VAPOUR COMPRESSION REFRIGERATION

TEST RIG

S.P. ENGINEERS EQUIPMENT PVT LTD

JOB NAME: -
VAPOUR COMPRESSION REFRIGERATION
TEST RIG

Head Office: - 903, Shamali Building, DSK Raanwara, Bavdhan Pune-411021

M.S (INDIA) TELE PHONE :- 020 25290159, 9975504040
Email: spefactorygroup@[Link]

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Index

[Link]. DESCRIPTION PAGE NO.

1 WARRANTY CERTIFICATE 02

2 THEORY 03

3 COMPONENT LIST 05

4 SYSTEM DESCRIPTION 06

5 ASSEMBLY DRAWING 08

6 PRECAUTION SHEET 09

7 INSTALLATION PROCEDURE 10

8 OPERATIONAL PROCEDURE 11

9 OBSERVATION TABLE 12

10 CALCULATION PROCEDURE 13

11 RESULT TABLE 16

12 SAMPLE OBSERVATIONS 17

13 SAMPLE RESULTS 21

14 MAINTENANCE PROCEDURE 22

15 WIRING DIAGRAM 23

16 P&ID DIAGRAMS 24

17 GLOSSARY 25

18 NOTES 26

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MANUFACTURERS WARRANTY CERTIFICATE

TO WHOMSOEVER IT MAY CONCERN

REFERENCE:
[Link]: DATE : 22.09.15
PLACED BY: SUMAN RAMESH TULSIANI, KHAMSHET PUNE
ITEM DESCRIPTION: VAPOUR COMPRESSION REFRIGERATION
TEST RIG
QUANTITY: 1 NO.
This is to certify that, the equipments under above reference are thoroughly inspected
before dispatch and therefore can be depended upon for long and trouble-free service. We
undertake to make goods by replacement or repair, defects arising out of faulty design,
material or workmanship within 12 months of the date of dispatch providing that if we so
require the parts in respect of which a claim is made, must be sent at purchaser’s expense
to our works before liability can be entertained under this clause. Such expenses will be
refunded if our liability is admitted.
Bought out components are guaranteed by us only to the extent of guarantees given to us
by our suppliers. Electrical components such as motors, dimmer stat etc., and instruments
such as dial gauges etc., are however not covered under this warranty.
This warranty is valid subject to
1. Installation having been completed within one months of dispatch of the equipment and
as per our installation instructions.
2. The supply/installation having been formally accepted
3. The equipment or part thereof not being subject to accident, alteration, abuse or misuse.
4. The equipment being operated and maintained as per our operation and maintenance
manual.
For S. P. ENGINEERS

AUTHORIZED SIGNATORY

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THEORY

A simple vapor compression refrigeration system consists of the following

equipments: i) Compressor ii) Condenser iii) Expansion valve iv) Evaporator

The low temperature, low pressure vapor at state B is compressed by a

compressor to high temperature and pressure vapor at state C. This vapor is
condensed into high pressure vapor at state D in the condenser and then passes
through the expansion valve. Here, the vapor is throttled down to a low pressure
liquid and passed on to an evaporator, where it absorbs heat from the
surroundings from the circulating fluid (being refrigerated) and vaporizes into low
pressure vapor at state B. The cycle then repeats.

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The exchange of energy is as follows:

Compressor requires work, δw. The work is supplied to the system from the
surroundings.

During condensation, heat δQ1 the equivalent of latent heat of condensation etc,
is lost from the refrigerator.
During evaporation, heat δQ2 equivalent to latent heat of vaporization is absorbed
by the refrigerant.

There is no exchange of heat during throttling process through the expansion

valve as this process occurs at constant enthalpy.

Factors Affecting the Performance of Vapor

Compression

Refrigeration System:

(a) Sub-cooling of Liquids:

In simple vapor compression cycle, condensation process CD resulted in the liquid

at saturated state D. If it was possible to further cool down the liquid to some lower
value then the net refrigeration effect will be increased as (Hence, the sub cooling
of the liquid increases the refrigerating effect without increasing the work
requirement. Thus COP is improved. The sub cooling may be achieved by any of
the following methods:

By passing the liquid refrigerant from condenser through a heat exchanger through
which the cold vapor at suction from the evaporator is allowed to flow in the

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reversed direction. This process subcools the liquid but superheats the vapor.
Thus, COP is not improved though refrigeration effect is increased.

By making use of enough quantity of cooling water so that the liquid refrigerant is
further cooled below the temperature of saturation. In some cases, a separate
subcooler is also made use of for this purpose. In this case, COP is improved.

Superheating of Vapor:

If the vapor at the compressor entry is in the superheated state , which is produced
due to higher heat absorption in the evaporator, then the refrigerating effect is
increased .However, COP may increase, decrease or remain unchanged
depending upon the range of pressure of the cycle.
Change in suction pressure (PS):

Let the suction pressure or the evaporating pressure in a simple refrigeration cycle
be reduced.

Decrease in suction pressure decreases the refrigeration effect and at the same
time increases the work of compression. But, both the effects tend to decrease the
COP.

Change in discharge pressure (Pd):

let us assume that the pressure at the discharge or the condensing pressure is
increased.

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Therefore, the increase in discharge pressure results in lower COP. Hence, the
discharge pressure should be kept as low as possible depending upon the
temperature of the cooling medium available.

(e) Effect of Volumetric Efficiency of Compressor:

The factors like clearance volume, pressure drop through discharge and suction
values, leakage of vapor along the piston and superheating of cold vapor due to
contact with hot cylinder walls, affects the volume of the vapor actually pumped by
the compressor. The volumetric efficiency of a compressor is defined as;

Actual mass of vapor drawn at suction conditions

ηvol = -------------------------------------------------------------
Theoritical mass that can be filled in the
displacement volume

A vapour compression system is improved type of air refrigeration system in which

suitable working substance termed as refrigerant is used, it condensates and
evaporates at temperature and pressure close to atmospheric conditions. The
refrigerants used for this purpose are ammonia, carbon dioxide, and sulphur
dioxide.
The refrigerant used does not leave the system, alternatively condensing and
evaporating. In evaporation, the refrigerant absorbs it’s latent heat from which it is
used for circulating it around the cold chamber while cost during it gives latent heat
to the circulating water of the cooler. The VCS is thus latent heat pump as it
pumps
its latent heat from brine end and delivers it to the cooler. It is generally used for
all individual purposes from small domestic refrigerator to a big air conditioning
plant.

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ADVANTAGES:
1. It has similar size for given capacity of refrigerator.
2. It has less running cost.
3. It is employed for large range of temperature.
4. The COP is quite higher.
DISADVANTAGES:
1. The initial cost is higher.
2. The leakage of refrigerant is difficult to avoid.

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COMPONENT LIST
After unpacking you will find following things:

Sr. Description Part No.

No.

01 Base stand SPREFACM0001

02 Pressure gauge: 0 to 500 psi SPREFACM0002
03 Compound gauge. 0 to -150psi SPREFACM0003
04 Temperature Indicator. SPREFACM0004
05 Condensers SPREFACM0005
06 Evaporators SPREFACM0006
07 Hermetically Sealed compressor SPREFACM0007
08 Condenser motor & fan blade SPREFACM0008
09 Thermostat SPREFACM0009
10 R134A gas SPREFACM0010
11 Rotameter SPREFACM0011
12 Capillary tubes. SPREFACM0012
13 ON/OFF Switch SPREFACM0013
14 Pt 100 sensor pencil type & bulb type. SPREFACM0014
15 Instructional Manual SPREFACM0015

(A) Kindly remove all the packing material & clean the components with cloth.
Please check the components as per list mentioned above. If you have any
difficulty please feel free to contact us.

Follow the installation procedure carefully

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SYSTEM DESCRIPTION

In refrigeration test rig, working medium is liquid; which involves

sensible as well as latent heat. And coefficient of performance of
refrigeration test rig is more than that of air compression system. Most of
the modern refrigerators work on refrigeration test rig.

Therefore it is necessary for engineering students to Study the

performance of refrigeration cycle & its different parameter, performance,
calculations is focus of this trainer.

S.P. Engineers have designed this system in such a fashion that, Vapour
Compression Refrigeration cycle & its components can be easily
understood. The system can be easily operated; demonstrated & requisite
experimentation can be performed.

 Base Stand:
This is made up of CRCI square tubes & sheets. This is painted
specially with Powder coating. All equipments are mounted on Base
stand.

 Hermetically Sealed Compressor: This is used to take the refrigerant

Vapor at low pressure & low temperature & compress it to a high
pressure & high temperature. The capacity of compressor is 0.75 HP
 Condenser: The condenser is the forced air-cooled type for which
condenser fan and motor has been provided. The function of
condenser is to convert high-pressure refrigerant Vapor into high-
pressure refrigerant liquid. The outside diameter of condenser is

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3/8”. Size of condenser as per standard specification is 11” x 10” x 3

Rows

 Expansion Devices: (Capillary Tube): Capillary tube is the expansion

device which is used for small units of ½ to 3 tons. The purpose of
expansion valve in a refrigeration system is to reduce the high side
pressure to the low side pressure so that liquid can evaporate by
picking up heat. The length and the small diameter reduce the
pressure from condensing pressure to evaporator pressure. Overall
Dimension is
(Bore x Length) = 0.50” x 5” x 1

 Drier: The primary function of the drier is to separate gas and liquid.
The secondary purpose is to remove moisture and filter out dirt.

 Pt 100-sensors (Pencil Type & Bulb Type): The temperatures at

different points in the system are measured by using RTD (PT – 100)
sensors. These are Resistance Temperature Detectors operating on
principle of change in Resistance with change in temperature.
 Evaporator: This is made up of S.S material having inbuilt coil and
heater. It is used as a evaporator in the system.
A. Instrument Panel consists:
The temperatures at different points are recorded in following order
T1 = Temperature at compressor suction
T2 = Temperature at compressor discharge

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T3 = Temperature after condenser

T4 = Temperature after expansion
T5 = Temperature of tank water

 Rotameter: This is a variable area glass tube liquid flow-measuring

device. The glass tube is enclosed in M.S. structure with transparent
glass at two sides to read the readings. Calibrated scale is mounted
in the enclosure. The float is lifted up as liquid flows through the
glass tube and the lift is proportional to the flow rate. Its range is 6.8-
68 LPH
 Pressure Gauge (0 to 300 PSI.): It is a Bourdon type pressure gauge.
This is used to measure pressures at discharge point of compressor
 Compound Gauge. (-30 to 150 PSI.): This Bourdon type pressure

gauge measures both negative pressure (Vacuum) as well as positive

pressure. This is used to measure pressures at suction point of
compressor.

 Motor pump : the pump is used as stirrer in the system so as the

refrigeration effect should uniformly done.
 Energy meter : its main purpose is to indicate the energy consumed
by the compressor
 Thermostat : it acts as a cut off of the system it switch off the
compressor as soon as the temperature of the evaporator drops
below set point.
 Herter coil : it acts as the load to the refrigeration effect and the
heater is placed inside the evaporator.

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 Volt and Ammeter meter : the volt meter indicates the voltage across
the heater coil while the ammeter indicates the current drawn by the
heate

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ASSEMBLY DRAWING

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PRECAUTION SHEET

1. Ensure that equipment is placed on horizontal level structure.

2. Keep the system in clean and dry place.
3. Connect the 230-VA.C. Supply to the unit. Use Proper neutral &
Earthing.
4. Before operating the system check level of water inside
evaporator tank. Fill the same with water, till the evaporator
coil dips in the water.
5. Switch on the electric supply of compressor only if the pressure
shown on the gauges is nearly equal.
6. Do not switch on the compressor until the condenser fan is
switched ON .
7. Do not operate the hand valve.
8. Use the apparatus after every 15 days.

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INSTALLATION PROCEDURE

1. Unpack the equipment.

2. Connect the 230-VA.C. Supply to the unit. Use Proper neutral & Earthing.
3. Fill the water in the evaporator tank.
4. Switch on the Compressor on/off switch only if the pressure shows on the
Gauges are nearly equal.
5. Check that temperature indicator shows ambient temperature for all the five
channels.
6. The Rotameter shows the flow of refrigerant gas, which is indicated by lift of float
in the glass tube. Also check that suction pressure P1 drops and discharge
pressure P2 increases.
7. Observe with channel 5, the temperature T5 of the Evaporator tank & see that it
is reducing. That means the trainer is giving refrigeration effect.
8. Clean the trainer with dry cloth.
9. Now the trainer is installed completely & readies for conduct the experiments.

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EXPERINTAL PROCEDURE

EXPERIMENT NO. 1 TO 3
Aim: 1. Demonstration of Refrigeration cycle.
2. Calculation of coefficient of performance.
3. Plotting Pressure-Enthalpy Diagram.

System Components:
 Compressor
 Condenser
 Rotameter
 Evaporator
 Temperature indicator
 Pressure gauges and compound gauges
 Expansion device
 Energy meter

Experimental Procedure:

1. Fill the evaporator tank up to the end level.

2. Ensure that hand valve is in fully closed.
3. Apply 230 V supply by inserting the three pin top in socket provided on
the distribution board in your laboratory.

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4. Switch on the mains supply and stirrer on/off switch.

5. Switch on electric heater by rotating dimmer in clockwise direction,

and if the ambient temp is less Please load the system initially to 35 0 C
before starting the compressor.
6. Switch on the compressor on/off switch.
7. Check that compressor energy meter starts & Rotameter float is lifted
up indicating that the compressor is working. The pressure gauge
reading is increasing and compound gauge reading is decreasing.
8. Observe that Temperature of load tank (T5) decreases showing cooling
effect.
9. Note down the readings according to observation table
10. Switch off the compressor on/off & stirrer on/off switch.
11. Switch off the main switch.
12. Repeat the above procedure for other experiments.

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OBSERVATION TABLE

Sr. Refrigerant
No. T1 T2 T3 T4 T5 flow
(lph)
01
02
03
04

Energy
Suction Discharge meter
pr. pr. reading Voltage Current
P1 P2 (W) (V) (I)

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CALCULATION PROCEDURE

Calculation Procedure for calculating Coefficient Of Performance:

T1
1. C.O.P (Carnot Cycle) = ----------- (Where temperature is in 0 K)
T2 - T1
T1 = Saturation temperature at suction pressure of compressor.
T2 = Saturation temperature at Discharge pressure of compressor.
Convert the pressure in psi to pressure in atmosphere
P1
P1 (bar) = ------------ + 1
14.5

P2
P2 (bar) = ------------ + 1
14.5

Refer table (Saturated properties of R -134 liquid and vapor)

h1 – h4
2. C.O.P. (Theoretical) = -----------
h2 – h1

Find out the enthalpy values using Property chart of R-134

h1 = Enthalpy (for gas) of R-134 at compressor inlet (P1)
h2 = Enthalpy (for gas) of R-134 at compressor exit (P2)

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h3 = h4 = Enthalpy (for Liquid) of R-134 at condenser exit (P2)

Refrigeration Effect
3. COP actual = ----------------------------------------
Energy consumed by Compressor

Refrigeration Effect = mrefri. (h1 – h4)

= --------- kW

Where m refri. :
Refrigerant flow rate * density of refrigerant at condenser outlet
=---------------------------------------------------------------------------------------
3600 * 1000

=--------- kg/sec

Energy consumed by Compressor = WC

3600X no of blinks
= --------------------------------------- KJ/S2
3200x time for no of blinks

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RESULT TABLE

SR. C.O.P C.O.P. C.O.P.

NO. (CARNOT CYCLE) (THEORETICAL) (ACTUAL)

CONCLUSION:

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Calculation of heat balance at evaporator, condenser, and

overall system
1. Heat accepted at compressor = mrefri. (h2 – h1)
m refri. = {LPH / (1000 X 3600)} x Density of Refrigerant at Condenser
Outlet
2. Heat rejected at Condenser = mrefri. (h2 – h3)
3. Heat accepted at Evaporator = mrefri. (h1– h4)

Refer the Property chart of R-134. to find out the Density at condenser
outlet
Find out the enthalpy values using Property chart of R-134
h1 = Enthalpy (for gas) of R-134 at compressor inlet (P1)
h2 = Enthalpy (for gas) of R-134at compressor exit (P2)
h3 = h4 = Enthalpy (for Liquid) of R-134 at condenser exit (P2)

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RESULT TABLE

[Link] Heat accepted at Heat rejected Heat accepted

compressor at Condenser at Evaporator
(watt) (Watt) (watt)

1.
2.

CONCLUSION:

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EXPERIMENT NO. 4

Aim: To Determine Compressor efficiency at various loads.

System Components:
 Compressor
 Condensor
 Rotameter
 Evaporator
 Temperature Indicator
 Pressure Gauges and Compound Gauges
 Expansion Device
 Energy Meter

Experimental Procedure:

1. Fill the load tank up to the end level.

2. Apply 230 V supply by inserting the three pin top in socket provided
on the distribution board in your laboratory.
3. Switch on the mains supply and pump on/off switch.
4. Switch on electric heater by rotating dimmer in clockwise direction.
We can see that the temperature of water in load tank is increases.
5. When it reaches to 35 0C, Switch on the compressor on/off switch.

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6. Check that compressor energy meter starts & Rotameter float is

lifted up indicating that the compressor is working.
7. Note down the readings according to Observation Table.

8. Observe that Temperature of load tank (T5) decreases. When

temperature T5 reaches at 18 0C, Note down the readings according
to observation table.
9. Switch off the compressor.
10. Increase the heater load by dimmer.
11. Repeat the above procedure to get different sets of heater load
readings.
12. Switch off the compressor &pump

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. OBSERVATION TABLE

Sr. Refrigerant
No. T1 T2 T3 T4 T5 T6 flow
(lph)

Suction Discharge Condenser Compressor

Pr. Pr. Pr. Power Voltage Current
P1 P2 P3 (W) (V) (I)

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CALCULATIONS
Compressor Work Done
Compressor Efficiency = ---------------------------------------------- X 100
Energy Consumed by Compressor

Where,
 Compressor Work done = m refri (h2 - h1)
 m refri. = Swept volume x Density of Refrigerant at Condenser Outlet
m refri. = {LPH / (1000 X 3600)} x Density of Refrigerant at Condenser
Outlet
Refer the Property chart of [Link] out the Density of Refrigerant at
Condenser Outlet
Find out the enthalpy values using Property chart of F-134
h1 = Enthalpy (for gas) of F134 at compressor inlet (P1)
h2 = Enthalpy (for gas) of F134 at compressor exit (P2)
h3 = h4 = Enthalpy (for Liquid) of F134 at condenser exit (P2)

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RESULT TABLE

[Link] Load Compressor

(KW) Efficiency

1.
2.
3.
4.

CONCLUSION:

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SAMPLE OBSERVATIONS & RESULT TABLE

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MAINTENANCE PROCEDURE

[Link] Trainer should kept in dry and proper place.

2. Do not touch the temperature sensors.
[Link] trainer should kept in use [Link] least once in month.
4. If the whole system is not working properly then check for proper
regulated 230 V supply.
5. check for proper regulated 230 V supply.
6. Check the supply and proper connections of wiring. If the connections
are loose then fit them properly.
7. Use the apparatus after every 15 days.

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GLOSSARY

References:
1. Refrigeration and air conditioning: C. P. Arora.
2. Refrigeration and air conditioning: P. L. Ballaney.
3. Refrigerant’s properties and psychrometric properties: Domkundwar and
Domkundwar.

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NOTES

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