) • ANSI/ASHRAE Standard 15-2013, Safety Standard for Refrigeration Systems • ANSI/ASHRAE Standard 34-2013, Designation and Safety Classifation of Refrigerants • ANSI/ASHRAE Standard 147-2013, Reducing Release of Halogenated Refrigerants from Refrigerating and Air-Conditioning Equipment and Systems ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 www.ashrae.org/bookstore Bookstore Ad 8_5x11.indd 12/4/2013 10:00:03 AM The Essential Guide for Commissioning Refrigeration Systems Because deficiencies in system design found at start-up are not easily resolved, maintenance managers or operators may deal with unnecessary shortcomings and expenses over the life of the facility Commissioning helps project teams avoid these “surprises” by establishing a consistent, stepwise process that helps “get it right the first time.” The commissioning process starts with the initial planning and design and continues through construction, installation, start-up, and the first year of system operation Commissioning also sets the stage for ongoing servicing and maintenance of performance The result is refrigeration systems that are easier and less expensive to install and maintain, with lower energy costs, minimized liabilities from refrigeration system leaks, and reduced loss of refrigerated product due to system failures or unreliable performance Using this Guide will help achieve cost-effective and cost-efficient refrigeration systems for new projects, expansions, remodels, and existing systems that simply need a tune-up Refrigeration Commissioning Guide for Commercial and Industrial Systems The first of its kind, Refrigeration Commissioning Guide for Commercial and Industrial Systems provides guidance to owners and managers of commercial and industrial facilities that use refrigeration systems to help ensure that project requirements are met and owners’ expectations are achieved For commercial facility owners and managers, this means improved profitability through lower operating and service costs as well as reduced product loss Refrigeration Commissioning Guide for Commercial and Industrial Systems Commissioning Refrigeration Systems in ASHRAE 1791 Tullie Circle Atlanta, GA 30329-2305 404-636-8400 (worldwide) www.ashrae.org ISBN 978-1-936504-53-4 781936 50453 Product code: 90315 12/13 ThisfileislicensedtoMuhammaFaooqSaeed(saeedmfarooq@gmail.com).ASHRAEREFCXDownloadDate:1/6/2014 • Food Retail and Convenience Stores • Small Retail Stores • Food and Beverage Facilities • Food Distribution Centers • Industrial Plant Applications ... Refrigeration Commissioning Guide for Commercial and Industrial Systems provides user-friendly, how-to guidance for commissioning of customengineered refrigeration systems in commercial and industrial. .. appropriate processes, and develop a guide specifically tailored for the commissioning of refrigeration systems THE NEED FOR COMMISSIONING Refrigeration systems for most commercial and industrial facilities... written permission Refrigeration Commissioning Guide for Commercial and Industrial Systems The Guide emphasizes refrigeration systems commonly used in commercial and smaller industrial facilities