Refrigerant Pipe Sizing

Refrigerant Piping
Cross Selling Expert

Refrigerant Piping
period one
Refrigerant Piping Requirements
Vapor-Compression Refrigeration
condenser
CONFIDENTIAL AND PROPRIETARY – © Trane 2008 – All rights reserved
D C
expansion
device
compressor
A B
evaporator
Trane Academy Refrigerant piping
Interconnecting Refrigerant Piping
C
discharge
line
condenser
liquid
expansion
line device B compressor
A
suction
D
line
evaporator
Refrigerant Piping Requirements
• Return oil to compressor

• Ensure that only liquid refrigerant enters the
expansion device
• Minimize system capacity loss

• Minimize refrigerant charge

Scroll Compressor
stationary
scroll
seal discharge
discharge
port
intake intake
motor
driven shaft
scroll
Return Oil to Compressors
discharge
line
hot
liquid condenser
vapor
line
expansion
warm device compressor
liquid
suction
line
cool
vapor
evaporator
Thermostatic Expansion Valve (TXV)
distributor
TXV
evaporator
remote
bulb
liquid
refrigerant
external equalizer
refrigerant
vapor
Subcooling
subcooling
condenser saturated
{
A vapor curve
pressure
expansion mixture of liquid

device B and vapor compressor
C
evaporator
saturated
liquid curve
enthalpy
Pressure Drop in a Suction Line
100
impact on system performance, %
98
efficiency
96
capacity
94
92
90 R-22
13.8 27.6 41.4 55.2 69.0 82.7
pressure drop, kPa

Minimize Refrigerant Charge
filter
drier
evaporator
liquid line suction line

compressor
discharge
line
condenser
Involve the Manufacturer
• If provided, use refrigerant line

sizes recommended by
manufacturer

General Piping Requirements
• Use clean Type L copper tubing

– Copper-to-copper joints: BCuP-6 without flux
– Copper-to-steel (or brass) joints: BAg-28, non-acid flux
• Properly support piping to account for expansion,
vibration, and weight

• Avoid installing piping underground
• Test entire refrigerant circuit for leaks
Type L
Outside Diameter Wall Thickness
inch mm inch mm
3/8 9.5 0.03 0.76
1/2 12.7 0.035 0.89
5/8 15.9 0.04 1.02
3/4 19.1 0.042 1.07
7/8 22.2 0.045 1.14
1 1/8 28.6 0.05 1.27
1 3/8 34.9 0.055 1.40
CAUTION
1 5/8 41.3 0.06 1.52
2 1/8 54.0 0.07 1.78 R410A application requires thicker
2 5/8 66.7 0.08 2.03
tube above 1 5/8 diameter.
3 1/8 79.4 0.09 2.29
Refrigerant Piping
period two
Suction Line
suction line
Requirements for Sizing and Routing
• Ensure adequate velocity to return oil to

compressor at all steps of unloading
• Avoid excessive noise
• Minimize system capacity and efficiency loss

suction line
Sizing “Rules”
old rules new rules

minimum velocity
5 m/s based on diameter of riser
for vertical risers
2.5 m/s percentage of minimum
for horizontal sections riser velocity
maximum velocity
20 m/s 20 m/s
maximum pressure drop
20 kPa based on specific system
requirements
suction line
Process for Sizing
1 Determine total length of piping

2 Calculate refrigerant velocity at maximum and

minimum capacities
3 Select largest pipe diameter that results in
acceptable velocity at both maximum and minimum
capacities
4 Calculate total equivalent length of straight pipe and
fittings
5 Determine pressure drop due to pipe and fittings
6 Add pressure drop due to accessories

Unloading Refrigeration Circuits
reciprocating or screw
compressors with
scroll compressors
unloaders
manifolded on a
single circuit
suction line
Determine Refrigerant Velocity
pipe diameter, in. (mm)

25.4
velocity, fpm (m/s)
10.2
5.1
2.5
R-22
3.5 7.0 17.6 35 70 176 352 703
Trane Academy
evaporator capacity, kW Refrigerant piping
suction line
pipe velocity, m/s

diameter, 70.3 kW 35.2 kW

in. (mm)
1 1/8 (28) 35.6 17.8
1 3/8 (35) 23.4 11.7
1 5/8 (42) 16.5 8.3
2 1/8 (54) 9.4 4.7
2 5/8 (67) 6.1 3.1
3 1/8 (79) 4.3 2.2

suction line
Minimum Allowable Velocities
pipe diameter, minimum velocity, m/s

in. (mm) riser horiz/drop
3/8 (10) 1.9 1.4

1/2 (12) 2.3 1.8
5/8 (15) 2.6 2.0
3/4 (18) 2.8 2.1
7/8 (22) 3.1 2.3
1 1/8 (28) 3.6 2.7
1 3/8 (35) 4.0 3.0
1 5/8 (42) 4.3 3.2
2 1/8 (54) 5.0 3.7
2 5/8 (67) 5.5 4.1
3 1/8 (79) 6.0 4.5
3 5/8 (105) 6.5 4.8
4 1/8 (130) 6.9 5.2
Select Suction Line Size
circuit velocity inside minimum velocity for 2 1/8 in.

capacity, 2 1/8 in. (54 mm) (54 mm) pipe, m/s
kW pipe, m/s riser horiz/drop

70.3 9.4
5.0 3.7
35.2 4.7

70.3 16.5
4.3 3.2
35.2 8.3

Selected Suction Line Sizes
2 1/8 in. 1 5/8 in. (42 mm)

(54 mm) riser
evaporator
2 1/8 in.
(54 mm)
drop
compressor

Double Suction Riser
circuit velocity inside minimum velocity for

capacity, 1 5/8 in. (42 mm) 1 5/8 in. (42 mm) riser,
kW pipe, m/s m/s
70.3 16.5
4.3
17.6 4.1
circuit velocity inside minimum velocity for

capacity, 1 3/8 in. (35 mm) 1 3/8 in. (35 mm) riser,
kW pipe, m/s m/s
70.3 23.4
4.0
17.6 5.9

Double Suction Riser
smaller
riser
larger
riser
trap

Sizing a Double Suction Riser
• Sizing the smaller riser

circuit velocity inside minimum velocity

capacity, 1 3/8 in. (35 mm) for 1 3/8 in. (35 mm)
kW pipe, m/s riser, m/s
17.6 5.8 4.0
• Sizing the larger riser
circuit velocity inside minimum velocity

capacity, 1 5/8 in. (42 mm) for 1 5/8 in. (42 mm)
kW pipe, m/s riser, m/s
52.8 12.4 4.3

Calculate Total Equivalent Length
radius of curvature (r)
Leq is based on r/d
diameter (d)

Leq for Long-Radius Elbows
elbow equivalent length, m

diameter,
in. (mm) “old” data “new” data
1 1/8 (28) 0.6 0.24
1 3/8 (35) 0.7 0.27
1 5/8 (42) 0.8 0.30
2 1/8 (54) 1.0 0.43
2 5/8 (67) 1.3 0.46
3 1/8 (79) 1.6 0.52

suction line
Determine Pressure Drop

23.0
11.5
pressure drop, kPa/10 m
4.6
2.3
1.2
R-22
3.5 7.0 17.6 35 70 176 352 703
Trane Academy evaporator capacity, kW Refrigerant piping

suction line
Add Pressure Drop of Accessories
• Suction filter = 13.8 kPa

• Angle valve = 6.9 kPa
• Ball valve = equivalent to 0.3 m
suction line filter

TXV Installation
distributor
TXV
evaporator
remote
bulb liquid
refrigerant
refrigerant
vapor
external equalizer line

single distributor on circuit
Evaporator Coil Connection
must rise above

height of evaporator
TXV
bulb
must drop below suction header

header outlet

single distributor on circuit
Evaporator Coil Connection
must rise above

TXV
bulb
must drop below suction header

header outlet

multiple distributors on circuit
Evaporator Coil Connections
must rise above

TXV
bulb
must drop below

lowest header outlet double-elbow
Trane Academy configuration Refrigerant piping
suction line
Riser Traps Are Not Required

suction line
Other Considerations
• Do not use suction riser traps: they are not

required
• Pitch horizontal sections to drain toward

evaporator
• Insulate entire suction line
– Prevents condensation
– Minimizes loss of capacity due to heat gain
• Install suction-line filter close to compressor
– Manual shutoff valves allow isolation for replacement
• Install access ports to measure suction pressure
and superheat

Suction-Line Accumulator
• Check with equipment

manufacturer to
determine if required,
recommended, or
discouraged
photo provided by Henry Technologies

Refrigerant Piping
period three
Discharge Line
discharge line
• Ensure adequate velocity to return oil to

compressor at all steps of unloading

• Minimize efficiency loss

discharge line
Sizing “Rules”
old rules new rules

minimum velocity
5 m/s based on diameter of riser
for risers
2.5 m/s percentage of minimum
for horizontal sections riser velocity
maximum velocity
17.5 m/s 17.5 m/s
41 kPa based on specific system
requirements
discharge line
Process for Sizing

2 Calculate refrigerant velocity at maximum and

minimum capacities
3 Select largest pipe diameter that results in
acceptable velocity at both maximum and minimum
capacity
4 Calculate total equivalent length of straight pipe and
fittings

discharge line

25.4
velocity, fpm (m/s)
10.2
5.1
2.5
R-22
3.5 7.0 17.6 35 70 176 352 703
Trane Academy
evaporator capacity, kW Refrigerant piping
discharge line
pipe velocity, m/s

diameter, 70.3 kW 35.2 kW

mm
7/8 (22) 20.6 10.3
1 1/8 (28) 12.2 6.1
1 3/8 (35) 7.9 3.9
1 5/8 (42) 5.6 2.8
2 1/8 (54) 3.3 1.7

discharge line
Minimum Allowable Velocities
pipe diameter, minimum velocity, m/s

in. (mm)
riser horiz/drop
5/16 (8) 1.1 0.8
3/8 (10) 1.3 0.9
1/2 (12) 1.4 1.1
5/8 (15) 1.6 1.2
3/4 (18) 1.8 1.3
7/8 (22) 1.9 1.4
1 1/8 (28) 2.2 1.7
1 3/8 (35) 2.4 1.8
1 5/8 (42) 2.6 2.0
2 1/8 (54) 3.0 2.3
2 5/8 (67) 3.4 2.5
3 1/8 (79) 3.7 2.8
Select Discharge Line Size


70.3 5.6
2.6 2.0
35.2 2.8

Selected Discharge Line Size
1 5/8 in.
(42 mm)
condenser
1 5/8 in. (42 mm)
riser
1 5/8 in.
(42 mm)
compressor

discharge line

23.0
11.5
pressure drop, kPa/10 m
4.6
2.3
1.2
R-22
3.5 7.0 17.6 35 70 176 352 703

discharge line


discharge line
• Do not use discharge riser traps: they are not
required
• Pitch horizontal sections to drain toward
condenser
• Insulate only to prevent accidental burns or when
system must operate in cold ambient conditions

Refrigerant Piping
period four
Liquid Line
liquid line
• Ensure that only liquid refrigerant enters expansion

device
• Minimize refrigerant charge

• Avoid excessive noise and pipe erosion

Subcooling
subcooling
43.3°C
2020
{
pressure, kPa
51.7°C
1662
mixture of liquid
saturated and vapor
liquid curve
enthalpy, kJ/kg
Impact of Refrigerant Density Change
available subcooling, °C
liquid line outdoor

diameter, temperature leaving loss due remaining
in. (mm) subcooler to piping at TXV
A 7/8 (22) high 10 - 3.2 = 6.8

B 1 1/8 (28) high 10 - 2.1 = 7.9
A 7/8 (22) low 7.2 - 4.1 = 3.1
B 1 1/8 (28) low 4.0 - 2.9 = 1.1

liquid line
Sizing “Rules”
old rules for R-22 new rules


41 kPa 2°C subcooling
remaining at inlet of expansion
device at all operating conditions
maximum velocity
1.8 m/s 3 m/s

liquid line
Process for Sizing

2 Obtain subcooling provided by condenser

3 Determine refrigerant velocity
4 Select smallest pipe diameter that results in
acceptable velocity at maximum capacity
5 Calculate total equivalent length of pipe and fittings
8 Calculate loss of subcooling due to pressure drop and
elevation change

System Operating Envelope
condensing unit,
low OA temperature
system cooling capacity
evaporator,
high cooling load
evaporator,
low cooling load condensing unit,
high OA temperature
saturated suction temperature

System Operating Envelope
high cooling load,

D low OA temperature
system cooling capacity
C
low cooling load,
low OA temperature A high cooling load,
high OA temperature
B
low cooling load,
high OA temperature
saturated suction temperature

effect of cooling load and outdoor temperature
Subcooling Leaving Condenser
cooling outdoor subcooling leaving

load temperature condenser*, °C
A high high 10.0
B low high 11.7
C low low 7.2
D high low 2.8
* This example system uses a TXV for the expansion device.

Involve the Manufacturer
• If provided, use refrigerant line

sizes recommended by
manufacturer

liquid line

5.1
2.5
velocity, m/s
1.0
0.5
0.25
R-22
3.5 7.0 17.6 35 70 176 352 703

liquid line
pipe velocity, m/s

diameter, 70.3 kW
in. (mm)
1/2 (12) 4.3
5/8 (15) 2.7
3/4 (18) 1.8
7/8 (22) 1.3
1 1/8 (28) 0.8
1 3/8 (35) 0.5

liquid line
Calculate Total Equivalent Length
5/8 in.
(15 mm)
5/8 in.
(15 mm)
5/8 in.
(15 mm)
drop
riser
evaporator
condenser

liquid line

115
pressure drop, psi/100 ft (kPa/10 m)
46
23
11.5
4.6
2.3 R-22
3.5 7.0 17.6 35 70 176 352 703

liquid line
• Filter-drier = 41.4 kPa

• Solenoid valve = 27.6 kPa
• Sight glass = equivalent to 0.3 m

solenoid
valve

liquid line
Pressure Drop Due to Elevation
evaporator
condenser 4.6 m 3.4 m
vertical rise vertical drop
creates creates
pressure drop pressure gain

liquid line
Pressure Drop Due to Elevation
12.4
pressure drop/net liquid rise, kPa/m
11.9
11.3
10.7
10.2
9.6
4.4 15.6 26.7 37.8 48.9 60.0 71.1
Trane Academy
liquid temperature, °C Refrigerant piping
liquid line
Calculate Loss of Subcooling
62.2
49.7
loss of subcooling, kPa/°C
37.3
24.9
12.4
0
4.4 15.6 26.7 37.8 48.9 60.0 71.1
Trane Academy
liquid temperature, °C Refrigerant piping
Subcooling Remaining at Expansion
Device
subcooling, °C
remaining at
leaving loss due to expansion
condenser liquid line device
8.3 - 5.5 = 2.8

liquid line
Evaporator Coil Connections
TXV
solenoid
valve
evaporator
distributor

liquid line
Refrigerant Accessories
condenser
liquid line
sight
glass
TXV
filter-drier
evaporator
solenoid
Trane Academy
valve Refrigerant piping
Liquid Line Routing
evaporator
condenser
evaporator
condenser
route the horizontal leg below the riser
liquid line
• Pitch horizontal sections to run alongside suction
or discharge line
• Insulate lines that are routed through very warm
spaces

Refrigerant Piping
period five
Hot-Gas Bypass Line
hot-gas bypass line
• Ensure that oil and refrigerant are not trapped in

piping
• Proper routing is more critical than pipe diameter

Hot-Gas Bypass to Evaporator Inlet
TXV
evaporator
liquid line
hot-gas
distributor
bypass valve
suction line
condenser
compressor

Hot-Gas Bypass Valve Installation
hot-gas pilot
bypass valve line pitch away
from hot-gas
pitch back toward bypass valve
discharge line hot-gas
bypass line
condenser suction
line
compressor
discharge
line
Hot-Gas Bypass Risers
hot-gas
bypass valve hot-gas
bypass riser
drain leg
condenser
suction
oil-return
compressor line
line

hot-gas bypass line
Connection to Evaporator
solenoid
valve
evaporator
liquid
line
TXV
distributor
hot-gas
bypass line
hot-gas bypass line
Connection to Evaporator
check
valves
solenoid
valve
evaporator
TXV
distributor
hot-gas
bypass line
Hot-Gas Bypass to Suction Line
TXV
liquid line
evaporator
hot-gas
bypass valve
liquid-injection
condenser valve
suction line
compressor

hot-gas bypass line
Connection to Suction Line
hot-gas liquid-injection
bypass valve valve
liquid
line
solenoid
valve
condenser
suction line
compressor

Hot-Gas Bypass Line Sizing
pipe velocity, m/s

diameter, 35.2 kW
in. (mm)
1/2 (12) 34.0
5/8 (15) 21.3
3/4 (18) 14.4
7/8 (22) 10.3
1 1/8 (28) 6.1
1 3/8 (35) 3.9

hot-gas bypass line
• Insulate entire line to prevent refrigerant vapor
from condensing
• Minimize overall length of the line
• Install solenoid valve if system includes a pump-

down cycle

Refrigerant Piping
period six
Review
Review—Period One
• Refrigerant Piping Requirements

– Return oil to compressor
– Ensure that only liquid refrigerant (no vapor) enters the
expansion device
– Minimize system capacity loss
– Minimize refrigerant charge
• If provided, use line sizes recommended by the
manufacturer

Review—Period Two
• Suction line
– Ensure adequate velocity to return oil to the compressor
at all steps of unloading
– Avoid excessive noise
– Minimize system capacity and efficiency loss

Review—Period Three
• Discharge line
– Ensure adequate velocity to return oil to the compressor
at all steps of unloading
– Minimize efficiency loss

Review—Period Four
• Liquid line
– Ensure that only liquid refrigerant enters the expansion
device
– Minimize refrigerant charge
– Avoid excessive noise and pipe erosion

Review—Period Five
• Hot-gas bypass line

– Ensure that oil and refrigerant are not trapped in the
piping
– Proper routing is more critical than pipe diameter

Refrigerant Pipe Sizing

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Refrigerant Piping

Cross Selling Expert

• Return oil to compressor

• Minimize system capacity loss

Trane Academy Refrigerant piping

expansion mixture of liquid

pressure drop, kPa

liquid line suction line

• If provided, use refrigerant line

Trane Academy Refrigerant piping

• Use clean Type L copper tubing

vibration, and weight

• Ensure adequate velocity to return oil to

Trane Academy Refrigerant piping

old rules new rules

1 Determine total length of piping

2 Calculate refrigerant velocity at maximum and

Trane Academy Refrigerant piping

pipe diameter, in. (mm)

velocity, fpm (m/s)

pipe velocity, m/s

diameter, 70.3 kW 35.2 kW

Trane Academy Refrigerant piping

pipe diameter, minimum velocity, m/s

3/8 (10) 1.9 1.4

circuit velocity inside minimum velocity for 2 1/8 in.

kW pipe, m/s riser horiz/drop

circuit velocity inside minimum velocity for 1 5/8 in.

Trane Academy Refrigerant piping

2 1/8 in. 1 5/8 in. (42 mm)

Trane Academy Refrigerant piping

circuit velocity inside minimum velocity for

kW pipe, m/s m/s

circuit velocity inside minimum velocity for

Trane Academy Refrigerant piping

Trane Academy Refrigerant piping

• Sizing the smaller riser

circuit velocity inside minimum velocity

17.6 5.8 4.0

• Sizing the larger riser

circuit velocity inside minimum velocity

52.8 12.4 4.3

Trane Academy Refrigerant piping

radius of curvature (r)

Leq is based on r/d

Trane Academy Refrigerant piping

elbow equivalent length, m

Trane Academy Refrigerant piping

pipe diameter, in. (mm)

Trane Academy evaporator capacity, kW Refrigerant piping

• Suction filter = 13.8 kPa

suction line filter

Trane Academy Refrigerant piping

Trane Academy Refrigerant piping

must rise above

must drop below suction header

Trane Academy Refrigerant piping

must rise above