HOT GAS DEFROST SYSTEMS FOR LARGE EVAPORATORS IN AMMONIA

LIQUID OVERFEED SYSTEMS.( T 163)

INTERNATIONAL INSTITURE OF AMMONIA REFRIGERATION.
BY – GEORGE C. BRILEY / THOMAS A. LAYONS
PRESENTED AT 14TH ANNUAL MEETING OF IIAR MARCH 22-25-1992.

1.0 INTRODUCTION
There are several methods that are used for defrosting coils in areas that operate below 35°F.:
i. Hot Refrigerant Gas Water
ii. Water
iii. Air
iv. Combinations of (1), (2), and (3)
. The predominant method is Hot Gas.

2.0 HOT GAS DEFROST SYSTEMS

The evaporator (heat exchanger) in a liquid overfeed system is circuited for a refrigerant flow that will
provide maximum cooling efficiency. The evaporator will also work adequately as a condenser, if the
necessary piping and flow modifications are made. When acting as a condenser, the refrigerant is giving
up heat; and with the fans shut down, the ability of the coil to transfer that heat to the air is severely
limited. Thus, the heat from the hot gas is absorbed by the metal in the coil. As the metal absorbs the
heat, its temperature rises, and once the surface temperature is high enough, any ice and/or frost on the
surface will melt and drain off. The method is effective but can be troublesome and inefficient, if not
properly engineered.
While the ability of a coil to transfer heat with the fans not operating is severely retarded, it does not
become zero. Some of the heat being given up by the refrigerant is transferred to the space. The means
by which the transfer takes place is a combination of radiation and convection, both occurring because
the temperature of the unit is higher than the temperature of the space. The authors estimate that up to
50% or even more of the heat given up by the refrigerant is lost to the space.

Since the rate of heat transfer is a function of the temperature difference between the coil
surface and the room air, the lower refrigerant temperature/pressure during defrost , the lower
will be the magnitude of the heat losses to the space.

Another incentive to maintain the lowest possible defrost temperature/pressure particularly in

freezers, is the tendency of coil to steam when the temperature is too high. When the air around a
coil is heated by the unit during defrost, its temperature rises and its relative humidity drops. As the
relative humidity falls, the rate of evaporation of the surface water increases. Whatever water re-
evaporates adds to the refrigeration load. When steaming occurs, in addition to the increased
refrigeration -load, there is the icicle or frost formation to contend with. The icicle formation
necessitates increased maintenance during clean-up. The ice formed during defrost tends' to collect
at. the fan rings sometimes restricting fan operation.

At lower. defrost pressures, the defrosting takes slightly longer than at higher pressures.
Obviously the shorter the period of time that the unit is allowed to add heat to the space, the more
efficient the defrost. However, with slightly extended defrost times at lower temperature, the
overall defrosting efficiency is much better than at higher temperature/pressure due to the
reduction of refrigeration requirements.

The maximum efficiency in defrost occurs when the losses are minimized. One of the losses
during defrost can be hot gas, or uncondensed gas, that blows through the coil and the relief
regulator, and vents back to the compressor. Some of this gas load cannot be contained, therefore,
it must be vented to the compressor thru the wet return line. It is most energy efficient to vent this
hot gas to the highest suction possible. Thus, an evaporator defrost relief should be vented to the
intermediate or high stage compressor, if the system is two stage. See Figures 1 and 2 for a
conventional hot gas defrost system for evaporator coils of 15 TR and below.

Note that with this system , it is assumed that the wet return is above the evaporator & that a
single riser is employed. Wet returns below the coil & double risers will be discussed later in
this paper.

3.0 DEFROST ONLY WHEN NECESSARY (DEMAND DEFROST)

Since defrosting efficiency is so low, it is obvious that both the frequency and the duration
,
of defrost should be kept to an absolute minimum. The defrosting ought not be initiated any more
than necessary to keep the coils clean. Certainly less defrosting would be required during the
winter than during the hotter, more humid periods; so an effective energy saving measure would
be to reset defrost schedules in the winter.

Demand defrost, actuated by a pressure device that measures the air pressure drop across
the coil is a good way to minimize total daily defrost time. . Other methods of sensing frost
formation on coils are available, however, we will discuss a pressure sensing device. Using this
 method, the coil is defrosted automatically only when necessary. This initiation system, plus the
addition of a float drainer to dump the liquid formed during defrost to an intermediate vessel,
comprises the most efficient defrost system available. See Figures 3 and 4 for details.

Estimates indicate that the probable load placed on a refrigeration system by a coil during
defrost is up to three (3) times the design load during the operating cycle. Thus it behooves. us
to properly engineer hot gas defrost systems.

4.0 DESIGNING HOT GAS DEFROST SYSTEMS

There are several approaches to designing hot gas defrost systems. Figures 3 and 4 show a typical
demand defrost system for both upfeed and down feed coils. This design returns the defrost liquid
to the system's intermediate pressure. An alternate way to do this is to direct the defrost liquid into
the wet suction. It is much better to employ a float drainer or thermostatic trap in lieu of the relief
regulator and install a hot gas regulator at the hot gas inlet to the coil. See Figures 3 and 4.

Most defrost systems now installed (Figure 1 and 2) use a time clock to initiate defrost; a "demand
defrost" system is shown in Figures 3 and 4. The system uses a photo helix pressure switch for
measuring the air pressure drop across the coil and in turn actuating the defrost. It uses a
thermostat to terminate the defrost cycle. A timer is also used as a back up to make sure the
defrost terminates.

5.0 SIZING & DESIGNING HOT GAS PIPING

Basically there are two approaches to supplying hot gas to the evaporators; the first option
is recommended:
1. Install a pressure regulator in the equipment room at the hot gas take off, set
at approximately 100 psig, and size the piping accordingly.
2. Install a pressure regulator at each evaporator or group of evaporators and
size the piping for minimum design condensing pressure, which should be 75
to 85 psig.
To size hot gas piping to coils, multiply the evaporator tons by three (3) and size the line
from the following chart:
 TABLE "A"
HOT GAS
LINE SIZE TONS OF REFRIGERATION

1 inch 1- 8
1/4 inch 20
1-1/2 inch 30
2 inch 2- 58
1/2 inch 92
3 inch 162
4 inch 328
5 inch 594
6 inch 970
This chart is based on 100 psig hot gas pressure and 1.5 psi per 100 equivalent feet of pipe.

ONLY ONE THIRD OF THE COILS IN A SYSTEM SHOULD BE DEFROSTED AT

ONE TIME; thus, the hot gas piping system can be designed accordingly. If a system has
300 tons of refrigeration of coils requiring defrost, then only 100 tons of refrigeration can
be defrosted at one time. Thus the main supply pipe could be sized for 100 tons of
refrigeration x 3 = 300 tons of refrigeration from the above chart; i.e., 4 inch.

The outlet pressure regulating valve should be sized in accordance with the manufacturers
engineering data.

Hot gas branch piping should be sized using chart "A."

There are advantages to reducing the defrost hot gas pressure in the equipment room, the main
one being less liquid will condense in the hot gas line as the condensing temperature is reduced to
52°F to 64°F.

A typical equipment room hot gas pressure control system is shown in Figure 5. Where
hot gas lines in the system are trapped, it is imperative that a condensate drainer be
installed at each trap and at the low point in the hot gas line. See Figure 6.
 IT IS RECOMMENDED THAT ALL STOP VALVES IN ALL OF THE HOT
GAS DEFROST SYSTEMS BE ANGLE VALVES; SEAL CAP VALVES
SHOULD ALSO BE EMPLOYED WHERE THE VALVES ARE IN THE
REFRIGERATED SPACE.

Defrost condensate liquid return piping (DC) from coils where a float or thermostatic
valve is employed should be sized one size larger than the liquid feed piping to the
coil.

6.0 ADVANTAGES OF DEMAND DEFROST FOR ANY SIZE

SYSTEM
1. This system uses the least amount of energy possible for
defrost.
2. Increases total system efficiency as the coils are "off-line" for a minimum
amount of time
3. Less stress on the piping system as there £!re less defrost
cycles.

7.0 OTHER ADVANTAGES OF DEFROST SYSTEMS PIPED PER FIG. 3 AND

4

♦ By regulating the hot gas to approximately 100 psig in the equipment

room, there is less chance of the hot gas condensing in the. supply
piping. Liquid in hot gas systems may cause problems due to the
hydraulic shock created when the liquid is forced into an evaporator
(coil). Many coils in hot gas pans have been ruptured in this manner.
♦ Draining the liquid formed during defrost with a float or thermostatic
drainer eliminates hot gas blow-by norma1ly associated with pressure
regulating valves riorma1ly insta1led around the wet suction return line
pilot check.
♦ Returning the ammonia liquid to the intercooler or high stage
recirculator saves considerable energy in a system. A 20 ton
refrigeration coil defrosting for 12 minutes wi1l condense up to
 24 pounds per minute of ammonia or 288 pounds total. The
enthalpy difference between returning to the low stage recirculator (-
40°F) and the intermediate recirculator (+20°F) is 64 BTU/pound or
18,432 BTU total or 7.68 tons of refrigeration removed from the -40°F
booster for 12 minutes and this assumes that only liquid is drained.
This is the saving when you drain liquid to the intermediate, not the
total cost to defrost. If a pressure reducing valve is employed around
the pilot check, this rate could double or triple as hot gas flows through
these valves in unmeasurable quantities.

8.0 SOFT HOT GAS DEFROST SYSTEM SDS FOR LARGE

EVAPORATOR COILS ABOVE 15 TONS OF REFRIGERATION
WITH SINGLE WET RETURN RISERS

The Soft Hot Gas Defrost System is a must for large evaporators. They should be used
on all coils 15 T.R. or over. This SDS system eliminates the valve clatter; pipe
movements and noise associated with large coils during hot gas defrost.

The SDS system can be employed for upfeed or downfeed coils, however the
piping systems differ. Figure 7 shows the SDS piping arrangement for upfeed
coils. Figure 8 shows the SDS piping arrangement for downfeed coils. WHERE
COILS ARE OPERATED IN THE HORIZONTAL PLANE THEY MUST BE
ORIFICED. VERTICAL COILS WHICH USUALLY ARE CROSS FED ARE
ORIFICED TOO.

The SDS system is designed to gradually increase the coil pressure as the defrost is
initiated. This is accomplished by using a small hot gas feed with a capacity of about
25 to 30% of the estimated duty with a solenoid and a hand expansion valve adjusted
to bring the pressure up to about 40 psig in 3 to 5 minutes. After defrost a small
suction line solenoid is opened so that the coil can be gradually broug4t down to
operation pressure before liquid is introduced and the fans started.
The SDS can be initiated by a pressure switch just as the demand defrost system;
however, for large coils in Spiral or IQF freezing systems manual initiation is usually
recommended.
There are lots of advantages to this Soft Hot Gas Defrost System.
♦ It eliminates check valve chatter.
♦ It eliminates most, if not all of the liquid hammer, i.e. hydraulic problems
in the piping.

Note: Advantages (items 4, 5 and 6) of the Demand .Defrost system apply to the
SDS System also.

9.0 DOUBLE RISER DESIGNS FOR LARGE EVAPORATOR COILS -- OR HOW

TO
OVERCOME THE EFFECTS OF "STATIC HEAD" IN A DEFROST SYSTEM

"Static Head" penalty is the pressure/temperature loss associated with a refrigerant vapor stream
bubbling thru a liquid bath. If the velocity in the riser is high enough it will "carry over" a certain
amount of liquid and the penalty is reduced. If you divide 144 by the refrigerant density in
pounds/cf at a given temperature and pressure you obtain the equivalent feet of liquid column
per psi change. As an example, at -40°F ammonia weighs 43.08 pounds/ct. 144 divided by 43.08
equals 3.34 feet/psi change. Thus a 16 foot riser would have 16 divided by 3.34 equals 4.8 psi.
At -40°F ammonia is 10.41 psia plus 4.8 equals 15.21 psia at the bottom of the riser or -27°P.
This is a 13° difference or about 0.81°P penalty per foot of riser. If we selected a riser that was
oversized to a point that the vapor did not carry the liquid to the wet return, the evaporator would
be at -27°P instead of -400P.
Observations of a large evaporator (100 TR +/-) with a single riser slightly oversized,
where obviously there was some liquid carried over, operating at full load, provided
some interesting data. Par several minutes the liquid temperature at the bottom of the
riser would stay at -4()OF and the top of the riser the temperature was -42/-43 of. Then
the temperature at the bottom of the riser started to rise, and continued to rise until it
reached -29 to -30°F. At that time the slug of liquid in the riser was propelled into the
recirculated suction and the temperature at the bottom of the coil returned to -40°F. This
sequence took about 12 minutes.

There are several ways to solve this

problem.

♦ Install the recirculated suction line (LTRS) below the evaporator. This is
very effective for down feed evaporators.

Note that the suction from the coil should not be trapped. This piping
arrangement also assures oil return to the recirculator.

♦ Where the recirculated suction (LTRS) is above the evaporator install a

"liquid return system" below the evaporator. (See Figure 9.) The
arrangement shown in Figure 9 eliminates static penalty. This is
particularly advantageous for plate, IQF and spiral freezers.
♦ . Use dual risers from the evaporator to the low temperature recirculated
suction (see Figure 10).

Dual risers have been employed in direct expansion air conditioning systems for many
years. An article by D.K. Miller published in Chemical Engineering magazine in
September 24, 1979 suggests that this is a solution to the problem. The authors have
employed double risers for large evaporators since approximately 1974.

Besides the D.K. Miller paper, the Carrier Refrigerant Piping Manual has some good
data regarding double risers.

Why are double risers needed? If we size a single riser for "minimum pressure drop" at
full load then at part load the static head penalty would be excessive plus oil return
could prove to be a problem. If we size the single riser for "minimum load" then the'
pressure drop in the riser would become excessive and counter productive.

Double risers solve this problem. Referring to figure 10 when the maximum load occurs
when both risers return vapors/liquid to the wet suction. When the load is at a
minimum this large riser is sealed by the liquid ammonia in the large trap and the
refrigerant vapor flows thru the small riser. The use of a small trap on this riser
assures some oil and liquid return to the wet suction.
Size the risers so the pressure drop calculated on a dry gas basis is at least 0.3 psi/l00
feet. Set the larger riser for approximately 65 to 75% of the flow and the small one for
100% minus 65 to 75%. This will result in velocity of approximately 5000 FPM or
higher. Some coils may require 3 risers (large, medium and small sizes).

Over the years the size of &11 types of freezers has continued to become larger and
larger. As they got larger so did the evaporators (coils). Where these freezers are "in
line" and the product to be frozen is 'wet" the defrost cycle can be every 4 hours or 8
hours. Many production lines limit the defrost cycle to 30 minutes. Where this is the
situation and the coils are large (some freezers today have 200 to 3.00 TR of coils), it is
difficult to design a hot gas defrost system that can complete a safe defrost in 30
minutes. Sequential defrost systems where the coils are defrosted alternately during
production are feasible but require special treatment. This should be covered in another
paper.
This also brings us to a plausible alternative which is a water defrost system which
should be covered in another paper.

10.0 CONCLUSION

1. Hot gas defrost system requires detailed engineering analysis as they become
larger & larger.
2. Other types of defrost, particularly 'water", should be considered where
large evaporators require a short defrost interval.
3. Familiarize yourself with the articles mentioned in the bibliography before
designing a defrost system for large evaporators.
BIBLIOGRAPHY

"Guidelines for Avoiding Component Failure in Industrial Refrigeration Systems Caused

by Abnormal Pressure or Shock, " lIAR Bulletin. No. 116.

"Refrigerating Piping, " 1996 ASHRAE Handbook of

Fundamentals.

Lyko, L., "Hydraulic Shock in Ammonia Systems," lIAR Technical Paper T-

125, 1989.

Miller, D.K., "Sizing Dual-Suction Risers in Liquid Overfeed Refrigeration

Systems," Septem:ber 24, 1979.

Stoecker, W.F., Industrial Refrigeration Business News Publishing Company. Chapter 9,

Troy, MI, 1988.

Strong, A.P., "Hot Gas Defrost A-One-A-More-A-Time," lIAR Technical Paper

T-53. 1984.
 LEGEND
CONVENTIONAL HOT GAS DEFROST FIG 1 & 2

LTRL Low Temperature Recirculated Liquid

LTRS Low Temperature Recirculated Suction
HGD Hot Gas Defrost Supply (185 psig to 100 psig)
DPR Differential Pressure Regulator (set at 90 psig+/-)
SV-LTRL Solenoid Valve, Low Temperature Recirculated Liquid
TL Thermostat-Operates SV-LTRL on Demand
TC Time Clock
DHC Defrost Heater Cable
SV-HGD Hot Gas Defrost Solenoid Valve
A Gas-Powered Automatic Shut-off Valve
G 0-150# 3-1/2 "Gauge with Valve

DEFROST CYCLE ACTUATED BY TIME CLOCK

A De-energize SV-LTRL and stop fans. .

Delay 2 to 3 minutes for downfeed & crossfedd coils & 4 to 8 minutes for
ipfeed. Energize SV-HGD closing (A)

B Coil defrost period terminated by Time Clock.

( keep defrost period time to a minimum - just enough to clean the coil &
drain pan)
C Energizes SV-LTRL- Delay 2 minutes
D Start Fans
 LEGEND
DEMAND DEFROST FOR COILS 15 TR OR BELOW FIG 3 & 4

D Defrost Condensate Return Drainer

LTRL Low Temperature Recirculated Liquid
LTRS Low Temperature Recirculated Suction
HGD Hot Gas Defrost Supply (75 psig to 90 psig)
TS Thermostat used to terminate HGD Cycle
PS Pressure Switch
TSL Thermostat-Operates SV-LTRL on Demand
SV-LTRL Solenoid Valve, Recirculated Liquid
SV-HGD Hot Gas Defrost Solenoid Valve
A Gas-Powered Automatic Shut-off Valve
G 0-150# 3-1/2 "Gauge with Valve
DHC Defrost Heater Cable
DC Return Liquid Defrost Condensate

DEFROST CYCLE ACTUATED BY PS AT PREDETERMINED SETTING

( APPROX 1" WATER PRESSURE)

A De-energize SV-LTRL and stop fans. .

Delay energize SV-HGD closing (A)
Coil Will Defrost

B Coil defrost period terminated by TS set at 40 Deg F.

Use Override timer after 30 minutes to force SV-HGD to de energize if TS
malfunctions
C De Energizes SV-HGD Via Thermostat TS opening Valve (A)
D Energize SV-LTRL Delay 2 to 4 minutes
E Start Fans
F Return Liquid to intercooler of intermediate TWEmperature Recirculator.
This saves energy

ALTERNATE: Return Liquid to wet suction downstream of the stop valve

This assumes a hot gas outlet pr. Regulator in the equipment room. If high pr
Hot Gas is used, an outlet pr. Regulator with electric shut-off should be
substituted for SV-HGD & set at 75 to 90 PSIG
 LEGEND
SOFT HOT GAS DEFROST CYCLE
FOR COILS ABOVE 15 TR - FIGURES 7 & 8

LTRL Low Temperature Recirculated Liquid

LTRS Low Temperature Recirculated Suction
HGD Hot Gas Defrost Supply at 75 PSIG to 90 PSIG
TS Thermostat - Used to Terminate Defrost Cycle Pressure Switch
PS Pressure Switch
TSL Thermostat-Operates SV-LTRL on Demand
SV-LTRL Liquid Line Solenoid Valve
SV-HGD1 Hot Gas Solenoid Valve (Main Hot Gas Defrost Supply)
SV-HGD2 Hot Gas Solenoid Valve (25% Hot Gas Defrost Supply)
SV-HGD3 Hot Gas Solenoid Valve (To operate Valve A)
PS2 Pressure Switch to Operate SV-HGD1
SVLTRS A Solenoid Valve Bypass to L TRS
A Gas-Powered Automatic Shut-off Valve LTRS
G 0-150# 3-1/2 "Gauge with Valve
DHC Drain Heater Cable
DC Defrost Condensate Return Liquid
D Defrost Condensate Drainer

HOT GAS DEFROST CYCLE ACTUATED BY PS** AT

PREDETERMINED SETTING (APPROX 1" WATER PRESSURE)

A De-energize SV -LTRL and stop fans

Energize SV-HGD3 which closes (A)
B After 60 seconds, energize SV-HGD2, which will gradually increase the coil
internal pressure

C When coil pressure reaches approximately 40 psig, pressure switch PS2

energizes SV-HGD1 and defrost continues
D When liquid temperature reaches 40F , temperature switch TS closes
SV-HGDl and SV-HGD2

E Wait one minute and open the small solenoid valve SV-LTRS. Wait 2-4 mnts
F De-energize SV-HGD3 which opens (A) and close SV-LTRS. G. Energize
SV-LTRS
G Energize SV-LTRL
H Start Fans

I Return Defrost Condensate (DC) to intercooler or intermediate temperature

recirculator .This saves energy
Alternate Return liquid toLTRS downstream of stop valve.

This assumes outlet pressure regulator in the equipment room. If high pressure hot gas is
used , an outlet pressure regulator installed at the HGD inllet.

**The SDS Defrost System may be manually initiated also.