CONSTRUCTION OF 1.

5 HP SPLIT UNIT

AIR CONDITIONING SYSTEM

BY

1. BABATUNDE BABAJIDE SAMUEL

P/ND/12/3430035
2. IKPERHA ISAAC JOMA
P/ND/11/3430069

A PROJECT SUBMITTED TO
DEPARTMENT OF MECHANICAL ENGINEERING FOR THE AWARD OF
NATIONAL DIPLOMA

YABA COLLEGE OF TECHNOLOGY

YABA, LAGOS

NOVEMBER 2015
 CONSTRUCTION OF 1.5 HP SPLIT UNIT

AIR CONDITIONING SYSTEM

BY

1. BABATUNDE BABAJIDE S P/ND/12/3430035

2. IKPERHA ISAAC JOMA P/ND/11/3430069

A PROJECT SUBMITED TO

DEPARTMENT OF MECHANICAL ENGINEERING

YABA COLLGE OF TECHNOLOGY

FOR THE AWARD OF NATIONAL DIPLOMA

November 2015
 CERTIFICATION

This is to certify that the project conform to acceptable standard of

scholarly presentation and is fully adequate in scope and quality and
has been originally carried out by.

1. BABATUNDE BABAJIDE S P/ND/12/3430035

2. IKPERHA ISAAC JOMA P/ND/11/3430069

In the Department of Mechanical Engineering, school of Engineering,

Yaba College of Technology Yaba, Lagos.

_________________ _________________

ENG. S. E AZIKE

PROJECT SUPERVISOR PROJECT CO-ORDINATOR

_____________________

H. O. D
 DEDICATION
This project is highly dedicated to Almighty God for taking control of
every aspect of it; and also to our parent, for their moral and
financial contribution.
 ACKNOWLEDGEMENT
We wish to express our indebtedness to the author of textbook and
references we consulted in this preparation of this project. Details
are provided in the references.

In particular, our thanks are due to Engr. S Azike for taking time to
read the manuscript and offering helpful suggestion and brotherly
advice.

I render my gratitude to my beloved daddy late.

 APPRECIATION
We appreciate the assistance, criticism, correction and guidance
given to us by our project supervisor: Engr. S. Azike and our parents
and other well-wisher. They all, have indeed made this project
successful.

Thanks.
 TABLE OF CONTENTS
ii. Certification
iii. Acknowledgement
iv. Appreciation
v. Dedication
vi. Table of contents
vii. Nomenclature
viii. List of Figures
CHAPTER ONE
1.0 Introduction history of Air conditioning system
1.1 Fundamental of Air conditioning
1.2 Purpose of construction
1.3 Importance of specification of the project
1.4 Scope and limitation
CHAPTER TWO
2.0 Air Conditioning as related to thermodynamic process
2.1 Psychometric properties of Air
2.2 Psychometric chart
CHAPTER THREE
3.0 Cooling
3.1 Cooling load and calculation
3.1.1 Heat leakage
3.1.2 Heat gain from occupants
3.2 The project load
3.2.1 Air infiltration
3.2.2 Determination of the design standard component
3.2.3 Coefficient of performance
3.2.4 Design Analysis
3.3 Refrigeration cycle
3.3.1 Heat gain calculator
CHAPTER FOUR
3.0 Function of major parts
4.1 Refrigerant
4.2 Compressor oil properties
4.3 Simple saturated cycle
4.4 Principle of operation
4.5 Construction (Housing)
4.6 Electrical Components
CHAPTER FIVE
4.0 Charging
5.1 Charging methods
5.2 Charging process
CHAPTER SIX
5.0 Operational deficiency and remedies
6.1 Maintenance
6.2 General safely rules on Air conditioning & refrigerating
system
6.3 Conclusion & Recommendation
6.4 Materials
6.5 Costing
6.6 References
 NOMENCLATURE
L – Length
A – Area
P – Pressure
M – Mass
M – Mass flow rate
D – Density
G – Gravity
At – Temperature difference
E – Efficiency
H – Enthalpy
Ah – Enthalpy difference
Q – Heat quantity
T – Temperature
V – Volume
U – Internal energy
S – Entropy
C.O.P – Co-efficient of performance
K – Thermal conductivity
X – Thickness of material
“Q” – Heat transfer per Area
C – Specific heat
Hi – Latent heat of fusion
Gr – Equivalent load
H.P – Horse power
V – Flow rate
e/v – Volumetric efficiency
Vs – Swept Volume
A.C – Alternating current
– Fuse
 LIST OF FIGURES
Equivalent cycle
Reversed carnot cycle
Schematic arrangement of Brayton’s cycle
Reversed Rankine
Vapour compression cycle
Pressure – enthalpy diagram
Temperature – enthalpy diagram
Relative humidity
Effect of frequency on ear’s
Heat leakage
Simple saturated cycle
Compressor diagram
Simple saturated cycle
Metal base & casting diagram
A/C unit
Comprehensive writing diagram of A/C unit
Simple diagram of A/C unit
 CHAPTER ONE

1.0 INTRODICTION

HISTORY OF AIR CONDITIONING SYSTEM

Climate which is the weather condition of an area.

These condition include; temperature ,humidity, sunshine, and air

movement, which has been designed by God, the creator of heaven
and earth.

This project which is 1.5HP split air conditioning unit shows the extent
to which God bestowed power, knowledge, wisdom and understanding
on man to control the climate in order to meet a particular purpose in a
designated area or space.

In a developed country like Nigeria, the need for room unit cannot be
over-emphasized. Air-conditioning unit has been found acceptable
within the market economy and commercial enterprises.

However, hotels and restaurants need an air-conditioning unit for

cooling. Individual also have great demand for simple unit for cooling
purpose on home, offices etc.

It becomes imperative that nearly most establishment that produces

low temperature product needs air-conditioning unit.
The machines are range in different capacities which depend on the
function of the unit and the size of components.

This project aims at constructing and designing air-conditioning system

(1.5 HP) that will cool about three rooms daily with regards to temp 0c
degree, humidity and air passages/flow (filter) condition.

1.1 FUNDAMENTAL OF AIR CONDITIONING

History records that in all activities of human race, efforts have been on
the creating a conducive atmosphere.

Air conditioning can be define as the process of treating air so as to

control simultaneously its temp0c, humidity cleanliness and distribution
to meet the requirement of the conditioned space.

The important actions involves in the operation of an air conditioning

system are:-

TEMPERATURE CONTROL.

HUMIDITY CONTROL.

Air filtering, cleaning, purification and distribution of air movement and

circulation.

Temperature control for winter conditions requires automatic control

of the refrigerating system to maintain the desire room temperature.
While temperating control for summer heating conditions requires
automatic control of the heating source as means of maintaining
desired room temperatures.

Humidity control requires the automatic control of dehumidifiers. This

is done when the air to cool is passed over the cold evaporating
surfaces.

Air filters usually consist of very fine porous substances through which
air is drawn to remove contaminating particles.

1.2 PURPOSE OF CONSTRUCTION

The purpose of the construction is as follows:

1. To increase the life span and service of air-conditioning unit.

2. To produce air-conditioning unit that is easily available.
3. To construct air conditioning unit which is efficient, practical and
maintainable?
4. To improve on the existing design taking into consideration the
Nigeria factor.
5. To design air-conditioner which makes use of 90 to 96 percent
local technology?
1.3 IMPORTANCE AND SPECIFICATION OF THE PROJECT

The importance of this design is for homes and offices, for both
domestic use and commercial purpose. It is to serve mainly the function
of producing cool air in a condition or a space which level to stability in
terms of equilibrium for human comfort and healthy, for specified
period of time.

However, it’s major specification is based on the extent to which air

could be treated to meet the requirements of the conditioned space,
which lead to the cabinet dimension of 670mm (2.02 feet), by 250mm
(0.86 feet’s) in area and 480mm (1.6 feet’s) in height.

The above parameters would be used to compare the cooling load

which will be used to determine the size of the air-conditioning
component.

The essential design parameters are:-

A. Compressor
B. Condenser
C. Evaporator
D. Air filter
E. Fan motor
F. Grill
 G. Thermostat
H. Switch
I. Valve
J. Copper tube

However, the performance of the design will be improved by

incorporation of certain innovation into the system.

Such as:-

i. Use of alley material

ii. Size minimization
iii. Spraying under pressure

1.4 SCOPE AND LIMITAION

Generally, air-condition is divided mainly into three groups:-

i. The heating type

ii. The cooling type
iii. Both heating and cooling type

The scope is therefore the design of air-conditioning for domestic use.

In the domestic application, it will be used for homes, offices, business
centers e.t.c
However, the roof top of these systems must be string to carry extra
weight and its openings must be leak proof.

Limitation arises due to the specification in term of the size, capacity,

conformity (in terms of iso, su) and application which means that the
design is not suitable for industrial purpose where large air-
conditioning units is needed.
 CHAPTER TWO

2.0 AIR-CONDITIONING AS RELATED TO THERMODYNAMIC PROCESS

The laws and theories propagated by the early scientist were the fact
that was collected together that tells while each unit like compressor,
evaporator, condenser, expansion valve were put together to perform a
common function, which is to extract as much heat from the cold body
as possible and expelled to a hot body with expenditure of a little work
as possible without violating any of the thermodynamic laws and why
all these items are needed in a mechanical air-conditioning system.

It is the science of thermodynamics which enables us to deal

qualitatively with the analysis of the machine which are used to convert
energy into useful work.

Some of the pioneer scientists and engineers in the field of

thermodynamics whose laws and finding helps in generating a
mechanical refrigerating system were: SADI CARNOT, KELVIN-PLANCK,
CLANSIUS, BRAYTON, RANKINE, and others.

The basic principle of modern day air-conditioning design was based on

two classical statements, both of which are called the second law of
thermodynamic. One is due to CLANSIUS and other is due to KELVIN
PLANCK statement.

The clansius statement states that “it is impossible to design a device

that operates thermo-cycle of which air is to produce heat from lower
temperature to higher temperature region”. And for this to occur a
work must be produced.

Kelvin Planck statement states that “it is impossible to contract a device

that executes a thermodynamics cycle, exchange heat energy with a
single reservoir and produces an equivalent amount of work.

This tells us that at least two reservoirs are needed for heat exchange
process. It was observed that if the carnot cycle is traced counter
clockwise, it require work input and heat is transferred from a low
temperature (TL) reservoir to a high-temperature (TH) reservoir. The
cycle is then said to operate as a REFRIGERATION OR AIR
CONDITIONING.

When the objective is to extract heat from the low-temperature

reservoir (Evaporator) and transfer it to high-temperature reservoir
(condenser).

Therefore, the combination of Clansius and Kelvin Plank statements has

its application in Sadi Carnot reverse air-conditioning system whereby
work is applied by the compressor to the system and the
condenser/evaporator serves as high and low temperature reservoir
with the refrigerant as the working agent.

Fig 1A shows the equivalent cycle.

2.1 Fig. A

Demonstration of the two statement of the second law.

Theoretically and on ideal basis, the co-efficient of performance of the
reverse carnot cycle in the maximum obtainable for stated temperature
of source and sink.

Figure 1b depicts the reverse carnot cycle on the T-S plane

(Temperature – entropy ptane).

Figure 1b. Reversed carnot cycle

The appearance of the cycle in figure 1b is the same as that of power

cycle, but the order of the cyclic process of reversed starting from state
1 of the figure 1b, with the fluid at temperature TH of the hot body, the
order of cycle events is as follows:

i. ISENTROPIC EXPANSION: 1 – 2, of the refrigerant fluid of the

temperature Tc of the cold body.
ii. ISOTHERMAL EXPANSION: 2 – 3, at temperature Tc of the cold
body during which the cold body gives up heat to the
refrigerant fluid in the amount Qc represented by the area 2-3-
b-a.
iii. ISENTROPIC COMPRESSION: 3 – 4, of the fluid to the
temperature TH of tot body.
iv. ISOTHERMAL COMPRESSION: 4 – 1, at the temperature TH of
the hot body, during this process, the hot body receives heat
from the refrigerant fluid in the amount Q H represented by
area 1-2-3-4 is the network which must be supplied to the cycle
by the external system (compressor).

Figure 1b indicates that Qc and the network rectangle each have area
in proportion to their lengths. Thus the co-efficient of performance
(C.O.P) which is the yard stick is measuring the performance of air-
conditioning cycle, define as the ration of Qc (heat removed) to the
network i.e

TC
(TH – TC)
Another specialist is Brayton who made one of the first cycle used
for mechanical refrigeration and air-conditioning. Before Freon and
other condensable fluid were developed for the vapour compression
cycle, the cycle operated on the Brayton cycle using air as their
working substance Fig 2. A, B & C.
The disadvantage of this cycle is as shown on the diagram in figure
2c stated by Sybil P. Parker (1883 – 1889).
If the temperature of ‘E’ represent ambient, then only way that air
can reflect a significant quantity of heat along the line b-c of for ‘b’
to be considerable higher than ‘c’ correspondingly if the cold body
service temperature is ‘a’, the air must be at a much cycle were used
with a working substance under changes in state, the fluid would
transverse path a-f-c-e instead of path a-b-c-d.
The reverse carnot cycle would accept more heat along path e-a
than the reverse Brayton cycle remove from the cold body along
path d-a. Also, since work area required by the reverse carnot cycle
is much smaller than the corresponding area for the reverse Brayton
cyle is preferred in refrigeration and air-conditioning practice.
Nevertheless, it is quite obvious that the reverse carnot cycle does
not lead itself to practical adaptation because it required both an
expanding and a compressor. Nevertheless, its performance is a
limiting idea to which actual refrigeration and conditioning
equipment’s can be compared.
The use of reversed Rankine cycle is one change from the carnot
cycle which is always made in real vapour compression plant by
substitution of an expansion value for the expansion engine.
Even if the isentropic were possible, the work delivered by the
expansion engine would be very small and the irreversibility present
in any real operation would further release the work delivered by
the expanding engine. The substance of an expansion value or
trothing orifice, with constant enthalpy expansion changes the
theoretical performances and greatly simplifies the apparatus.
Figures 3 below shows the reverse Rankine cycle. The irreversible
adiabatic expansion 1-2 differs and slightly from the vertical
isentropic expansion.
Another practical change from the ideal carnot cycle substitude dry
compression 3-4 for net compression e-d in figure 3a, planning state
4 in the super heat region above ambient temperature; the process
is called dry compression in contrast to the wet compression of the
carnot cycle. Dry compression introduces a second irreversibility by
exceeding coefficient of performance. Dry compression is usually
preferred, however, because it simplifies the operation and control
of a real machine. The vapour gives no readily observable signal as it
approaches and passes point ‘e’ in the course of evaporation, but it
will undergo a temperature rise if it accepted heat beyond point “3”.
This cycles using dry compression is the one which has over
whelming acceptance for refrigeration and air conditioning work.
The commonly used basic cycle, in order of importance, and vapour
compression, absorption steam jet or steam ejector and air, each
cycle operates between two pressure levels and all except the air
cycle use a two phase working medium which alternate between the
liquid and vapour phases.
The vapour compression cycle (on which his desing is based upon)
consists of boils at low temperature to product cooling, a
compressor to raise the pressure and temperature of the vapour
refrigerant, a condenser in which the refrigerant discharges its heat
to the environment usually a receiver for storing the liquid
refrigerant condensed in the condenser and expansion valve through
which the liquid expands from the high-pressure level in the
condenser to the low-pressure level in the evaporator. (Any larger
design), but air cooled condenser and capillary tube are used in this
design.
The diagram below in figure 4 show the sketch of a general adapted
vapour compression system.
Diagram 4

2.2 PSYCHOMETRIC PROPERTIES OF AIR

Psychometric is the science and practice of dealing with air mixtures
and their control. It deals mainly with dry air and water vapour
mixtures. Psychometry deals with the specific heat of dry of dry air
and its volume. Also, it deals with the heat of water, heat of
vaporization or condensation and the specific heat of steam in
reference to moisture mixed with dry air. The psychometry tables
and charts are based on 1kg of dry air, plus the water vapour to
produce the air conditions being studied.
PSYCHOMETRIC CHART
Psychometric chart is a graph of temperature pressure relationship
of water vapour. The horizontal scale is the temperature, while the
vertical scale is the water vapour pressure scale.
Figure 5

2.3 OPERATIONAL DEFINITION OF TECHNICAL (KEYWORDS)

TERM
AIR CONDITIONING
Is the control of the temperature, humidity, air movement and
cleaning of air in a confined space.
AIR CONDITIONER
Device used to control temperature, humidity, cleanliness and
movement of air in conditioned space.
TEMPERATURE
Degree of hotness or coldness of an environment or body, measured
in degree Celsius or Fahrenheit. The instrument use to measure
temperature is THERMOMETER.
COMFORT ZONE
Area on psychometric chart which shows conditions of temperature,
humidity and sometimes air movement in which most people are
confortable.
COMFORT CONDITION

It is obtainable from a combination of temperature humidity air

movement and cleanliness. The table below shows the Beaufort scale
of wind velocity.

Beaufort Win Velocity Observed wind effect Terms used in

using forecast
number d Knot
MPH
0 X1 1 Calm, smoe rises vertically
LIGHT
1. 1-3 1-3 Direction of wind shown by
smoke drift out not wind
vanes.
2. 4-7 4-7 Wind felt on tape lecues
rustle, ordinary vane
moved by wind.
3. 8-12 7-10 Leaves and small twigs in
constant motion, wind
extends light flag
4. 13- 11-16
18

DEW POINT:It is the temperature below which moisturein air will start
condensing. However , it is measured by Alnon instrument.

AIR MOVEMENT: An important condition which attests human comfort.

And it is very important in a conditioned space. It’s too faster, the
person feels uncomfortable and it is too low, the person feels the same
which means the air is stake and hence lack of oxygen.
AIR VELOCITY: The air velocity from the air-conditioning system is
measured with the following instrument Anemometer, velocimeter,
velocity pressure, and anemometer with hot wire.
VENTILATION: Is a term applied to changing the air in a work place or
living space.
CLIMATE: (outdoor-indoor) describes as the weather conditions of a
region. These conditions are temperature, humidity sunshine, pressure
and air movement. Outdoor climate cannot be affected by any type of
air conditioning system while indoor climate is provided to meet any
desired conditioned.
WEATHER: Is defined as the condition in the atmosphere such as
temperature, wind velocity and direction, direction, clouds, moisture
and atmospheric, pressure.
TEMPERATURE CONTROL: Heating air-conditioned space, the amount
of heat supplied regulated the temperature; and when cooling air-
conditioned space, the amount of cooling depend on temperature of
the cooling surface (evaporator) the rate of flow of air over the cooling
surface and the initial temperature of the air in a conditioned space.
CHILL FACTOR (WIND CHILL): This is computed during the winter period
by united states weather bureau via weather forecasting channel. This
is based on the temperature and wind speed and of unit mph. Beaufort
scale: this scale is used to indicate wind velocity.
SUPER HEAT: Temperature of vapor above its boiling temperature as a
liquid pressure.
Sub cooling: cooling of liquid refrigerant below its condensing
temperature.
Latent heat of fusion: the quantity of heat required to be given to or
taken from a substance to change its state from liquid to solid of form
solid to liquid, without changing its temp0C.
SENSIBLE HEAT: heat which cause a change in temperature of a
substance without of change in the shape.
SPECIFIC HEAT
Ratio of quantity of heat required to raise temperature of a body by 1
degree to the amount required to change an equal mass of water by 1
degree.
TEMPERATURE DIFFERENCE
This is the difference in temperature between air or gas, and the
medium by which it is being cooled in air conditioning system.

RELATIVE HUMIDITY
Ratio of amount of water vapour present in air to greatest amount
possible at same temperature. It is usually expressed in percentage
30%, 65%, 85% e.t.c.
HUMIDITY
This is the amount of moisture of water vapour the air holds which
depend on the temperature of the air. That is warmer air holds
moisture while lesser air (colder) holds less moisture.
The above graph shows increase in temperature in the air which had to
increase in moisture content in air.

STRATIFICATION

Occurs when cold air sinks to the floors and the warmer air rises to the
ceiling. Movement of the air is accomplished by fan located in the air-
condition.

REFRIGERANT

This is the working fluid in air-conditioner. It is a heat carrying fluid

which change early from liquid to vapour, and from vapour to liquid by
absorbing heat during their cycle at low temperature and discharges at
high temperature due to the action of compressor.

AIR INFILTRATION
Leakage of air into rooms through cracks, windows, doors and other
openings.

REFRIGERATING EFFECT

The amount of heat removed from the cold chamber by the circulating
refrigerant.

COOLING LOAD

The summation of the heat which usually evolves from several different
sources.

ADIABATIC PROCESS

Any thermodynamic process taking place in a closed system without

the addition or removal of heat.

ISOTHERMAL PROCESS

Change of volume or pressure under conditions of constant

temperature.

CO-EFFICIENT OF PERFORMANCE
A ratio which indicate the efficiency of the system. It is expressed in
percentage.

ABSOLUTE PERFORMANCE

The temperature of a substance measured above absolute zero.

CURRENT

Transfer of electrical energy in a conductor by means of electrons

changing position.

CURRENT RELAY

Device while opens or closes a circuit base on change of current flow.

OVERLOAD PROTECTOR

A device dither temp0c, pressure, or current operated which will stop

operation of unit if dangerous condition arise.

DRY BULB TEMPERATURE

Air temperature as indicated by an ordinary thermometer.

WET BULB TEMPERATURE

It is the temperature of evaporation for an air sample.

ENTHALPY
Total amount of heat in one kilogram of a substance calculated from a
accepted temperature base.

ENTHROLPY

In thermodynamics the base of a heat diagram, the area of which is

heat unit and the attitude of which is absolute temperature. It is a
property that indicates reversibility of a process.

PSYCHOMETRIC CHART

This is a graph of temperature pressure relationship of steam (water

vapour). The vertical side represents the water vapour scale while the
horizontal side represent the temperature.

COMPRESS0R

A mechanism which works upon a fluid (the refrigerant), compresses it

into condensing sides of the cycle.

CONDENSER: A component of the air condition which receives gas from

the compressor and cools it to liquid state.
SUCTION LINE

This is otherwise known as return line, it is a low temperature region in

the flow circuit of compressed refrigerant, a part where fluid refrigerant
returns into compressor.

LOW SIDE

The portion of air conditioning system which is below evaporating

pressure.

HIGH SIDE

Parts of air conditioning system which are under condensing or high

side pressure.

LOW SIDE PRESSURE

Pressure in the cooling side of air conditioning.

HEAT SINK

This occur when heat from the sun or from radiator strike a cold space
of which some are loss while some are absorbed.

NOISE
The air-conditioning system must be designed for handling both warm
and fresh air needed so that these functions must be done in a manner
it will not annoy the occupant. The two causes of annoyance are
objectivable noise and draft. These are three type of noise problem viz:

i. Noise source
ii. Noise carriers
iii. Noise amplifier or reflectors

However, they can be rectified when directed to equipment vendors

and services technical.

This chart shows effect of frequency on the ear’s ability to hear sounds.
These three should level all appear of the same length to human ear,
yet the describes rating for each of the frequencies is different.
WET BULB DEPRESSION: The difference between dry bulb and wet bulb
temperatures.

WAX: A solid substance which may be deposited if a mixture of all and

refrigerant is cooled.

TON OF REFRIGERATION: A conventional British unit of refrigeration

capacity, equaling the refrigerating effect of one short ton of ice
melting over a period of 24hours. 12000 Btu/hr equals 35l6W. (A “short
ton” is 2000ib; a “long ton” is 2240lb).

System (Thermodynamics). It is a region containing a quantity of matter

whose properties are of interest and hence under investigation.

(Open): known as control volume is a system which has a boundary

across which heat, work and matter may flow.

(Close): Known as Quasi-static – is a system which exchanges only heat

and work with the surrounding.

LIQUID LINE: A pipe used to convey liquid refrigerant from the receiver
or condenser of a system to its refrigerant control device.

HOT GAS LINE: A pipe used to convey discharge gas from a compressor
to the entrance of condenser.
FROST BACK: Flooding of liquid refrigerant from evaporator into the
suction line, usually then frosts over.

DIRECT EXPANSION: The process of heat removed by the evaporation

of a refrigerant in a cooling coil (evaporator).

DEFROSTING: The removal of accumulated ice from the surface of

cooling coils which operates below freezing point.

CALORIE: The amount of heat required to raise the temp 0C of 1g of

water through 10C.

AZEOTROPE

A mixture of two refrigerants which behave as one substance when

they evaporate or condense.

BRITISH THERMAL UNIT: The amount of heat required to raise the

temperature of 1lb of water through 10F.

ADSORPTION: A process incurring the removal of one or more

constituents of a mixture of liquids and gases by surface adherence to
another material which does not undergo any physical or chemical
change.