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Peer Review Project Proposal: Refrigerant Sensor Locking Caps

Dave Philpott Ms. Catherine Gorman ECPI University 10 March 2014
I pledge to support the Honor System of ECPI. I will refrain from any form of academic dishonesty or deception, such as cheating or plagiarism. I am aware that as a member of the academic community, it is my responsibility to turn in all suspected violators of the honor code. I understand that any failure on my part to support the Honor System will be turned over to a Judicial Review Board for determination. I will report to the Judicial Review Board hearing if summoned.

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Project Purpose The destruction of the ozone layer and global warming are two major environmental concerns for our generation. Our reliance upon mechanical refrigeration for heating and cooling, both for comfort and the preservation of goods, contributes to ozone depletion and the rise of greenhouse gasses in the atmosphere. The problem is two-fold: Chlorofluorocarbons (CFCs) and hydro-chlorofluorocarbons (HCFCs) were used extensively as refrigerants until 2010. Any release of these refrigerants results in the introduction of chlorine to the atmosphere. One molecule of chlorine destroys 100,000 molecules of ozone (Whitman, Johnson, Tomczyk, and Silberstein, 2009, p. 165). Hydrofluorocarbons (HFCs), the primary
Figure 1: Refrigerant cylinder, 410A

refrigerant for automobiles since 1995 and comfort cooling equipment since 2010, are classified as greenhouse gasses. If released, HFCs do not deplete ozone but have global warming potential (The ESCO Institute, 2001, p. 7). Refrigerant release also contributes to reduced unit efficiency. When system capacity is compromised, the equipment must run longer to accomplish the same task. The energy required to power the equipment results in greater demands on power plants, causing larger amounts of exhaust gasses belched into the atmosphere. These gasses contain carbon dioxide, another global warming contributor. Minimizing refrigerant release contributes to the health of our atmosphere.

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Hypothesis Refrigeration units remove heat through a latent heat exchange; liquid refrigerant, boiling at low temperatures, absorbs heat energy and becomes a vapor. A compressor compresses the vapor to increase its temperature; the heated gas loses heat outdoors, becoming a liquid refrigerant once more. This cycle requires a proper balance of refrigerant for efficient operation. Technicians measure refrigerant levels by connecting a hose of a gauge manifold set to a service port on the refrigeration unit. Refrigerant, either in liquid form or vapor form, fills the hose; the gauge measures and displays the pressure. Because the system pressure and pressure of the refrigerant in the hose are equal, the refrigerant cannot re-enter the unit; it is trapped in the hose. Removal of the hose causes the refrigerant to be released to
Figure 2: Gauge manifold set

the atmosphere; code requires technicians to use a speciallydesigned low-loss fitting to prevent such release.

The problems with this procedure are: The refrigerant in the hose is refrigerant removed from the system. Technicians cannot re-use the refrigerant in the hose and must recover it properly. Most vent it to the atmosphere. Refrigerant release could be reduced if service technicians could measure refrigerant levels and pressures without connecting the gauge manifold set.

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One other form of refrigerant release occurs when a person removes vapor from a unit for the purpose of inhaling the refrigerant, known as huffing. Most refrigerants create a mild sensation of euphoria when inhaled; abusers access the gas through the service port of a refrigeration unit by depressing the check valve (Schrader stem), filling a small plastic bag with vaporized refrigerant, and inhaling the contents. To combat such illegal access, units are now required by code to be equipped with a locking cap over the access fitting. I propose a solution to both of these issues. I believe a locking cap can be equipped with a pressure sensor and wireless transmission technology so that refrigerant pressure can be monitored through a software application without the need for connecting the gauge manifold set. This fitting could also be equipped with a thermocouple to monitor the physical temperature of the refrigerant line; this
Figure 3: Locking caps

enables the technician to measure superheat and subcooling in the system. Superheat (vapor) and subcooling (liquid) tell the technician if the system is properly charged and if it is efficiently absorbing and rejecting heat. Use of this fitting prevents illegal access to the refrigerant while enabling a technician to monitor refrigerant levels without loss. Solving the Problem The locking cap must meet the following criteria: It must meet specifications for a code-approved locking cap. It should contain a pressure sensor for continuous monitoring of refrigerant pressure. It should contain a thermocouple for continuous measurement of sensible refrigerant line temperature. It should contain technology for wirelessly transmitting data.

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It must be small enough for practical use. It must be durable enough for continuous outdoor use. It must be priced to encourage wide-spread use in the HVAC industry.

Right now, the technology for all of the above criteria exists in separate forms. I need to aggregate the separate constituents into a single component. Intended Audience People all over the world use refrigeration units. These units can be used to preserve products, keeping them frozen or cold for storage and transportation. These units can also be used for comfort; air-conditioners keep spaces cool and dry; heat pumps use refrigeration to act as both air-conditioning and heating units. The component I propose could help home owners with comfort costs; it could also help business owners such as grocers and restaurant owners with refrigeration needs in addition to comfort costs. Reduction of ozone depletion and global warming concerns affect everyone on the planet. Research and Discussion of Sources To meet the criteria for the proposed device, the following must be researched: Code requirements for the locking cap will be determined through the International Mechanical Code book and correspondence with NOVENT, the manufacturer of refrigerant locking caps. These resources will provide the basic design of the component. Refrigerant pressure sensors will be researched through correspondence with Sensata, a manufacturer of refrigerant sensors and transducers; and Bartec USA, a leading manufacturer of wireless tire pressure management systems (TPMS) that offer similar technology to what I am proposing.

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Wireless thermocouple technology will be researched through correspondence with Birk, a company specializing in thermocouple engineering. The thermocouple may be an optional feature; temperature sensing is essential to determining superheat and subcooling as is therefore important to the technician. I believe it to be an essential feature.

Wireless data transfer will be researched through correspondence with LORD Microstrain, a company specializing in wireless networks for small sensor applications and through two texts: Electronic Communications: Principles and Systems (Thomson Delmar Learning) and Electronic Communication Systems (Delmar Cengage Learning). My first choice for wireless transmission is Bluetooth, as the technology implements a common frequency spectrum (2 2.4 GHz) but avoids interference through frequency hopping technology.

These resources are referenced as: Blake, R. (2002). Electronic communication systems (2nd ed.). Clifton Park, NY: Delmar. Stanley, W. and Jeffords, J. (2006). Electronic communications: Principles and systems. Clifton Park, NY: Thomson Delmar. http://www.bartecusa.com/. Retrieved 9 March 2014. http://www.birkmfg.com/thermocouples.html. Retrieved 9 March 2014. http://www.microstrain.com/wireless/sensors?gclid=CJD___yChr0CFYY7MgodDkAAsw. Retrieved 9 March 2014. http://www.noventcaps.com/. Retrieved 9 March 2014. http://www.sensata.com/sensors/pressure-sensor-hvac.htm. Retrieved 9 March 2014. I hope to use these references as sources of information to develop a proposal. I do not expect the individual companies to divulge proprietary information on their respective

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intellectual property; rather, I hope to gain some insight as to how the separate technologies may be assembled. The goal would be a product manufactured from original engineered specifications; however, a prototype may be fabricated from parts purchased from these separate sources.

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References The ESCO Institute. (2001). EPA certification exam preparatory manual. Mount Prospect, IL: ESCO Press. Whitman, W., Johnson, W., Tomczyk, J., & Silberstein, E. (2009). Refrigeration & air conditioning technology (6th ed.). Clifton Park, NY: Delmar. Figure 1: http://image.made-in-china.com/43f34j00ZjsQycHzEDoP/30lb-Cylinder-RefrigerantR410A.jpg. Retrieved 9 March 2014. Figure 2: http://static.coleparmer.com/large_images/07164_57.jpg. Retrieved 9 March 2014. Figure 3: http://pump.rectorseal.com/wp-content/uploads/2013/03/no-vent-caps.png. Retrieved 9 March 2014.