ASSIUT UNIVERSITY

FACULTY OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT

Refrigeration System with Two Different

Evaporator Pressures

Course: Mechanical Power Laboratory

Dr. Hossam Eldien
By :Mark Bahaa Aziz

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 System Components and Their Functions

The experimental setup consists of several key components that form the multi-evaporator
refrigeration cycle. Below is a detailed description of each component, its function, and the
specific types used in this experiment:

1. Compressor

• Function: It is the primary component that circulates the refrigerant. It draws low-pressure
vapor from the evaporators and compresses it to a high-pressure, high-temperature state.

• Type in Experiment: Semi-Open Reciprocating Compressor.

• Other Common Types: Scroll, Screw, Centrifugal, and Rotary

compressors.

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 2. Condensers

• Function: These act as heat exchangers that reject the heat absorbed from the evaporators
(and the heat of compression) to the cooling water, causing the refrigerant to condense into a
liquid.

• Types in Experiment: The system utilizes two types of water-cooled condensers: a

Shell-and-Tube heat exchanger and a Double-Pipe (tube-in-tube) heat exchanger.

• Other Common Types: Air-Cooled Condensers and Evaporative Condensers.

3. Cooling Tower (Auxiliary System)

• Function: It serves as the heat sink for the entire system. It receives the warm water leaving
the water-cooled condensers and cools it through partial evaporation before recirculating it back to
the condensers.

• Relation to Experiment: Necessary for the continuous operation of the water-cooled

condensers used in the setup.

• Common Types: Forced draft, Induced draft, and Natural draft cooling towers.

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 4. Evaporators

• Function: These are the components where the actual

cooling effect takes place. The low-pressure liquid refrigerant
absorbs heat from the surrounding air and evaporates.

• Type in Experiment: Two Forced-Draft Fin-and-Tube

evaporators operating at two different pressure levels.

• Other Common Types: Shell-and-tube and plate heat

exchangers.

5. Expansion Valves

• Function: They reduce the pressure of the liquid refrigerant coming

from the condenser and control the mass flow rate entering each evaporator.

• Type in Experiment: Two Thermostatic Expansion Valves

(TXV).

• Other Common Types: Capillary tubes and Electronic Expansion

Valves (EEV)

• How the Thermostatic Expansion Valve (T.E.V.) Works

The T.E.V. reduces the high condenser pressure to the low evaporator pressure while regulating the
refrigerant mass flow rate. Its primary goal is to maintain a constant degree of superheat at the
evaporator exit, ensuring only vapor reaches the compressor.
Working Principle & Logic:
The valve's operation is governed by the balance of three internal forces (P_1 = P_2 + P_3):
1. Sensing Bulb Pressure (P_1): Acts as the opening force. It senses the evaporator exit
temperature; higher heat increases P_1.
2. Evaporator Pressure (P_2): Acts as a closing force.
3. Spring Pressure (P_3): Acts as a constant closing force (used to set the desired superheat).
Logic: When the cooling load increases, the superheat rises, expanding the bulb fluid (P_1).
This overcomes the closing forces (P_2 + P_3), opening the valve wider to admit more
refrigerant. Conversely, if the load drops, P_1 decreases, and the valve partially closes.

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 6. Liquid Receiver

• Function: A storage vessel that holds the high-pressure liquid refrigerant after
it leaves the condenser, ensuring a steady supply to the expansion valves.

7. Oil Separator

• Function: Located in the discharge line to separate lubricating oil from the
refrigerant gas and return it to the compressor crankcase.

8. Instrumentation and Measurement Stations

• Function: Used to monitor the thermodynamic states of the refrigerant at various points for
performance calculations.

• Types in Experiment:

• Pressure Gauges (P): To measure inlet/exit pressures.

• Thermocouples (T): To measure temperatures at the compressor, condenser, and evaporators.

• Flow Meters (F): To measure the refrigerant mass flow rate.

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[Link] Cycle Defrost Mechanism
Frost accumulation on evaporator coils acts as a thermal insulator, significantly reducing the system's
heat transfer efficiency and overall capacity. The Reverse Cycle Defrost is a highly efficient method
used to eliminate this frost without relying on external electric heaters.
Working Principle:
Flow Reversal: The system utilizes a 4-way reversing valve to change the direction of the
refrigerant flow.
• Component Role Switch: The hot, high pressure discharge gas from the compressor is redirected
directly into the frosted evaporator, temporarily converting it into a condenser.
• Defrosting Process: As the hot gas condenses inside the cold coil, it releases its latent heat,
rapidly melting the ice from the inside out. The indoor evaporator fan is typically turned off during
this phase to prevent blowing unconditioned air into the space.

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Table : Final Experimental Data
No. Measured Parameter Unit Run 1 (2C, Run 2 (2C, Run 3 (1C, Run 4 (1C,
2ev) 1ev) 2ev) 1ev)
1 𝑇1 (Compressor suction) °C 22 20 18 19
2 𝑇2 (Compressor °C 74 70 66 67
discharge)
3 𝑇3 (Inlet to condenser) °C 65 59 56 54
4 𝑇4 (Outlet from °C 27 25 28 26
condenser)
5 𝑇5 (Outlet from receiver) °C 24 24 25 25
6 𝑇6 (Before TEV Evap. A) °C 23 23 23 24
7 𝑇7 (After TEV Evap. A) °C 3 3 3 3
8 𝑇8 (Exit from Evap. A) °C 2 4 3 5
9 𝑇9 (Before TEV Evap. B) °C 23 14 24 17
10 𝑇10 (After TEV Evap. B) °C 2 14 1 17
11 𝑇11 (Exit from Evap. B) °C 14 8 13 9
12 𝑃𝑐 (Condenser Pressure - psi 100 100 85 85
Gauge)
13 𝑃𝑐 (Condenser - psia 114.7 114.7 99.7 99.7
Absolute)
14 𝑃𝑐 (Condenser - bar 7.91 7.91 6.87 6.87
Absolute)
15 𝑃𝑒𝑣𝑎𝑝𝐵 (Evaporator B - psi 25 22.5 25 22.5
Gauge)
16 𝑃𝑒𝑣𝑎𝑝𝐵 (Evap B - psia 39.7 37.2 39.7 37.2
Absolute)
17 𝑃𝑒𝑣𝑎𝑝𝐵 (Evap B - bar 2.74 2.57 2.74 2.57
Absolute)
18 𝑃𝑒𝑣𝑎𝑝𝐴 (Gauge) psi 20 10 20 10
19 𝑃𝑒𝑣𝑎𝑝𝐴 (Absolute) psia 34.7 24.7 34.7 24.7
20 𝑃𝑒𝑣𝑎𝑝𝐴 (Evap A - bar 2.39 1.70 2.39 1.70
Absolute)

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General Assumptions & Governing Equations
* Working Fluid: Refrigerant R-12.
* Enthalpy Extraction: All enthalpy values (ℎ) in kJ/kg are extracted from the R-12 Pressure-
Enthalpy (P-h) chart using absolute pressures and measured temperatures.
* Mass Flow Rate Assumption: For runs operating with two evaporators, the total refrigerant mass
flow is assumed to divide equally between them (𝑚̇𝑒𝑣𝑎𝑝𝐴 = 𝑚̇𝑒𝑣𝑎𝑝𝐵 = 0.5𝑚̇𝑐𝑜𝑚𝑝 ). For runs with a
single evaporator, 100% of the mass flow passes through the active evaporator (𝑚̇𝑒𝑣𝑎𝑝 = 𝑚̇𝑐𝑜𝑚𝑝 ).
The Coefficient of Performance (C.O.P.) is calculated as:

TotalSpecificCoolingEffect 𝑞𝑡𝑜𝑡𝑎𝑙
𝐶. 𝑂. 𝑃. = =
SpecificCompressorWork 𝑤𝑐𝑜𝑚𝑝

Calculations for Run 1 (2 Condensers, 2 Evaporators)

* Operating Conditions: Both evaporators (A & B) are active.
* Enthalpy Values:
Compressor Suction (𝑇1 = 22∘ C): ℎ1 ≈ 203kJ/kg
Compressor Discharge (𝑃𝑐 = 7.91bar, 𝑇2 = 74∘ C): ℎ2 ≈ 232kJ/kg
Evap A Inlet (𝑇6 = 23∘ C): ℎ𝑖𝑛,𝐴 ≈ 58.5kJ/kg
Evap A Exit (𝑃𝑒𝑣𝑎𝑝𝐴 = 2.39bar, 𝑇8 = 2∘ C): ℎ𝑜𝑢𝑡,𝐴 ≈ 190kJ/kg
Evap B Inlet (𝑇9 = 23∘ C): ℎ𝑖𝑛,𝐵 ≈ 58.5kJ/kg
Evap B Exit (𝑃𝑒𝑣𝑎𝑝𝐵 = 2.74bar, 𝑇11 = 14∘ C): ℎ𝑜𝑢𝑡,𝐵 ≈ 198kJ/kg
* Specific Compressor Work (𝑤𝑐𝑜𝑚𝑝 ):

𝑤𝑐𝑜𝑚𝑝 = ℎ2 − ℎ1 = 232 − 203 = 29kJ/kg

* Specific Cooling Effect:

𝑞𝑒𝑣𝑎𝑝𝐴 = 0.5 × (ℎ𝑜𝑢𝑡,𝐴 − ℎ𝑖𝑛,𝐴 ) = 0.5 × (190 − 58.5) = 65.75kJ/kg

𝑞𝑒𝑣𝑎𝑝𝐵 = 0.5 × (ℎ𝑜𝑢𝑡,𝐵 − ℎ𝑖𝑛,𝐵 ) = 0.5 × (198 − 58.5) = 69.75kJ/kg

𝑞𝑡𝑜𝑡𝑎𝑙 = 𝑞𝑒𝑣𝑎𝑝𝐴 + 𝑞𝑒𝑣𝑎𝑝𝐵 = 65.75 + 69.75 = 135.5kJ/kg

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* C.O.P. Calculation:

135.5
𝐶. 𝑂. 𝑃. = = 4.67
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Calculations for Run 2 (2 Condensers, 1 Evaporator)

* Operating Conditions: Evaporator B is active, Evaporator A is isolated (100% flow to Evap B).
* Enthalpy Values:
Compressor Suction (𝑇1 = 20∘ C): ℎ1 ≈ 201kJ/kg
Compressor Discharge (𝑃𝑐 = 7.91bar, 𝑇2 = 70∘ C): ℎ2 ≈ 229kJ/kg
Evap B Inlet (𝑇9 = 14∘ C): ℎ𝑖𝑛,𝐵 ≈ 49kJ/kg
Evap B Exit (𝑃𝑒𝑣𝑎𝑝𝐵 = 2.57bar, 𝑇11 = 8∘ C): ℎ𝑜𝑢𝑡,𝐵 ≈ 194kJ/kg
* Specific Compressor Work (𝑤𝑐𝑜𝑚𝑝 ):
𝑤𝑐𝑜𝑚𝑝 = ℎ2 − ℎ1 = 229 − 201 = 28kJ/kg

* Specific Cooling Effect (𝑞𝑡𝑜𝑡𝑎𝑙 ):

𝑞𝑡𝑜𝑡𝑎𝑙 = 1.0 × (ℎ𝑜𝑢𝑡,𝐵 − ℎ𝑖𝑛,𝐵 ) = 194 − 49 = 145kJ/kg

* C.O.P. Calculation:
145
𝐶. 𝑂. 𝑃. = = 5.18
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Calculations for Run 3 (1 Condenser, 2 Evaporators)

* Operating Conditions: Both evaporators (A & B) are active.
* Enthalpy Values:
Compressor Suction (𝑇1 = 18∘ C): ℎ1 ≈ 199kJ/kg
Compressor Discharge (𝑃𝑐 = 6.87bar, 𝑇2 = 66∘ C): ℎ2 ≈ 227kJ/kg
Evap A Inlet (𝑇6 = 23∘ C): ℎ𝑖𝑛,𝐴 ≈ 58.5kJ/kg
Evap A Exit (𝑃𝑒𝑣𝑎𝑝𝐴 = 2.39bar, 𝑇8 = 3∘ C): ℎ𝑜𝑢𝑡,𝐴 ≈ 191kJ/kg
Evap B Inlet (𝑇9 = 24∘ C): ℎ𝑖𝑛,𝐵 ≈ 59.5kJ/kg
Evap B Exit (𝑃𝑒𝑣𝑎𝑝𝐵 = 2.74bar, 𝑇11 = 13∘ C): ℎ𝑜𝑢𝑡,𝐵 ≈ 197kJ/kg
* Specific Compressor Work (𝑤𝑐𝑜𝑚𝑝 ):

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 𝑤𝑐𝑜𝑚𝑝 = ℎ2 − ℎ1 = 227 − 199 = 28kJ/kg

* Specific Cooling Effect:

𝑞𝑒𝑣𝑎𝑝𝐴 = 0.5 × (191 − 58.5) = 66.25kJ/kg

𝑞𝑒𝑣𝑎𝑝𝐵 = 0.5 × (197 − 59.5) = 68.75kJ/kg

𝑞𝑡𝑜𝑡𝑎𝑙 = 66.25 + 68.75 = 135kJ/kg

* C.O.P. Calculation:

135
𝐶. 𝑂. 𝑃. = = 4.82
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5.5. Calculations for Run 4 (1 Condenser, 1 Evaporator)

* Operating Conditions: Evaporator B is active, Evaporator A is isolated (100% flow to Evap B).
* Enthalpy Values:
Compressor Suction (𝑇1 = 19∘ C): ℎ1 ≈ 200kJ/kg
Compressor Discharge (𝑃𝑐 = 6.87bar, 𝑇2 = 67∘ C): ℎ2 ≈ 228kJ/kg
Evap B Inlet (𝑇9 = 17∘ C): ℎ𝑖𝑛,𝐵 ≈ 52kJ/kg
Evap B Exit (𝑃𝑒𝑣𝑎𝑝𝐵 = 2.57bar, 𝑇11 = 9∘ C): ℎ𝑜𝑢𝑡,𝐵 ≈ 195kJ/kg
* Specific Compressor Work (𝑤𝑐𝑜𝑚𝑝 ):

𝑤𝑐𝑜𝑚𝑝 = ℎ2 − ℎ1 = 228 − 200 = 28kJ/kg

* Specific Cooling Effect (𝑞𝑡𝑜𝑡𝑎𝑙 ):

𝑞𝑡𝑜𝑡𝑎𝑙 = 1.0 × (ℎ𝑜𝑢𝑡,𝐵 − ℎ𝑖𝑛,𝐵 ) = 195 − 52 = 143kJ/kg

* C.O.P. Calculation:
143
𝐶. 𝑂. 𝑃. = = 5.11
28

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 Results Discussion and Conclusions
Summary of Results
The calculated Coefficient of Performance (C.O.P.) for the four experimental runs are as follows:
* Run 1 (2 Condensers, 2 Evaporators): C.O.P. = 4.67
* Run 2 (2 Condensers, 1 Evaporator): C.O.P. = 5.18
* Run 3 (1 Condenser, 2 Evaporators): C.O.P. = 4.82
* Run 4 (1 Condenser, 1 Evaporator): C.O.P. = 5.11
Analysis of C.O.P. Variations

• Effect of Isolating an Evaporator (Run 1 vs. Run 2):

When one evaporator was isolated (Run 2), the C.O.P. surprisingly increased from 4.67 to 5.18. By
analyzing the data, this occurred because shutting down one evaporator reduced the total thermal load on
the system while utilizing the full capacity of the two water-cooled condensers. This resulted in a massive
degree of subcooling. The temperature of the liquid refrigerant entering the expansion valve (𝑇9 ) dropped
significantly (from 23∘ C in Run 1 to 14∘ C in Run 2). This lower inlet enthalpy dramatically increased the
specific refrigerating effect (𝑞𝑒𝑣𝑎𝑝 ) per kilogram of refrigerant, leading to a higher C.O.P.

• Effect of Isolating a Condenser (Run 1 vs. Run 3):

Comparing Run 1 and Run 3, the C.O.P. slightly increased from 4.67 to 4.82. The data shows that the
condenser pressure dropped from 100psi to 85psi. A lower discharge pressure directly reduces the
compressor’s specific work (𝑤𝑐𝑜𝑚𝑝 ). Since the compressor worked against a lower pressure ratio, it
consumed less energy per unit mass, which improved the overall system efficiency.
System Logic and Fault Finding (Engineering Observations)
* Logical Assessment: The C.O.P. values ranging from 4.6 to 5.2 are highly logical and realistic for
a laboratory vapor-compression cycle operating with R-12 under moderate pressure ratios
(𝑃𝑐 /𝑃𝑒𝑣𝑎𝑝 ≈ 3).
* Fault Finding / Data Anomaly: An interesting thermodynamic anomaly is observed when
transitioning from 2 condensers to 1 condenser (Run 1 to Run 3). Theoretically, reducing the
condenser heat transfer area should increase the discharge pressure. However, the experimental data
shows the discharge pressure decreased (from 100psi to 85psi). This implies an external factor was
altered during the test—most likely, the cooling water flow rate passing through the remaining
condenser was significantly increased, or the ambient heat load dropped.

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