EXPERIMENTAL STUDY OF VAPOUR

COMPRESSION REFRIGERATION SYSTEM

WITH VARIOUS MASS FLOW RATES
A project report submitted in partial fulfilment of the requirements for the award of the
degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
By
MADIYA LOKANADHAM 314126520202
PAKKI RAVI 314126520198
VASAMSETTI SHARNU KUMAR 314126520164
YAKASIRI SUJAN KUMAR 314126520155

Under the esteemed guidance of

G.NARESH, (B.E,M.E)
ASSISTANT PROFESSOR, ANITS

DEPARTMENT OF MECHANICAL ENGINEERING

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY AND

SCIENCES
(Affiliated to Andhra University)
SANGIVALASA, VISAKHAPATNAM (District)-531162
 ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES
(Affiliated to Andhra University, Approved by AICTE, Accredited by NBA & NAAC with A
grade)
SANGIVALASA, VISAKHAPATNAM (District) -531162

AGNANAM BRA
AHM*

ANITS
CERTIFICATE
This is to certify that the Project Report entitled EXPERIMENTAL
STUDY OF VAPOUR COMPRESSION REFRIGERATION SYSTEM WITH
VARIOUS MASS FLOW RATES." being submitted by MADIYA
LOKANADHAM 314126520202, PAKKI RAVI 314126520198, VASAMSETTI
SHARNU KUMAR 314126520164, SUJAN KUMAR YAKASIRI 314126520155,
in partial fulfillments for the award of degree of BACHELOR OF
Y TECHNOLOG
in MECHANICAL ENGINEERING of ANDHRA UNIVERSITY. It is the work
of bona-fide, carried out under the guidance and supervision of Mr. G. Naresh,
Assistant Professor, Department Of Mechanical Engineering, ANITS during the
academie year of 2014-2018

Approved By
PROJECT GUIDE HEAD OF THE DEPARTMENT

Mr. G.Naresh) (Dr. B. Naga Raju)

Assistant Professor Head of the Department
Mechanical Engineering Department Mechanical Engineering Department
ANITS, Visakhapatnam. ANITS, Visakhapatam.

PROFESSOR & HEAD

Deparkment ot MechanicalEngineering
ANIL NEERUKONDA INSTITUTE B TECHNOL OG& SCH N:.E°
Sangivaasa-531 162 ViSAKHAPATAM DISI At
 BOARD OF EXAMINERS
THIS PR0JECT IS APPROVED BY THE

INTERNAL EXAMINER:
kaju
Dr. B.MNaga
.Tech,M.E.,Ph.d
Professor & HOD
Engineering9
Mechanical

Dept of
ANITS.Sangivalasa.
isakhapatnam-53 1 162.

EXTERNAL EXAMINER:
 ACKNOWLWDGEMENT

We are happy to present this report on “EXPERIMENTAL STUDY OF

VAPOUR COMPRESSION REFRIGERATION SYSTEM WITH VARIOUS
MASS FLOW RATES” in partial fulfilment of the requirement for the award of
B.E., Degree in Mechanical Engineering.
We take this opportunity to express our deep and sincere indebtedness to our
esteemed guide Mr.G.NARESH,Assistant Professor, ANITS, a source of constant
motivation in successfully completing our project.
We intend to express our thanks with sincere obedience to
Prof.B.NagaRaju, Head of Mechanical engineering department and
Prof.T.V.Hanumantha Rao, Principal for facilitating the execution of this work.
Lastly, we will be grateful to one and all who have contributed either directly
or indirectly in completion of the project.

MADIYA LOKANADHAM 314126520202

PAKKI RAVI 314126520198
VASAMSETTI SHARNU KUMAR 314126520164
YAKASIRI SUJAN KUMAR 314126520155
 NOMENCLATURE

Nomenclature:
A surface area of tubes
C specific heat
COP coefficient of performance
h specific enthalpy
mr mass flow rate
M mass
P pressure
Q heat transfer rate
t temperature
U overall heat transfer coefficient
W power consumption of compressor

Subscripts
ac actual
b brine
c condenser
e evaporator
i inlet
isen isentropic
m mean
o outlet
r refrigerant
th theoretical
w water
 ABSTRACT
A refrigerator is machine which cool and maintain a body at a temperature
below that of surrounding. Majority of refrigerator system works on vapour
compression refrigeration system.The performance of vapour compression
refrigeration system (VCRS) depends on the performance Of all its components like
compressor, condenser, expansion value and evaporator. To Improve the Coefficient
of Performance (COP), it is required to decrease the Compressor Work and increase
the Refrigerating Effect. Experimental analysis on vapour compression refrigeration
(VCR) system with R134A (Tetra Fluro Ethane) refrigerant was done and their
results were recorded.
The effects of the main parameters of performance analysis are mass flow rate of
refrigerant, suction pressure of compressor, delivery pressure of compressor,
temperature of evaporator and condenser. The results from vapour compression
refrigerant syatem was taken where the variables like suction pressure of
compressor, delivery pressure of compressor, temperature of evaporator and
condenser were noted and coefficient of performance (COP) was calculated.
The main objective of this project is to fabricate the vapour compression
refrigeration system with R-134a as refrigerant and To study the system by changing
the mass flow rate of the refrigerant for one ton of refrigeration at different
loads.This project is intended to address challenges faced in the real world and some
practical issues. Theoretical and experimental approaches used as a methodology in
this work.
 LITERATURE REVIEW:
In study of applied thermo dynamics all the while we have been observing
heat transfer from a system at higher temperature to that at lower temperature. Now
in the study of refrigeration we will be observing various methods of coling the
objects and maintaining the temperatures of badies at values lower than surrounding
temperature.
According to American society of Heating, Refrigeration and Air-conditiong
engineers (ASHARE) “ Refrigeration is the science of providing and maintaining
temperature below that of the surrounding temperature”.
In the olden days around 2500 years B.c Indians, Egyptians. Etc... were
producing ice by keeping water in the porous posts open to cold atmosphere during
the night period. The evaporation of water in almost cool dry air accompanied with
recitative heat transfer in the clear night caused the formation of ice evan when the
ambient temperature was above the freezing temperature. Further reference are
available which support the use of ice in china 1000 years BC. Nero, the emperor.
Was using ice for cooling beverages further.the east Indians were able to produce
refrigeration by dissolving salt in water as early as 4th centyry A>D,. Of course , on
very small scale the use of evaporative cooling is another application of
refrigeration used olden days. The cooling of weater in earthen ports for drinking
purpose; is the most common example where the evaporation for water through the
pores of earthen pot is accompanied with cooling of water.produce refrigeration by
dissolving salt in water as early as 4th century AD,. Of course , on very small scale
the use of evaporative cooling is another application of refrigeration used olden
days. The cooling of weater in earthen ports for drinking purpose; is the most
common example where the evaporation for water through the pores of earthen pot is
accompanied with cooling of water.
M.S.Kim :
M.S.Kim have experimentally investigated the performance of a heat pump
with two azeotropic refrigerant mixtures of R290/R134a and R134a/R600a with the
mass fractions of 45%/55% and 80%/20%. The performance parameters of the
azeotropes were compared with pure R12, R134a, R290 and R22 at the both heating
and cooling conditions with suction-liquid heat exchanger. The COP of R134a/R290
was lower than that of R22 and R290, and R600a/R134a shows higher COP than
R12 and R134a. The capacity for R134a/R290a was higher than that for R290 and
R22, and R600a/R134a exhibits higher system capacity than R12 and R134a.
Experimental results show that the compressor discharge temperatures of the
considered azeotropic mixtures are lesser than those of the pure refrigerants i.e., R22
and R12.
H.M.Hughes:
H.M.Hughes have addressed the issues by blending the components of
zeotropic mixtures and subsequent packing. Assessment was carried out with the
blend of R32, R125 and R134a with the mass fraction of 23%, 25% and 52%
respectively. He focused on the issues related to blending equipment and techniques,
the number and quantity of components and the temperature of the blend. While
preparing the blends in the cylinder, introduce the individual components of the
mixture serially starting with the lowest vapour pressure component and progressing
to the highest.

2
 1 INDEX

2 INTRODUCTION ........................................................................................................... 6
2.1 Introduction to refrigeration: ......................................................................... 6
2.2 Principle of Refrigeration: ............................................................................. 8
2.3 Definition of refrigeration: ............................................................................ 8
2.4 Unit of refrigeration: ..................................................................................... 8
2.5 Ton of refrigeration: ...................................................................................... 9
2.6 Coefficient of performance of refrigeration: ................................................ 9
2.7 Classification of Refrigerators:...................................................................... 9
2.7.1 Air refrigerators.............................................................................................. 10
2.8 Vapour refrigerators. ................................................................................... 10
2.8.1 Vapour compression refrigerator ................................................................... 10
2.8.2 Vapour absorption refrigerator....................................................................... 10
2.9 Methods of Refrigeration: ........................................................................... 10
2.9.1 Ice refrigeration .............................................................................................. 10
2.9.2 Dry Ice refrigeration....................................................................................... 10
2.9.3 Air expansion Refrigeration ........................................................................... 10
2.9.4 Evaporative refrigeration ............................................................................... 10
2.9.5 Gas throttling refrigeration............................................................................. 10
2.9.6 Steam jet refrigeration .................................................................................... 10
2.9.7 Liquid gas refrigeration.................................................................................. 10
2.9.8 Vapour compression refrigeration ................................................................. 10
2.9.9 Vapour absorption refrigeration. .................................................................... 10
2.10 Vapour compression refrigeration system: .................................................. 10
2.10.1 Principle : ....................................................................................................... 10
2.10.2 Pressure entyhalpy chart: ............................................................................... 11
2.10.3 Domestic Refrigerator: ................................................................................... 12
2.11 Components: ................................................................................................ 13
2.11.1 Compressor .................................................................................................... 13
2.11.2 Air-Cooled condens ....................................................................................... 13
2.11.3 Receiver ......................................................................................................... 13
2.11.4 Drier ............................................................................................................... 13
2.11.5 Evaporator ...................................................................................................... 13

3
 2.11.6 Accumulator ................................................................................................... 13
2.11.7 Capillary tube. ................................................................................................ 13
2.12 Main Processes involved in the VCRS system: .......................................... 15
2.12.1 Compression : ................................................................................................ 16
2.12.2 Condensation : ............................................................................................... 16
2.12.3 Expansion ....................................................................................................... 16
2.12.4 Evaporation .................................................................................................... 16
2.13 Brief Study of basic components of vapour compression refrigeration
system (VCRS) ....................................................................................................... 17
2.13.1 Compressor: ................................................................................................... 17
2.13.2 Condenser: ..................................................................................................... 20
2.13.3 Evaporataor: ................................................................................................... 27
2.13.4 Capillary Tube: .............................................................................................. 34
2.13.5 Solenoid Valve: .............................................................................................. 35
2.14 Refrigerants: ................................................................................................ 36
2.15 Classification of refrigerants: ...................................................................... 37
3 FABRICATION ............................................................................................................. 38
3.1 Stages of fabrication: ................................................................................... 39
3.1.1 Brazing Process:............................................................................................. 39
3.1.2 Winding of Cu Tubes: .................................................................................... 39
3.1.3 Capillary Connection: .................................................................................... 40
3.1.4 Dehydrator: .................................................................................................... 40
3.1.5 Condenser Connections: ................................................................................ 40
3.1.6 Compressor Connection: ................................................................................ 42
3.1.7 Thermal Insulation: ........................................................................................ 42
3.1.8 Thermostat: .................................................................................................... 42
3.1.9 Gas Charging: ................................................................................................ 43
3.1.10 Fabrication Of Cabinet: .................................................................................. 43
3.1.11 Lubrication: .................................................................................................... 44
4 EXPERIMENTATION .................................................................................................. 45
4.1 Experimental data: ....................................................................................... 45
4.1.1 Condenser sizes:............................................................................................. 45
4.1.2 Evaporator ...................................................................................................... 46
4.1.3 Capillary:........................................................................................................ 46
4.1.4 Pressure Gauge (0 to 300 PSI.): ..................................................................... 46

4
 4.1.5 Compound Gauge. (-30 to 250 PSI.):............................................................. 46
4.1.6 ¼ control valves: ........................................................................................... 47
4.1.7 Filter: .............................................................................................................. 48
4.1.8 Guage adopters:.............................................................................................. 48
4.1.9 Thermometers: ............................................................................................... 48
4.2 Equipement details: ..................................................................................... 49
4.3 Experimental procedure: ............................................................................ 50
4.4 Experimentation Readings : ....................................................................... 51
5 CALCULATIONS ......................................................................................................... 52
6 RESULTS AND DISCUSSION .................................................................................... 56
7 CONCLUSION .............................................................................................................. 66
8 REFERANCES AND BOOKS ...................................................................................... 67

5
 2 INTRODUCTION

The present project is based on Vapour Compression refrigeration. The

cooling unit i .e. condenser is primary component on which the whole project is
based upon. The project is carried out in 4 steps. Firstly the parameter of existing air
cooled condenser measured such as pressure, temperature, power consumption etc.
For measuring the above parameter pressure gauge temperature gauge wattmeter and
refrigerant chart is used. Then we have changed the cooling medium of existing
condensing unit i .e. from air to water. Because the heat transfer coefficient of water
is almost 4 times the air. For this we have made a air tight casing in which the
existing condenser is place and water is circulated and then parameter are measured
such as pressure, temperature. In this cooled water is supplied at the inlet and hot
water extracted from the outlet due to which the refrigerant is sub cooled to a lower
temperature before entering the expansion valve in the condense itself by rejecting
heat to the cooling medium due to which there is small increases the C.O.P. of
refrigerator. After this we have changed the existing condenser with newly designed
condenser which is designed with optimal parameters and then parameters are
measured such as pressure, temperature .and a considerable amount of increase in
C.O.P.is observed due to considerable reduction in compressor work. Then again we
changed the cooling medium of condenser to water and due to this a considerable
amount of increase in the C.O.P. is observed due to increase in refrigeration effect
along with decreases in compressor work. And the mass flow rate of the refrigerant
of Ton of refrigeration is also reduced due to increases in refrigeration effect. Hence
it the size of the condenser and evaporator can be reduced witch result in reduction
in overall cost of the system.

2.1 Introduction to refrigeration:

“Refrigeration is the science of providing and maintaining temperature below
that of surrounding ambient temperature”. The term ‘maintain’ implies, the
continuous extraction removal of heat from a body which is already at lower
temperature than its surroundings.

Refrigeration is the process of removing heat from a space or substance to

reduce and maintain temperature lower than its surrounding. Before the advent of

6
mechanical refrigeration the natural phenomena was used produce and maintain a
lower temperature in a space or product. The value of ice as a preservative was
known and put to use thousands of years ago. Natural ice from lakes and rivers was
often cut during the winter and stored in saw dust insulated buildings, and can be
used as required. In the Middle East and India water was cooled by evaporating it
through porous clay pots. In favourable conditions it could be made cold enough to
form ice.
The early machines the air system was probably the most successful until the
development of vapour compression and absorption system using ammonia as
refrigerant. In 1859 Ferdinand carre devised vapour absorption system. And
ammonia –water cyclel still used in absorption type domestic refrigerators .Thomas
Midgely and his associates Henne and McNary discovered dichlorodiflluoro
methane, CCL2F2(Freon-12 which was) confirmed as super refrigerant with low –
level of toxicity and non-flammable.
The vapour compression system is the most widely used refrigeration system
in practice. This refrigeration system adopts the vapour compression cycle. This
cycle requires the addition of external work for its operation.
Basically itconsists of four processes namely:
1).Isentropic compression
2).Constant pressure heat rejection
3).Isenthalpic expansion
4).Constant pressure heat addition
Vapour compression cycle is an improved type of air refrigeration cycle in
which a suitable working substance, termed as refrigerant, is used. The refrigerant
used, does not leave the system, but is circulated throughout the system alternately
condensing and evaporating.

7
2.2 Principle of Refrigeration:
Refrigeration is defined as the production of temperature lower than those of
the surrounding and maintain the lower temperature within the boundary of a given
space. The effect has been accomplished by non cyclic processes such as the melting
of ice (o)r sublimation of solid carbon dioxide . However, refrigeration effect is
usually produced by transferring heat from a low temperature source to a high
temperature source by spending mechanical work. To produce this effect requires
certain machinery , hence, the method is called mechanical refrigeration. The
working media of such machines are called refrigerants.
2.3 Definition of refrigeration:
Refrigeration is the process of removing heat from substance or space to
reduce its temperature and transferring that heat to another substance or
Refrigeration is providing and maintaining the temperature below that of the
surrounding temperature.
2.4 Unit of refrigeration:
The capacity of a Refrigeration unit is expressed in terms of Ton. One ton of
refrigeration is equivalent to the rate of heat transferred needed to produce 1000Kg
of ice at 0 water in 24 hours.

One ton of refrigeration= 55 kcal/min=210kj/min or 3.5 Kw.

A refrigerant is the substance used for heat transfer in a refrigeration system.

It absorbs heat (latent heat and sensible heat) from the source at a low temperature
and pressure and gives up this heat at a high temperature and pressure. The
refrigerant which transfer heat in the form of latent heat is more efficient than the air
refrigerant which transfer heat in the form of sensible heat. The refrigerant in the
first group continuously change its phase from liquid to vapour and vapour to liquid.
However in the second group, the refrigerant exist in the gaseous phase only.
The refrigerant which absorb heat in the form of latent heat are more suitable and
widely used in the refrigeration system. In selecting a refrigerant for a particular
purpose its characteristic must be considered and the selection must be made on the
of its compatibility with the system.

8
 Secondary refrigerants are those which are cooled first by the primary
refrigerants and then employed for cooling purposes. Indirect method of cooling is
produced by absorption of sensible heat.

2.5 Ton of refrigeration:

The refrigeration capacity by of refrigeration is its cooling capacity or heat
transfer rate that it can provide forcooling. The SI unit for the heat transfer rate is
kW, however, the refrigeration capacity is still measured inTon of Refrigeration
(TR)”.One ton of refrigeration is equivalent to 3.5kW, and i.e. the heat is removed
from thesubstance to produce cooling effect.
2.6 Coefficient of performance of refrigeration:
Coefficient of perfoemance of refrigerator has been defined as the ration of
the amount refrigeration effect to the work of compression.

COP=refrigeration effect/compression work

2.7 Classification of Refrigerators:

Refrigeration implies the cooling of a system. It may be obtained by adopting
the following methods:

1. Natural methods.
2. Artificial or mechanical methods

Mechanical refrigerators found wide industrial applications. They may be

further classified as

9
2.7.1 Air refrigerators
2.7.1.1 Reversed carnot cycle
2.7.1.2 Bell coleman cycle
2.8 Vapour refrigerators.
2.8.1 Vapour compression refrigerator
2.8.2 Vapour absorption refrigerator
2.9 Methods of Refrigeration:
The refrigeration effect may be produced by bringing the substance to be
cooled in direct or indirect contact with cooling medium such as ice. The common
methods of refrigeration are as follows.

2.9.1 Ice refrigeration

2.9.2 Dry Ice refrigeration
2.9.3 Air expansion Refrigeration
2.9.4 Evaporative refrigeration
2.9.5 Gas throttling refrigeration
2.9.6 Steam jet refrigeration
2.9.7 Liquid gas refrigeration
2.9.8 Vapour compression refrigeration
2.9.9 Vapour absorption refrigeration.

2.10 Vapour compression refrigeration system:

2.10.1 Principle :
The ability of a substance to change from a liquid to a vapour under certain
pressure and temperature conditions is physical phenomenon called refrigeration
cycle.In order for substance to boil from liquid to a vapour or gas, it must absorb
heat ; in the absorption of the heat ,the vapourising substance cools the material,
whether it be air or water from which the heat is absorbed.

10
 Vapour Compression Cycle

2.10.2 Pressure entyhalpy chart:

The actual vapor compression cycle differ from the theoretical vapor
compression cycle in many ways, some of which are unavoidable and cause losses.
The main deviations between the theoretical cycle and actual cycle are as follows:

1. The vapour fefigerant leaving the evaporator is an superheated state.

2. The compression of refrigeration is neither isentropic nor polytropic.
3. The liquid refrigerant before entering the expansion valve is sub- cooled in
the condenser.The pressure drops in the evaporator and condenser.

p-h diagram

11
2.10.3 Domestic Refrigerator:
The domestic refrigerator works on vapour compression cycle. It is compact
and more efficient in use of electric energy. The refrigerant used in this is Freon 12.
Its main function is to provide low temperature space for the preservation of food.
The domestic Refrigerators also used in medical shops, hospitals, hotels, offices,
laboratories etc.

The domestic refrigerators capacity is the internal volume of the unit and is
expressed in litres. The various common sizes of refrigerators available are
100,165,200 and 300 litres.

12
2.11 Components:

The main components of a domestic refrigerator are;

2.11.1 Compressor
2.11.2 Air-Cooled condens
2.11.3 Receiver
2.11.4 Drier
2.11.5 Evaporator
2.11.6 Accumulator
2.11.7 Capillary tube.

The refrigerant vapour drawn from the evaporator is compressed in

compressor and deliver to the condenser. It is then expanded in capillary tube
and passed on to the evaporator. Capillary tubes is used as throttling device is
used to reduce the pressure of the refrigerant. The low pressure refrigerant
evaporates as absorbing its latent heat and thus producing refrigerating effect in the
evaporator.

13
 It consists a hermetically sealed compressor fitted at the base of the cabinet.
Condenser is air cooled coil. The evaporator is placed at the top of inside cabinet.
The evaporator produce low temperature about -15C and temperature around 7 to
10C can be maintained in the refrigerating space Heavy cold air from freezer moves
down wards and becomes warm air after cooling the products. This warm air moves
upward. Thus the air movement is maintained continuously in the refrigerated space.
The freezer is a mini cold storage in which ice-cubes , ice-creams , frozen foods,
meat poultry and fish can be preserved. A thermostat is provided to control the
temperature in the freezer. Chiller tray is provided below the freezer to prevent the
accumulation of water drops in the freezer. Below the freezer, it consists adjustable
shelves to preserve fruits, vegetables, cooked foodEtc. Egg tray, dairy bins ,bottle
shelves are provided in side the door of refrigerator. It should be placed in a clean
and well ventilated area and kept on the leveled place. It is important to check the
functioning of thermostat, door switch, light etc., and a separate plug must be
provided for the refrigerator.

14
The various functions of the components of domestic refrigerator
are:
1.11.1 Compresser:
In this, rotary type compressor is used and is sealed unit. It compresses the
refrigerant gas to high pressure and temperature .
1.11.2 Evaporator:
The evaporator cools the air in its surrounding in the cabinet. The cold air
being heavier moves downwards to cool the food stuff and becomes warm. This
warm air being lighter moves upward to take the place of cold air. The convection
currents are formed in the cabinet which enable the maintain of uniform temperature.
1.9.3. Drier :
A drier is connected between the receiver and the evaporator to eliminate the
traces of moisture, if any.
1.9.4. Accumulator :
It is connected between the evaporator and compressor, which accumulates
liquid droplets of the refrigerant and prevent the compressor from any possible
damage.
1.9.5. Capillary Tube:
The throttling device is a capillary tube. In this, the pressure equalizes
through out the system during off- cycle, and hence a low starting torque motor can
be used.

2.12 Main Processes involved in the VCRS system:

1.10.1. Compression
1.10.2. Condensation
1.10.3. Expansion
1.10.4. Evaporation

15
 Vapour compression refrigeration system(VCRS)

2.12.1 Compression :
The low pressure vapour refrigerant in dry state is drawn from the evaporator
during the suction stroke of the compressor. During compression stroke pressure and
temperature of the refrigerant increases.
2.12.2 Condensation :
The high pressure and high temperature vapour refrigerant enters in to the
condenser through the discharge line . Heat will be rejected in to the cooling
medium and the refrigerant change its state from vapour to liquid.
2.12.3 Expansion
After condenser, the liquid refrigerant is stored in the liquid receiver until it
passes through expansion valve. The function of the expansion is to allow the liquid
refrigerant under controlled pressure in to the low pressure path of the system.
2.12.4 Evaporation
The low pressure liquid refrigerant after expansion in the expansion device
enters the Evaporator or Refrigerated space and absorbs its heat. Due to this heat, the
refrigerant changes its state from liquid to vapour and then sucked back by the
compressor during its suction stroke . The cycle is repeated till the required
temperature gets inside the refrigerator.

16
2.13 Brief Study of basic components of vapour compression
refrigeration system (VCRS)
2.13.1 Compressor:
A compressor is that part in mechanical refrigeration system which sucks the
refrigerant vapours at low temperature and at low pressure and compresses it to a
lower volume at higher temperature and at higher pressure. Moreover , it creates the
flow of refrigerant from one place to another. A Compressor consists of an
arrangement in which an electric motor drives it. The compressor is located near the
condenser.

There are mainly two types of compressor are used,

They are:

a) Open type compressor

b) Semi-hermetically sealed ,
c) Hermetically sealed compressor.

17
 2.13.1.1 Open type Compressor:

Open type Compressor

An open type compressor is that in which the prime mover drives the
compressor by means of belt. In such a unit the prime mover and compressor are
separately serviceable. In this, the compressor is enclosed in crank case and crank
shaft projects out through the compressor housing.

The projected end of crank shaft is connected directly or through the belt to
the driving motor. The compressor and motor can be mounted on the same base
plate. A seal must be used to prevent refrigerant leaking out or air from leaking in if
the crank case pressure is lower than the atmospheric pressure.
These compressors are used in the plants employed for ice making, cold
storage and food processing applications

2.13.1.2 Hermetically Sealed Compressor:

In ordinary compressor the crank shaft extends through compressor
housing and it is connected to the driving motor . A seal must be provided at the
place where the shaft comes out through the compressor housing . This is necessary
to prevent the leakage of refrigerant outside or leakage of air inside. To avoid this
problem , the compressor and motor are enclosed in one housing which known as
Hermetically sealed compressor. These types of compressors are normally used for
small capacity Refrigerating systems as house hold Refrigerator or small capacity
coolers.

18
The main parts of a sealed unit are:
1. Electric motor,
2. Compressor,
3. Muffler,
4. Dome.
The Hermetically sealed Reciprocating compressor

Hermitically sealed Compressor

Advantages:
The advantages of hermetically sealed compressor s over ordinary type
compressors as follows:

1. The leakage of refrigerant is completely avoided.

2. It is less noisy.
3. It requires less space.
4. The motor is cooled more efficiently.

Disadvantages:

1. Maintenance is not easy

2. The welded joints has to be broken or cut for reparing the compressor.

19
3. The pressure of moisture in the refrigerant may harm the winding of the
motor.
4. A separate vaccum pump is required for evacuation and charging the
refrigerant.

The motor and compressor assembly is mounted in the unit in such way that
usually the motor is fitted on the top and the compressor on the bottom. But at
present in a specially designed sealed unit,for keeping the motor cool, it is dipped in
to the oil and bottom of the compressor is fitted at the top.The oil is forced to the
compressor, through the shaft of the motor. Some times the motor and compressor
and assembly is hung on the springs in the unit and sometimes it is press fitted.
As the motor is energised, it drives the compressor. The compressor sucks
the low temperature and low pressure gas, compresses it into high temperature and
high pressure gas and discharges it through the discharge line. Some of the examples
of refrigeration machines in which sealed units
are used are:
1. Refrigerator,
2. Bottle cooler,
3. Window-type Air conditioner,
4. Water cooler.

2.13.2 Condenser:

condenser is an heat exchanger in which heat transfer takes place from high
temperature vapour refrigerant to low temperature air or water which is used as
cooling medium. Its purpose is to covert all the vapour refrigerant to liquid
refrigerant delivered by the compressor.

20
Types of Condenser:

1.Air cooled condenser.

2.Water cooled condensers
3.Evaporative type condensers..

2.13.2.1 Air Cooled Condensers:

Air is used as the cooling medium in the air cooled condenser. Heat transfer
takes place air convection around the condenser surface.

There are two types of air cooled condensers are used.

2.13.2.1.1 Natural air cooled condensers

2.13.2.1.2 Forced air cooled condensers.

In the Natural air cooled condensers large condensing surface area is required
as the circulated air quantity is less. This type of condensers are used in domestic
refrigerator, deep freezer , etc.,

21
 These are cooled by natural air or atmospheric air. These are provided at the
back of the refrigerator.

Natural Convection Air Cooled Condenser

In the case of Forced air cooled condensers , air is circulated by means of a

fan or blower. This type of condensers are compact in design and are relatively more
efficient.

Forced Convection Air Cooled Condenser

These are commonly used for water coolers, bottle coolers and air conditioners.

22
Merits of Air Cooled Condensers:
1. Cheap due to simplicity of construction
2. Low maintenance cost.
3. No piping work involved.
4. Negligible corrosion effect.
5. Disposal of air is easier in comparison to disposal of water.
6. High flexibility.
Demerits of Air Cooled Condensers:
1. It is restricted to small capacity refrigeration units.
2. Rate of heat transfer is low.
3. Distribution of air on the condenser surface area is uneven.
4. Increase in ambient temperature causes reduction in the capacity Of the
condensers.

The air cooled condensers are preferred under the following circumstances
Minimum corrosion is the major requirement. Inadequate supply of cooling water
Expensive means of water disposal.

2.13.2.2 Water Cooled Condenser:

The condenser which cooled by water, is called water cooled condenser.

These are always preferred where adequate supply of and inexpensive means of
water disposal are available. These condensers are used in large capacity refrigerant
plant such as, cold storage, ice plants and central air-conditioners.

There are three types of water cooled condensers:

2.13.2.2.1 Shell and Tube Condenser:

A shell and tube condenser consists of a cylindrical shell, in which a large

number of parallel tubes are fitted and connected with tube sheets on both ends of
these tubes. These tubes are made of steel or copper tubes. These tubes are generally
finned to increase their surface area. The diameter of these tubes are
19mm,25mm,30mm etc.. The lengths are in between 1.5 m and 5.5m. These

23
condensers have the capacity ranging from 2 ton to 1000 ton. Cooling water enters
through the heads which are baffled to make one or more passes through the tubes.
Refrigerant vapour from the compressor enters shell at the top and gives its heat to
cooling water. After the completion of condensation , the liquid refrigerant flows
down and remain in the lower part of the shell. Which act as a liquid receiver.

Shell and tube type condenser

2.13.2.2.2 Shell and coil type condenser:

Shell and coil type condenser are used for small tonnage low pressure units.
It consists of shell that contains a coil for circulating the water . The shell ends are
not removable and the water side of the coil may ;be cleaned with chemicals. In case
of a coil leakage the entire coil must be replaced. These are preferable where clean
water is available because its coil cannot be cleaned easily.
These can be cleaned only by circulating acids or other chemicals through
them. In this, the water enters at the bottom and flows up through coil as shown in
fig. Vapour refrigerant from the compressor enters at the top and flows down, the
shell giving its heat to cool water. Refrigerant vapour gets

condensed and liquid refrigerant is collected at the bottom of the shell which
acts also as receiver. These are used upto 50 ton capacity plants. Shell and coil type
condenser

24
2.13.2.2.3 Double tube type Condenser:

A double type condenser has the condensing water tube in side the refrigerant
tube. The refrigerant flows in the space between the tubes while water is pumped
through inner tube. Water flows in the opposite direction to the refrigerant. The
refrigerant vapour from the compressor enters at the top and flows downwards in the
clearance space between the two tubes. As result of heat transfer from refrigerant to
water, the refrigerant gets condensed. The liquid refrigerant leaves the condenser at
the bottom. The scales formed in tubes are removed by chemical treatment. Since
copper tubes cannot be used with ammonia. These are made of steel pipes for
ammonia.

Shell and coil type condenser are used for small tonnage low pressure units.
It consists of shell that contains a coil for circulating the water . The shell ends are
not removable and the water side of the coil may ;be cleaned with chemicals. In case
of a coil leakage the entire coil must be replaced. These are preferable where clean
water is available because its coil cannot be cleaned easily.
These can be cleaned only by circulating acids or other chemicals through
them. In this, the water enters at the bottom and flows up through coil as shown in

25
fig. Vapour refrigerant from the compressor enters at the top and flows down, the
shell giving its heat to cool water. Refrigerant vapour gets condensed and liquid
refrigerant is collected at the bottom of the shell which acts also as receiver. These
are used upto 50 ton capacity plants.

Double Tube type Condenser

2.13.2.2.4 Evaporative Condenser:

The Evaporative condenser combines the function of the condenser and

cooling tower. Its works on the principle of Evaporative cooling. The water
evaporation when it comes in contact with the refrigerant flowing in the condensing
coil. In this, both air and water are used as the cooling media.
The condensing coil are encased in galvanized steel cabinet. Water is sprayed
over the condensing coil through which hot refrigerant vapour flowing. A pump is
utilized for this purpose. An exhaust fan is fitted at the top of the condenser. It sucks
air from side opening. Eliminators are provided in the condenser to prevent the
escaping of water particles with air.

26
 The air carries away the heat taken from refrigerant by the water vapour at
about 3 to 5% of water circulated evaporates, make up water is admitted to tank
through float operated valve. Water treatment should also be used to reduce the scale
formation in the coil. The atmospheric air enters at the bottom and drawn over the
coils by a fan. The air flowing up words through the water spray carries out the heat
from the refrigerant .
These are used where there is scarcity of water, draining facilities are in
adequate. The use of cooling tower is un economical. It is suitable for refrigerant
plants above 100 ton capacity.

Evaporative Condenser

2.13.3 Evaporataor:

The Evaporator is a device in which the heat is removed from the substance
to be cooled . It is part of the system in which the refrigerant evaporates or boils; It is
the cooling unit and some times called the cooling coil Or freezing coil or liquid
cooler .

27
Classification of Cooling Evaporator:
There are many types of evaporators used in the refrigeration and Air
conditioning systems;
They may be classified:
2.13.3.1 According to the refrigerant feed
2.13.3.1.1 Flooded evaporator
2.13.3.1.2 Dry-Expansion evaporator
2.13.3.2 According to the type of construction
2.13.3.2.1 Bare tube coil evaporator
2.13.3.2.2 Finned tube evaporator
2.13.3.2.3 Plate evaporator
2.13.3.2.4 Shell and tube evaporator
2.13.3.2.5 Shell and coil
2.13.3.2.6 Tube- In-Tube evaporator or Double tube evaporator
2.13.3.3 According to the mode of heat transfer
2.13.3.3.1 Natural convection evaporator
2.13.3.3.2 Forced convection evaporator
2.13.3.4 According operative condition
2.13.3.4.1 Frosting evaporator
2.13.3.4.2 De-Frosting evaporator.

a). Dry –Expansion Evaporation:

In this, the liquid refrigerant is fed by expansion valve. The refrigerant
entered in to one end of the tube and the other end of tube is connected to suction
line. The evaporator is filled with mixture of liquid and vapour refrigerant. As
refrigerant passes through the evaporator, more and more liquid is vapourised. Thus,
the refrigerant leaves the evaporator in dry state. A Feeder bulb is provided to
control the flow of refrigerant in to the evaporator .

28
 Dry - Expansion Evaporation
It is used in small capacity units of below 150 tons.

b). Flooded type Evaporator:

In a Flooded type evaporator a constant refrigerant liquid level is maintained.
A float valve is used as throttling device which maintains a constant liquid levlel in
the evaporator. It consists of a shell in to which the refrigerant liquid is fed through
the float valve. The shell is connected to the top and bottom of the coil. The liquid
flows from the bottom of the shell by gravity to coil tubes in which it evaporates by
absorbing heat from the surrounding. The liquid vapour mixture from the coil returns
to the shell. In the shell, the liquid and vapour are separated. The vapour is collected
at the top of the shell (Flash chamber) from there it enters into the compressor
through suction line. Flooded type evaporators provide rapid cooling and used in
large capacity equipment .

Flooded type evaporator

29
c). Bare tube Evaporator:
Bare tube evaporators are constructed of either steel pipe or copper tubing.
Steel pipe is used for large evaporators and copper tube is used for small evaporator.
Using Freon as refrigerant these are also used with secondary refrigerant as in the
case of water chiller and ice making plants. This is shown in fig These are used
where the temperature is maintained below 0C.

Bare tube evaporator

e). Finned Tube Evaporator:

Finned coils are bare tube coils upon which metal plates or
fins are installed. Fins increase the surface area of the evaporator and there by
improves effective cooling. The number of fins provided depends on the capacity of
evaporator. These evaporators are mostly used in Air-Conditioning system.

Pinned tube evaporator

f). Plate Surface Evaporator:

surface area of evaporator and hence, higher rate of heat transfer from
surrounding to the refrigerant. It is easily clean and defrosted manually. It is used in
domestic Refrigerator or Freezes.

30
g). Shell and Tube Evaporator:
Shell and tube evaporator consists a steel cylindrical shell fitted with a large
number of parallel tubes. These are used for chilling water or brine. These are mainly
two types
1. Flooded shell and tube type
2. Non-Flooded shell and tube type.

h). Flooded Shell and Tube Evaporator:

In flooded shell and tube type evaporators, the fluid to be cooled flows
through the tubes and refrigerant flows over the tubes. Liquid refrigerant absorb heat
from water and evaporates completely. The dry refrigerant vapour is sucked in the
compressor.

These are used for refrigerating units of capacity at about 100 ton.

Flooded Shell and Tube Evaporator

i). Non - Flooded Shell and Tube type Evaporator:

In Non-Flooded shell and tube evaporator, the
refrigerant flows inside tubes and evaporates as it abstract heat from the fluid being
cooled flows over the tubes as shown in fig. In this , the baffles are provided to
improve the heat transfer.

31
 Non - Flooded Shell and Tube type Evaporator
These are used upto 50 ton capacity.

j). Shell and Coil Evaporator:

Shell and coil evaporator consists of shell and helical coil. The fluid to be
cooled enters at the top and leaves the bottom of the shell. The refrigerant flows
through the coil . The fluid to be cooled , comes in direct contact with coil. These are
used in water cooler and small capacity units ranging from 2 to 10 ton capacity.

Shell and Coil Evaporator

k). Tube – in – Tube Evaporator:

These are called as double tube evaporators. It
consists two concentric tubes. The fluid to be cooled flows through inner tube where

32
as the refrigerant flows through the annual space between the two tubes. This
arrangement improves the heat transfer. These are used in dairy, beverages
and oil plant

Shell and Coil Evaporator

1.11.4. Expansion Deveices or Valve:

Expansion device or valve is a dev ice which regulates
or meters flow of liquid refrigerant to an evaporator. It also divides high pressure
side from low pressure side of the system.

Functions:
It reduces the pressure of the refrigerant coming from condenser and
temperature as per the requirement of system It regulates the flow of refrigerant as
per the loan on the evaporator. The various types of evaporators are

a. Capillary tube
b. Pressure control or automatic expansion valve
c. Thermostatic expansion valve
d. High-side float valve
e. Low-Side float valve
f. Solenoid valve

33
2.13.4 Capillary Tube:

Capillary tube is a coil or length of fine tube that has a very small orifice
usually 0.5 to 2.25 mm inside diameter and length is about 1 to 6 m. It is a constant
restrict type expansion device,

Capillary tube
because the opening through which the refrigerant flow is constant. It controls the
flow of refrigerant in to the evaporator. It is used with smaller hermitic units such as
room Air-Conditioners and its application extends up to refrigerating capacity about
10 kw. The usual form of capillary tube installed in refrigerating plant is shown in
Fig 2.20 One end of capillary tube is connected to filler at the outlet of the
condenser. The other end is connected to evaporator. The capillary tube reduces the
pressure of the refrigerant from high-side pressure to low-side pressure. Liquid
refrigerant from condenser enters in to the capillary tubes and as it flow through the
tube pressure drops due to friction.

The capillary tube replaces thermostatic expansion valve for small units such
as Domestic Refrigerator, Room Air-Conditioner and deep Freezers

34
The advantages of capillary tubes are:

1. It is simple in construction and requires no maintenance When the

compressor stops,
2. the refrigerant continues to flow from high pressure side to low pressure side
unless pressure is equalized. This requires low starting torque to start the compressor
so a low starting torque motor can be used with these unit.
3. No receiver is required for systems using this device.
4. Its cost is much less as compared to other devices.

Disadvantages:
The refrigerant must be free from moisture and dirt other wise it will choke
the tube and stop the flow of refrigerant . It cannot be used with high fluctuating
loads.

2.13.5 Solenoid Valve:

The solenoid valve is shut off valve that is actuated by a electromagnetic coil
when the coil is energised .An armature or plunger placed inside the coil. A stem or
pin attached to plunger open or close. When the coil energised by passing current
through it , the magnetic field attracts the plunger up into the core of the coil which
causes the opening of the valve. When the coil is deenergised due to break in the
circuit, the plunger fall of its own weight and pin closes the valve. These valves
fitted vertical and allows the fluid flow in one direction.

Solenoid Valve

35
 Solenoid valve is installed in the liquid line just a head of the expansion
valve. They are used to control the condensing fluid when ever solenoid valve is
used in a system, it is essential that the strainer should be installed ahead of it to
prevent the entry of any contaminants.

2.14 Refrigerants:

The refrigerant is a heat carrying medium which during their cycle in the
refrigerant system absorb heat from a low temperature system and discard the heat so
absorbed to a higher temperature system.

The natural ice and a mixture of ice and salt were the first refrigerants. In
1834, either, ammonia, sulphur dioxide, methyl chloride and carbon dioxide came
into use as refrigerant in compression cycle refrigerant machines. Most of the early
refrigerant materials have been discarded for safety reasons or for lack of chemicals
or thermal stability. In the present days, many new refrigerant including halo-carbon
compounds are used for air conditioning and refrigeration applications.
The suitability of a refrigerant for a certain application is determined by its physical,
thermodynamic, chemical properties and by various practical factors. There is no one
refrigerant which can be used for all types of applications. If one refrigerant has
certain good advantages, it will have some disadvantages also, Hence, a refrigerant is
chosen which has greater advantages and less disadvantages.

2.14.1 desirable properties of an ideal refrigerant:

We have discussed above that there is on ideal refrigerant. A refrigerant is
said to be ideal if it has all of the followings properties :

1. Low boiling point.

2. High critical temperature.
3. High latent heat of vaporization.
4. Low specific volume of vapour.
5. Low specific volume of vapour.
6. Non-corrosive to metal.
7. Non-flammable and non-explosive
8. Non-toxic.

36
9. Low cost.
10. Easy to liquefy at moderate at pressure and temperature.
11. Easy of locating leaks by odder or suitable indicator.
12. Mixes well with oil.

The standard comparison of refrigerant, as used in the refrigeration industry, is based

on an evaporating temperature of 150C and a condensing temperature of +300C.

2.15 Classification of refrigerants:

The refrigerant may, broadly, be classified into the following two groups:
1. Primary refrigerants and
2. Secondary refrigerants.
The refrigerant which directly take part in the refrigerant system are called primary
refrigerants whereas the refrigerants which are first cooled by primary refrigerants
and then used for cooling purpose, are known as secondary refrigerants.
The primary refrigerant are further classified into the following four groups :
1. Halo-carbon refrigerant.
2. Azeotrope refrigerants.
3. Inorganic refrigerants.
4. Hydro-carbon refrigerants.
1.11. Applications of refrigeration system:

• Central air conditioning

• Food storage
• Making of ice
• Ice-Cream plants
• Industrial applications
• Hospital operation theatre
• Research laboratories
• Computer rooms
• Storage and transportation of food stuff
• Cooling of concrete for special application like dams
• Production of Rocket fuels

37
 3 FABRICATION

In vapor compression refrigerating system basically there are two heat

exchangers. One is to absorb the heat which is done by evaporator and another is to
remove heat absorbed by refrigerant in the evaporator and the heat of compression
added in the compressor and condenses it back to liquid which is done by condenser.

This project focuses on heat rejection in the condenser this is only possible
either by providing a fan or by extending the surfaces. The extended surfaces are
called fins. The rate of heat rejection in the condenser depends upon the number of
fins attached to the condenser. In the present domestic refrigerator copper material
fins are used.

The performance of the condenser will also help to increase COP of the
system as the sub cooling region incurred at the exit of the condenser. The
performance of the condenser is also investigated by existing and modification
condenser. In general domestic refrigerators have no fans at the condenser and hence
extended surfaces like fins play a very vital role in the rejection of heat.

In order to know the performance characteristics of the vapor compression

refrigerating system the temperature and pressure gauges are installed at each entry
and exit of the component. Experiments are conducted on condenser having fins.
Different types of tools are also used like snips to cut the fins to required sizes, tube
cutter to cut the tubes and tube bender to bend the copper tube to the required angle.

Finally the domestic refrigerator is fabricated as for the requirement of the

project. All the values of pressures and temperatures are tabulated. In order to know
the performance characteristics of the vapour compression refrigeration system the
temperature and pressure gauges are installed at each entry and exit of the
components. Experiments are conducted on condenser with coil spacing of the
condenser on a refrigerator of capacity 180liters. All the values of pressures and
temperatures are tabulated.

38
3.1 Stages of fabrication:

2.1.1. Brazing process

2.1.2. Winding of copper tubes
2.1.3. Capillary connection
2.1.4. Dehydrator
2.1.5. Condenser connections
2.1.6. Compressor connections
2.1.7. Evaporator connections
2.1.8. Thermal insulation
2.1.9. Thermostat
2.1.10. Gas charging
2.1.11. Fabrication of cabinet
2.1.12. lubrication

3.1.1 Brazing Process:

It is process of joining metal pieces by means of hard solder. Brass is

mainly the main constituent of this solder. The brazing solder used in modern
practice is commercially known as spelter, which is mixture of Cu, Zn and Sn. The
most important phenomenon in this that the pieces to be joined are heated instead of
the bit.

3.1.2 Winding of Cu Tubes:

Once the internal container is repaired, it is soldered at its ends. Now 5/6"
copper tubes of length 22 feet was wound a round the outer surface of the sheet
metal internal container, with equal spacing between them. These "Cu" tubes were
positioned in their place firmly and rigidly with the help of soldering at place. Now
these assembly functions as our Evaporator and these coils are called as "Evaporator
Coils."
Both the ends of the Cu tubes Viz, the top and bottom of the internal container,
where left free or unwound the upper portion of the tube was taken below along the
external surface of the container and finally taken out of the bottom of the plastic
bucket through a small boring. The other end of the coil was connected to the

39
accumulator which is placed in between the bottoms of the bucket and the container.
Ten this end was also taken out of the same boring and connected to the capillary
tubes.

3.1.3 Capillary Connection:

One end of the capillary was brazed inside the accumulator to prevent
leakage. The total length used for the purpose was 12feet. Initially, some portion of
the capillary was wound around the 5/16' tube coming out from the lop surface of the
container. Then, this capillary is made in the from of a uniform coil and was
suspended freely. This capillary tube acts as an expansion valve.

3.1.4 Dehydrator:

The dehydrator or the filter drier is located in the fluid line at the outlet end
of the condenser. Its purpose is to filter, trap minute particles of foreign materials
and absorb any moisture which may be in the system. Fine mesh screens filter out
foreign particles and the desiccant absorbs the moisture. The one used in this
refrigerator desiccants is silica gel (silicon dioxide).

3.1.5 Condenser Connections:

Now a small piece of copper tubes id again brazed to the free end of he filter
drier, which is then connected to the condenser. The condenser used in this unit is of
air cooled type. In this the tube is bent in the shape of U and placed in conjunction
with the fins are responsible for holding the air in their gaps that extract heat from
the hot refrigerant flowing in the tubes of the condenser.

40
The evaporator coils surrounding the internal container absorb the heat from the hot
boy inside the container and this heat is taken by the refrigerant. This refrigerant
which is ultimate passing through the condenser radiates heat to the atmosphere with
help of the condenser fins.

In our unit the condenser is fixed to the rear side of the cabinet, facing the
atmosphere air.

41
3.1.6 Compressor Connection:

The 5/16' copper tube of the evaporator oil is connected to one end the
compressor with the help of brazing. The outgoing end of the compressor is brazed
to the condenser to complete the circuit.
The compressor used in this case is reciprocating type sealed unit. The
horsepower of the compressor is 1/6 HP. Compressor is used to establish a pressure
difference and thus cause the refrigerant to flow from one part of the system to the
other. At the same time the compressor raises the refrigerants pressure above the
condensing pint.
At the temperature of the room air, so it will condense. It is this difference in
pressure between the high low sides forces liquid refrigerant through the capillary
tube an into the evaporator.

3.1.7 Thermal Insulation:

In any refrigeration process thermal insulation is necessary so that no heat is

radiated out of the system thereby reducing its efficiency.
Since heat will always flow from a region of high temperature to a region of low
temperature, there is always a continuos flow of heat into the refrigerated region
from the warmer surroundings. The various types of the insulators used are –

1. Thermocoal
2. Glass Wool.

In this unit glass wool is used which was stuffed between the two surfaces of
the plastic bucket and sheet-metal container. The glass wool is tightly packed by
ramming heavily so that no air gap remains between the glass wool and hence
provides maximum operating efficiency.

3.1.8 Thermostat:

This is a temperature controlled electrical switch located on the evaporator

wall. It is fastened to the evaporator will with a clamp at the lower region of the
internal container. When the sensing element mounted on the evaporator wall senses
the temperature lower than the operating conditions then it sends the signal to the

42
thermostat switch immediately breaks the circuit in the relay and thus gets Tripped
Off. The thermostat switch is connected to the relay. The rely thermostat has the
bimetal strips, which is responsible for the make and break of the circuit.

3.1.9 Gas Charging:

When the whole of the connections has been made then gas is charged with
the help of the charging cylinder and the value is closed. The whole is now checked
for the leakage by applying soap solution to the joints formed by brazing. Now when
no leakage was there then the gas was filled. The amount of gas by weight was 15
ibs. The gas used for this was refrigerant 12 or Freon 12 (CCl2F2 – Dichloro- Difluro
– Methane).

3.1.10 Fabrication Of Cabinet:

Wooden planks used to make the table of appropriate shape and size to
accommodate the bucket in the bucket in the top tier while the other components in
the basement.

43
 The top plank is cut in the from of a round hole in which 2/3nd of the bucket
can go inside with remaining portion projecting outwards. It has got one more
bottom plank supporting the compressor, the condenser and other accessories. The
compressor is rigidly with the help of 4 bolts bolted to the base. This table-like
structure is mounted on four wheel making the whole unit mobile.

3.1.11 Lubrication:

• Function of lubricating oil in a refrigeration system.

• Understand the importance of and dangers associated with draining oil
• Describe the properties of refrigerate oils
• Describe the purpose and functions of an oil separator
• List and explain three types of indirect oil cooling systems
• Identify major oil contaminants and described contamination control in
refrigerant oils
• Explain three types of heat exchange in lubrication.

44
 4 EXPERIMENTATION

3.1. Experimental setup:

The main loop of the system under study was composed of five basic
components, i.e., a compressor, an evaporator, a condenser, capillary tubes and a
liquid line filter–drier, as shown in Fig..There was used a system of a three-phase,
220 V, reciprocating compressor originally designed for R134a refrigerant. The input
power of the compressor within the system varied between 230 and 300 W. The
major ingredient of the compressor lubricant was mineral oils. A silica gel drier filter
was used to absorb the moisture. Compact forced air cooled type condenser was used
for their good heat transfer performances. Capillary tubes of different internal
diameters were used to find the optimum operating points of the system. For
minimizing the heat loss, the evaporator cabinet was well insulated by foam and
thermocaol. The refrigerant used were R134a. Some other measuring and controlling
components were used in the system, that were, an electrical switch, an,valve for
controlling mass flow rate of the refrigerant, bourdon tube type pressure gauge and
compound pressure gauge, ‘J’ type thermocouples and indicator and gas flow
control valves.

4.1 Experimental data:

Refrigerant used: R-134a

Capacity of The Refrigerator: 180 liters
Compressor capacity: 0.125 H.P.

4.1.1 Condenser sizes:

Type of condenser: air cooled condenser

Diameter – 4.76 mm
Lenght-10.41m
Size of condenser as per standard specification is 11” x 10” x 3 Rows

45
4.1.2 Evaporator:
Length – 8.52 m
Diameter – 5.23 mm
4.1.3 Capillary:

Length - 2.428 m
Diameter - 0.8 mm

4.1.4 Pressure Gauge (0 to 300 PSI.):

Bourdon type pressure gauge which is used to get pressures at discharge

point of compressor exit.

4.1.5 Compound Gauge. (-30 to 250 PSI.):

Bourdon type pressure gauge which shows both negative pressure (Vacuum)
as well as positive pressure in the VCR system. This is used to measure pressures at
suction point of compressor.

46
The pressure gauge in the high pressure line was installed just next to the filter/drier
and just before the capillary tube. Another pressure gauge was installed in the low
pressure return line to measure the pressure of the fluid returning back to the
compressor.. A digital thermometer was used to determine the temperatures that
were to be used in the analysis of the system. The readings of the temperature and
pressure of VCR were plotted on the P-H chart and the corresponding enthalpies
were noted down and from the values of the enthalpies obtained, the parameters such
as refrigeration effect and the compressor work were determined. The carnot or ideal
COP of the system was determined by using the temperature limits of the system and
the actual COP of the VCR system was calculated by considering the ratio of the
refrigeration effect and the compressor work obtained from the PH chart. Refrigerant
used for the analysis of VCR system is R134a.

4.1.6 ¼ control valves:

one valve is placed between the compressor and condenser,another valve is

between condenser and capillary tube. Which are used to control the flow rate of the
refrigerant.

47
4.1.7 Filter:

Smart ¼ filter is placed between tyhe condenser and capillary tube. Which
is used to filter the dust particles in refrigerant.

4.1.8 Guage adopters:

Adopters which are used to connect the pressure gauges to the circuit.

4.1.9 Thermometers:

Which are used to measure the temperature of the refrigerant at various sections.

48
4.2 Equipement details:

SI no Name of the Quantity Each component Total

component cost cost
1 Compressor 1 1000 1000
2 180 lts Condenser 1 250 250
3 Capillary tube 1 110 110
4 Evaporator 1 600 600
5 Filter 1 280 280
6 ¼ control valve 2 180 360
7 BPL relay valve 1 180 180
8 Guage adopters 3 40 120
9 ¼ flatnut 8 28 224
10 ¼ copper pipe 2ft 1 230 230
11 Pressure guage 2 375 750
12 Compound guage 1 400 450
13 Thermometer 2 275 550
14 Supporting stand 1 600 600
15 Foam 1 100 100
16 R-134a 250
17 Unions 2 50 100
Total 6454

49
4.3 Experimental procedure:

The following procedure is adopted for experimental setup of the vapor

compression refrigeration system
1. The domestic refrigerator is selected, working on vapor compression refrigeration
system.
2. Pressure and temperature gauges are installed at each entry and exit of the
components.
3. Flushing of the system is done by pressurized nitrogen gas.
4. R 134a refrigerant is charged in to the vapor compression refrigeration system by
the following process:
5. Leakage tests are done by using soap solution, In order to further test the
condenser and evaporator pressure and check purging daily for 12 hours and found
that there is no leakages which required the absolutely the present investigation
to carry out further experiment.
6. Switch on the refrigerator and when the evaporator temperature reaches -5 degrees
centigreade is required to take the pressure and temperature readings at each
section.
7. The performance of the system is investigated, with the help of temperature and
pressure gauge readings
8.Now by changing the mass flow rate of the refrigerant by using valve arrangement.
9.By using the above proceedure we can calculate the required parameters.

50
4.4 Experimentation Readings :
Repeating the experimentation using the same refrigerant R134a, by
changing the valve arrangement and load, then observed readings are tabulated as
follows:

Pressure(psi) Temperature(*c)
Si Load(lts) Time
P1 P2 P3 P4 T1 T2 T3 T4
no
1 0 20 16 170 170 16 12 59 37.3 -5

0 16 14 195 190 14 13 58 39 -5

0 15 12 180 180 12 14.2 58.6 45 -5

2 1 28 15 170 170 15 12 56 39.1 -5

1 22 14 190 190 14 13.3 57 45.3 -5

1 15 10 180 180 10 15.1 62 40 -5

3 2 30 16 175 170 16 14.3 61.1 44 -5

2 20 13 190 190 13 15.3 60.3 47.1 -5

2 14 10 180 180 10 13 57 44.6 -5

4 3 45 16 170 170 16 13.4 55 43.2 -5

3 34 14 190 190 14 12.4 61 47.2 -5

3 28 10 180 175 10 13.8 62 42.5 -5

51
 5 CALCULATIONS

As shown in P-h diagram (Moeller diagram) for refrigeration cycle with four
basic processes are frequently used in the analysis of vapour compression
refrigeration cycle, process 1to 2 is compression, process 2 to 3 heat rejection in the
condenser, process 3 to 4 expansion (Throttling) and process 4 to 1 is Evaporation
i.e. heat absorbed in the evaporator. [5-6] described the performance of air
conditioner components. The performance characteristics are can be computed for
compressor work (Wc), Refrigeration Effect (QE) and Coefficient of Performance
(COP) is expressed by the ratio of amount of heat taken by the cold body to the
amount of work supplied by the compressor; this ratio is called Coefficient of
performance.

Vapour compression refrigeration cycle on p-h diagram

The system performance is calculated as follows:

The work done during the isentropic compression per kg of refrigerant is
given by
Wc = mᵣ×(h2- h1) ------------------------------ (1)
The refrigerant effect or heat absorbed or extracted by the liquid-vapour
refrigerant during evaporation per kg of refrigerant is given by
QE = mᵣ ×(h1 - h4) ------------------------------(2)

52
 The Coefficient of performance (C.O.P.) is the ratio of heat extracted in the
refrigerator to work done on the refrigerator.

COP = Refrigeration Effect/ Work Done ------------- (3)

COP =H1−H4/h2−h1---------------------------------------------- (4)
Pressure ratio =𝑃𝑐/pe ------------------------------------- (5)
Energy Efficiency Ratio (EER) =3.5× COP ------------ (6)
Capacity of the system = 1 TR = 3.5 kW -------------- (7)
Heat rejected in the condenser = mᵣ ×(h2 –h3) ------------ (8)
Heat absorbed in the evaporator = mᵣ × (h1 – h4) --------- (9)
Where,
h1and h2 are enthalpies of refrigerant at the inlet and outlet of
compressor (kJ/kg). h3= h4 are enthalpies of refrigerant at the inlet and outlet of
expansion valve (kJ/kg). For the air conditioning system of 1 TR capacity, with the
following operating conditions the Performance of the system can be computed as:
The operating conditions have been chosen for condenser temperature of and
evaporator temperature for selected three different type’s refrigerants (R134a) in
vapour compression cycle. [7-9] explained the different studies of vapour
compression cycle analysis.

By using P-h chart of R-134a the following properties are

Enthalpy of the refrigerant at entry to compressor is h1 = .........kj/kg
Enthalpy of the refrigerant at the at outlet of the compressor is h2 =....... kJ/kg
Enthalpy of refrigerant at outlet of the expansion valve h3 =h4=........ kJ/kg
Pressure at the in the evaporator =........bar
Pressure in the condenser = .........bar

Model calculations:
Temperatures:
Compressor suction temperature ,T 1= 12ᵒc
Compressor Discharge Temperature ,T2 = 59ᵒc
Condensing Temperature ,T3 = 37.3ᵒc
Evaporator Temperature ,T4 = -5

53
Pressure:
Compressor Suction pressure,P1= 16 psi
Compressor Discharge Pressure ,P2= 170 psi
Condensing Pressure,P3= 170 psi
Evaporator pressure, P4= 16 psi

Convert all the pressure in to Bar:

Conversion pressure Unit -1.psi = 0.069 bar
P1 =16 x 0.069 = 1.104 bar
P2 =170 x 0.069 = 11.73 bar
P3 = 170 x 0.069 = 11.730 bar
P4 = 16 x 0.069 = 1.104 bar

Formulas used:
Enthalpy at superheated condition:
H=hg+cp(Tsup-Tsat)
Enthalpy at saturated condition:
H=hg
Enthalpy at saturated liquid condition:
H=hf
From pressure enthalpy Chart for r 134a, enthalpy values at state points 1, 2,
3, 4. The state points are fixed using pressure and temperature and each point.
h 1 = 265.20 KJ/Kg
h2 = 289.92 KJ/Kg
h3 = 104.210 KJ/Kg
h4 = 104.210 KJ/Kg

Calculations Performance Parameters:

1. Net Refrigerating Effect (NRE) = (h1 – h4) = (265.20 – 104.210) = 160.99 KJ/Kg

2. Circulating rate to obtain one tone of Refrigeration, kg/min. mᵣ= 210/ NRE =
210/160.99=1.3044Kg/min

54
3. Heat of compression = (h2 – h1 )= (289.92 – 265.20 )= 24.71 KJ/Kg

4. Heat Equivalent of work of compression = mᵣ x ( h2 – h1 ) = 1.304 x (24.71)

=32.23 kJ/min

5. Compressor power =(32.23 /60 )=0.5372 kW

6. Coefficient of performance (COP) =Net refrigerating/EffectHeat of Compression

=(160.99/24.71)=6.51
7. Heat rejected in condenser = (h2 –h3 ) = (289.92-104.21) =185.71 kj/kg

8. Heat rejection Rate = (210/160.99) x 185.71 =244.24 kj/min

9. Pressure Ratio=Pd/Ps =170/16=10.625

55
 6 RESULTS AND DISCUSSION

the performance parameters for all the values are calculated and tabulated as
follows:

Parameter(lts) 0 0 0 1 1 1
Compressor 12 13 14.2 12 13.3 15.1
suction
temperature,T1(°C)
Compressor 59 58 58.6 56 57 62
discharge
temperature,T2(°C)
Condensing 37.3 39 45 39.1 55.3 40
temperature,T3(°C)
Evaporator -5 -5 -5 -5 -5 -5
temperature,T4(°C)
Compressor 16 14 12 15 14 10
suction
pressure,P1(psi)
Compressor 170 190 180 170 190 180
discharge
pressure,P2(psi)
Condenser 170 195 180 170 190 180
pressure,P3(psi)
Evaporator 16 14 12 15 14 10
pressure,P4(psi)
Enthalpy,h1 (kJ/kg) 265.20 264.1 264 263.52 262.84 266.08
Enthalpy,h2 (kJ/kg) 289.92 286.27 287.12 287.07 287.46 292.31
Enthalpy,h3 (kJ/kg) 104.21 106.74 119.78 114.8 117.8 109.6
Enthalpy,h4 (kJ/kg) 104.21 106.74 119.78 114.8 117.8 109.6

56
Load(lts) 0 0 0 1 1 1
Refrigeration 160.99 157.26 144.22 148 144.2 156.48
effect(kj/kg)
Circulating rate to 1.304 1.335 1.456 1.4185 1.45 1.342
obtain one tone of
Refrigeration(mr)
(kj/min)
Heat of 24.71 23.1 23.125 23.55 25.46 26.23
compression(kj/kg)
Heat Equivalent of 32.23 30.713 33.67 33.425 37.07 35.21
work of
compression(kj/min)
Compressor power 0.5372 0.511 0.56 0.5561 0.61 0.586
per ton of
refrigeration(kw)
Compressor power 6.51 6.837 6.23 6.28 5.66 5.96
Coefficient of
performance (COP

Heat rejected in 185.71 179.53 167.34 148.64 144.2 182.53

condenser(kj/kg)

Pressure Ratio 10.625 13.92 15 11.33 13.57 18

57
Load(lts) 2 2 2 3 3 3
Compressor 14.3 15.3 30 13.4 12.4 13.78
suction
temperature,T1(°C)
Compressor 61.1 60.3 57 55 61 62
discharge
temperature,T2(°C)
Condensing 44 47.1 44.6 43.2 47.2 42.5
temperature,T3(°C)
Evaporator -5 -5 -5 -5 -5 -5
temperature,T4(°C)
Compressor 16 13 10 16 14 10
suction
pressure,P1(psi)
Compressor 175 190 180 170 190 1750
discharge
pressure,P2(psi)
Condenser 170 190 180 170 190 180
pressure,P3(psi)
Evaporator 16 13 10 16 14 10
pressure,P4(psi)
Enthalpy,h1 (kJ/kg) 261.12 266.39 264.43 260.73 261.6 267.57
Enthalpy,h2 (kJ/kg) 291.49 288.24 285.93 288.31 287.57 291.25
Enthalpy,h3 (kJ/kg) 116.38 119.58 118.64 114.48 121.5 112.98
Enthalpy,h4 (kJ/kg) 116.38 119.58 118.64 114.48 121.5 112.98

58
Parameter(lts) 2 2 2 3 3 3
Refrigeration 144.74 146.81 146.1 146 138.01 154.59
effect(kj/kg)
Circulating rate to 1.45 1.43 1.45 1.435 1.51 1.36
obtain one tone of
Refrigeration(kj/min)

Heat of 30.37 21.85 20.57 29.21 27 23.43

compression(kj/kg)
Heat Equivalent of 44.53 31.25 31.25 42.01 40.9 31.9
work of compression
(Kj/min)
Compressor power 0.73 0.52 0.5442 0.7 0.68 0.53
per ton of
refrigeration(kw)
Compressor power 4.76 6.71 7.019 5.034 5.11 6.49
Coefficient of
performance (COP

Heat rejected in 176.9 168.66 165 173.73 166 178.27

condenser(kj/kg)

Pressure Ratio 10.625 14.615 18 10.625 13.5 18

59
Results:
Effect of coefficient of performance with mass flow rate of refrigerant
for one ton of refrigeration:
coefficient of performance of a Vapour compression refrigeration system
with refrigerant R-134a is slightly decreases with increase of mass flow rate per one
ton of refrigeration.the variation of coefficient of performance with mass flow rate
as shown in graph-1.

mass flow rate vs cop

6
cop

3
1.30 1.35 1.40 1.45 1.50
mass flow rate

Graph-1

Effect of refrigeration effect with mass flow rate of one to of refrigeration:

Refrigeration effect of a Vapour compression refrigeration system with
refrigerant R-134a is decreases with increase of mass flow rate per one ton of
refrigeration.the variation of refrigeration effect with mass flow rate as shown in
graph-2.

60
 mass flow rate vs refrigeration effect
165

160

refrigeration effect 155

150

145

140

135
1.30 1.35 1.40 1.45 1.50
mass flow rate

Graph-2

Effect of compressor work with mass flow rate for one ton of refrigeration:
Compressor work of a the system is increase with mass flow rate.the
variation in compressor work for different mass flow rates is shown in geaph-3.

mass flow rate vs compresor work

60

50
compressor work

40

30

20

1.30 1.35 1.40 1.45 1.50

mass flow rate

Graph-3

61
Effect of refrigeration effect with pressure ratio:
Refrigeration effect of the vapour compressor refrigeration system with r-
134a as refrigerant is increase with increase of pressure ratio.the variation in
refrigeration effect with different pressure ratios is shown in graph-4.

pressure ratio vs refrigerationeffect

180

170
refrigeration effect

160

150

140

130

120
10 11 12 13 14 15 16 17 18
pressure ratio

Graph-4
Effect of coefficient of performance with refrigeration effect:
Coefficient of performance of a refrigeration system is the ratio of
refrigeration effect to the compressor work so that if increase of refrigeration effect
then the coefficient of performance will increase. In the present work the effect of
coefficient of performance of a refrigeration system with increase of refrigeration
effect is shown in graph-5. Observed that coefficient of performance is increases
with increase of refrigeration effect.
refrigeration effect vs cop

7
cop

3
140 145 150 155 160
refrigeration effect

Graph-5

62
Effect of coefficient of performance with compressor work:
Coefficient of performance of a refrigeration system is the ratio of
refrigeration effect to the compressor work so that if increase of refrigeration effect
then the coefficient of performance will decrease. In the present work the effect of
coefficient of performance of a refrigeration system with increase of compression
work is shown in graph-6. Observed that coefficient of performance is decreases
with increase of compressor work.

compressor work vs cop

9

6
cop

30 32 34 36 38 40 42 44 46
compressor work

Graph-6

Effect of compressor work with load:

In the present work The variation of compressor work with load is shown in
graph-7.observed that compressor work will increase with increase of load.

63
 load vs compressor work
50

45
compressor work

40

35

30

25

20

0.0 0.5 1.0 1.5 2.0 2.5 3.0

load

Graph-7

Effect of heat rejection in condenser with mass flow rate:

In the present work the effect of heat rejection with incease of mass flow rate
is shown in graph-8.observed that with increase of mass flow rate of the system per
ton of refrigeration the heat rejection in the condenser will slightly decreases. The
variation of heat rejection in condenser with defferent mass flow rates has been
shown in graph-8.

mass flow rate vs heat rejection in condenser

220

210
heatrejection in condenser

200

190

180

170

160

150

140

130
1.30 1.35 1.40 1.45 1.50
mass flow rate

Graph-8
64
Effect of compressor work with pressure ratio:
In the present work The variation of compressor work with
different pressure ratios is shown in graph-9.observed that compressor
work will increase with increase of pressure ratio.in low pressure ratio
the compressor work will be high further increasing the pressure ratio
the compressor work will decreases upto some extent if further increase
the pressure ratio then the compressor work will increases

pressure ratio vs compressor work

50

45
compressor work

40

35

30
10 11 12 13 14 15 16 17 18
pressure ratio

Graph-9

65
 7 CONCLUSION

In the present work fabrication of a vapour compression refrigeration system

and experimental investigation is carried out to investigate the performance of
vapour compression refrigeration system of a domestic refrigerator of 170 liters
capacity, with R-134a as refrigerant with different mass flow rates and different
loads..

After conducting the experiments, the following conclusions are drawn.

• coefficient of performance of a vapour compression refrigeration system

decreases with increase of mass flow rate per one ton of
refrigeration.coeffient of performance will increase for mass flow rate up to
1.4 kj/min if further increase in mass flow rate will decrease the coefficient of
performance.
• Refrigeration effect of a Vapour compression refrigeration system is
decreases with increase of mass flow rate per one ton of refrigeration.
• Compressor work of a the system is increase with increase of mass flow rate.
• Refrigeration effect of the vapour compressor refrigeration system with r-
134a as refrigerant is increase with increase of pressure ratio.
• The coefficient of performance of a refrigeration system with increase of
refrigeration effect.
• coefficient of performance is decreases with increase of compressor work.
• compressor work will increase with increase of load.
• heat rejection in the condenser will slightly decreases with incease of mass
flow rate of the refrigerant per ton of refrigeration
• compressor work will increase with increase of pressure ratio.in
low pressure ratio the compressor work will be high further
increasing the pressure ratio the compressor work will decreases
upto some extent if further increase the pressure ratio then the
compressor work will increases.

66
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