Technical Bulletin No 97 c

Horizontal Accumulator Selection

This Technical Bulletin has been revised to update the accumulator capacity charts and to
include ammonia heat pump applications.

The purpose of this Technical Bulletin is to make the selection of horizontal accumulators for
pump circulation and gravity fed systems quicker and easier by providing sizing curves. There is
also guidance given for the allowances which are needed to make adequate provision for liquid
storage and surge volume. Guidance has been added on sizing vessels for HP float expansion
valve operation where we need a slightly larger vessel but we can reduce the refrigerant charge
and total system cost.

1.0 Introduction

Star Refrigeration prefers to use a more efficient type of accumulator with internal baffles
and distribution slots rather than the simple type with minimal internal components.
Details of the standard range of efficient accumulators are given in this bulletin, as well
as some guidance on the positioning of level control devices.

All accumulators must be sized to accommodate varying amounts of liquid and this must
be taken into consideration when calculating the size required. This is especially true at
smaller vessel diameters, such as the 610mm Star efficient accumulator. It is important
to note that the limiting factor in selection is often not the diameter required to
give good droplet separation, but the storage volume required to accommodate
variations in the liquid level. Pump circulation systems require that there be sufficient
liquid storage on start-up to flood the evaporators while maintaining a good working level.
There must also be provision for surges in liquid level, for example when hot gas defrost
coolers come off defrost. These requirements must be checked as part of the selection
process.

The selection curves and associated tables have been calculated assuming that the
liquid supply prior to the expansion valve is at or near condensing pressure and has not
been sub-cooled. It is possible to add a percentage increase to the stated capacities
where the condensing pressure is relatively low or an economiser is fitted. Refer to the
capacity graph for guidance.

Table 4 gives values of volume fraction related to liquid height fraction for horizontal
vessels. This can be used to calculate storage volumes from minimum and maximum
liquid heights as well as actual working liquid level and high level trip positions from start-
up and surge volumes required. Calculation is based on shell volume only, not end caps.

Vessel volumes for the range of Star efficient accumulators are given in Table 1. Table 5
gives further details of the liquid levels associated with these volumes.

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Technical Bulletin No 97 c
2.0 Star Efficient Accumulators

The Star design of efficient accumulator produces better separation of liquid droplets and
vapour by returning the wet vapour to a primary separation chamber, usually at one end
of the vessel. Most of the larger liquid droplets separate in this section of the vessel.
The vapour is then fed into the main part of the vessel by means of a slotted tube. This
slot faces downwards and is directly beneath the dry suction take-off points. The
arrangement is such that most of the length and the full diameter of the separator can be
used to calculate the vapour velocity.

The refrigerant volume flow should be calculated from the mass flow relevant to the duty
and operating conditions by multiplying by the specific volume of the saturated refrigerant
vapour in the accumulator.

2.1 Selection from Curves

Selection curves for the Star efficient design of accumulator are given in Figures 1 to 4 in
this Bulletin. The curves are given in the form of duty in kW plotted against evaporating
temperature in ºC for the various standard vessel sizes. For guidance on how the
separation capacities were generated, refer to the following link:

G:\Design\Document Development\Reference Calculations for Standard

Documents\Technical Bulletins\TB097 - Horizontal Accumulator\TB 94 & 97 Calculation
Method.doc

To make a selection, follow the gridline up for the required evaporation temperature until
the required duty is reached. The next curve up gives the required vessel selection for
these conditions. If the selection falls on a curve, then take the next size up as the duties
given are the maximum values.

For applications with little flash gas from the liquid inlet, i.e. systems with intercoolers or
economised plants with sub-cooled liquid onto the vessel, the maximum duties can be
taken as several percent higher than the curves given. The increase depends on the
refrigerant and amount of subcooling. Refer to figures 1-4 for guidance.

For example, a 914 OD efficient accumulator has a capacity of 1160kW with R717 @ -
30ºC, but if condensing at 32ºC where the liquid off condenser will be less than 35ºC
then we can take the 5% capacity benefit, so the 914 OD efficient accumulator capacity
would go up to 1218kW. If the plant had an economiser with a liquid off economiser
temperature below -10ºC, we can take the 24% capacity benefit so the 914 OD
efficient accumulator capacity would go up to 1438kW.

The curves are valid for condensing temperatures up to 45oC. A separate curve is
provided for ammonia heat pump applications with condensing temperatures up to 90°C.
Selections requiring a higher condensing condition should be referred to the Technical
Department.

2.2 Sample Calculation

Select a Star Efficient Accumulator for a duty of 211kW on ammonia evaporating at -

40oC. The vessel is to be installed on a spiral freezer with a coil volume of 0.8m3.

From Selection Curves (Figure 1) for R717 Efficient Accumulators a 610mm OD vessel
provides more than adequate separation.
75
From Table 2, start-up volume = 75% of coil volume = x 0.8 = 0.667m 3
100

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Technical Bulletin No 97 c
Comparing this to the start-up volume shown in Table 1, this drum is obviously too small.
The first vessel with a start-up volume of at least 667 litres is the 914 OD x 6000 long
vessel.

Check surge volume, from Table 2, surge volume = 100% of coil volume = 0.8m3

From Table 1 this size of vessel has a typical surge volume of 1279 litres.

∴ 914 OD x 6000 long Accumulator selected

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Technical Bulletin No 97 c
3.0 Vertical Accumulator Vessels

The velocities given in Table 3 are the maximum vertical velocities for droplet separation
used to calculate the curves given in this Technical Bulletin. These velocities can also be
used to size vertical separator vessels such as intercoolers, economisers and suction
knock out pots. A safety margin must be applied by reducing these values by 25% to
give the design velocity used in sizing the vessel.

Date Rev Changes Section Issued by

July 1991 1 DJH
Oct 1994 2 DJH
Dec1994 3 DJH
May 2001 4 PAS
June 2008 E Guidance on sizing vessels for HP float Table 2B DAH
operation added Table 1, 5,
1220 OD x 3.75m vessel added Figs 1 - 3
Oct 2011 F Economiser guidance updated Fig. 1, 2, 3, 4 JRC
Oct 2011 F Calculation method revised Fig. 1, 2, 3, 4 JRC

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Technical Bulletin No 97 c
Table 1: Standard Star Efficient Accumulator Vessels

Maximum Minimum Maximum Typical Typical

Size Liquid Liquid Operating Start-up Surge
Volume l Volume l Volume l Volume l Volume l
610 OD x 3m 473 93 380 133 247
762 OD x 3.75m 932 136 796 278 518
914 OD x 3.75m 1375 145 1230 430 800
1220 OD x 3.75m 2485 172 2313 810 1503
1220 OD x 6m 4035 274 3761 1316 2445
1321 OD x 6m 4762 513 4249 1487 2762
1524 OD x 6m 6403 551 5852 2048 3804
1829 OD x 7.5m 11670 759 10911 3819 7092
2032 OD x 7.5m 14492 812 13680 4788 8892

Notes: 1. High level trip is set at 60% of vessel diameter if fitted.

2. Maximum liquid level is 25mm below height of high level trip, HL.
4. Level control is set at working liquid level, hw.
4. Maximum operating volume is volume at maximum liquid level, hmax, less
volume at minimum liquid level, hmin.
5. Low level alarm is set at hmin if required.

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Technical Bulletin No 97 c
Table 2a: Recommended Liquid Volumes for Horizontal Suction Accumulators (LP level
control applications).

Application Start-Up Volume Surge Volume

50% of all coils
50% of largest single coil or group of
Pumped circulation cold room air coils or
coils
100% of all defrosting coils
100% of largest coil
or
75% of largest single coil or group of 100% of all coils that defrost
Blast spiral and tunnel freezers
coils simultaneously
or
50% of all coils

Vertical plate freezers 100% volume of two largest freezers 100% of all freezers

Horizontal plate freezers 60% volume of largest freezer 60% of all freezers

Plate heat exchanger No special requirement 100% of refrigerant side volume

Plate and shell heat exchanger No special requirement 100% of refrigerant side volume

Notes: 1. For cold room air coils and all freezers, use the method that gives the larger value for surge
volume.
2. Wet return lines to slope down into the plant room. If a riser is present in the wet return, the surge
vessel must also be able to accommodate 100% of the volume of the wet return line between the
evaporator and the riser.
3. An allowance for the volume of liquid in the wet return pipe must be made of at least the full volume
of the liquid line.
4. In the above table ‘Group of coils’ means multiple coils operated from same valve station.
5. Typical coil volumes (for initial selections only) are 4.2litres/kW for spiral or blast freezers and 2.6
litres/kW for cold store coolers.
6. Any vessel will only be suitable for use on a system when:
Start-Up Volume + Surge Volume ≤ Maximum Operating Volume
(Calculated using these recommendations) (Given in Table 1 for all Star Efficient Accumulators)

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Technical Bulletin No 97 c
Table 2b: Recommended Liquid Volumes for Horizontal Suction Accumulators (HP float
applications).

Application Operating Volume Required*

Pumped circulation cold room air coils
Blast spiral and tunnel freezers
Vertical plate freezers
Horizontal plate freezers
Plate heat exchanger (gravity fed)
Plate and shell heat exchanger (gravity fed)
80% of all evaporator coils plus pumped liquid line volume plus an
allowance for liquid in wet return line plus an allowance for liquid in
condenser
90% of all evaporator coils plus pumped liquid line volume plus an
allowance for liquid in wet return line plus an allowance for liquid in
condenser
95% of all evaporator coils plus pumped liquid line volume plus an
allowance for liquid in wet return line plus an allowance for liquid in
condenser
90% of all evaporator coils plus pumped liquid line volume plus an
allowance for liquid in wet return line plus an allowance for liquid in
condenser
100% of all evaporator heat exchangers plus an allowance for liquid in
condenser
100% of all evaporator heat exchangers plus an allowance for liquid in
condenser

*The operating volume required must be less than the maximum operating volume in table 1.

Notes: 1. When HP float control is used the vessel must be able to contain the charge of the full system,
including the condenser, pumped liquid and wet return lines.
2. When the system does not include an HPR (especially for large cold store applications) it is
recommended that double isolation is included on refrigerant pump suctions so refrigerant does not
have to be recovered from the plant should one stop valve fail to seal tight. Typically this would
mean a straight RFF refrigeration stop valve in the drop leg and a full bore ball valve sized to match
the pump suction immediately before the pump suction flange.
3. For a particular refrigeration duty, a vessel sized using table 2b may be larger than one sized using
table 2a. Note, however, that the connection sizes will be dictated by the refrigeration duty only, not
the storage volume. This should be noted for pricing purposes, as a vessel sized using table 2b
may cost less than guideline prices indicate.
4. The high stage vessel on a two-stage plant will (in most cases) need sufficient capacity over and
above the required chill circuit operating volume to pump out the entire low stage system.
5. The liquid held up in the wet return line can be estimated as equal to the pumped liquid line volume.
6. Refer to example calculation 019 in the Design Manual for further guidance on refrigerant charge
calculation.

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Technical Bulletin No 97 c
Table 3: Maximum Vertical Vapour Velocities for Separation (m/s)

Saturated Suction Pressure at Accumulator (oC)

Refrigerant
+10 0.0 -10.0 -20.0 -30.0 -40.0 -50.0
R717 0.34 0.39 0.44 0.50 0.57 0.66 0.77
R404A 0.23 0.26 0.31 0.36 0.42 0.50 0.60
R134A 0.33 0.38 0.44 0.51 0.61 0.72 0.87

These velocities can be used for a vertical separation vessel such as an intercooler or a suction
knock-out pot. Refer to ASHRAE Refrigeration Handbook 1998 Chapter 1 on Liquid Overfeed
Systems for the recommended design method.

A safety margin of 25% must be applied when using the above velocities to size suction
accumulators.

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Technical Bulletin No 97 c

Table 4: Liquid volume fractions (Fvol) in horizontal vessels as a function of the liquid
height fraction (Fht)

Height Volume Height Volume Height Volume Height Volume

Fht Fvol Fht Fvol Fht Fvol Fht Fvol
0.01 0.0017 0.26 0.207 0.51 0.513 0.76 0.815
0.02 0.0048 0.27 0.218 0.52 0.525 0.77 0.826
0.03 0.0087 0.28 0.229 0.53 0.538 0.78 0.837
0.04 0.0134 0.29 0.241 0.54 0.551 0.79 0.847
0.05 0.0187 0.30 0.252 0.55 0.564 0.80 0.858
0.06 0.0245 0.31 0.264 0.56 0.576 0.81 0.868
0.07 0.0308 0.32 0.276 0.57 0.588 0.82 0.878
0.08 0.0375 0.33 0.288 0.58 0.601 0.83 0.887
0.09 0.0446 0.34 0.300 0.59 0.614 0.84 0.897
0.10 0.0520 0.35 0.312 0.60 0.626 0.85 0.906
0.11 0.0599 0.36 0.324 0.61 0.639 0.86 0.915
0.12 0.0680 0.37 0.336 0.62 0.651 0.87 0.924
0.13 0.0764 0.38 0.349 0.63 0.664 0.88 0.932
0.14 0.0851 0.39 0.361 0.64 0.676 0.89 0.940
0.15 0.0941 0.40 0.374 0.65 0.688 0.90 0.948
0.16 0.103 0.41 0.386 0.66 0.700 0.91 0.955
0.17 0.113 0.42 0.399 0.67 0.712 0.92 0.963
0.18 0.122 0.43 0.411 0.68 0.724 0.93 0.969
0.19 0.132 0.44 0.424 0.69 0.736 0.94 0.976
0.20 0.142 0.45 0.436 0.70 0.748 0.95 0.981
0.21 0.153 0.46 0.449 0.71 0.759 0.96 0.987
0.22 0.163 0.47 0.462 0.72 0.771 0.97 0.981
0.23 0.174 0.48 0.474 0.73 0.782 0.98 0.995
0.24 0.184 0.49 0.487 0.74 0.793 0.99 0.998
0.25 0.196 0.50 0.500 0.75 0.805 1.00 1.000

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Technical Bulletin No 97 c
Table 5: Standard Star Efficient Accumulator Vessel Liquid Levels and Total Volumes

HL hmin
VTOT hw hmax
High Minimum
Size Total Vessel Typical Working Maximum Liquid
Level Trip Liquid
Volume m3 Height m Height mm Height m Level m
610 OD x 3m 0.823 0.355 100 0.189 0.330
762 OD x 3.75m 1.598 0.442 100 0.225 0.417
914 OD x 3.75m 2.326 0.533 100 0.262 0.508
1220 OD x 3.75m 4.203 0.717 100 0.352 0.692
1220 OD x 6m 6.725 0.717 100 0.340 0.692
1321 OD x 6m 7.910 0.777 150 0.389 0.752
1524 OD x 6m 10.583 0.899 150 0.442 0.874
1829 OD x 7.5m 19.162 1.082 150 0.523 1.057
2032 OD x 7.5m 23.718 1.204 150 0.572 1.179

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Technical Bulletin No 97 c

Fig 1 - R717 Star Efficient Accumulator Selection

Valid for Condensing Temperatures up to 45ºC
For Liquid off Economiser/Condenser:
Below 35°C add 5% to the vessel capacities in the table below
Below 15°C add 14%, Below -10°C add 24%
2 0 3 2 OD 18 2 9 OD 15 2 4 OD
10000 13 2 1 OD
12 2 0 x 6 m
8000

6000
12 2 0 x 3 . 7 5 m
5000
4000 9 14 x 3 . 7 5 m

7 6 2 OD
3000

6 10 OD
2000
Capacity kW

1000

800

600

500
400

300

200

100
-50 -40 -30 -20 -10 0 10 20
Evaporating Temperature deg.C

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Technical Bulletin No 97 c

Fig 2 - R717 Star Efficient Accumulator Selection

Valid for Condensing Temperatures up to 90ºC
For Liquid off Economiser/Condenser:
Below 70°C add 14% to the vessel capacities in the table below
Below 60°C add 21%, Below 50°C add 28%
2 0 3 2 OD 18 2 9 OD 15 2 4 OD 13 2 1 OD 12 2 0 x 6 m
10000

8000

12 2 0 x 3 . 7 5 m
6000

5000
9 14 x 3 . 7 5 m
4000
7 6 2 OD

3000
6 10 OD

2000
Capacity kW

1000

800

600

500
400

300

200

100
-20 -10 0 10 20 30 40 50
Evaporating Temperature deg.C

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Technical Bulletin No 97 c

Fig 3 - R134a Star Efficient Accumulator Selection

Valid for Condensing Temperatures up to 45ºC
For Liquid off Economiser/Condenser:
Below 35°C add 10% to the vessel capacities in the table below
Below 15°C add 30%, Below -10°C add 53%
10000 2 0 3 2 OD
18 2 9 OD
8000

15 2 4 OD
6000
13 2 1 OD
5000 12 2 0 x 6 m

4000

3000 12 2 0 x 3 . 7 5 m

9 14 x 3 . 7 5 m
2000
7 6 2 OD
Capacity kW

6 10 OD

1000

800

600
500
400

300

200

100
-50 -40 -30 -20 -10 0 10 20
Evaporating Temperature deg.C

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Technical Bulletin No 97 c

Fig 4 - R404A Star Efficient Accumulator Selection

Valid for Condensing Temperatures up to 45ºC
For Liquid off Economiser/Condenser:
Below 35°C add 16% to the vessel capacities in the table below
Below 15°C add 44%, Below -10°C add 77%
2 0 3 2 OD
10000
18 2 9 OD
8000

15 2 4 OD
6000
13 2 1 OD
5000 12 2 0 x 6 m

4000

3000 12 2 0 x 3 . 7 5 m

9 14 x 3 . 7 5 m

2000
7 6 2 OD
Capacity kW

6 10 OD

1000

800

600

500
400

300

200

100
-50 -40 -30 -20 -10 0 10 20
Evaporating Tem perature deg.C

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