REFRIGERATION & AIR CONDITIONING LABORATORY

LIST OF EQUIPMENT

1. REFRIGERATION TEST RIG

2. ICE PLANT RIG

3. MECHANICAL HEAT PUMP

4. COLD STORAGE REFRIGERATION SYSTEM

5. EVAPORATIVE CONDENSER TEST RIG

6. CASCADE REFRIGERATION TEST RIG

7. AIR CONDITIONING TEST RIG

8. ELECTROLUX VAPOUR ABSORPTION REFRIGERATION SYSTEM

9. COOLING TOWER TEST RIG

10. REFRIGERATION CHARGING TEST RIG

11. MODELS FOR VARIOUS TYPES OF EVAPORATORS

12. MODELS FOR VARIOUS TYPES OF CONDENSERS

13. PIPE CUTTING & FLARING TOOL KIT

14. WORKING CUT SECTION MODEL FOR HERMETIC COMPRESSOR

15. ANEMOMETER & PSYCHOMETER

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REFRIGERATION & AIR CONDITIONING LABORATORY

LIST OF EXPERIMENTS

1. To Evaluate the Performance of Refrigeration Test Rig and Determine Theoretical &
Actual COP, Relative COP

2. To Evaluate the Performance of the Experimental Ice Plant Unit and Determination of
Actual COP and Theoretical COP

3. To Evaluate the Performance of the Mechanical Heat Pump and Determination of Actual
COP and Theoretical COP

4. To Evaluate the Performance of the Experimental Mini Cold Storage Plant & Determine of
COP, Cooling Load, By-Pass Factor

5. To Evaluate the Performance of the Evaporative Condensing Unit (capacity 1/3 HP) and
Actual & Theoretical C.O.P. of the system

6. Study OF Cascade Refrigeration System & Determination of C.O.P. of each unit and
C.O.P. of the system

7. Study and Performance on Air Conditioning Test Rig and Determination of Actual and
Theoretical COP

8. To Evaluate the Performance of the Electrolux Vapour Absorption system & Determine
C.O.P. of the System

9. To Evaluate the Performance of the Experimental Water Cooling Tower Unit

10. To Study the Evacuation & Gas Charging Procedure for Refrigeration Systems

11. Study of Various Types of Evaporators and Condensers

12. Practice in Cutting, Bending and Flaring, Swaging of Copper Tube

13. Study of Reciprocating Hermetically Sealed Compressor

REFRIGERATION & AIR CONDITIONING LAB

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 EXPERIMENT-01

To Evaluate the Performance of Refrigeration Test Rig and Determine

Theoretical & Actual COP, Relative COP

OBJECT: To Calculate
 Theoretical coefficient of Performance
 Actual C.O.P.
 Relative C.O.P.

SPECIFICATIONS OF REFRIGERATION BENCH:

Nominal H.P. of compressor : 1/3 H.P.
Nominal Capacity : 1/4 Ton (Approx.)
Refrigerant : Freon 134a (R134a)

Specifications of the components:

1. Compressor:
Make : Kirloskar Hermatic
2. Condenser : Air cooled condenser 3/8” O.D. copper tube suitable for
compressor with an exhaust fan.
3. Expansion Devices:
i. A capillary tube 2/3 mm O.D. about 30-60cm length
ii. Thermostatic expansion valve
4. Rotameter : Range 9 to 90 litres / hr for R1341 liquid
5. Voltmeters : Digital Type 0-250 V
6. Energy meter : Single phase 0-5/10A
7. Ammeters : Digital Type 0.5 A
8. Dimmerstat : 0-4 A, 0-230 V
9. Pressure gauge : 0-300 psi
0-150psi
10. Thermometers : Digital Temperature Indicators
11. H.P./L.P. cutout : 1 No.
12. Thermostat : 1 No.

THEORY: VAPOUR COMPRESSION SYSTEM

In vapour compression system, the low-pressure refrigerant is compressed
to high pressure in the compressor. It is then condensed to liquid state in the condenser,
throttled in the throttling device and again evaporated to gaseous state by extracting heat from
the evaporator section. Refrigeration system consists of four important components i.e.
Evaporator, Compressor, Condenser and Capillary Tube. When these components are joined

3
together and refrigerant (R-134a) is charged into the system, then this forms a perfectly sealed
vapour

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5
6
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OBSERVATIONS

Compressor discharge pressure (Condenser pressure) P1 = Kg/ cm2 = Bar

Compressor suction pressure (Evaporator pressure) P2 = Kg/cm2 = Bar
Compressor outlet temperature T1 = Kg/cm2 = Bar
Condenser outlet temperature T2 = °C
Compressor inlet temperature T3 = °C
Calorimeter temperature (at start of Experiment) T4 = °C
Calorimeter water temp. (steady state, final temp.) T4’ = °C
Time of experiment, t = sec
Compressor power time for N revolutions (10 No.s) X = sec

Rate of flow (rotameter) mref = grams/sec

Volume of water in Calorimeter = 20 litres = 20 x 10-3 m3 =
Mass of water in Calorimeter = Volume x Density = (20x10-3 m3) x (1000Kg/m3) = 20Kg

CALCULATIONS
From Charts

P – h chart for Freon-134a

h1= kJ/kg

h2= kJ/kg

h3= kJ/kg

h2a= kJ/kg

Theoretical Refrigeration Effect = mr (h3–h2a) = kW

Theoretical Work Done = mr (h1–h3) = kW

Theoretical C.O.P. = h3–h2a =

h1–h3

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PRECAUTIONS
i. Do not forget to put on solenoid valve switch while the plant is on thermal expansion
valve. If not opened condenser pressure will shut and H.P. cut out will stop compressor.
ii. Start the system on capillary first. Starting the system initially on thermostatic expansion
valve will demand the compressor to work against heavy condenser pressure.
iii. Do not open charging valve No. 1 unless required for charging.
iv. Observe condenser inlet temperature that should lie between 70 to 75 ° C and should not
exceed 75 °C. If exceeds, stop the plate. Hence it means the condenser cooling temperature is
high. Cooling table fan adjacent to the compressor is advised.

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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-02
To Evaluate the Performance of the Experimental Ice Plant Unit and
Determination of Actual COP and Theoretical COP

OBJECT: To determine the

1 Theoretical C.O.P. & Actual C.O.P.
2 Capacity of Refrigerating Ice Plant

THEORY:
Natural ice was used for preservation purposes for a long time. But it has been replaced
to a large extent by manufactured ice since the beginning of twentieth century because of the
uncertainty of the natural supply also because of the cost of transportation for the retail trade.
The manufacture of ice is one of the principle needs of refrigeration and it will continue,
as ice is the cheapest means of preservation of food. A vast amount of research has been put in
developing a least expensive means of manufacture.
The quantity of ice required for different purposes is very large so that the manufacturer
of ice is one of the principal applications of refrigeration. Ice factories are commonly installed
nowadays in every small town of India to fulfill day to day requirements of the people.
The appearance of the ice plays an important role for the sale in the retail trade.
Therefore, preliminary chemical treatment and filtration of water, agitation of water during
freezing to issue transparency, core sucking to remove impurities in the water supply and
scoring of the ice cakes in sizes required for retail trade are important features of ice
manufacturing.
In present day Ice factories, all the operations mentioned above are automatically done to
keep the speed of production and distribution.

PRINCIPLE OF ICE PRODUCTION

The conventional vapour compression refrigeration system used for ice production. The
indirect method of cooling is used for ice production. The brine is cooled first in the
evaporator and then it is circulated around the can of ice, which contains water. The heat is
extracted from the water through the can and is transferred to the brine. The brine is
continuously circulated around the can with the help of pump till the water in the can is
converted into ice. When the water is converted into ice, the circulation of brine is
automatically stopped, the can is lifted and the ice is taken out and sized in the required forms.

The important parts of an ice plant are:-

1. A conventional refrigeration system using R-134a as refrigerant.
2. A freezing tank.
3. Ice cans and their lifting arrangement.
4. Dip tanks and ice dumps; Ice storages.

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 5. Ice manufacture.

CAN SYSTEM OF ICE MANUFACTURE

In can system, the galvanized iron cans containing water are placed in brine tank where
brine is circulated by the pump. The following points should be given due importance when
the ice is manufactured by using this system:-
1. Preliminary treatment of water.
2. Filtration of water before freezing.
3. Agitation of water before freezing.
4. Sucking of core to remove impurities in the raw water supply.
5. Cutting of ice cakes in required sizes.

TREATMENT OF WATER FOR MAKING THE ICE

Water generally used contains air, C02 and some solid impurities dissolved in it. Unless
means are introduced to prevent it, air and other impurities have a tendency to collect n a core
in the centre of the can. Making ice from distilled water will eliminate this trouble but due to
its high cost, it is not widely used. There is a general tendency to use raw water (well or tap
water) and to agitate it in order to eliminate the air and impurities. This is usually
accomplished by special agitation method.

BRINES
The usual brines used in the freezing tanks are sodium chloride or calcium chloride.
Sodium chloride is used where the cooling surfaces will not be exposed to damage if freezing
occurs, such as on pipe coil coolers and trunk evaporators. Calcium chloride brine is preferred
in shell tubular coolers but where the brine flows inside the tubes, sodium chloride brine may
be used. The brine temperature for making ice should be maintained at -12°C to -7°C and the
back pressure in the ammonia coils from 1.3 to 2 atmospheres.

FREEZING TANKS
Ice freezing tanks are usually constructed of 6mm steel plate. Tank depths must be such
that as to submerge all can water levels below the brine level by 25mm. The freezing tank
contains the direct expansion freezing coils equally distributed throughout the tank and these
coils are submerged in brine. The tank is provided with a suitable frame of hard wood for
supporting the ice cans and an agitator for keeping the brine in motion. The brine in the tanks
acts as a medium of contact only, the ammonia evaporator in the freezing coils extracts the
heat from the brine, which again absorbs the heat from the water in the cans, thereby freezing
it.

ICE CANS
Ice cans are secured in practically any desired size and shape from 10kg to 200kg
capacity. Usual commercial sizes are 28cm x 56cm x 30cm depth with 2.5cm inclination
towards the bottom to facilitate dumping. Cans are fabricated from galvanized sheet by single

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riveting having a weight of 25 kg to prevent floating to the can. Around the top of the can is a
galvanized band to provide a means for lifting and attaching to the grid.

AIR AGITATION
Blowing air through cans filled with raw water is necessary for making clear ice. The
purpose of air is to effect water agitation during freezing, which assists in forming clear ice
crystals and major dissolved salts are pushed in the frozen core. The concentration of salts in
the core increases which is pumped out and filled with fresh water. High-pressure air at
1.5kgf/cm2 is used for agitation. 5 litres of free air per minute is provided per can.

QUALITY OF ICE
The manufacture of ice is influenced by the rate at which heat is absorbed by the brine
from the solution of water and salts. If the ice is formed rapidly, there is tendency for the
formation of a strong concentration at the surface of the ice and diffusion must be augmented
by mechanical agitation if opacity is to be prevented. As the ice thickens, the rate of heat
conduction through the ice and the metal walls decreases and the freezing temperature of the
core water decreases, so that the need of mechanical agitation decreases and opacity will result
only when the unfrozen water has reached the critical concentration.

SPECIFICATIONS:

1. Compressor: Type: ISI Hermatically Sealed Compressor

No. of cylinders-1
Displacement per rev.-32.61 cc
Power – 530 watts.
Primary Refrigerant – R-134a
Secondary Refrigerant- Brine Solution
2. Condenser: Fins and copper tube type air-cooled condenser
3. Condenser Fan Motor: One no. (1/10 FHP)
4. Receiver: Heavy-duty sheet type
5. Brine Tank: Stainless steel with 4” thermocol insulation
6. Cooling Coil: Water Immersed type (Copper tube-cooling coil
3/8” OD)
7. Agitator: 1 No. along with Electric Motor for Brine circulation
8. Ice Cans: 2 Nos, immersed in stainless steel Brine tank
9. Temperature Indicator: 1 No. Digital with RTD Sensors for various
Temperature Applications.
10. Electricals: Single Phase, 220 V, 50 Hz, A.C. Supply.
11. Base: Heavy Duty Angle Iron Base.

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CONTROL PANEL BOARD
The following controls and components shall be provided on Dull Sunmica Board:
 Glass tube Rotameter to measure the flow of liquid refrigerant gas for Freon -134a,
Density meter for measuring Brine density, Suction pressure gauge for low pressure
measurement, Discharge pressure gauge for high pressure measurement, Filter Drier,
Capillary tube type expansion device, Gas charging valve.
 Main Switch, Voltmeter, Ammeter, Energy meter for compressor input, Switches and
Indication Lights-One Lot

OBSERVATIONS:

Rotameter reading (mref) = kg/min

Volume of water in cans = 6 litre = 6000 cc = 6 x 10-3 m3

Mass of water in cans = Volume x Density = (6 x 10-3 m3)x(1000)

= 6 kg

Initial temperature of can water Ti = (°C)

Final temperature of can water Tf = (°C)

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Energy meter rating = 450 rev./kWhr

Pressure at compressor discharge P1= Bar

Pressure at compressor suction P2= Bar

Discharge Temperature Compressor outlet T1 = (°C)

Discharge Temperature at Condenser outlet T2 = (°C)

Suction Temperature at compressor inlet T3 = (°C)

Time for N (10) revolutions = (X) min.

[Link] Brine Water Can Water Temp.(T5) REMARKS

Temp.(T4) (°C)
(°C)

1. At start of
experiment
2. At end of
experiment

Time of Study (t) = min

CALCULATIONS:

Plot the various points on (P – h) chart and read

h1 = kJ/kg

h2 = kJ/kg

h2a = kJ/kg

h3 = kJ/kg

Theoretical Refrigeration Effect = mr (h3 - h2a) = kW

Theoretical Work done = mr (h1 – h3) = kW

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Theoretical C.O.P. = h3 – h2a =
h1 – h3

Actual Ref. effect Nact. = mw [cpw (Ti – 273) +335+Cpi (273 – Tf)] kW
t

= kW

Where cpw = 4.186 kJ/kg.K, cpi = 2.09 kJ/kg.K

Actual Ref. effect Nact.= kW

Power consumed Wact = N x 3600 =

450.X

Where N is number of revolutions of energy meter & ‘X’ is the time taken for ‘N’ number of
revolutions

Actual C.O.P. = Nact =

Wact

where N is number of revolutions of energy meter & ‘X’ is the time taken for ‘N’ number of
revolutions

PRECAUTIONS:

1. Voltage should not be less than 220/230 volt, single phase, 50 Hz.
2. Do not run the agitator motor more than 5 minutes.
3. Whenever the compressor is switched off, do not switch on the compressor, before two
minutes interval.

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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-03

To Evaluate the Performance of the Mechanical Heat Pump and

Determination of Actual COP and Theoretical COP

OBJECT: To calculate:
 Actual/Theoretical Refrigerating Effect
 Actual/Theoretical Compressor Work
 Actual/Theoretical C.O.P. of Refrigerating Machine
 Actual/Theoretical C.O.P. of Heat Pump
 Verify the relation [C.O.P.]HP= 1+[C.O.P.]Ref

THEORY:
Systems, which have thermodynamic importance, are mainly divided into two
groups:

1. Work developing systems: All types of engines producing power using thermal
energy are of this type.

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 2. Work Absorbing Systems: Compressors, refrigerators and heat pump are the
example of work absorbing type. As refrigeration and air conditioning are
concerned, we are mostly interested in Refrigerators and Heat Pumps.

The performance of any system depends on what get and what we pay. In case of the
engine, we are interested to get maximum amount of Work (W), with supply energy (Q).
The performance of an engine is taken into account by the ratio W/Q. Thus, efficiency of
the engine is given by,

η = Woutput
Qinput

In, case of refrigerator, we are interested to maintain temperature of the system below
that of its surroundings i.e. T1<T2, WHERE T2 is the atmospheric temperature and for
doing so most economically, the maximum Q must be taken from the system (confined
space) with the minimum amount of work input (W). So the performance of the
refrigerator is taken into account by a ratio Q/W and it is known as COP (Coefficient of
Performance) and is given by

COP = Refrigeration Effect

Work Input

A Heat Pump is a Refrigeration unit capable of extracting heat from low-temperature

source such as atmosphere, sea, ground, and provide useful heat energy to system so as to
maintain temperature of enclosed space above that of surroundings. The cycle, which is

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used for the refrigerator is also used for the heat pump. Only the difference is, we are
interested to deliver the quantity of heat to the system at higher temperature instead of
absorbing the heat from the system. The performance of the heat pump is taken into
account by a ratio (Q+W)/W and it is known as Energy Performance Ratio (EPR).

EPR = Qc+ W = 1+ Qc/W

W

EPR = 1 + COPref

The value of COP for a refrigerator system may be taken less than one or greater
than one, which depends on the type of the refrigerator system used; but the value of EPR
will always greater than one. The main difference between a refrigerator and a heat pump
is in their operating temperatures. A refrigerating machine operates between the ambient
temperature Ta = T2 and a low temperature T1. A Heat Pump operates between the
ambient temperature Ta = T1 and a high temperature T1.

Another essential difference is their useful function. In a refrigerating machine, the

heat exchanger that absorbs heat is connected to the conditional space. In a heat pump,
instead, the heat exchanger that rejects the heat is connected to the conditional space. The
other heat exchanger in each case is connected to the surroundings. As such operation of
a refrigerating machine is termed as reversed cycle heating.

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OBSERVATIONS:

Working Fluid: Freon -134a

Evaporator water flow rate, mcw = litres/hour = kg/hr.

Condenser water flow rate, mhw = litres/hour = kg/hr.

Refrigerant flow rate, mref = kg/min.

Watt Meter Reading – Time for (N=10) revolutions = (X) sec.

(450 rev = 1 KWh.)

Ambient temperature TA = °C

Mass flow rate of refrigerator = mref = kg/min

Refrigerant Absolute Pressure, P1 = Bar

Refrigerant Absolute Pressure, P2 = Bar

Discharge Temperature Compressor outlet T1 = °C

Discharge Temperature Compressor outlet T2 = °C

Suction Temperature at compressor outlet T3 = °C

Water inlet temperature for condenser/evaporator, T4 = °C

Water outlet temperature for condenser, T5 = °C

Water outlet temperature for evaporator, T6 = °C

CALCULATIONS:

From Charts

P – h Chart for Freon-134a

h1= kJ/kg

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 h2= kJ/kg

h3= kJ/kg

h4= kJ/kg

Theoretical Refrigeration Effect = mr( h3– h2a) = kW

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Theoretical Work done = mr (h1 – h3) = kW

Theoretical C.O.P. = h3 –h2a =

h1 – h3

Heat rejects in condenser = mr (h2 – h3) = kW

Theoretical C.O.P. of Heat Pump = h1 –h2 =

h1-h3

Also C.O.P. of Heat Pump = (h1 – h3) + (h2 – h3)

h1-h3

= 1 + h3 – h2
h1 – h3

= 1 + [C.O.P.]R

Actual Refrigeration Effect, R.E. = Qc = mcwcpw (T4 – T6) = kW

Actual Energy required to operate the system = 3600.N = kW

450.T

Where N is the number of revolutions of energy meter & ‘X’ is the time taken for ‘N’
number of revolutions

Actual Heating Effect = Qh = = mcwcpw (T5 – T4) = kW

By conservation of energy,

Qc = W – Q h = 0

Actual COP of Heat Pump = Qh =

Wact

Actual COP of Refrigerator = Qc =

Wact

REMARKS:
i.
ii.

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PRECAUTIONS:

1. Do not start the unit, before filling the evaporator tank and in condenser also.
2. Voltage should not be less than be less than 220/230 volts.
3. Whenever the compressor is switched off. Do not switch on the compressor,
before five minutes of interval.
4. Mount rotameter vertically and maintain upward flow run.
5. Void sudden opening / closing of valve in line.
6. When the plant is not in use, drain out the water from evaporator and condenser
and wash the tank properly.

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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-04

To Evaluate the Performance of Experimental Mini Cold Storage Plant &

Determination of COP, Cooling Load, By-Pass Factor

OBJECT: To determine
 Cooling Load (Refrigeration effect) of the plant.
 C.O.P. of Mini Cold Storage Plant
 By pass factor of a cooling coil (Cooling & Dehumidification)

INTRODUCTION:
All natural foods i.e. fruits, vegetables, meats & dairy products are living organisms.
Even after these goods are removed from their natural surroundings, to be prepared for human
consumption, they continue to live & certain changes occur within the product. These changes
may be physical, chemical or a combination of the two. Physical changes include
crystallization, expansion & dehydration or desiccation; chemical changes include ordinary
chemical changes, enzymic changes & those caused by micro-organisms (bacteria, yeast,
molds). Most of these changes occur more rapidly at a higher temperature, so, in general
control of temperature & humidity conditions make it possible to control the rate of change.
Heat is required to create & develop life, but if it is not controlled, it can haste the destruction
of living matter & can be utilized to maintain foods for long periods.
Foods that are intended for consumption within a few days or weeks are usually stored at
temperatures a few degrees above their freezing point (28° to 40°F). If the storage is for a
longer period, products are usually frozen by one of the several methods.

QUICK FREEZING PROCESS:

During this process of quick freezing, the product temperature drops down fast to the
freezing temperature of 0°C. Thereafter the latent heat of the water content in the product has
to be removed & during this process, the temperature doesn’t fall. As the major portion of the
water product has been frozen, the remaining water will have a high concentration of salts, &
so it can freeze only at a much lower temperature. Once the stage is reached, the temperature
falls down further to the required level. To retain the quality of the food, freezing should be
accomplished quickly. Quick freezing is obtained by one of the following methods:

FREEZING TUNNEL OR BLAST FREEZER:

Air at low temperature of say -30 to -40°C is passed over the food stuff to be frozen to
obtain good heat transfer coefficient on the surface of the foods, the air velocity is kept high,
which calls for powerful fans. Size of the items of packages determines the duration for which
the product to be held in the tunnel. Generally the products are precooled to about 0°C prior to

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their introduction into the tunnel. Conveyer belts or mobile trolleys are used to move the
products through the tunnel for a predetermined period to achieve quick freezing.

PLATE FREEZER: (By direct contact with metal surfaces maintained at low temp.)
The plate freezer is a well-insulated cabinet with a number of horizontal moving plates
tacked apart. By the use of hydraulic pressure, the plates can be moved to draw closer or wider
apart. The plates with refrigerant passages within, form the evaporator of the freezer. The
product to be frozen is packed in carton of uniform sizes or kept in metal trays & placed
between the plates, which are drawn closer to press the food packing or tray. In this method,
the spacers with thickness less than carton by about 1-1.5 mm are placed to prevent the
crushing of the carton or tray, when the plates are drawn closer by hydraulic pressure. The
plate freezer accomplishes fast & efficient freezing, it can freeze the products packed in
regular shaped containers only.

The capacity of the refrigeration equipment should be equal to or slightly more than the
sum of the following load components.
 Heat transmission through the walls, roof & floor.
 Heat infiltration through the door openings.
 Product load
 Internal heat load
To carry the above calculations, the following details are needed:
 Size of the room, its location & orientation.
 Insulation material used & its thickness.
 Details about the product to be stored i.e. type of the product, quantity, temperatures &
R.H. required, chilling time, storage period, loading pattern etc.
 Frequency of door openings.

The machine works on the vapour compression system with R-134a as refrigerant.

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SPECIFICATIONS:
Compressor: Hermetically sealed, Kirloskar make using R134-a
Condenser: Fins & tube type air-cooled condenser
Condenser fan motor: 1/10 F.H.P.
Cabinet: Outer Cabinet 18 SWG CRC sheet, Inner cabinet 20 SWG GP sheet
Insulation: 4” Thermocol sheet
Floor: 16 SWG, Aluminum chakkar plate
Fan coil unit: Fins & tube type air-cooled cooling coil.

Observations:
Pressure at compressor discharge P1 = Bar

Pressure at compressor suction P2 = Bar

Discharge Temperature Compressor outlet T1 = °C

Discharge Temperature at Condenser outlet T2 = °C

Suction Temperature at compressor inlet T3 = °C

Mass flow rate of refrigerant mr = kg/min.

(Rota-meter Reading)

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Energy meter rating = 450 rev/kWh

Time for N (10) revolutions = (X) min.

Air before entering the cooling coil

DBT: °C
WBT: °C

Air coming out of the cooling coil

DBT: °C
WBT: °C

Temperature of Cold Storage Cabinet at the start of the experiment, Ta = °C

Temperature of Cold Storage Cabinet at the end of the experiment, Tb = °C

Time of the experiment, t = minutes

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CALCULATIONS:
From Charts

P – h chart for Freon-134a

h1= kJ/kg

h2= kJ/kg

h3= kJ/kg

h2a= kJ/kg

Theoretical Refrigeration Effect = mr (h3–h2a) = kW

Theoretical Work done = mr (h1–h3) = kW

Theoretical CO.P. Cooling = h3 – h2a =

h1 – h3

Volume of Cold storage cabinet = L*B*H = (6’4”х4’5”х6’4”) = (1.930 х 1.3462 х 1.930) m3

= 5.014 m3

Mass of air (ma) = Volume of air х density of air = 5.014 m3 х 1.2 kg/m3 = 6.0168 kg

Actual Refrigeration Effect = ma . cpa (Ta – Tb) = kW

t

= kW
where cpa = 1.005 kJ/kg.K
Actual Compressor Work from Energy meter

Wactual = N x 3600 =
450.X

Where N is number of revolutions of energy meter & ‘X’ is the time taken for ‘N’ number of
revolutions

Actual C.O.P. = Actual Refrigeration Effect =

Actual Work Done

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32
By pass factor = [DBT(2) – ADP] =
[DBT(1) – ADP]

PRECAUTIONS:
 Check the voltage, it should not be less than 220/230v; single phase, 50 Hz A.C.
supply

 Don’t run the cooling coil / fan coil unit, without starting of fan motor.

 Mount rotameter vertically & maintain upward flow run.

 Whenever the compressor is switched off, don’t switch over the compressor before
5 minutes of interval.

 Avoid sudden opening of the valves in the line to prevent float hunting & possible
glass tube breakage.

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REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-05

To Evaluate the Performance of the Evaporative Condensing Unit

(capacity 1/3 HP) and Actual & Theoretical C.O.P. of the system

OBJECT: To determine:
 Actual & Theoretical C.O.P. of the system
 Effect of evaporative condensation on the system performance
 Heat rejection ratio

EXPERIMENTAL FEATURES:
Refrigeration control panel:
 Glass tube rotameter
 Capillary tube expansion device
 Filter drier
 Suction pressure gauge for low pressure measurement
 Discharge pressure gauges for high pressure measurement
 Gas charging valve
 Electrical controls: Main switch, voltmeter digital type, Ammeter digital type, Energy
meter, Switches, Indication lights etc.
 Digital temperature indicator: Provided with RTD sensors for various temp.
applications
 Voltage: Single phase, 220 v, 50 Hz, A.C. supply
 Refrigerant: Freon R-134a refrigerant gas

THEORY:
An evaporative condenser in interesting combination of an air-cooled condenser, a water
cooled condenser, and a water cooling tower of the forced draft type. A typical evaporative
condenser as shown in figure.
Air is drawn in near the bottom and flows upward across the many tubes of the
refrigerant coil, through sprays and eliminations in to the fans and on out at the top. The tubing
of the condensing coils is usually prime surface i.e. nonfinned, since these cause a problem
with scaling and also obstructs the path of air over the coil. The condenser can be mounted
indoors or out. If indoors, the discharge air can be used to ventilate the machine room or it
may be ducted to the outdoors. Intake air must be pulled from outside, since the outside air wet
bulb temperature governs the operation of the unit.
As the refrigeration condensers in the coils, it drains down into the liquid receiver, which
is ordinarily located in the water tank at the base of the condenser. Further sub cooling of the
liquid refrigerant is thus obtained. A pump draws water from the tank and discharges it
through spray nozzles at a pressure of about 15 psi over the refrigerant coil. About 3 gpm/ft2 of

35
coil face area is an average water quantity. Air velocities of about 600 fpm into the coil are
commonly used. Higher air velocities tend to pull water droplets on through the eliminator
plates.

The action of evaporative condenser can be explained as follows: (1) Hot compressed
refrigerant vapor enters the refrigerant coil from the compressor, and heat transfer through the
tube walls to the water film sprayed on the coil occurs. It is assumed that the coil is kept wet
by the sprayers at all times. (2) Some of the water is evaporated by the heat from the
refrigerant, and the high latent heat of vaporization of water 1036BTU/lb at 100 F produces a
very significant cooling and condensing effects for a small weight of water evaporated. (3) The
unevaporated water is warmed up as t absorbs heat from the refrigerant and would soon
become unsuitable for further cooling use if were not for the fact. (4) The air being pulled
down through the dripping water and sprays results in adiabatic cooling of the water by
evaporation. The water will be cooled to within a few degrees of the leaving air wet-bulb if the
sprays and fan are opening satisfactorily.
All these processes take place simultaneously and continuously, and the temperature of
water is nearly constant as it passes over the refrigerant coils. About 5% of water circulated
evaporates, and make up water is supplied to the tank through a float valve. Partial evaporation
will increase the salt conc. in remaining water, and water treatment is usually necessary. A
small continuous overflow helps to keep down the mineral condensation.
Evaporated condensers are manufactured in single units for capacities up to 100 nominal
tons and can be used in the range from 10 to 50 tons. Their use is indicated on applications
where water is not scare or costly, where water disposal is a problem, and where use of an
atmospheric eater cooling towers not practical. Evaporator condensers represent an overall
saving of space since refrigerant and water cooling facilities are confined in the same cabinet.
The loading on the condenser per unit of refrigerant is called Heat Rejection Ratio, since

Qc = Q e + W

We have for the heat rejection ratio

Qc = 1 + 1 =
Qe C.O.P.

This experimental system works on R-134a as refrigerant in order to avoid

maintenance and leakage problems.

OBSERVATIONS:

SET – I CALCULATIONS WITHOUT EVAPORATIVE COOLIN

Pressure at compressor discharge P1 = Bar
Pressure at compressor suction P2 = Bar
Discharge Temperature Compressor outlet T1 = °C
Discharge Temperature at condenser outlet T2 = °C

36
Suction Temperature at compressor inlet T3 = °C
Ambient Temperature/Air inlet temperature,T4 = °C
Evaporator Air outlet temperature T5 = °C

Mass flow rate of refrigerant mr = kg/min.

(Rota-meter Reading)

Area of the evaporator duct (1 feet x 1 feet) = (304.8 mm x 304.8mm) – 0.0929 m3

Air flow rate through evaporator duct = m/sec

Energy meter rating = 450 rev/kWh

Time for N (10) revolutions = (X) min

SET – II CALCULATIONS WITH EVAPORATIVE COOLING

Pressure at compressor discharge P1 = Bar
Pressure at compressor suction P2 = Bar
Discharge Temperature Compressor outlet T1 = °C
Discharge Temperature at condenser outlet T2 = °C
Suction Temperature at compressor inlet T3 = °C
Ambient Temperature/Air inlet temperature,T4 = °C
Evaporator Air outlet temperature T5 = °C

Mass flow rate of refrigerant mr = kg/min.

(Rota-meter Reading)

Area of the evaporator duct (1 feet x 1 feet) = (304.8 mm x 304.8mm) – 0.0929 m3

Air flow rate through evaporator duct = m/sec

Energy meter rating = 450 rev/kWh

Time for N (10) revolutions = (X) min

CALCULATIONS:

SET – I CALCULATIONS WITHOUT EVAPORATIVE COOLING

Plot the various points on p-h chart for 134-a and psychometric chart as shown here

37
From Charts

P – h chart for Freon-134a

h1= kJ/kg

h2= kJ/kg

h3= kJ/kg

h2a= kJ/kg

Theoretical Refrigeration Effect = mr (h3–h2a) = kW

Theoretical Heat Lost in Condensation = mr (h1–h2) = kW

Theoretical Work Done = mr (h1–h3) = kW

Theoretical [Link] = h3 – h2a =

h1 – h3

38
39
Theoretical C.O.P. Heating = h1 – h2 =
h1 – h3

Heat rejection Ratio = Qc = 1 + 1 =

Qc C.O.P.

Actual Compressor Work from Energy meter

Wactual = N x 3600 = = kW
450.X

Where N is number of revolutions of energy meter & ‘X’ is the time taken for ‘N’
number of revolutions

Volume of air flow rate through evaporator = Area of the duct x average velocity of air

= m3/sec

where Area of the duct = (304.8 mm x 304.8mm) = 0.0929 m2

Mass of air (ma) = Volume of air x density of air = kg/sec

where density of air = 1.2 kg/ m3

Actual Refrigeration Effect = ma . cpa (T4 – T5) = kW

= kW
where cpa of air = 1.005 kJ/kg.K

Actual C.O.P. = Actual Refrigeration Effect = =

Actual Work Done

SET – II CALCULATIONS WITH EVAPORATIVE COOLING

Plot the various points on p-h chart for 134-a and psychometric chart as shown here

40
From Charts

P – h chart for Freon-134a

h1= kJ/kg

h2= kJ/kg

h3= kJ/kg

h2a= kJ/kg

Theoretical Refrigeration Effect = mr (h3–h2a) = kW

Theoretical Heat Lost in Condensation = mr (h1–h2) = kW

Theoretical Work Done = mr (h1–h3) = kW

Theoretical [Link] = h3 – h2a =

h1 – h3

41
42
Theoretical C.O.P. Heating = h1 – h2 =
h1 – h3

Heat rejection Ratio = Qc = 1 + 1 =

Qc C.O.P.

Actual Compressor Work from Energy meter

Wactual = N x 3600 = = kW
450.X

Where N is number of revolutions of energy meter & ‘X’ is the time taken for ‘N’
number of revolutions

Volume of air flow rate through evaporator = Area of the duct x average velocity of air

= m3/sec

where Area of the duct = (304.8 mm x 304.8mm) = 0.0929 m2

Mass of air (ma) = Volume of air x density of air = kg/sec

where density of air = 1.2 kg/ m3

Actual Refrigeration Effect = ma . cpa (T4 – T5) = kW

= kW
where cpa of air = 1.005 kJ/kg.K

Actual C.O.P. = Actual Refrigeration Effect = =

Actual Work Done

CONCLUSIONS:
EFFECT OF EVAPORATIVE COOLING ON THE SYSTEM PERFORMANCE:
(1)

(2)

(3)

43
PRECAUTIONS:

1. Voltage should be less than 220/230 v.

2. Do not start the compressor without checking/putting water into the evaporative
condenser
3. Whenever the compressor is switched off, do not switch on the compressor before
five minutes of interval.
4. Whenever the machine is not in use, drain out evaporative condenser water and
wash the same with the plain water.
5. Always open the Head shut off valve, which has been provided on the compressor-
discharge the line connected with the evaporator.
6. Adjust the L.P./H.P. cut out according to pressure requirements.

44
 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-06

Study of Cascade Refrigeration System 7 Determine C.O.P. of each unit and

C.O.P. of the system

OBJECT:
 To Study Cascade Refrigeration System
 To verify the heat transfer Exchanger for low temperature applications
 To find out C.O.P. of each unit and C.O.P. of the system

CASCADE SYSTEM

Cascade system is just similar to the binary vapour cycle used for power plant. In binary
vapour cycle, a condenser for mercury works as boiler for water. Similarly in the cascade
system, the condenser for low temperature cycle works as an evaporator for the high
temperature cycle. In cascade system, a series of refrigerants with progressively lower freezing
points is used in series of single stage unit. The cascade system combines two or more vapour
compression units. The high temperature cascade produces refrigeration at a certain
temperature say t1. The low temperature cascade produces refrigeration at a still further low
temperature t2 using the refrigeration effect of high temperature cascade at temperature t1 for
rejecting heat in its condenser temperature, which in the limit is equal to t1. It is to be noted
that each cascade works on a separate refrigerant. The high temperature cascade uses a boiling
refrigerant such as R-22, whereas the low temperature cascade uses a low boiling refrigerant
such as R – 134a or R - 404a depending on requirements.

The minimum lower temperature achieved by compound compression system is a

function of the freezing point temperature of the refrigerant used in the system. This difficulty
can be solved by using the cascade system in which two or more refrigerants can be used
separately and combining the operating cycle of one with other.

The principle advantages of cascade refrigeration system compared with simple vapour
compression refrigeration system include:

1. The principle advantage of the cascade system is that, it permits the use of two or
more refrigerants & the circuit is comparatively simple.
2. Each refrigerant can be chosen that operates best within the required
comparatively narrow temperature and pressure range. For example, a refrigerant,
which does not require a vacuum in evaporator to produce a low suction
temperature, is selected for low stage system. Another refrigerant such as F-22,
which does not require an excessive pressure in condenser, is selected for use in
high stage system.

45
3. As each cycle is separately operating, there is no difficulty of providing
lubrication under extremely severe conditions.
4. The refrigerants used in the system will have successively low freezing
temperature, so that refrigerants having low freezing point can be used in high
temperature circuit and refrigerant having high freezing point can be used in low
temperature circuit.
5. The inclusion of inter-cooling with liquid refrigerants in cascade system improves
the performance of the system.

46
SPECIFICATIONS:
1. Compressors : 2 Nos (Hermetically sealed Kirloskar make)
Compressor model : i) ISI Kirloskar Hermetically Sealed compressor Model
KCJ-515HAE for R-22
ii) ISI Kirloskar Hermetically Sealed compressor Model
KCH423LAG for R-134a
Rating : High temp R-22 Low temp R-404a
2. Condenser : Air cooled 01 No. for R -22 unit
3. Cascade Condenser : Tube in tube type
4. Condenser Fan motor : 1 No. for R – 22 unit
5. Evaporator : Made of M S sheet provided with 6 inch thick high density
Thermocol insulation
6. Structure : Complete structure of the unit of 18 SWG CRC sheet, enameled
painted, provided with a wheel trolley
7. Oil Separator : 2 Nos.
8. Accumulator : 2 Nos.
9. Expansion Valve : 2 Nos. Capillary Tube for R -404a & Thermostatic Expansion
valve for R – 22 unit
10. L.P/H.P. cut out : 2 Nos.
11. Cooling Coil : 1 No.
12. Pressure gauge : 2 set
13. Drier : 2 Nos.
14. Refrigerants : R-404a & R-22

47
48
OBSERVATIONS:

FOR R – 404a UNIT

T1 = Suction Temperature Compressor inlet = °C
T2 = Discharge Temperature Compressor outlet = °C
T3 = Discharge Temperature Condenser outlet / HE inlet = °C
T4 = Discharge Temperature HE outlet = °C
T5 = Suction Temperature HE inlet = °C
T6 = Suction Temperature HE outlet = °C

Rotameter Reading mr1 = kg/min

Energy meter Reading at start of experiment = kW

Energy meter Reading at end of experiment = kW

Actual Energy consumed in the experiment = kW

Evaporator Pressure Reading Pc=bar

Condenser Pressure Reading Pc= bar

Evaporator Chamber dimensions: (Inside): 6 ft3

Volume of inside air = 0.1699 m3

Temp. of Cabinet at start f experiment Ta= °C

Temp. of Cabinet at end of experiment Tb= °C

Time of experiment = minutes

49
FOR R – 22 UNIT

T1΄ = Suction Temperature Compressor inlet = °C

T2΄= Discharge Temperature Compressor outlet = °C
T3΄= Discharge Temperature Condenser outlet / HE inlet = °C
T4΄ = Discharge Temperature HE outlet = °C
T5΄= Suction Temperature HE inlet = °C
T6΄= Suction Temperature HE outlet = °C

Rotameter Reading mr2 = kg/min

Energy meter Reading at start of experiment = kW

Energy meter Reading at end of experiment = kW

Actual Energy consumed in the experiment = kW

Evaporator Pressure Reading Pc΄= bar

Condenser Pressure Reading Pc΄= bar

50
CALCULATIONS:

Plot the points on P – h diagrams for R - 404a, R – 22.

FOR R – 404a UNIT

Determine from P – h chart for R – 404a

h1 = kJ/kg
h2 = kJ/kg
h3 = kJ/kg
h4 = kJ/kg
h5 = kJ/kg
h6 = kJ/kg

51
heat Exchanger Energy Balance
(h3 – h4) = (h5 – h6)
Theoretical Capacity of Cascade refrigeration system = mr1 (h5-h4) =
(R – 404a cycle)
= kW

Theoretical energy input for R – 404a cycle = mr1 (h2-h1) =

= kW

Theoretical C.O.P. of R – 404a cycle = Refrigeration effect = h5 – h4 =

Energy Input h2 – h1

Mass of air in the cabinet ma = Volume x density (1.2 kg/m3) = kg/min

Actual Refrigeration Effect (Nactual) = ma x cp x (Ta – Tb) =

t

= kJ/min
where (t) is the duration of trial in minutes

Actual energy required by the compressor = kW= kJ/min

Actual C.O.P. of R – 404a cycle = Actual Refrigeration effect =

Actual Energy Input

Total actual capacity of Cascade refrigeration system (R – 404a cycle) = NActual

210

= TR

FOR R – 22 UNIT

Determine from P – h chart for R – 404a

h1’= kJ/kg
h2’= kJ/kg
h3’= kJ/kg
h4’= kJ/kg
h5’= kJ/kg
h6’= kJ/kg

heat Exchanger Energy Balance

52
 (h3’ – h4’) = (h5’ – h6’)

Theoretical Capacity of R – 22 cycle = mr2 (h5’-h4’) =

= kW

Theoretical energy input for R – 22 cycle = mr2 (h2’-h1’) =

= kW

Theoretical C.O.P. of R – 22 cycle = Refrigeration effect = h˙5 – h˙4 =

Energy Input h˙2 – h˙1

CASCADE REFRIGERATION SYSTEM

Theoretical C.O.P. of Cascade Refrigeration System

= Refrigeration effect in R – 404a cycle = mr1(h5 – h4) =

Total Energy Input mr1(h2-h1) = mr2(h˙2-h˙1)

Total actual capacity of Cascade Refrigeration System (R – 404a cycle) = NActual =

210
= TR

PRECAUTIONS:

1. Connect 220 V ± 5%, 50 Hz single phase stabilized A.C. power supply.

2. Earth the chamber to an efficient earthing point by shortest possible route.
3. Do not use the fuses of higher current than the specified one.
4. Do not use metal wires but use HRC fuses.
5. Do not touch any terminal inside the control chamber while the power supply is on.

53
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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-07
Study and performance on Air Conditioning Rig and Determination of Actual and
Theoretical COP

OBJECT: To determine
1. Theoretical & Actual C.O.P.
2. Rate of moisture Condensed

AIR CONDITIONING SYSTEMS:

Air conditioning means conditioning of air for maintaining specific conditions of
temperature, relative humidity and low dust levels inside an enclosed space. The conditions to
be maintained are governed by the application.

SUMMER AIR CONDITIONING:

In summer, the outside air temperature & humidity are both high. The room therefore,
gains, heat as well as moisture. The introduction of fresh outside air for the ventilation of
conditioned space is necessary to dilute the odors and other contaminants to maintain the
purity of room air. In genera, the processes in winter air conditioning for comfort involve
cooling & dehumidifying.

WINTER AIR CONDIONING:

In winter, the building sensible heat losses are partially compensated by solar heat gains
and internal heat gains such as those from occupancy, lighting etc. so in winter heating load is
less than cooling load in summer. In general, the processes in winter air conditioning for
comfort involve heating & humidifying.

CLASSIFICATION ON BASIS OF AIR-CONDITIONING APPLICATIONS:

1. COLD STORAGE: It is complete air-conditioning system in which air is cooed over a

cooling coil and supplied back to storage space. Conditions maintained inside the
storage space depend on the nature of product stored.
2. INDUSTRIAL AIR CONDITIONING: Inside design conditions depend on type of
application, e.g. in metrology laboratories, maintenance of temperature within close
limits is prime consideration whereas paper and textile mills require humidity to be
maintained constant at a high value.
3. COMFORT AIR CONDITIONING: Usually a single parameter called effective
temperature (which includes all 3 parameters governing comfort viz. temperature,
humidity & air velocity) is used as an index of comfort. It is the temperature of
saturated air at which subject experiences same feeling of comfort as in actual
unsaturated environment. Based on effective temp, comfort charts and comfort
equations are also developed.

56
WINDOW AIR CONDITIONER:

The unit consists of:

1. The refrigeration system
2. The control system (thermostat & selector switch)
3. Electrical protection system (motor overload switches & winding protection thermostat
on compressor motor)
4. Air circulation system (fan motor, centrifugal evaporator blower & propeller fan for air
cooled condenser)
5. Ventilation and Exhaust system

Usually the refrigerant used is R-22. The evaporator fan sucks the air from the room to
be conditioned through the air filter and cooling coil of refrigeration unit and delivers the
cool & dehumidified air back to the room. This air mixes with the room air and brings
down the temperature and humidity levels to maintain comfortable conditions. By
incorporating a reversing valve, the unit can be used for heating the room during winter.
Generally, the room A.C.’s are designed to operate on 230V, single phase a.c. supply and
are available from 0.5 – 3 tonnes capacities.

EQUIPMENT:
i. Anemometer,
ii. Sling psycho meter
iii. Window AC unit

OBSERVATIONS:

Pressures:
1) Compressor discharge P1 = bar
2) Compressor inlet P2 = bar

Temperatures:
1) Discharge temperature Compressor outlet T1 = °C
2) Discharge temperature Condenser outlet T2 = °C
3) Suction temperature Compressor inlet T3 = °C
4) Coil surface temperature T4 = °C
5) Ambient temperature – air inlet temperature T5 = °C
6) Air outlet temperature – Conditioned temp. T6 = °C

Mass flow rate (Throough Rotameter) = mr = kg/min

Voltage Reading = V

Ammeter reading = A

57
CALCULATIONS PROCEDURE

From Charts

P – h chart for Freon-22

h1= kJ/kg

h2= kJ/kg

h3= kJ/kg

h2a= kJ/kg

Theoretical Refrigeration Effect = mr (h3–h2a) = kW

Theoretical Work done = mr (h1–h3) = kW

Theoretical CO.P. = h3 – h2a =

h1–h3

Actual Power consumed by compressor = [Link]Ø = 0.8 V . I = kW

Actual Heat transfer in evaporator

Qc = mass flow rate of air * enthalpy difference = kW

= kW

Where mass flow rate of air = ρ*A*V = kg/sec

ρ = Density of air on evaporator side = 1.2 kg/m3 (Depending upon air temperature)
A = Evaporator coil area & fin factor (0.85) = (6.5” x 10.5”)x0.85 = 0.044x0.85
= 0.03743 m2

V = Air velocity on evaporator side = m/min = m/sec

(Using anemometer)

58
Actual C.O.P.= Actual Heat Transfer In Evaporator =
Power Consumed By Compressor

Rate of Moisture condensed = ma (W1 – W2) = kg/sec

PRECAUTIONS:

1. Voltage should not be less than 220/230 volt.

2. Whenever the compressor is switched off, do not switch on the compressor, before two
minutes interval.
3. Mount Rote meter vertically.
4. Avoid sudden opening/closing of valves in line.
5. Make sure that HP/LP cutouts and other safety devices are working properly.

59
60
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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-08

To Evaluate the Performance of the Electrolux Vapour Absorption System &

Determine C.O.P. of the System

OBJECT: To study the following

1. Performance of Electrolux Vapour Absorption System
2. Determine C.O.P. of the system

ELECTROLUX REFRIGERATOR

INTRODUCTION:

The Electrolux refrigerator works on the vapour absorption refrigeration system is one of
the oldest method f producing refrigerating effect. The principle of vapour absorption was
discovered by Michel Faraday in 1824 while performing a set of experiments to liquefy certain
gases. This system may be used in both the domestic and large industrial refrigerating plants.

The vapour absorption system uses heat energy; instead of mechanical energy as in
vapour compression system .In order to change the conditions of refrigerant required for the
operation of the refrigeration cycle.

In this system, the compressor is replaced by an absorber, a pump a generator and a

pressure reducing valve .These component in vapour absorption system, performs the same
function as that of a compressor in a vapour compression system. In this system, the vapour
refrigerant from the evaporator is drawn into an absorber where it is absorbed by the weak
solution of the refrigerant forming a strong solution. The strong solution is pumped to the
generator where it is heated by some external source. During the heating process, the vapour
refrigerant is driven of by the solution and enters into the condenser, where it is liquefied. The
liquid refrigerant then flows into the evaporator and thus the cycle is completed.

SIMPLE ABSORPTION SYSTEM

The simple vapour absorption system as shown in figure, consists of an absorber, a

pump, a generator and a pressure reducing valve to replace the compressor of vapour
compression system the other components of the system are condenser, receiver, expansion
valve and evaporator as in the vapour compression system.

In this system, the low pure ammonia vapour leaving the evaporator, enters the absorb
where it is absorbed by the cold water in the absorber. The water has the ability to absorb very

63
large quantities of ammonia vapour and the solution thus formed, ids known as aqua –
ammonia.

The absorption of ammonia vapours in water lower the pressure in the absorber which in turn
draws ammonia. The absorption of ammonia in water lower the pressure in the absorber which
in turn draw more ammonia vapour from the evaporator and thus raises the temperature of
solution. Some form of cooling arrangement is employed in the absorber to remove the heat of
solution evolved there. This is necessary in order to increase the absorption capacity of water,
because at higher temperature water absorbs less ammonia vapour. The strong solution thus
formed in the absorber is pumped to the generator by the liquid pump. The pump increases the
pressure of the solution up to 10 bar.

The strong solution of ammonia in the generator is heated by some external source such
as a gas or steam. During the heating process the ammonia vapour is driven at the solution at
higher pressure leaving behind the hot weak ammonia solution in the generator.

The weak ammonia solution flows back to the absorber at low pressure after passing through
the reducing valve. The high pressure ammonia vapour from the generator is condensed in the
condenser to a high pressure liquid ammonia. This ammonia is passed to the expansion valve

64
through the receiver and hen to the evaporator. This completes the simple vapour absorption
cycle.

DOMESTIC ELECTROLUX REFRIGERATOR

The domestic absorption type refrigerator was invented by two Swedish engineers Carl
Munter and Baltzer Vonplatan in 1925. The idea was first developed by the “Electrolux
Company” of Luton England.

65
66
67
 This type of refrigerator is also called three fluids absorption system. The main purpose
of this system is to eliminate the pump so that in the absence of moving parts, the machine
becomes noise less. The three fluids used in the system are ammonia, hydrogen and water. The
ammonia is used as a refrigerant because it possesses most of the desirable properties. It is
toxic, but due to absence of moving parts, there are very little chances for the leakage and the
total amount of refrigeration uses is small. The hydrogen being the lightest gas is used to
increase the rate of evaporation of the liquid ammonia passing through the evaporator. The
hydrogen is also non-corrosive and insoluble in water. This is used in low pressure side of the
system. The water is used as a solvent because it has the ability to absorb ammonia readily.
The principle of operation of a domestic Electrolux type refrigerator.

68
OPERATON CYCLE – The strong ammonia solution from the absorber through heat
exchanger is heated in the generator by applying heat from an external source usually a gas
burner. During this heating process, ammonia vapours are removed from the solution and
passed to the condenser. A rectifier or a water separator fitted before the condenser removes
water vapour carried with the ammonia vapours, so that dry ammonia vapours are supplied to
the condenser. These water vapours, if not removed, they will enter into the evaporator causing
freezing and chocking of the machine. The hot weak solution left behind in the generator flow
to the absorber through the heat exchanger. This hot weak solution while passing through the
exchanger is cooled. The heat removed by the weak solution is utilized in raising the temp. of
strong solution passing through the heat exchanger. In his way, the absorption accelerated and
the improvement in the performance is achieved.

The ammonia vapours in the condenser are condensed by using external cooling source.
The liquid refrigerant leaving the condenser flows under gravity to the evaporator where it
meets the hydrogen gas. The hydrogen gas which is being fed to the evaporator permits the
liquid ammonia to evaporate at a low pressure and temperature according to Dalton’s
principle. During the process of evaporation the ammonia absorbs latent heat from the
refrigerated space and thus produces cooling effect.

The mixture of ammonia vapour and hydrogen is passed to the absorber where ammonia
is absorbed in water the hydrogen rises to the top and flows back to the evaporator.

COP OF THREE FLUID ELECTROLUX VAPOUR ABSORPTION SYSTEM

HG = Heat given to refrigerant in generator

HC = Heat discharged to atmosphere from condenser & absorber
HE = Heat absorbed by refrigerant inn evaporator
HP = Heat added to refrigerant due to pump work (HP Very small)
TG = Temperature at which heat (HG) is given to generator
TC = Temperature at which heat (HC) is given to atmosphere
TE = Temperature at which heat (HE) is absorbed in evaporator

HC = H G + H E

In A Reversible System

Initial entropy = Final entropy

HG + HE = HC = HG + H E
TG TE TC TC

COPmax. = HE = TG . TG – TC
HG TC – TE TG

69
C.O.P. = Heat absorbed in the evaporator
Heat supplied in the generator
T1 = Ambient temperature = TA = °C +273 = °K

T2 = Generator temperature = TG = °C +273 = °K

T3 = Ambient temperature = TC = °C +273 = °K

T4 = Ambient temperature = TE = °C +273 = °K

COPmax. = HE = T E . TG – TA
HG T C – T E TG

PRECAUTIONS
1. Check the voltage, it should not be less than 220/230v; single phase, 50Hz C.C. supply.
2. Do not touch the heating (generator) section of the unit with bare hands during
operation.

70
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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-09

To Evaluate the Performance of the Experimental Water Cooling Tower Unit

OBJECTIVES:
1. To study the fundamentals of cooling tower.
2. To calculate the approach and range of cooling tower.
3. To study the variation in efficiency and cooling capacity at the different flow rates of
water.
4. To calculate the tower load
INTRODUCTION
A cooling tower is a steady flow device that uses a combination of mass and energy transfer to
cool water by exposing it as an extended surface to the atmosphere. The water surface is
extended by filling, which presents a film surface or creates drops due to splashing or by the
spraying, producing droplets. The airflow may be caused by the mechanical means or by
natural winds currents. Counter flow usage of mechanical draft tower is found principally in
air conditioning application. The principal advantage of counterflow is the adaptability to
restrictive space limitations. Factory assembled towers usually employ centrifugal blower in
forced draft configuration.

COOLING TOWER
Cooling towers are desired when positive control on the temperature of water is required
and the space required by a cooling tower is a considerable factor. Cooling towers are used for
big plants as absorption refrigeration systems, steam jet refrigeration systems and centrifugal
units of above 100 tons because below 100 tons capacity the evaporative condensers with
reciprocative compressors is found more economical.
The principal of cooling tower is similar to the evaporative condenser. The water goes in
the air in the form of vapour taking its latent heat from the remaining water and causes
reduction in temperature. The rate of evaporation from the tower depends on the following
factors:
1. Amount of water surface exposed.
2. The time of exposure.
3. The relative velocity of air passing over the water droplets formed in the cooling tower.
4. The R.H. of air and difference between WBT and water inlet temperature.
5. The direction of air flow relative to water.

73
 Theoretically, the water can be cooled to wet bulb temperature of entering air if the air
leaving cooling tower becomes saturated. Generally the temperature of water coming out of
cooling tower is 3 to 5 degrees above the WBT of entering air.
The temperature difference between the WBT of incoming air and outgoing temperature
of water is known as cooling tower’s “approach”. Higher the quantity of water circulated,
lower will be the approach of tower. The quantity of water circulated economically is also
limited by the power requirements of the pump.

-MECHANICAL DRAFT TOWER

These towers are generally used for all modern industrial processes due to small space
requirement for the same range than the natural draft towers. They have added the advantage
of not possessing the dominating height and also not requiring high pumping heads. Also they
offer some facility in the water temperature control. This incorporates a fan, which provides a
steady flow of air through the packing, making the dependence upon atmospheric conditions
even less. Here the only atmospheric factor affecting the performance is wet bulb temperature.
Provision of fan permits relatively high airflow & consequently smaller tower height for given
duty. The water temperature can be controlled accurately by regulating amount of air passing
through the tower, by fan speed, using controls etc. One of the major advantages of these
towers is that it can be cooled to lower water temperature then a natural a natural draft tower.
Additionally, this will cool more easily through much large temperature ranges.

DESCRIPTION
Experimental water-cooling tower model comprises of a tower of (0.3 x 0.3) m cross-
section area and approximately 1.5 m working height. Tower is fabricated out of M.S. sheet
and angle frame and is provided with a Perspex sheet for visualization of tower operation. Hot
water spray arrangement is provided at the top of the tower to distribute water over the
packing. Just below the packing, a wind box is fitted, provided with drills on all sides for
uniform entry of air in the tower. Bottom end of the tower goes in the water-measuring tank
used for water measuring. At the top end of the tower & in the wind box, dry/wet bulb
thermometers are fitted to measure air entry & exit condition in the tower. Five additional
thermometer pockets at air bleed tapping are provided along the tower height at equal
intervals.
Expended wire is used as a tower packing material. This type of wire mesh is considered
as a unique for film packing. Unlike solid film packing, wire mesh presents the minimum
restriction to the passage of air. A 3 H.P. centrifugal air blower is used to supply air to the
cooling tower. Air piping is provided with control valve and orifice meter for airflow variation
and measurement respectively. Water line for cooling tower is connected through a rotameter
for flow measurement and through a series of electrical geysers for water heating. A
thermometer is provided at inlet to water line is used to vary flow rate. By simultaneously
varying water flow rate and changing number of geysers; various inlet water temperatures can
be achieved. Water after passing through the tower packing is carried to a measuring tank for

74
measuring out going water flow for measuring evaporation loss. After measurement, water is
directed to the sump.
A new concept of psychometric gun is used to measure dry/wet bulb temperature of air at
intermediate point of tower packing of depths. By this method air is sucked through the tower
packing with the help of supply blower and passed over the dry/wet bulb thermometers. This
gives fairly good indication of the condition of air in the packing at specific section of the
tower.
An orifice meter fitted in the suction line of the psychometric guns measure aspiration
velocity of air sucked through tower. This aspiration velocity is responsible for the accuracy of
wet bulb depression.
A control panel is provided with (1) A rotameter for water flow measurement (2) D.P.
switches for putting ON/OFF individual geysers (3) U tube manometer for air flow
measurement (4) Well type manometer for aspiration velocity measurement through
psychometric gun (5) A suitable cupboard is provided at the bottom of control panel for
keeping the accessories. Suitable thermometers are provided at various locations in the set up
for temperature measurement.

FACTORS AFFECTING PERFORMANCE OF COOLING TOWER:

The cooling tower under observation is FORCED DRAFT COOLING TOWER. The
performance of cooling tower is measured in terms of its efficiency which is defined as:

Efficiency= Twi – Two = Twi – Two = Range =

Twi – Tab (Twi - Two)+(Two – Tab) Range + Approach

Where Twi and Tw0 are inlet and outlet temperatures of water and Tab is wet bulb
temperature of inlet air.

The efficiencies of different types of cooling systems are given below:

1. Spray-ponds : 40 – 50 %
2. Natural draft tower : 50 – 70%
3. Mechanical draft tower : 60 – 80 %

Factors affecting performance of cooling tower:

1. The amount of exposed water surface and length (time) of exposure.
2. The velocity of air passing through the tower.
3. The direction of air flow with relation to the exposed water surface (parallel,
transverse, or counter wise)

The exposed water surface includes:

1. The surface of water in the tower basin.
2. All wetted surfaces in the tower.
3. The combined surface of water droplets falling through tower.

75
 The temperature reduction experienced by the water in passing through the tower is called
“RANGE” of the tower. Naturally to maintain equilibrium in the condenser water system,
the tower range must always be equal to the temperature rise of water in the condenser.

SPECIFICATIONS
1. Tower size : Cross section 0.3 x 0.3m, height : 1.5m
2. Packing : Expended wire mesh (two sets)
3. Centrifugal blower : 3 H.P.
4. Dry bulb, wet bulb thermometer : 2 sets range 0-100 °C
5. Geysers to provide hot water : 02 Nos
6. Rotameter to measure water inlet flow
7. Psychometric gun to measure wet and dry bulb temperature at 5 positions in the tower
along with Orifice meter
8. Mercury/Alcohol in glass thermometer, measuring water temperature at 5 positions in
the tower.
9. Calibrated water outlet measuring tank.
10. Panelized electric control and switches.

OPERATIONS:
Operation and test procedure
1. Fill the tank up to half of its capacity.
2. Switch on the main board, check voltage. It should not be less than 190 volts.
3. Now start the pump and circulate the water at full flow to equalize the temperature.
4. Note down the readings of room air temperature for both DBT and WBT.
5. Now start the blower and ensure that its suction valve should not be closed.
6. Adjust the water flow rate any desired value and note the inlet temperature.
7. Note down the temperature of incoming air.
8. Now run the machine at least for 30 min. and take the readings of
a. Outlet water temperature.
b. DBT and WBT of outgoing air.
9. Now switch on the heater and adjust the water flow rate at 250 lt/hr and after 20 min.
take the next reading.
10. Now decrease the flow rate stepwise to take 4-5 readings of duration 20 min. and make
table for all the observations.

OBSERVATIONS:

T1-Dry Bulb Temperature (Ambient) =

T2-Tab Wet Bulb Temperature (Ambient) =
T3-Dry Bulb Temperature (Tower Inside) =
T4-Wet Bulb Temperature (Tower Inside) =
T5-Twi-Water Inlet Temperature =

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 T6-Two-Water Outlet Temperature =

CALCULATIONS:

Performance of the cooling tower is evaluated by using experimental results obtained during
testing. The analysis can be carried out as described below:

1. Calculate the approach: the approach is defined as the difference between the water
outlet temperature and wet temperature of the entering air.
Let Two- water inlet temperature
Tab- wet bulb temperature of incoming air

Approach = Two-Tab =

2. Cooling range this is defined between inlet water temperature and outlet temperature

Range = Twi – Two

Where Twi-water inlet temperature &

Two-water outlet temperature

3. Cooling tower efficiency this is defined as ratio of actual decrease in water temp to the
maximum theoretically possible drop in water temp.

Efficiency = Twi – Two = Twi – Two = Range =

Twi – Tab (Twi-Two)+(Two-Tab) Range + Approach

4. Tower Load = [Link].(Twi – Two) kW

3600

= kW

= TR
Where cpw = 4.186 kJ/kg.k

PRECAUTIONS:
1. Check the voltage before starting the unit.

77
2. Do not run the geyser in empty condition. First switch on the pump, re-circulate water
for one minute and then start heating if required.

3. Do not start the unit before putting the water in the storage tank.

4. Do not run the blower when the suction is fully closed.

5. Mount rotameter vertically and maintain upward flow run.

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 RE
FRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-10
To study the Evacuation & Gas Charging Procedure for Refrigeration Systems

OBJECT: To study the following

1. Evacuation procedure for refrigeration systems
2. Gas charging procedure for refrigeration systems

79
EQUIPMENT: Unitools Gas Charging & Evacuating Station ‘Junior’ B Model

THEORY

UNITOOLS strongly recommends the use of their “JUNIOR” B Model gas charging &
evacuating station for training institutes a maintenance shops having different type of cooling
units with refrigeration charge R-134a & R-22. This station is designed in such a way that two
cooling unit having difference refrigerant charge I.E R-134a Or R-22 can be dehydrated,
degassed and be charged at a same time/or one by one.

Evacuation:

To evacuate the entire system fitted on the board see that the suction line of the vacuum
is connected with the copper line provided on back side of the board. Three pin plug provided
with the board lead may be put to main supply 220 volts single phase.

To evacuate the system fitted on the board keep open hand shut off valves Nos. 1, 2, 3
and storage cylinder valves. Where as all other valves will remain closed.

Switch on vacuum pump run the same for sufficient time till the required vacuum is
created in the compound gauge fitted on the one side gauge manifold. Close valve no.3 of both
the sides and switch-off vacuum pump now the entire system is evacuated.

Note that if the storage cylinder fitted on the back side of the board are fitted with gas
then please do not open storage cylinder valve because the refrigerant filled in the cylinder will
run into the entire system till vacuum pump.

CHARGING REFRIGERANT INTO STORAGE CYLINDER (BACK SIDE):

R-134a or F-22 : Close valve no.1 and storage cylinder valve remove storage cylinder
from the board, fill the same with gas and refit the same as its own position and connect it with
its supply line.

FILLING THE GAS INTO GAS CHARGING CYLINDER:

Open storage Cylinder valve no.1 and permit the flow of liquid gas into the gas charging
cylinder. Open air purging valve no.4 for a while and purge air out of graduated cylinder and
closed the same immediately. When the liquid gas flow into the glass tube 5 OZS, Close
graduated cylinder See that valves nos.2, 3 and 4 are closed.

EVACUATION OF MACHINE TO BE CHARGED:

80
 To evacuate the entire system or refrigeration or air-conditioner or any other machine
which is to be charged connect the low side of the machine through flexible charging line
proved with gauge manifold no. 5. Open valve no. 5 and valve of the machine widely of the
machine to charged. Open valve no. 3. Be sure that all the other valves are closed. Switch on
vacuum pump for sufficient until you get entire vacuum on the compound gauge fitted with
gauge manifold. When the required vacuum is created, closed valve no. 5 and 3 immediately
and switch of the vacuum pump. Now the machine is evacuated and ready for refrigerant
charge.

TO CHARGE THE REFRIGERATION SYSTEM (MACHINE):

The low side of the machine is already connected with gauge manifold valve no. 5
connect the high side of the machine with gauge manifold valve no. 5 through flexible rubber
charging line provided on it if so desired. See that values of the machine to be charged are
widely open and gauge manifold valve no. 5, open valve no. 2 gradually and allow the flow of
the gas into the machine.

Watch graduated cylinder and when the desired quantity of gas has been charged close
down valve no.2 open valve no.5 plug on the machine, to be repaired with the board and
switch on. Let the machine run, watch the low and high pressure on the gauges provided on
gauges provided on gauge manifold and machine is charged.

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 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-11
Study of Various Types of Evaporators and Condensers

OBJECT: To study the following

1. Various types of Evaporators
2. Various types of Condensers

VARIOUS TYPES OF EVAPORATORS

(A)Fins & Tube Type Evaporator

It consists of bare tubes or coils over which the metal plates or fins are fastened. The metal fins
are constructed of metal having good thermal conductivity. The shape, size or spacing of the
fins can be adapted to provide best rate of heat transfer for a given application. Since the fins
greatly increase the contact surfaces for the heat transfer, so these evaporators are also called
extended surface evaporators.
The finned evaporators are designed for air conditioning applications where the
refrigeration temperature above 0°C. a finned coil should never be allowed to frost because the
accumulation between the fins reduces the capacity. The air conditioning coils which operate
at suction temperatures high enough that frosting never occurs, have fin space as small as
3mm. the finned coils, which frost on the on cycle and defrost on the off cycle have wider fin
spacing.

(B) Shell & Tube Evaporator

It consists of no. of horizontal tubes enclosed in a cylindrical shell. The inlet and outlet
headers with perforated metal tube sheets are connected at each end of the tubes. These
evaporators are used to chill water or brine solution. When it is operated as a dry expansion
evaporator, the refrigerant circulates through the tubes and the liquid to be cooled fills the
space around the tubes within the shell. The dry expansion shell and tube are used for the
refrigerant units of 2 to 250 TR capacity. When it is operated as flooded evaporator, the water
and brine flows through the tubes and the refrigerant circulates around the tubes. The flooded
shell and tube evaporators are used for refrigerating units of 10 to 5000 TR capacity.

(C) Tube In Tube Evaporators

The tube in tube evaporator consists of one tube inside another tube. The liquid to be
cooled flows through the inner tube while primary refrigerant or secondary refrigerant (i.e.
water, air or brine) circulates in the space between the two tubes. The tube in tube evaporators
of same heat transfer rates. However, they require more space than shell and tube evaporators

82
of same capacity. These evaporators are used for wine cooling and in petroleum industry for
chilling of oil.

(D) Plate Evaporators

These are of two types

 Tube and plate type

 Tube with in plate type

In tube and plate type evaporator tubes are welded on the one side of the plate either on
upper side or on inner side. In tube with in plate type tubes are inbuilt between the two
layers of plates which are joined together and welded at the edges. This provides better
heat transfer ability. The plate evaporators are generally used in house-hold refrigerators,
home freezers, beverage cooers, ice cream cabinets, locker points etc.

(B) Shell & Coil Evaporator / Immersion Type

The shell and coil evaporators are generally dry expansion evaporators to chill water.
The cooling coil is continuous coil that can be in the form of single or double spiral. The shell
may be sealed or open. The sealed shells are generally found in shell and coil evaporators used
to cool drinking water. The evaporators having flanged shells are often used to chill water in
secondary refrigeration systems. These are used for 2 to 10 TR capacity units.

VARIOUS TYPES OF CONDENSERS

(A) Fins & Tube Type Condenser

It consists of bare tubes or coils over which the metal plates or fins are fastened. The
metal fins are constructed of metal having good thermal conductivity. The shape, size or
spacing of the fins can be adapted to provide best rate of heat transfer for a given application.
The condenser with single row of tubing provides most efficient heat transfer. This is because
air temperature rises as it passes through each row of tubing. The temperature difference
between the air and vapour refrigerant decreases in each row of tubing and therefore each row
becomes less effective. However, single row condenser requires more space than multi row
condenser. The single row condenser are usually used in small capacities refrigeration systems
such as domestic refrigerators, freezers, water coolers and room conditioners.

(B) Tube In Tube Condenser

It consists of a water tube inside a large refrigerant tube. In this type of condenser the hot
vapour refrigerant enters at the top of condenser. The water absorbs heat from refrigerant and
condensed liquid refrigerant flows at bottom. Since the refrigerant tubes are exposed to
ambient air, therefore some of the heat is also absorbed by the natural convections.

83
 The cold water in the inner tubes may flow in either direction. When the water enters at
the bottom and flows in the direction opposite to the refrigerant, it is said to be counter flow
system. On the other hand, when the water enters at the top and flows in the same direction as
the refrigerant, it is said to be a parallel flow system.

(C) Shell & Tube Type Condenser

It consists of a cylindrical steel shell containing no. of straight water tubes. The tubes are
expanded into grooves in the tube sheet holes to form a vapour tight fit. The tube steels are
welded to the shell at both ends. The removal water boxes are bolted to the sheet at each end to
facilitate cleaning of the condenser. The intermediate supports are provided in the shell to
avoid sagging of the tubes. The tubes are made of either steel or copper.
In this condenser the hot vapour refrigerant enters at the top of shell and condenser as it
comes in contact with water tubes. The condensed liquid refrigerant drops to the bottom of the
shell which often serves as receiver. However, if the storage capacity for the liquid refrigerant
is less than the total charge of the system then a receiver of adequate capacity has to be added
in the case the pump down facility is to be provided as in the ice plants, cold storage etc. in
some condensers, extra row of water tubes are provided at the lower end of the condenser for
sub cooling of the refrigerant below the condensing temperature.

(D) Shell & Coil Condenser / Immersion Type

It consists of one or more water coils enclosed in a welded steel shell. It may either be
vertical or horizontal. In this hot water vapour refrigerant enters at the top of shell and
surrounds the water coils. As the vapour condenses, it drops to the bottom of the shell which
serves as a receiver. Most vertical type shell and coil condenses use counter flow water system
as it is more effective than parallel flow water system. In shell and coil condenses, coiled
tubing free to expand and contract with temperature changes. Since the coils are enclosed in a
welding steel shell, so mechanical cleaning is not possible. The coils are cleaned chemically. It
is used for 50 TR capacity units.

84
 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-12
Practice in Cutting, Bending and Flaring, Swaging of Copper Tube

OBJECT: To study
1. Know the method of cutting of copper tubes used in RAC equipment.
2. Know the techniques of bending and flaring of copper tubes used in RAC equipment.
3. Know the technique of swaging and brazing of copper tubes.

TOOLS AND EQUIPMENT REQUIRED

1. Copper tubes hard and soft (3mm, 6mm, 12.5mm diameters)
2. Tube cutter
3. Bending tool (outside bending spring)
4. Flaring tool (block and yoke)
5. Vernier caliper
6. Micrometer 25mm
7. File
8. Steel rule
9. Swaging tool
10. Brazing rod (composition 60% copper + 40% lead)
11. Blow lamp
12. Flux material

PROCEDURE

CUTTING OPERATION: Refer figure – 1

1. Measure the copper tube (3mm, 6mm, 12.5mm) required to be cut with the help of steel
rule or tape.
2. Place the copper tube in V-guide of the tube cutter.
3. Place the cutting edge of the cutter at the point measured for cutting.
4. Tighten the screw such that cutting edge is having a considerable pressure against the
copper tube.
5. Revolve the cutter slowly around the copper tube in such a way that the cutting edge is
gradually fed into the copper tube (which may be visible cutting ring around the tube).
6. Apply pressure with the thumb screw by turning the thumb screw into the tube and
given a turn to the cutting tool.
7. Repeat this process again and again till the tube is cut.
8. Ream and file the edge of the copper tube cut. Keeping the opening of the copper tube
downward while reaming the tube such that the chips do not remain inside the tube.
9. Measure the inside diameter of the copper tube with inside caliper.
10. Measure outside diameter of copper tube with micrometer.

85
11. While revolving the cutting tool around the tube it should be slowly revolved to avoid
excessive pressures which may cause hardening of tubes.
12. While cutting the pieces on a refrigeration unit, copper tube end must be sealed after
cutting to protect it against dirt and moisture, etc.

86
BENDING: Refer figure – 2
1. After cutting the required size of copper tubing mentioned in the above part the copper
tube is required to be Benton lever type tool bender at 90 deg, 180 deg bends (or as
required in the job).
2. Unscrew the nut, remove the bolt, fit the tube in the grooves both at the top and bottom,
tighten the nut and bolt to lock the tube in the lever.
3. Hold the tube with the clamp holder.
4. Hold the copper tubing in the bending tool with your hand and bend it to form 90 deg
(one quarter of circle bend) by turning the lever rod.
5. Bend the tube by turning the lever rod further to 180 deg bend.

87
Flaring: Refer figure – 3
1. Copper tube required to be flared is cut according to size and is placed in the flaring
block (as shown). The tube is projected up to a height of about 1.5mm.
2. Tighten the clamp to lock the tube.
3. Select the yoke according to the size of the copper tube to be flared.
4. Attach the yoke to the flare block and check the taper of the cone, it should be 45
deg.
5. Apply a small amount of lubricating oil on the cone and place the cone on the mouth
of the tube (as shown).
6. Tighten the cone by screwing the handle into the mouth of the copper tube.
7. Fare is made on the tube by gently tightening the screw by rotating the handle as
shown.
8. Unscrew the screw handle and unlock the tube.
9. Flare is ready to use.
10. Check for flaring defects, if any. (Flaring defect can be, for example, because of
uneven the copper tube flare).

88
SWAGING: Refer figure – 4
1. Properly place the flared copper tube in the flaring block after flaring operation has
been completed and hold the block in the bench vice. (Keep copper tube projected
above the block for a distance of (d tube +4mm) (see fig.).
2. Oil the tip of the punch (equal to diameter of the copper tube).
3. Forces feed the punch with the help of hammer by applying the force slowly and punch
it up to a depth just approximately equal to the diameter of the tube plus 2 mm (d tube
+2mm).
4. Now gradually hammer the punch little more and remove the punch slowly by applying
little force.
5. The whole operation of swaging has been completed and thus removes the tube for
further use.

89
BRAZING:
1. Clean the surface of the tubes to be brazed with the help of sandpaper.
2. Apply fuse material to clean the surface chemically; this will dissolve oxides formed in
the surface.
3. Achieve a force fit between the parts to be brazed.
4. Hold the brazing rod in one hand and blow lamp in the other hand. Heat both the tubes
with the help of a blow lamp uniformly from all sides.
5. Apply brazing material which is in the form of a rod (40%lead + 60%copper). This rod
is known as easy flow brazing rod made from copper and lead.
6. Feed the brazing material by melting it over the fitting till joint is achieved.

PRECAUTIONS:
1. After cutting the copper tubing in a refrigerator unit, it should be covered/sealed so that
no moisture or dust particle enters into the refrigeration system.
2. Avoid excessive handling of copper tube otherwise, due to its softness, it can become
hard.

90
 REFRIGERATION & AIR CONDITIONING LAB

EXPERIMENT-13
Study of Reciprocating Hermetically Sealed Compressor

OBJECT: To study the construction, working, advantages and limitations of Reciprocating

Hermetically Sealed Compressor

TOOLS AND EQUIPMENTS REQUIRED

1. Hermatic compressor 6. Electric arc welding

2. Hacksaw 7. Cleaning rags
3. Spanner set 8. Petrol
4. Screw driver 9. Nitrogen gas at pressure
5. Tray

RELATED THEORY

WHAT IS HERMETIC COMPRESSOR?

The motor in a Hermetic Compressor is sealed inside the housing and is directly
connected to the pump of the compressor. Crankshaft seal is not required.

A motor rotor is usually press fit onto the pump crankshaft. The unit is usually spring
mounted inside the hermetic dome. Reciprocating compressor, because of unique nature of
internal spring mounting, has the least discharge pulsation and vibration and hence is less
noisy in the air conditioner. This feature of low noise level made the reciprocating technology
popular in domestic air conditioning.

The exhaust and suction lines inside the dome are made flexible. The electrical
connections to the motor pass through the dome by means of insulated leak proof seals.

In case of reciprocating compressors, the motor is suction cooled. Hence the life of the
compressor is more specially in the case of tropical conditions with high ambient.

To lubricate the compressor, the oil is fed to the shaft and by centrifugal force the oil is
thrown on to the motor. The centrifugal force makes the heavy particle remains away from the
shaft and hence only the oil and refrigerant remain in the centre.

The rotary motion of the shaft is converted into a reciprocating motion by means of a
connecting rod. The piston and the connecting rod are housed in a leak proof crankcase, which
is very efficient.

91
 Usage of mufflers is possible in case of reciprocating compressors and hence the noise
level of the hermetic compressor is further reduced. Many manufacturers utilize the space
available in the reciprocating hermetic compressors and reinforce the motor to take care of the
wide voltage fluctuations.

Reciprocating technology with its robust and efficient mechanism supported the need of
human comfort. It marks the efficient journey of refrigeration and air conditioning.

Hermetic Compressors is one, which has the motor, sealed inside the compressor
housing; the motor operates in an atmosphere with the refrigerant.

Hermetic reciprocating–compressor–motor assembly contained in a welded steel case, is

typically used in household refrigerators, residential air conditioners, smaller commercial air
conditioning and refrigeration units.

1/8 to 5 horsepower hermetic reciprocating compressors provides cost effective solutions

to systems requiring a wide range of evaporating capability. Typical applications include food
service, ice machines, and beverages dispensers.

The basic function of the compressor is to move the refrigerant from the evaporator to
condenser at a temperature and pressure, at which it will be cooled, giving its latent heat and
changing back to liquid. A refrigerating hermetic compressor is a compressor sealed in a single
covering with electric motor. There is no need of shaft seal and no chances of leakage with this
unit. This is widely used in small units such as refrigerator, water cooler and air-conditioner.

Fig. 1 and 2 show the details of a hermetic compressor. The numbers of the parts and the
names of the parts are shown below:

1. Bottom shell (Lower doom) 30. Suction reed

2. Suction tube 31. Flapper valve plate
3. Rubber dead plug 32. Discharge valve reed
4. Base support 33. Stop spring
5. Base support 34. Stop valve
6. Oil cooler tube 35. Screw valve plate
7. Fustile terminal guard 36. Head gasket
8. Bracket 37. Retainer
9. Fustile terminal 38. Rubber seal
10. Charging tube 39. Bolt cylinder head
11. Rubber dead plug 40. Spring washer
12. Spring holder 41. Cylinder head
13. Upper dome 42. Discharge muffler assembly
14. Motor housing 43. Clip
15. Washer 44. Discharge tube

92
 16. Screw for fixing stator 45. Spring damper
17. Stator 46. Washer for muffler
18. Oil stirrer 47. Screw muffler bracket
19. Rotor 48. Spring mounting
20. Eccentric shaft 49. Suction muffler
21. Eccentric 50. Screw
22. Sleeve 51. Washer
23. Cylinder head 52. Screw cylinder mounting
24. Connecting head 53. Washer
25. Gudgeon pin
26. Piston
27. Gudgeon pin retainer
28. Piston ring
29. Valve plate gasket

PROCEDURE
1. Take out the oil from the dome of the compressor through suction or charging line.

2. Cut the welding of dome with the help of hacksaw and separate the two halves of the
dome.

3. Clean the dome properly.

4. Take out the compressor motor assembly from the dome by removing spring attached to
the dome.

5. Remove the suction and discharge mufflers and study their function.

6. Open the valve assembly.

7. Note the construction of suction valve.

8. Note the construction of discharge valve and retainer and spring for discharge valve.

9. Study the working of both valves.

10. Rotate the crankshaft and note how the motion is transferred from crankshaft to the
piston.

11. Also note the type of crankshaft to be used.

12. Dismantle the crankshaft and connecting rod.

93
13. Also separate the piston from the connecting rod by taking out the piston pin.

14. Note the material the rings are used on the piston or not.

15. Note the material of each and their functions.

16. See if there is any defect by repairing or changing the part if required.

17. Remove the defect by repairing or changing the part if required.

18. See if there is any defect in electric motor with the help of a multimeter and note it.

19. Get it rectified from the electrician if there is any defect.

20. Now assemble the parts in correct sequence using the proper size gasket (please refer to
fig.1 and 2)

21. Give the supply to electric motor and check the working of compressor.

22. Place the compressor, motor assembly in the dome properly with the help of springs
and get the dome welded.

23. Give the required pressure and test it for leakage.

24. If there is no leakage make the vacuum and fill the lubricating oil.

25. Place the compressor in the system. Make required joints at the suction and discharge
points.

26. Achieve perfect vacuum, dehydrate it and charge the system with required quantity of
proper refrigerant.

27. Start the compressor and complete the charging operation.

28. Check for its satisfactory working.

29. If required discharge pressure is not achieved, check for the leakage of the refrigerant in
the system/plant/equipment.

30. Repair the leakage and check for its satisfactory working.

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 ADVANTAGES OF HERMETIC COMPRESSOR:

This compressor has many advantages over the ordinary type of compressor as listed
below:
 The leakage of the refrigerant is completely avoided.

 It is less noisy than the ordinary systems.

 Being more compact it requires small space.

 This type of construction is generally used for small capacity refrigerating systems
as household refrigerator or small capacity coolers.

DISADVANTAGES OF HERMETIC COMPRESSOR:

 While known for their reliability, the hermetic compressors are neither energy efficient
or powerful when compared to other types.

 This is primarily due to the fact that they are sealed units. Therefore, the enclosed motor
is cooled by the circulating refrigerant rather than the surrounding air.

 This additional heat, which must flow now be removed by the refrigerating system, may
equal 40% more of that of the actual ice box.

 The net effect is to substantially increase the total heat load and the energy required to
remove it.

PRECAUTIONS
1. Always place all the parts of the compressor in a tray.

2. See that no part is lost while assembling and disassembling in a proper sequence.

3. Clean all parts well before assembly.

4. Always replace the gaskets whenever the compressor is re-assembled.

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