Lab Manual

Refrigeration and Air Conditioning

Course Code: MT-373 L

Section: ________________________________________

Reg. No.: ________________________________________

Lab Instructor: Engr. Hifzur Rahman

Department of Mechanical Engineering
Faculty of Engineering & Technology
International Islamic University Islamabad
 TABLE OF CONTENTS

EXPERIMENT NO. 1 BASIC REFRIGERATION UNIT

Demonstration and working of basic refrigeration unit

EXPERIMENT NO. 2 BASIC REFRIGERATION UNIT

To carry out the thermodynamic analysis of the Simple Vapour Compression Refrigeration
Cycle

EXPERIMENT NO. 3 AUTOMOBILE AIR CONDITIONING UNIT

Study of characteristics of automotive refrigeration cycle and to find coefficient of
performance

EXPERIMENT NO. 4 REVERSE AIR CONDITIONING SYSTEM

Demonstration and Working of reverse air conditioning system

EXPERIMENT NO. 5 VAPOUR ABSORPTION REFRIGERATION SYSTEM

Demonstration and working of Vapour Absorption Refrigeration System

EXPERIMENT NO. 6 HVAC LABORATORY UNIT

Demonstration and working of Air Conditioning Laboratory Unit

EXPERIMENT NO. 7 HVAC LABORATORY UNIT

Study the characteristics of air on psychrometric chart during cooling & dehumidification
process

EXPERIMENT NO. 8 RECIRCULATING AIR HANDLING UNIT

Study the characteristics of air on psychrometric chart during heating & humidification
process on recirculating air conditioning unit

EXPERIMENT NO. 9 COOLING TOWER

Demonstration and General Observation of the Forced Draught Cooling Tower

EXPERIMENT NO. 10 COOLING TOWER

Investigation of the Relationship between Cooling Load and Cooling Range.

EXPERIMENT NO. 11 MECHANICAL HEAT PUMP

Determination of power input, heat output and coefficient of performance of Mechanical Heat
Pump
 EXPERIMENT NO. 1 BASIC REFRIGERATION UNIT

OBJECTIVE
Demonstration of domestic refrigerator

APPARATUS REQUIRED

Basic Refrigeration Unit.

THEORY

Refrigeration
It is the process of continuous cooling or extraction of heat to below that of the
atmosphere from a substance with a help of the external work. It is based on the
second law of thermodynamics that the heat can made to flow from cold body to a hot
body with the help of external source.

Domestic Refrigerator
To preserve
foods/vegetables and for
drinking cold water, we
normally rely on the
domestic refrigerator, it is
a machine which produces
cold. It is used to remove
heat from the refrigerated
space and reject it to
atmosphere. Hence it
maintains the temperature
below the surrounding
atmosphere.
Actually, the domestic
refrigerator is a heat pump
which throws the heat of
the foods or stuff to be
cool to the atmosphere by
taking the power of a
compressor. The second
law of thermodynamics
with its Clausius statement
suggests, to throw heat
from low temperature to
high temperature, one
must put extra efforts in
the form of work. The same is done by the compressor in the domestic refrigerator.

Figure 1: Domestic Refrigerator Cycle Diagram

Labelled Diagram:

Figure 2: Basic Refrigeration Unit

1. Frame
2. Manometer for high-pressure side (HP)
3. Expansion valve with
4. Temperature sensor
5. Manometer for low-pressure side (LP)
6. Sight glass (refrigerant)
7. Evaporator
8. Water tank
9. Condenser
10. Compressor
11. Filler valve
12. Pressostat
13. Main switch
 Working of function unit:
The basis for the functioning of a basic refrigeration unit is a thermodynamic cycle
called 'Vapor Compression Refrigeration Cycle '.The vapour compression cycle
works on closed cyclic operation with the help of heat transfer media called
'refrigerant'. Refrigerant is the working fluid used in the refrigerator. e.g. ammonia,
methyl chloride, freon etc. This refrigerant passes through various change of state in a
pre-set sequence. The changes of state are repeated cyclically, so the refrigerant
repeatedly returns to its initial state. That is why the process is termed a cyclic
process.

Components
 A compressor compresses the vaporous refrigerant, whereby mechanical energy Win
is absorbed.
 In the condenser the heat Qout is drawn off of the refrigerant (at the same
temperature) and the refrigerant is liquefied.
 In an expansion valve pressure is relieved from the liquid refrigerant, thereby cooling
it down.
 An evaporator evaporates the refrigerant, with heat absorption Q in.

Figure 3: Components of Vapour Compression Cycle

 Compression means absorption of mechanical energy

 Expansion means discharge of mechanical energy
 Heating means absorption of thermal energy (heat)
 Cooling means discharge of thermal energy

Cycle of operation
The cycle of operation is as follows:
1. The liquid refrigerant (usually R-12 or R-134a) enters the evaporator.
2. The refrigerant boils and absorbs heat in the evaporator. The vapour is drawn
through the suction line back to the compressor.
 3. In the compressor the vapour is compressed to a high pressure, and by doing
so, its temperature is increased. The compressed vapour flows through the
high-pressure vapour line and into the condenser.
4. In the condenser, the high-pressure, high-temperature vapour gives up its heat
to the surrounding air. The vapour is condensed back to a liquid. The liquid is
shown in the bottom of the condenser.
5. Liquid refrigerant then flows through the filter-drier and enters the expansion
valve. The expansion valve, refrigerant flow control, reduces the pressure and
the temperature of liquid refrigerant by expansion process.
6. The low-pressure liquid now enters the evaporator and the cycle is completed.

This is the simplest type of automatic domestic refrigerator.

Figure 4: Phase cycle of refrigerant

COMMENTS
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EXPERIMENT NO. 2

BASIC REFRIGERATION UNIT

OBJECTIVE
To carry out the thermodynamic analysis of the Simple Vapour Compression
Refrigeration Cycle.

APPARATUS REQUIRED
Basic Refrigeration Unit.

THEORY
 A compressor compresses the vaporous service product, whereby mechanical
energy Win is absorbed.
 In the condenser the heat Qout. is drawn off of the service product (at the
same temperature) and the medium is liquefied.
 In an expansion valve pressure is relieved from the liquid service product,
thereby cooling it down.
 An evaporator evaporates the service product, with heat absorption Qin.

PROCEDURE
 Fill two vessels with cold water of approximately 25°C
 Position the vessels (8) as shown underneath the condenser and the
evaporator.
 Measure the water temperatures in the two vessels with two laboratory
thermometers
 Switch on the compressor by throwing the main switch
 Record and plot the measured values on the table.

Figure 1: Position of vessels in unit

The resulting heat delivered to the water being heated between states 1 (at the
beginning) and 2 at the point of measurement) is
 Qout =m × Cp× (THP2-THP1) (2.1)
With Cp = 4.19kJ/kg.K i.e specific heat capacity of water. The output heat power
(useful heat flow) is thus
Q out =Qout/t (2.2)
The input power is composed of the input mechanical power Pin (compressor) and the
heat power drawn from the second water vessel

Qin =m × Cp× (TLP1-TLP2)/t (2.3)

Defined and measured variables:
t- Time in sec.
m- Water quantity per water vessel
PHP - Pressure upstream of the condenser
PLP - Pressure at the inlet into the compressor
THP - Temperature of water being heated
TLP - Temperature of water delivering heat

OBSERVATIONS
Water vessel content: _____ ml Inlet Temperature = THP1 = TLP1 = ______
Time t
[sec] PHP [bar] PLP [bar] THP2 [°C] TLP2 [°C] Q out Q in

COMMENTS

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EXPERIMENT NO. 3
AUTOMOBILE AIR CONDITIONING UNIT

OBJECTIVE
Study of characteristics of automotive refrigeration cycle and to find
coefficient of performance.

APPARATUS REQUIRED
Automobile Air Conditioning System unit
THEORY
When a liquid turns to a vapor it absorbs heat. In this case it is sucking the heat out of
environment. The opposite is also true. If that vapor then loses that heat, it will turn
back into a liquid.

In a refrigeration system, a liquid is forced to become a vapor in the evaporator, thus

absorbing heat from the refrigerated space. A compressor is then used to move that
vapor to the condenser. In the condenser vapor is forced to reject the heat and thus
turn back into a liquid so that it can be re-used. At the end, liquid is metered back into
the evaporator to complete the loop and do it time and again. The boiling point is the
temperature at which the liquid turns to vapor when heat is added. It is also the
temperature at which a vapor turns to liquid when heat is removed. Boiling point
increases or decreases with pressure respectively.

In the evaporator we force liquid to become a vapor by lowering its pressure until its
boiling point/evaporating temperature is lower than the air it is trying to cool.

In the condenser we force the vapor to become a liquid by raising its pressure until its
boiling point/condensing temperature is higher than the air it is trying to heat.
Different substances have different boiling points at different pressures.

We can tell what the boiling point/saturation temp/evaporating temp/condensing temp

is at various pressures for common refrigerants by checking a pressure/temperature
chart.
General Description

1. Condenser fan 2. Condenser

3. Receiver Drier 4. Compressor
5. Expansion valve 6. Evaporator
7. Evaporator Fan (Blower)

Figure 1: Automobile air conditioning system

Main Parts of Apparatus:

1. Control Box 2. Gauges

3. Fan 4. Flow meter
5. Compressor 6. Condenser
7. Expansion Valve 8. Receiver
Refrigeration System component:

Basic Components of refrigeration system are:

 Compressor
 Condenser
 Expansion Valve
 Evaporator

Figure 2: Flow of refrigerant

Compressor:

The compressor transports the refrigerant at the required pressure through the air
conditioning system. The refrigerant is a low pressure gas as it enters the compressor
from the evaporator. The compressor increases the refrigerant pressure and also
its temperature so it becomes a high pressure gas which, in turn, helps the refrigerant
condense more rapidly in the next component, which is the condenser. The
compressor is mounted on the engine and is driven by a belt from the engine's
crankshaft pulley. The most common reasons for failure are lack of oil, pulley
bearing wear, electromagnetic coil burn-out and lack of regular servicing.

Condenser:

The condenser works in the opposite way to the evaporator. The refrigerant gives up
its heat generated by the compressor by passing cold air across its fins and tubes by
ram air or by an extra fan. The end result of this change is that the refrigerant is now
a high pressure liquid and is forced out to the receiver drier through the liquid
line. Because the condenser is usually located at the front of the vehicle it can become
damaged by debris or corroded by materials from the road. It can also fail because of
weak spots in its construction and also lack of regular servicing.

Expansion Valve:

The Expansion Device comes in many forms. It can be a brass internally or

externally equalized valve, a block type valve or an orifice tube (the latter being part
of an Accumulator type air conditioning system). Expansion Devices have an inlet
and an outlet which separates the high side of the system from the low side. A small
restriction in the valve allows only a small amount of refrigerant to pass through it
into the Evaporator, the amount of refrigerant passing through the valve depends on
the Evaporator temperature. The most common reasons for failure are contamination,
moisture and lack of regular servicing.

Evaporator:

As soon as the liquid pressure drops, the refrigerant begins to boil (R134a refrigerant
boils at approximately -26 degrees centigrade). As it continues to boil the evaporator
absorbs the heat passing over its tubes and fins and as a result the air is cooled.
Remember that heat is being removed from the warm air and cold air is not being
created. The compressor, on its suction side, removes the low pressure vapor from
the evaporator and the cycle starts all over again. The most common reasons for
failure are corrosion, weak spots in construction and lack of regular servicing. Other
component of system includes

Filter Drier:

Depending on the type of air conditioning system fitted, this item can be called a
receiver drier or an accumulator.

Accumulator

This is fitted on the low pressure gas line of an air conditioning system between the
compressor and the evaporator and is used in conjunction with an orifice tube.

Receiver drier

This is fitted on the high pressure liquid line of an air conditioning system between
the condenser and expansion device. The receiver drier has two parts to it, the
receiver and, of course, the drier. The receiver section holds the right amount of
refrigerant required by the system to ensure correct operation and to supply a steady
flow of liquid refrigerant to the expansion device. The drier section is responsible for
removing moisture from the air conditioning system by means of a bag of desiccant
which absorbs small quantities of moisture. The most common reasons for failure is
corrosion and desiccant deterioration which leads to severe system failure.
PROCEDURE
 Plug in the main Power supply and turn the breaker on.
 After Power on the motor switch, turn on remaining power switches on.
 Now, Push the AC button and let the system stable for a short time.

OBSERVATIONS
T=Dry bulb temperature

Test Ref.
Condenser Inlet T1 °C
Condenser Outlet T2 °C
Evaporator Inlet T3 °C
Evaporator Outlet T4 °C
Evaporator Outlet Pressure P1 bar
Condenser Outlet Pressure P2 bar

Draw Refrigeration cycle on P-h Diagram and calculate COP.

COMMENTS

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EXPERIMENT NO. 4
REVERSE AIR CONDITIONING SYSTEM.
OBJECTIVE
Demonstration and Working of reverse air conditioning system.

APPARATUS REQUIRED
1) Reverse air conditioning system
2) Remote controller
3) Jug for drainage water

THEORY
Heat Pump Reversing Valve.
The heat pump reversing valve is the only difference between the heat pump and
standard air conditioner. We concluded it works just like an air conditioner, moving
heat from one place to another. But the heat pump reversing valve allows us to move
the heat from inside the house to the outdoors (cooling mode) or to reverse the cycle
and remove the heat from outside the house to the indoors (heating mode).In the
figure below, you will notice the valve has 4 tubes or connections. This valve is also
referred to as a 4-way valve.

Figure 1: 4-way valve

A heat pump reversing valve is an electro-mechanical 4-way valve that reverses the
refrigerant (Freon) flow direction, using an electrical magnet. It works very similar
solenoid valve
In case of washer water solenoid valve when you connect electricity to a valve
(energize it), it opens and lets water in and when you disconnect the electricity (de-
energize it), it closes the valve and the water stops flowing.

Figure 2: Parts of Solenoid Valve

Identification of Solenoid Parts:
1) Valve Body
2) Inlet Port
3) Outlet Port
4) Coil/Solenoid
5) Coil Winding
6) Lead Wire
7) Plunger/Piston
8) Spring
9) Orifice
PROCEDURE
Energized mode, cooling mode:

Figure 3: Cycle of Cooling Mode

The heat pump reversing valve has 4 large tubes (A, B, C, D ) that’s why they call it a
4 way valve and it also has:- capillary tube (1), capillary tube (2), capillary tube (3),
slider (4), block (5) ,electrical coil (6), electrical magnet (7), and spring (8)
 We notice that the compressor’s discharge port (high pressure) is always connected to
tube A in the reversing valve and the return port (low pressure) in the compressor is
always connected to tube B. Therefore tube A always has higher pressure refrigerant,
and tube B always has lower pressure refrigerant. Notice also that capillary (2) is
always connected to tube A, thus capillary (2) also has a high pressure.
 When we energize the electrical coil (6) it energizes the magnet (7) that pulls the
block (5) which will blocks the capillary tube (3) and compresses the spring (8).
 So we notice that the capillary tube (3) is now blocked, and the high pressure
refrigerant will flow from capillary (2) to capillary (1 ) straight to the left side of the
heat pump reversing valve’s body that will push the slider to right hand side from
the valve’s body which will allow the high pressure refrigerant to go from the tube A
to tube D to the outdoor coil, through the metering device to drop its pressure, then to
the indoor coil to cool the inside of the house ( cooling mode ) then back to tube C .
 If you had notice the slider has a top grove which allows the low pressure refrigerant
to flow from tube C to tube B then back to the return port in the compressor to repeat
the cycle again.
 De-energized mode, heating mode:

Figure 4: Cycle of Heating Mode

 We notice that the coil (6) lost its power, or de-energized, which makes the electrical
magnet (7) lose its magnetic power. When this occurs, the spring (8) will decompress
and push the block (5) to the left, and block the capillary tube (1). The capillary tube
(1) is now blocked and the high pressure refrigerant will flow from capillary (2) to
capillary (3) straight to the right side from the reversing valve’s body. This in turn
will push the slider to the left hand side of the valve’s body, which will allow the
high pressure refrigerant to go from the tube A to tube C. This allows refrigerant to
flow to the indoor coil to heat the inside of the house (heating mode), then through
the metering device to drop its pressure then to the outdoor coil then back to tube D.
 Again the slider has a top grove this will allow the low pressure refrigerant to flow
from tube D to tube B then back to the return port in the compressor to repeat the
cycle again. That’s it that’s how the heat pump reversing valve works in real-life.
 When we energize the reversing valve we start the cooling mode, and when we de-
energize it, we start the heating mode.
 However, in almost all Heat Pumps, the cooling mode starts when we energize the
reversing valve, so if the electrical coil fails (and it cannot energize the reversing
valve anymore) you will be able to have a heating function and you won’t freeze.
COMMENTS

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EXPERIMENT NO. 5
VAPOUR ABSORPTION REFRIGERATION SYSTEM

OBJECTIVE
Demonstration and working of Vapour Absorption Refrigeration System.

APPARATUS REQUIRED
Vapour Absorption Refrigeration System

THEORY
Absorption refrigeration systems are typically used in conditions that favor lower
power usage and no moving parts as compared to the conventional mechanically
driven compression refrigeration systems. They are widely used in domestic
refrigerators, recreational vehicles, and also in year-round air conditioning of homes
and larger buildings. Due to their easy adaptability to operate using either electricity
or fuel gas, they are useful in remote locations where the supply of electricity is not
readily available.

Figure 1: Domestic Electrolux Refrigerator

 Unit Assembly:

1. Temperature Display 2. Heater Watt Display

3. Power Controls 4. Heater Indicator
5. Condenser 6. Separator
7. Evaporators (High & Low Cooling) 8. Burner
9. Absorber 10. Absorber Vessel

Absorption Systems Principles and Applications:

The absorption system is different from the compression system. It uses heat energy
instead of mechanical energy to make a change in the conditions necessary to
complete a refrigeration cycle. The absorption system may use natural gas, LPG,
kerosene, steam or electric heating element as a source of heat.
The system has few moving parts. Smaller units have which parts only in the heat
source valves and in controls which are used. Some larger units also use circulating
pumps and fans.
The condenser, receiver, and evaporator (cooling coil) are quite similar to those used
in the compression system. The compressor has been replaced by a heater and
generator.

Types of Absorption System:

Absorption systems are based on several combinations of substances which have an
unusual property. One substance will absorb the other without any chemical action
taking place. It will absorb the other substance when cool and release it when heated.
If the substance is a liquid, the process is called absorbing; there are two of absorption
refrigerators. One uses a solid absorbent material; the other uses a liquid absorbent.
Absorption systems are further classified as:
 Intermittent systems.
 Continuous systems.
Absorption systems have had several applications:
 Domestic.
 Recreational vehicle.
 Industrial.
 Air conditioning.
Absorption systems are also identified by heat source:
 Kerosene.
 Natural gas.
 Steam.
 Electrical heat.
 Solar energy.
Some absorption units used in family trailers and mobile homes can be heated either
electrically of by LPG.
Continuous Absorption System:
Principle of the Continuous Absorption System:
The absorption system uses ammonia, water and hydrogen. When it provides
refrigeration constantly, it is called a continuous absorption system. A continuous
refrigerating cycle operates automatically through the use of automatic controls.

The principle of operation remains the same. When the burner is lighted or heater is
turned on and its head applied to the generator at 1 in Fig below, ammonia vapor is
released from the solution. This hot vapor passes upward through the percolator tube
at 2. As the hot ammonia vapor rises through this tube, it carries the solution to the
upper level of the separator at 3.Most of the liquid solution settles in the bottom of the
separator and flows into the absorber. The hot ammonia vapor, being light, rises to the
top of the tube, marked 4, into the condenser. The hot ammonia vapor then condenses
into a liquid. Then ammonia is now in pure state and it flows by gravity into the
evaporator.

Because a liquid will always seek its own level, the liquid ammonia flows through the
liquid ammonia tube and spills into the evaporator. There it forms in large shallow
pools on a series of horizontal baffle plates. The hydrogen gas that is being fed to the
evaporator in large quantities permits the liquid ammonia to evaporate at a low
pressure and at a low temperature (Dalton’s principle). During this process of
evaporation, the ammonia absorbs heat from the food compartment of the refrigerator
and causes the water in the ice cube containers to freeze. The more hydrogen and less
ammonia, the lower the temperature. The evaporated ammonia mixes with the
hydrogen gas.

Fig.3: Air cooled continues refrigeration cycle. Note water circuit, ammonia flow, and
hydrogen circuit

Meanwhile, a weak solution of ammonia and water, is flowing by gravity from the
separator, at 3, down to the top of the absorber. Here it meets the mixture of hydrogen
gas and ammonia vapor coming from the evaporator. The weak and fairly cool
solution absorbs the ammonia vapor. The hydrogen gas is left free since hydrogen will
not mix the water. Because the hydrogen is also very light, it now rises to the top of
the absorber and returns to the evaporator. Being air cooled, the absorber has fins. The
cooling of the weak solution helps it to reabsorb the ammonia gas out of the mixture
of ammonia vapor and hydrogen gas
As the weak water solution reabsorbs the ammonia vapor, considerable heat is
liberated. The air-cooled fins remove this heat to permit refrigeration to continue.
 The ammonia liquid and water mixture flows back to the generator, where it again
starts its cycle.
The apparatus is a welded assembly. There are no moving parts to wear out or get out
of adjustment. Since the total pressure throughout the cycle is about 400 psi (2864
kPa) at a room (ambient) temperature of 100°F (38°C), construction must be rugged
to insure a long life.

Domestic Electrolux Refrigerator:

The evaporator is supplied with hydrogen. The hydrogen passes across the surface of
the ammonia. It lowers the ammonia vapor pressure enough to allow the liquid
ammonia to evaporate. The evaporation of the ammonia extracts heat from the
evaporator. This, in turn, extracts heat from the heat load. The mixture of ammonia
and hydrogen vapor passes from the evaporator to the absorber. A continuous trickle
of weak ammonia solution enters the upper portion of the absorber. It is fed by gravity
from the tube. This weak solution flows down through the absorber. It comes into
contact with the mixed ammonia and hydrogen gases. This readily absorbs the
ammonia from the mixture. The hydrogen is free to rise through the absorber coil and
to return to the evaporator. The hydrogen circulates continuously between the
absorber and the evaporator. The strong ammonia solution produced in the absorber
flows down to the absorber vessel. This cycle operates continuously as long as the
boiler is heated.

Fig.4: Schematic diagram of electrolux vapour absorption system

PROCEDURE
1. Prepare all equipment for this exercise.
2. Ensure that the gas is not connected to the system.

Note: For this operation the gas flame is not used because the heating-energy is from
the electric heater.
 3. Ensure that the system is connected to the correct power source (220-240VAC).
4. Adjust the thermostat to 5°C by turning the adjuster.
5. Switch ON the MCB and main power switch. Ensure that the system is powered by
correct power source (220-240VAC).
6. Switch ON the electric heater.
7. Let the system is running for about 30 minutes.
8. After you understand how to operate this system by using electric heater, switch OFF
the electric heater, main power switch and the MCB.

OBSERVATIONS
Measurement Value
T1 (°C)
T2 (°C)
T3 (°C)
T4 (°C)
T5 (°C)
T6 (°C)
T7 (°C)
T8 (°C)

COMMENTS

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EXPERIMENT NO. 6
HVAC LABORATORY UNIT

OBJECTIVE
Demonstration and working of Air Conditioning Laboratory Unit

APPARATUS REQUIRED
 HVAC Laboratory Unit
 Water for Boiler

THEORY

Introduction:
Air Conditioning Lab Unit is designed for students to the control of the atmosphere so
that a desired temperature, humidity, distribution and movement is achieved, is a
rapidly expanding activity throughout the world.
Obvious applications for air conditioning are homes, hospitals, public meeting places,
mines, shops, offices, factories, land, air and sea transport, but there are numerous other
applications in which human comfort is not the prime consideration. These include
textile and printing industries, computers, laboratories, photographic and
pharmaceutical industries, manufacture, inspection and storage of sensitive equipment,
horticulture, animal husbandry, food storage and many others.
Air Conditioning Plant:
Air conditioning plant usually consists of a number of components (e.g. fans, filters,
heat exchangers, humidifiers, etc.) enclosed in a sheet metal casing. Intake to the plant
is usually from a clean external atmosphere (plus, in some cases, air recalculated from
the building) and delivery from the plant is via ducting to suitable distribution points.
Alternatively small self-contained packaged units may be used to air condition
individual rooms or enclosures.

Refrigeration System Components:

There are five basic components of a refrigeration system, these are:
- Evaporator
- Compressor
- Condenser
- Expansion Valve
- Refrigerant
Unit Assembly:

1. Control Panel 2. Pre heater

3. Fan 4. Pre Humidifier
5. Low Pressure Gauge 6. High Pressure Gauge
7. Post Humidifier 8. Reheater
9. Duct 10. Evaporator

The unit is mounted on a mobile frame which houses the refrigeration unit and steam
generator. Untreated air entering the ducting passes in series through;
a) A centrifugal fan with speed control
b) A pre-heater
c) A cooler/dehumidifier
d) Steam can be added by a steam injector.
e) A re-heater
f) An air measuring duct orifice and manometer
The Refrigeration Cycle:
The refrigeration cycle (shown below) begins with the refrigerant in the evaporator.
At this stage the refrigerant in the evaporator is in liquid form and is used to absorb
heat from the product. When leaving the evaporator, the refrigerant has absorbed a
quantity of heat from the product and is a low-pressure, low-temperature vapour. This
low-pressure, low-temperature vapour is then drawn from the evaporator by the
compressor. When vapour is compressed it rises in temperature. Therefore, the
compressor transforms the vapour from a low-temperature vapour to a high
temperature vapour, in turn increasing the pressure. This high temperature, high
pressure vapour is pumped from the compressor to the condenser; where it is cooled
by the surrounding air, or in some cases by fan assistance. The vapour within the
condenser is cooled only to the point where it becomes a liquid once more. The heat,
which has been absorbed, is then conducted to the outside air. At this stage the liquid
refrigerant is passed through the expansion valve. The expansion valve reduces the
pressure of the liquid refrigerant and therefore reduces the temperature. The cycle is
complete when the refrigerant flows into the evaporator, from the expansion valve, as
a low-pressure, low-temperature liquid.

Figure 2: Refrigeration Cycle Diagram

 Components:
Filters
Coarse - usually wire mesh. To remove insects, leaves and other large
airborne particles.
Fine- paper or viscous or electrostatic type to remove most of the airborne
dust.

Fans- are required to cause the air movement and to make good the pressure drop due
to the duct and system resistances.

Heat Exchanger- which usually are finned on the air side, are needed to increase or
decrease the air temperature.

Heaters may use steam, hot water or electricity as the heating medium Cooler may be
supplied with chilled water or may be of the direct expansion type in which liquid
refrigerant boils at a low temperature within the heat exchanger.

Humidifiers are used to increase the moisture content of the air. Water may be
sprayed directly into the air, may be evaporated from a moist surface, or alternatively,
steam may be injected into the air. The latter also results in heating of the air.

Dehumidifiers- are used to reduce the moisture content of the air. This is usually
achieved by cooling the air below its dew point so that surplus moisture is
precipitated.

Sometimes hygroscopic materials are used to achieve dehumidification, but, of

course, these require regeneration.

Eliminators - are specially shaped baffles through which the air flows and which
remove entrained water droplets from the air stream.
.
Mixer -are employed to blend two streams of air to achieve a desired condition and/or
economy.

Instruments and Controls -are needed to sense the condition of the air at various
stations, and to vary the output of the components to bring about the desired final
condition. In many installations these may form part of a total building energy
management system.

Associated Equipment may include:

Boiler - for humidification and/or for the air heaters.
Refrigeration Plant - for the air coolers/dehumidifiers.
Hygrometers- are instruments for measuring the, moisture content of the atmosphere.
PROCEDURE
General Start-up Procedure:
This self-contained unit consists of several components joined by ducting through
which the air flows. These components, commonly found in an industrial or
commercial air conditioning unit, include a fan, a heater, a humidifier, a de-humidifier
(may be in conjunction with cooler) and a filter .The ducting and the components are
supported on a steel frame with wheels to facilitate movement of the apparatus.
The unit comes with a pressure boiler (for humidification) and refrigeration plant (for
cooling and de-humidification) which are housed in the lower part of the frame.
Air from the atmosphere enters a variable speed centrifugal fan before going into the
ducting. Upon leaving the fan the air passes through two 2kW externally finned
electric elements (pre-heating) which may be individually switched. The warmed air
then enters a stabilizing section where its condition is determined by humidity or
temperature sensor. Next the air flows through the evaporator of the refrigeration unit
where it may be cooled and will deposit some of its moisture content as liquid. The
cool and drier air passes into another stabilizing section with humidity or temperature
sensor before passing over the humidifier. Two individually switched 500W re-
heating elements are located at the end. The condition of the re-heated air is
determined and it then passes back to the atmosphere through an air flow meter.
The boiler which supplies the steam for humidification is controlled by a controller so
that the rate of steam production rate may be varied in accordance with relative
humidity. The refrigeration circuit is charged with refrigerant R134a. During the
process vapour formed in the evaporator is drawn into a hermetic compressor which
discharges into an air cooled condenser. The R134a liquid then passes through a flow
meter and thermostatically controlled expansion valve to the evaporator. Temperature
and pressure measuring points are provided in the refrigeration circuit. The fan speed
is fixed and air flow can be controlled by a variable damper.
With the physical arrangement described above and by selection of the individual
heaters, steam injection and refrigeration/cooling system, the following data may be
readily obtained:
a) The condition of the air before and after the various processes.
b) Air mass flow rates.
c) Pressures and temperatures of refrigerant.
d) Refrigerant mass flow rate.
e) The generation of a refrigeration cycle diagram on a pressure-enthalpy chart for the
refrigerant in use. The analysis of the energy transfers in the refrigeration system.
f) Rate of precipitation at cooler.
 General Shut-down Procedure:
Before switching of:
1. Switch off all boiler heaters.
2. Switch off all air heaters.
3. Switch off refrigeration circuit.
4. Set the fan to maximum speed.
Then allow the fan to run for at least five minutes to dry the ducting, after which the
main switch and isolator may be switched off.
Turn off the locally supplied water isolating valve and drain the steam generator to
reduce scale.

COMMENTS

_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
EXPERIMENT NO. 7
HVAC LABORATORY UNIT

OBJECTIVE
Study the characteristics of air on psychometric chart during cooling &
dehumidification process.

APPARATUS REQUIRED
HVAC Laboratory Unit

THEORY
Recommended Test Conditions:
Provided the air temperature is not allowed to exceed 500C, in any operating
conditions may be used. However, satisfactory results are more likely to be achieved
if the following points are noted;

De-Humidification:

I. When it is intended to demonstrate de-humidification, the air should be fairly

humid (say 65 %).
II. The cooler has a large surface area on which the condensation takes place.
Due to this, an appreciable time elapses before condensate is discharged from
the drain at the same rate as it is precipitated.
III. The change of moisture content of the air is easily determined from the
product of the air mass flow rate and the change of specific humidity.
Agreement between this and the drainage rate will be obtained after a
sufficient period under steady conditions.
Icing at Evaporator:
At low air flow rates, accompanied by low ambient temperature, it is possible for the
R134a evaporating conditions to fall below 0°C.If this happens, it is probable that ice
will form on the air side of the evaporator tubes and fins and on the expansion valve.

While no damage is likely to occur if operated in this condition for a few minutes, it is
inadvisable to operate in this condition since the ice will eventually stop the air now.
Icing can be avoided by increasing the air flow rate and/or switching on the air pre-
heaters.

PROCEDURE

Obtaining Stable Conditions:

The unit should be started according to the procedure described in previous
experiment and, depending upon the parameters to be investigated, the appropriate
controls turned on or adjusted. The time taken for the unit to stabilize will vary
depending upon the local ambient conditions. This can vary from 10 minutes to 20
minutes.
When changes are made to the conditions upstream of the evaporator, the refrigerant
flow rate will be seen to alter due to the increased or decreased heat loading.
OBSERVATIONS

 720W Pre-heating
 2kW Steam Injection
 Cooling/Compressor on
 Re-heating 290W
Air flow set to a low rate of .015 inch water gauge
T=Dry bulb temperature W= Relative Humidity

Test Ref. 1 2
T1 °C
At Fan outlet
W1 %
T2 °C
After Pre-heater
W2 %
T3 °C
After Evaporator (Dehumidifier)
W3 %
T4 °C
After Boiler (Humidifier)
W4 %
T5 °C
After Re-heater
W5 %
Condenser Inlet T6 °C
Condenser Outlet T7 °C
Evaporator Inlet T8 °C
Evaporator Outlet T9 °C
Evaporator Outlet Pressure P1 bar
Condenser Outlet Pressure P3 bar
Duct Differential Pressure ∆p Pa
Condensate Collected mc ml
Time Interval x s
RI34a Volume Flow Rate Vref LPM
Note: Draw process line through initial and final conditions of air and find out all
psychrometric Properties on chart.
COMMENTS

___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
___________________________________________________
EXPERIMENT NO. 8
RECIRCULATING AIR HANDLING UNIT
OBJECTIVE
Study the characteristics of air on psychrometric chart during heating &
humidification process on recirculating air conditioning unit

APPARATUS REQUIRED
 Recirculating HVAC Laboratory Unit
 Water for boiler

THEORY
Recommended Test Conditions:
Provided the air temperature is not allowed to exceed 500C, in any operating
conditions may be used. However, satisfactory results are more likely to be achieved
if the following points are noted;
Humidification:
When humidification is required, the rate of steam injection should not exceed that
which can be absorbed by the air. If it is found that mist is seen somewhere near
Steam distributor then follows the following steps.

I. Reduce the heat input to the boiler

II. Increase the air flow rate

PROCEDURE

Obtaining Stable Conditions:

The unit should be started according to the procedure described in previous
experiment and, depending upon the parameters to be investigated, the appropriate
controls turned on or adjusted. The time taken for the unit to stabilize will vary
depending upon the local ambient conditions. This can vary from 10 minutes to 20
minutes.
When changes are made to the conditions upstream of the evaporator, the refrigerant
flow rate will be seen to alter due to the increased or decreased heat loading.
OBSERVATIONS
 720W Pre-heating
 2kW Steam Injection
 Cooling/Compressor on
 Re-heating 290W
 T=Dry bulb temperature W= Relative Humidity
Test Ref. 1 2
T1 °C
At Fan outlet
W1 %
T2 °C
After Pre-heater
W2 %
T3 °C
After Evaporator (Dehumidifier)
W3 %
T4 °C
After Boiler (Humidifier)
W4 %
T5 °C
After Re-heater
W5 %
Condenser Inlet T6 °C
Condenser Outlet T7 °C
Evaporator Inlet T8 °C
Evaporator Outlet T9 °C
Evaporator Outlet Pressure P1 bar
Condenser Outlet Pressure P3 bar
Time Interval x s
RI34a Volume Flow Rate Vref LPM

Note: Draw process line through initial and final conditions of air and find out all
psychrometric Properties on chart.

COMMENTS

_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
 EXPERIMENT NO. 09 COOLING TOWER

OBJECTIVE
General Observation of the Forced Draught Cooling Tower.
APPARATUS REQUIRED
Forced draught cooling tower
THEORY
Large cooling towers are usually used in industries like power plants, petroleum
refineries, food and beverages, chemical industry etc. However, the most common
application of a cooling tower is inside an HVAC system for cooling buildings. An
HVAC cooling tower is used to dispose unwanted heat from a chiller. HVAC use of a
cooling tower pairs the cooling tower with a water-cooled chiller or water-cooled
condenser.
A cooling tower is a heat exchanger, inside of which heat is withdrawn from the water
by contact between the water and the air. The heat transfer occurs through the heat
exchange between air and water and through the evaporation of a small part of the
water that needs to be cooled. This will allow to cool down to a temperature lower
than the ambient temperature, which is an important advantage compared to dry
coolers.

Unit Assembly

Figure 1: Parts Identification of Cooling Tower

1. Orifice 6. Air Blower

2. Water Distributor 7. Differential Pressure Transmitter
3. Packed Column 8. Make-up Tank
4. Flow meter 9. Control Panel
5. Receiver tank 10. Load tank
Basic Principle:
First consider an air stream passing over the surface of a warm water droplet or film.
If we assume that the water is hotter than the air, then the water temperature will be
cooled down by radiation, conduction and convection, and evaporation. The radiation
effect is normally very small and may be neglected. Conduction and convection
depend on the temperature difference, the surface area, air velocity, etc. The effect of
evaporation is the most significant where cooling takes place as water molecules
diffuse from the surface into the surrounding air. During the evaporation process, the
water molecules are replaced by others in the liquid from which the required energy is
taken.
Evaporation from a Wet Surface:
When considering evaporation from a wet surface into the surrounding air, the rate is
determined by the difference between the vapour pressure at the liquid surface and the
vapour pressure in the surrounding air. The vapour pressure at the liquid surface is
basically the saturation pressure corresponding with the surface temperature, whereas
the total pressure of the air and its absolute humidity determines the vapour pressure
in the surrounding air. Such evaporation process in an enclosed space shall continue
until the two vapour pressures are equal. In other words, until the air is saturated and
its temperature equals the surface.

However, if unsaturated air is constantly supplied, the wet surface will reach an
equilibrium temperature at which the cooling effect due to the evaporation equals the
heat transfer to the liquid by conduction and convection from the air, which under
these conditions; will be at a higher temperature. Under adiabatic conditions, this
equilibrium temperature is the "wet bulb temperature".

For a cooling tower of infinite size and with an adequate air flow, the water leaving
will be at the wet bulb temperature of the incoming air. Therefore, the difference
between the temperature of the water leaving a cooling tower and the local wet bulb
temperature is an indication of the effectiveness of the cooling tower. Thus,
"Approach to Wet Bulb", an important parameter of cooling towers, is the difference
between the temperature of the water leaving the tower and the wet bulb temperature
of the entering air.

Cooling Tower Performance

A study on the performance of a cooling tower can be found through the following
factors
(i) Water flow rates
(ii) Water temperatures
(iii) Airflow rate
(iv) Inlet Air Relative Humidity
Components of the Basic Cooling Tower Unit

The unit comes complete with the following main components:

i) Load Tank

The load tank is made of stainless steel having a capacity of approximately 4 liters.
The tank is fitted with three cartridge heaters, 466.667W each, to provide a total of
1.4 kW cooling load. A make-up tank is fixed on top of the load tank. A float type
valve at the bottom of the make-up tank is to control the amount of water flowing into
the load tank. A centrifugal type pump is supplied for circulating the water from the
load tank through a flowmeter to the top of the column, into the basin and back to the
load tank. A temperature sensor and temperature controller is fitted to load tank to
prevent overheating. A level switch is fitted to the load tank so that when a low level
condition occurs, the heater and the pump will be switched off.

ii) Air Distribution Chamber

The stainless steel air distribution chamber comes with a water collecting basin and a
one-side inlet centrifugal fan.

iii) Column and Packing

One packed column is available. The column is a standard column that comes
together with this unit. The column is made of clear acrylic with a square cross-
sectional area of 225 cm2 (15cmx15cm) and a height of 60 cm. It comes with eight
decks of inclined packing. A top column that fitted on top of the column comes
standard with a sharp edged orifice, a droplet arrester and a water distribution system.

iv) Measurements

Temperature sensors are provided to measure the inlet and outlet water temperatures
as well as the make-up tank water temperature. In addition, temperature sensors have
been installed to measure the dry bulb and wet bulb temperatures of inlet and outlet of
the air. The followings show the list of codes assigned to each temperature sensors.

T1 Dry Bulb Temperature of the Inlet Air

T2 Wet Bulb Temperature of the Inlet Air
T3 Dry Bulb Temperature of the Outlet Air
T4 Wet Bulb Temperature of the Outlet Air
T5 Inlet Water Temperature
T6 Outlet Water Temperature
T7 Make up Tank Temperature
T8 Hot Water Tank Temperature

An inclined manometer is provided for the measurement of pressure drop across the
packed column. On the other hand, the inclined manometer and the orifice are also
used to determine the air flowrate.
A flowmeter is provided for the measurement of water flowrate. The flowmeter is
ranged at 1 to 7 LPM.
 The Process Involved in the Operation:

i) Water Circuit

Water temperature in the load tank will be increased before the water is pumped
through a control valve and flow meter to the column cap. Before entering the column
cap, the inlet temperature of the water is measured and then the water is uniformly
distributed over the top packing deck. This creates a large thin film of water, which is
exposed to the air stream. The water gets cooled down, while passing downward
through the packing, due to the evaporation process. The cooled water falls into the
basin below the lowest deck and return to the load tank where it is re-heated before re-
circulation. The outlet temperature is measured at a point just before the water flows
back into the load tank. Evaporation causes the water level in the load tank to fall. The
amount of water lost by evaporation will be automatically compensated by equal
amount from the make-up tank. At steady state, this compensation rate equals the rate
of evaporation plus any small airborne droplets discharged with the air.

ii) Air Circuit

A one-side inlet centrifugal fan draws the air from the atmosphere into the distribution
chamber. The air flow rate is varied by means of an intake damper. The air passes a
dry bulb temperature sensor and wet bulb temperature sensors before it enters the
bottom of the packed column. While the air stream passes through the packing, its
moisture content increases and the water temperature drops. The air passes another
duct detector measuring its exit temperature and relative humidity, then through a
droplet arrester and an orifice, and finally leaves the top of the column into the
atmosphere.

PROCEDURE
General Start-up Procedures

1) Fill the load tank with distilled or de-ionized water. It is done by pouring the water through
the opening at the top of the makeup tank. Replace the make-up tank onto the load tank and
lightly tighten the nuts. Fill the tank with distilled or de-ionized water up to the zero mark
on the scale.
2) Add distilled/deionized water to the wet bulb sensor reservoir to the fullest.
3) Connect all appropriate tubing to the differential pressure sensor.
4) Switch on the heater and heat up the water until approximately 40°C.
5) Switch on the pump and slowly open the control valve V1 and set the water flowrate to 2.0
LPM. Obtain a steady operation where the water is distributed and flowing uniformly
through the packing.
6) Fully open the fan damper, and then switch on the fan. Check that the differential pressure
sensor is giving reading when the valve manifold is switched to measure the orifice
differential pressure.
7) Let the unit run for about 20 minutes, for the float valve to correctly adjust the level in the
load tank. Refill the makeup tank as required.
8) Now, the unit is ready for use.
 Procedure for Experiment:

1. Perform the general start-up procedures and observe the forced draught cooling
tower proves.
2. As the warm water enters the top of the tower, it is fed into channels from which it
flows via water distribution system onto the packing. The channels are designed to
distribute the water uniformly over the packing with minimum splashing.
3. The packing surfaces are easily wetted and the water spreads over the surfaces to
expose a large area to the air stream.
4. The cooled water falls from the lowest packing into the basin and then is pumped to
the simulated load in the load tank.
5. During the process, some water is lost due to the evaporation. Thus, "make-up"
water must be supplied to keep the amount of water in the cooling system constant.
The make-up is observed flowing past the float-controlled valve in the load tank.
6. A “droplet arrester”, or “mist eliminator” is fitted at the tower outlet to minimize
loss of water due to escape of droplets of water (resulting from splashing, etc.) which
is entrained in the air stream. This loss does not contribute to the cooling, but must be
made good by "make-up". The droplet arrester causes droplets to coalesce, forming
drops that are too large to be entrained and these falls back into the packing.
7. The fan drives the air upward through the wet packing. At air outlet, the air leaving
the cooling tower is almost saturated, i.e. Relative Humidity is ~100%. The Relative
Humidity at the air outlet is much higher than the Relative Humidity at the air inlet.
The increase in the moisture content of the air is due to the evaporation of water into
steam and the "latent heat" for this account for most of the cooling effect.
8. When the cooling load is switched off and the unit is allowed to stabilize, it is
found that the water leaves the basin at temperature close to the wet bulb temperature
of the air entering. Wet bulb temperature is lower than the dry bulb temperature and
this varies according to the local atmospheric conditions (i.e. pressure and relative
humidity).
9. With no load, the water would be cooled to the incoming wet bulb temperature.
However, the condition cannot be achieved since the work done by the pump transfers
about 40W to the water.

OBSERVATIONS
Initial water level : __ cm
Final water level : ___ cm
Time Interval : 10 minutes
Description Unit Value

Packing Density m-1 110

Air Inlet Dry Bulb, T1 ˚C

Air Inlet Wet Bulb, T2 ˚C

Air Outlet Dry Bulb, T3 ˚C

 Air Outlet Wet Bulb, T4 ˚C

Water Inlet Temperature, T5 ˚C

Water Outlet Temperature, T6 ˚C

Water Make-Up Temperature, T7 ˚C

Orifice Differential, DP1 Pa

Water Flow Rate, FT1 LPM

Heater Power, Q1 Watt

COMMENTS

__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
EXPERIMENT NO. 10
COOLING TOWER

OBJECTIVE
To investigate the relationship between cooling load and cooling range.

APPARATUS REQUIRED
Forced draught cooling tower.

PROCEDURE
o Prepare and start the cooling tower with according to procedure explain in last
experiment.
o Set the system under the following conditions and allow stabilizing for about
15 minutes:

 Water flow rate : 2.0 LPM

 Air flow rate : Maximum
 Cooling load : 0.0 kW

o After the system stabilized, record a few sets of measurements (i.e.

temperature (T1-T6), orifice differential pressure (DP1), water flowrate (F1)
and heater power (Q1)), then obtain the mean value for calculation and
analysis
o Without changes in the conditions, increase the cooling load to 0.5 kW. When
the system stabilized, record all data.
o Similarly, repeat the experiment at 1.0kW and 1.5kW.
o The tests may be repeated:
 At other water flow rates
 At other air flow rate
OBSERVATIONS
Description Unit 0.0kW 0.5kW 1.0kW 1.5kW
110 110 110
Packing Density m-1

Air Inlet Dry Bulb, T1 ˚C

Air Inlet Wet Bulb, T2 ˚C

Air Outlet Dry Bulb, T3 ˚C

Air Outlet Wet Bulb, T4 ˚C

Water Inlet Temperature, T5 ˚C

Water Outlet Temperature, T6 ˚C

Orifice Differential, DP1 Pa

Water Flow Rate, FT1 LPM

Heater Power, Q1 Watt

COMMENTS

__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
EXPERIMENT NO. 11
MECHANICAL HEAT PUMP

OBJECTIVE
Determination of the power input, heat output and coefficient of performance of
Mechanical Heat Pump

APPARATUS REQUIRED
Mechanical heat pump
Water supply

THEORY
Heat pumps transfer heat by circulating a substance called a refrigerant through a
cycle of evaporation and condensation. A compressor pumps the refrigerant between
two heat exchanger coils. In one coil, the refrigerant is evaporated at low pressure and
absorbs heat from its surroundings. The refrigerant is then compressed en route to the
other coil, where it condenses at high pressure. At this point, it releases the heat it
absorbed earlier in the cycle.

Refrigerators and air conditioners are both examples of heat pumps operating only in
the cooling mode. A refrigerator is essentially an insulated box with a heat pump
system connected to it. The evaporator coil is located inside the box, usually in the
freezer compartment. Heat is absorbed from this location and transferred outside,
usually behind or underneath the unit where the condenser coil is located. Similarly,
an air conditioner transfers heat from inside a house to the outdoors.

The heat pump cycle is fully reversible, and heat pumps can provide year-round
climate control for your home – heating in winter and cooling and dehumidifying in
summer. Since the ground and air outside always contain some heat, a heat pump can
supply heat to a house even on cold winter days. An air-source heat pump absorbs
heat from the outdoor air in winter and rejects heat into outdoor air in summer. It is
the most common type of heat pump found in Canadian homes at this time. However,
ground-source (also called earth-energy, geothermal, geoexchange) heat pumps,
which draw heat from the ground or ground water, are becoming more widely used.
CALCULATIONS

Power input: Power of compressors in watts

Heat output: m. Cp. dT
COP: Coefficient of Performance can be computed by the energy output from the
condenser water divided by the energy input to the compressor.

COPH.P = Qh/Wcomp

Table

Calculation table

Refrigerant pressure, Low (P1) Bar

Refrigerant pressure, High (P2) Bar

Refrigerant temp TT1 °C

Refrigerant temp TT2 °C
Refrigerant temp TT3 °C
Refrigerant temp TT4 °C
Power of Compressor W
Cooling water flow rate F1 LPM
Cooling water inlet temp TT5 °C
Cooling water outlet temp TT6 °C