AIR CONDITION SYSTEM ON BOARD SHIPS

A GUIDE FOR SOLVING COMMON PROBLEMS PREPARED BY: Sharad Pradhan

INTRODUCTION

It is understood that the reader is familiar with the basic theory and operation of A/C and refrigeration systems. This presentation covers only how to solve problems associated with the systems. Reader is advised to read the makers instruction manual before attempting to solve any problems.

A/C SYSTEMS- WHAT COOMON PROBLEMS DO I ENCOUNTER?

MOST COMMON: COOLING EFFECT IS INSUFFICIENT. Evaporator gets blocked by ice. Compressor runs hot. Compressor has a history of breaking down frequently.

CHECKS ON A FAULTY PLANT

DOMESTIC A/C SYSTEM: Check the Condenser liquid level in gauge glass is at least 2 Cm from bottom, while the plant is running. The sight glass fitted on liquid line after the condenser is full, without any bubbles. The color of the centre dot in the glass should correspond to dry (green). Check that the compressor oil level is normal. Confirm the compressor suction pressure is at minimum 5.0 Kg/Cm2 This is an important check. On Air-Handling unit (Evaporator) Check that the air suction filters are clean. Air outlet is maximum 16 Deg.C. Check various flaps & dampers on cold air lines are open or closed as required.

WHAT DO THE CHECKS ON PAGE-3 TELL ME?

Condenser: Low liquid level shows under-charged system. The system may have refrigerant leaks. Liquid flow sight glass: Bubbles show that the system is under-charged or condenser needs cleaning. If the centre dot color matches wet, the system has moisture. Compressor oil level low: Oil Charge low or the Oil separator fitted on the compressor delivery may be malfunctioning. The oil separator may not be present in all installations. Suction pressure lower than 5.0 Kg/Cm2: shows either or all of the following: a) refrigerant charge low b) Expansion valve has been wrongly adjusted c) Liquid flow in the system is low due to throttled liquid line valve d) Evaporator blocked with ice formation. Air handling unit checks are self-explanatory.

CORRECTING FAULTS NOTICED DURING CHECKS

Charge the refrigerant in the system. Ensure that the evaporator sight glass level is at about 2 Cm from the bottom of gauge when the system is running. After charging sufficient gas, the liquid sight glass will be full. If still bubbles are visible, then lower the cooling water temperature or increase its flow. Charge the compressor Sump with recommended Lube oil till the level in the sight glass is about full. Adjust the compressor suction pressure is done by correctly adjusting the expansion valve & superheat. This is factory set and should never be adjusted by the ships staff. Best is to replace valve cages with original spare factory set pieces. Compare the spare valve cages number with originals to ensure correct capacity as designed. The method of carrying out superheat adjustment is explained on slide- 8

MOST COMMON OBSERVATIONS

Almost all of the faults encountered in the A/C system can be divided into 2 main categories as follows:1. Refrigerant charge low. Will cause a) Low cooling capacity b) Ice formation on evaporator c) Compressor suction pressure low. 2. Maladjustment of components. Will cause a) any or all symptoms as per above b) will cause total break-down of compressor.

ADJUSTING THE EXPANSION VALVE

Note that the adjustment should only be carried out as a last resort. Onboard vessels, you will find these 3 makes of expansion valves a) Saginomiya b) Alco C) Danfoss Read the instructions as given by these makers and adjust expansion valve cage/ Orifice to get a superheat of 4Deg.C. On Alco valve, you will have to turn the screw, causing valve spring tension to change. On the other 2 brands, spring tension is changed in a different way. The best suggestion is to order new valve cages and fit in place. Note that you will have to order these by the refrigeration capacity. Attach the expansion valve sensor bulb in a correct position as per the maker- this is very important. Always wait for few minuits for the system to stabilize after initial adjustmant before carrying out more adjustments.

MORE ON A/C SYSTEM

During my career, I have noticed the following wrong adjustments done by Ships staff. 1. Trying to increase the A/C cooling capacity: Looks like this is a desperate attempt (unfortunately) to get rid of some ships staff complaint of feeling too hot!. Please read the specifications of the A/C plant. The cooling capacity of the plant is normally sufficient to lower the inside accommodation temperature by maximum 6 Deg.C only. Believe it or not this is usually true with both A/Cs running. 2. Adjusting the Expansion valves. For all practical purposes, the factory set / commissioning adjustments must be retained forever. So called adjustments of the ships staff will eventually lead to complete break-down of the A/C plant.

MORE ON A/C SYSTEM

3. Changing adjustments of LP cut-out. This is the most common fault to be found. Too low setting of the LP cut-out pressure setting will cause: Icing of the evaporator. 4. Changing of Automatic un-loader Pressure settings. This has to be usually done after lowering the LP setting. This may cause total break-down of the compressor.

MORE ON A/C SYSTEM

The expansion valve thermal sensing bulb must be correctly attached to the return pipe as shown.

EXPANSION VALVE THERMAL SENSING BULB. LOCATION IS 3 OCLOCK

GAS RETURN PIPE

MORE ON A/C SYSTEM

Suction pressure: 5.0 to 5.6 normal