Rac Project Report

AIR CONDITION PROJECT REPORT
CHAPTER 1
INTRODUCTION
1.1 AIR CONDITIONING SYSTEM

The vapor absorption refrigeration system is one of the oldest methods of producing
refrigerating effects. The principle of vapor absorption was first discovered by Michael Faraday
in 1824 while performing a set of experiments to liquefy certain gasses. The first machine based
on the Vapor Absorption Refrigeration machine was developed by a French scientist,
Ferdinand Carry, in 1860. This system may be used in both the domestic and large industrial
refrigeration plants. The refrigerant commonly used in vapor absorption systems is Ammonia.
This system uses Heat energy instead of mechanical energy as in vapor compression system,
in order to change the condition of refrigerant required for the operation of the refrigeration
cycle.
This idea of refrigeration system is being utilized in our project for the purpose of air
conditioning
1.2 WHAT IS AIR CONDITION
Air-conditioning is that process used to create and maintain certain temperature,

relative humidity and air purity conditions in indoor spaces. This process is typically applied
to maintain a level of personal comfort.
It's also used in industrial applications to ensure correct operation of equipment or

machinery that need to operate in specific environmental conditions or alternatively to be able
to carry out certain industrial processes, such as welding, which produce considerable amounts
of heat that needs to be disposed of in some manner.
An air-conditioning system must be effective regardless of outside climatic conditions

and involves control over four fundamental variables: air temperature, humidity, movement
and quality.
1
GPTC PERINTHALMANNA DEPARTMENT OF MECHANICAL
ENGINEERING
The distinction between industrial and personal comfort applications is not always clear
cut. Industrial air-conditioning usually requires better precision as regards temperature and
humidity control. Some applications also demand a high degree of filtering and removal of
contaminants.
Comfort air-conditioning on the other hand, as well as needing to satisfy personal

temperature-humidity requirements, also involves other fields such as architectural design,
weather forecasting, energy consumption and sound emissions to recreate the ideal conditions
for human psychophysiological well-being.
1.3 UNIT OF REFRIGERATION
Capacity of a refrigeration unit is generally defined in ton of refrigeration (TR). A ton

of refrigeration is defined as the amount of refrigeration effect produced by uniform melting of
one ton of ice (1 US low ton = 907.18kg) from and at 0ºC in 24 hrs.)
• This is equivalent to 3.5 kJ/s (3.5 kW) or 210 kJ/min.
1.4 APPLICATIONS
● Maintain suitable humidity in all parts of a building.

● Free the air from excessive humidity during certain seasons.
● Supply a constant and adequate supply of ventilation.
● Efficiently remove from the air micro-organisms, dust, soot, and other foreign bodies.
● To create and maintain certain temperature & relative humidity
● air purity conditions in indoor spaces.
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ENGINEERING
1.5 LINE DIAGRAM FOR AIR CONDITION TEST RIG
Fig 1.1 Basic design for test rig
1.6 LINE DIAGRAM FOR NON WORKING AIR CONDITIONER
Fig 1.2 line diagram for non working AC
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ENGINEERING
CHAPTER 2
WORKING PRINCIPLE OF AIR CONDITON
2.1 VAPOR COMPRESSION REFRIGERATION SYSTEM

Vapor-compression refrigeration or vapor-compression refrigeration system (VCRS),
in which the refrigerant undergoes phase changes, is one of the many refrigeration cycles and
is the most widely used method for air conditioning
A vapor-compression refrigeration system is a system that uses liquid refrigerant in a

closed system which circulates the refrigerant through four stages in which it is alternately
compressed and expanded, changing it from liquid to vapor. As this change happens, heat is
either absorbed or expelled by the system, resulting in a change in temperature of the
surrounding air that is passing over the unit's components. Nearly all of the refrigeration
systems we use today use this cycle to accomplish cooling
vapor compression refrigeration systems are the most commonly used among all
refrigeration systems. As the name implies, these systems belong to the general class of vapor
cycles, wherein the working fluid (refrigerant) undergoes phase change at least during one
process. In a vapor compression refrigeration system, refrigeration is obtained as the refrigerant
evaporates at low temperatures. The input to the system is in the form of mechanical energy
required to run the compressor. Hence these systems are also called mechanical refrigeration
systems. Vapor compression refrigeration systems are available to suit almost all applications
with the refrigeration capacities ranging from few Watts to few megawatts. A wide variety of
refrigerants can be used in these systems to suit different applications, capacities etc. The actual
vapor compression cycle is based on Evans Perkins Cycle, which is also called reverse Rankine
cycle. Before the actual cycle is discussed and analyzed, it is essential to find the upper limit
of performance of vapor compression cycles. This limit is set by a completely reversible cycle.
VAPOR COMPRESSION REFRIGERATION SYSTEM WORKING PRINCIPLE
The compression refrigeration cycle consists of circulating a liquid refrigerant through

four stages of a closed system. As the refrigerant circulates through the system, it is alternately
compressed and expanded, changing its state from a liquid to a vapor. As the refrigerant
changes state, heat is absorbed and expelled by the system, lowering the temperature of the
conditioned space.
2.2 TYPES OF AIR CONDITION
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ENGINEERING
Central Air Conditioner.
Window Air Conditioner.
Smart Air Conditioner.
Ductless Mini-Split Air Conditioner.
Portable Air Conditioner.
Through-The-Wall Air Conditioner.
Geothermal Air Conditioner.
Evaporative Air Conditioner.
2.3 VAPOR COMPRESSION REFRIGERATION SYSTEM COMPONENTS
There are four main components in vapor compression refrigeration system.
• Compressor
• Condenser
• Expansion valve
• Evaporator
Fig 2.0 working principle of AC
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ENGINEERING
IN PROJECT WE CREATE WORKING AIR CONDITION TEST RING DISMANTLED

VIEW OF NON-WORKING AIR CONDITION
COMPONENTS OF AIR CONDITION
● Compressor
● Condenser
● Expansion valve
● Evaporator
2.3.1 COMPRESSOR
In a vapor compression system, the compressor is considered as the heart of the system.
The function of the compressor is
• To draw the low-pressure refrigerant from the evaporator
• To compress the refrigerant and to raise its pressure and temperature
• To deliver the high-pressure refrigerant to the condenser
• To maintain continuous circulation of refrigerant through the refrigerating system
Compressors may be of three types:
• Reciprocating
• Rotary and Centrifugal
When the volume flow rate of the refrigerant is large, centrifugal compressors are used.
Rotary compressors are used for small units. Reciprocating compressors are used in
plants up
to 100 tons capacity. For plants of higher capacities, centrifugal compressors are employed.
In reciprocating compressors, which may be single cylinder or multi cylinder ones,
because of clearance, leakage past the pistons and valves, and throttling effects at the suction
and discharge valves, the actual volume of gas drawn in to the cylinder is less than the volume
displaced in the system.
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ENGINEERING
fig 2.1 non working compressor
2.3.2 CONDENSER
It must de-superheat and then condense the compressed refrigerant. Condensers may
be air cooled or water cooler or Evaporative condensers. An air condenser is used in small
units. Water cooled condensers are used in large installations.
Condenser is an important equipment located on the high pressure side of the

refrigeration system. It is a heat exchanger where heat transfer takes place between the
superheated refrigerant received from the compressor and the cooling medium of the
condenser. The refrigerant is first cooled to saturation and then condensed to liquid state. The
cooling medium may be air or water or a combination of the two
fig 2.2 non-working condenser
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ENGINEERING
2.3.3 EXPANSION VALVE

It reduces the pressure of the refrigerant, and also regulates the flow of the refrigerant
to the evaporator. Two widely used types of expansion devices are: capillary tubes and throttle
valves (thermostatic expansion valves). Capillary tubes are only used for small units. Once the
size and length are fixed, the evaporator pressure, etc. gets fixed. No modifications in operating
conditions are possible. Throttle valves are used in larger units. These regulate the flow of the
refrigerant according to load on the evaporator.
An expansion device is an important component in a vapor compression system and is

located between receiver and evaporator. This device divides the high-pressure side and low-
pressure side of a refrigerating system. It is also called a metering device or throttling device.
It reduces high pressure liquid refrigerant coming from condenser to low pressure liquid
refrigerant before it is supplied to the evaporator. It regulates the flow of refrigerant according
to the load on the evaporator. It supplies refrigerant at the rate at which it evaporates.
Types of expansion valve are Capillary tube, Automatic expansion valve, Thermostatic
expansion valve
IN OUR WORKING AIR CONDITION AND NON-WORKING AIR CONDITIONER

CAPILLARY TUBE USED AS EXPANSION VALVE
CAPILLARY TUBE
This device is used for small capacity units like domestic refrigerators, water coolers
and small commercial freezers. It is a small diameter tube connected between condenser and
evaporator. Typical tube diameters of refrigerant capillary tubes range from 0.5 mm to 3 mm
and the length ranges from 1.0 m to 6 m. It is a constant restriction type device and is merely a
tube with a narrow area of flow.
The required pressure drops are obtained due to heavy frictional resistance offered by a small
diameter tube. The resistance offered is directly proportional to its length, and inversely
proportional to its diameter. The liquid refrigerant enters the capillary tube. Because of
frictional resistance offered by a small diameter tube, the pressure drops. The use of this
capillary tube is limited to small capacity units up to 1 ton.
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ENGINEERING
fig 2.3 non-working expansion valve
2.3.4 EVAPORATOR
A common type of evaporator is a coil brazed onto a plate, called a plate evaporator. In a
flooded evaporator the coil is filled only with an expansion coil, water or brine may be chilled
in the evaporator, and the chilled water or brine may then be used to cool some other medium.
The function of an evaporator is to absorb heat from the refrigerated space and to produce
required low temperature by means of a refrigerant.
It is the most important part of the refrigeration system and it is located on the low-pressure
side of the system. Refrigeration effect or coldness is produced in the evaporator. The
evaporator is known as cooler or freezers.
fig 2.4 non-working evaporator
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ENGINEERING
2.4 P-V and T-S Diagram of Vapor Compression Refrigeration System:
Fig 2.5 P-V diagram
Fig 2.6 T-S diagram
10
ENGINEERING
2.5 WORKING OF VAPOUR COMPRESSION REFRIGERATION

SYSTEM
The working of Vapor Compression Refrigeration System can be completed under 4
processes and are as follows.
Compression Process: The vapor at low temperature and low pressure enters the
compressor where it is compressed is entropically and subsequently, its temperature and
pressure considerably increase.
Condensation Process: This vapor after leaving the compressor enters into the
condenser, where it is condensed into high-pressure liquid and is collected in a receiver tank
Expansion Process: From the receiver tank, it passes through the expansion valve,
where it is throttled down to low pressure and temperature.
Vaporization Process: After finding its way through an expansion valve, it finally
passes onto the evaporator, where it extracts heat from the surroundings or circulating fluid and
vaporizes to lower pressure vapor.
2.6 C.O.P. OF VAPOR COMPRESSION REFRIGERATION SYSTEM:
The Coefficient of Performance (C.O.P) of a Simple Vapor Refrigeration

Cycle is as follows.
C.O.P. = (heat extracted or refrigerating effect)/Work done.
C.O.P. = (h2-h1)/(h3-h2) or C.O.P. = (h2-h4)/(h3-h2).
[h1=h4, since during throttling expansion 4-1, the total heat content remains
unchanged.]
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ENGINEERING
CHAPTER 03
PROCESSES CHART
3.1 LIST OF PROCESSES FOR NON-WORKING AIR

CONDITIONER
• DESIGN & DRAWING
● MEASURING
● MARKING
● CUTTING
● WELDING
● PAINTING
● ASSEMBLING ALL COMPONENTS
● LABELING
3.2 LIST OF PROCESSES FOR WORKING AIR CONDITIONER

● DESIGN & DRAWING
● MEASURING
● MARKING
● CUTTING
● WELDING
● PAINTING
● ASSEMBLING ALL COMPONENTS
● BRAZING
● SOLDERING
● GAUGE FITTING
3.3 DESCRIPTION
3.3.1 DESIGN & DRAWING
The process of creating a design can be brief (a quick sketch) ort lengthy and
complicated, involving considerable research, negotiation, reflection, modeling, interactive
adjustment and re-design. In some cases, the direct construction of an object without an explicit
prior plan (such as in craftwork and some engineering, coding, and graphic design) is also
considered to be a design activity. Since the beginning of time, drawings have been a way to
share ideas with others. Being able to describe your idea verbally is important, but drawings
are what allow you to show other people what’s in your imagination. Words can only translate
an idea to someone else’s mind and that allows for a new interpretation of what that idea may
look like. We don’t want our ideas to get lost in translation.
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ENGINEERING
3.3.2 MEASURING & MARKING
Measurement is the process of obtaining the magnitude of a quantity relative to an agreed

standard. From the design and drawing we measured dimensions of the plywood and M S
square pipe. The measuring has done by using steel rule, measuring tape., etc. Measuring tape
is mainly used. A measuring tape is a flexible tool used for measuring length. It is made up of
materials like fiberglass, cloth, plastic, metal ribbon or strip. So, it is a kind of flexible ruler
also known as a tape measure. It is marked in centimeters and inches
Marking is done by using scriber, punches retcon the ply wood and MS superpipe. Dotted the
point where drilling is needed in ply wood using scriber.
Fig 3.3.2.1 Measuring Fig 3.3.2.2 Marking
3.3.3 CUTTING
Cutting is a collection of processes where material is brought to as specified geometry

by removing excess material using various kinds of tooling to leave a finished part that meets
specifications. The net result of cutting is two products, the waste or excess material, and the
finished part. We cut the plywood using cutter machine as per the marked line and the MS
square pipe by metal cutting machine.
13
ENGINEERING
Fig 3.3.4 Cutting
3.3.4 WELDING
Welding is a process of joining similar metals by application of heat with or without application
of pressure and with or without the use of filler metal. Both DC and AC are used for electric
arc welding, each having its particular applications in some cases either is suitable DC welding
supply is usually obtained from generators driven by electric motors. For AC welding supply,
transformers are predominantly used for almost all arc welding where mainly electricity supply
is available. They have to step down the usual supply voltage (200-400V) to normal circuit
welding voltage (50-90V).A (100-200A) machine is small but portable and satisfactory for
light manual welding. A (300 or 400A) big size is suitable for manual welding of average work.
Automatic welding requires capacities between (800A and 300 A) either in a single unit or a
number of small units in parallel.
Fig 3.3.5 Welding
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ENGINEERING
3.3.5 DRILLING
Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-section in
solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed
against the work-piece and rotated at rates from hundreds to thousands of revolutions per
minute. This forces the cutting edge against the work-piece, cutting off chips (swarf) from the
hole as it is drilled. The hole is drilled at the points marked.
Fig 3.3.6 Drilling
3.3.6 PAINTING
Painting is defined as the process of applying paint, or another medium, to a solid

surface – usually a canvas. Paints or other forms of color are commonly applied to using a
paintbrush. The main objective of applying paints to wooden surfaces is to provide a smooth
protective cover of the desired color, with improved aesthetic appearance of wood structure.
Painted the plywood and the MS square pipe
15
ENGINEERING
Fig 3.3.7 Painting
3.3.7 ASSEMBLING OF CONPONENENTS
Assembling is the process of bringing of all components together as in a particular

place.We use nut and bolts, screws for fixing the components (compressor, evaporator,
expansion valve, condenser, energy meter, gauges) on the plywood.
We use nut and bolts for fixing compressor, condenser, evaporator, expansion valve.
And screws for fixing pressure gauge, energy meter, switch.
3.3.8 BRAZING
Brazing is a metal-joining process in which two or more metal items are joined together
by melting and flowing a filler metal into the joint, with the filler metal having a lower melting
point than the adjoining metal.
We use brazing for joining
16
ENGINEERING
Fig 3.3.9 Brazing
3.3.9 SOLDERING
Soldering is a process used for joining metal parts to form a mechanical or electrical
bond. It typically uses a low melting point metal alloy (solder) which is melted and applied to
the metal parts to be joined and this bonds to the metal parts and forms a connection when the
solder solidifies
We use soldering for joining energy meter
Fig 3.3.10 Soldering
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ENGINEERING
CHAPTER 04
MATERIAL AND COMPONENTS ARE USED
4.1 PLYWOOD
Plywood is a board material constructed from an odd number of (usually three, five, seven,
etc.) sheets of wood, termed plies, that are bonded together using a glue
Fig 4.1 plywood
4.2 PRESSURE GAUGE

Pressure gauges are used to monitor and control pressure – which is often a necessity in
industrial processing. Without pressure gauges, industrial processing systems would be both
unpredictable and unreliable
Fig 4.2 pressure gauge
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ENGINEERING
4.3 ENERGY METER

An electric meter, or energy meter, is a device that measures the amount of electric
energy consumed by a building, tenant space, or electrically powered equipment
Fig 4.3 energy meter
4.4 PAINT
Paint is any pigmented liquid, liquefiable, or solid mastic composition that, after
application to a substrate in a thin layer, converts to a solid film. It is most commonly used to
protect, color, or provide texture. Paint is used to decorate, protect and prolong the life of
natural and synthetic materials, and acts as a barrier against environmental conditions
Fig 4.4 Paint
19
ENGINEERING
4.5 NUT & BOLT

A nut is a type of fastener that is always used with bolts. The bolt is a solid cylindrical
fastener that is used with a nut. The nuts are hollow circular cylinders with a circular cross-
section. The bolts are solid cylinders with a circular cross-section.
USED: M8 Bolt Length 30 mm Mild Steel (12 No.)
Fig: 4.5 Nuts and Bolt
4.6 WASHER
Washer, machine component that is used in conjunction with a screw fastener such as
a bolt and nut and that usually serves either to keep the screw from loosening or to distribute
the load from the nut or bolt head over a larger area. For load distribution, thin flat rings of soft
steel are usual.
USED: M8, Steel, (10 No.)
Fig: 4.6 Washers
20
ENGINEERING
4.7 VARNISH
Varnish is a clear transparent hard protective finish or film. Varnish has little or no
color and has no added pigment as opposed to paint or wood stain which contains pigment.
Varnishes provide protective coatings for wooden surfaces, paintings, and various decorative
objects.
Fig 4.9 varnish
4.8 REFRIGERANT
A refrigerant is a working fluid used in the refrigeration cycle of air conditioning
systems and heat pumps where in most cases they undergo a repeated phase transition from a
liquid to a gas and back again. There are two main categories of refrigerants that residential
AC systems use. These are R-22 (Freon) and R-410A (Peron).
We use R-22 in our air condition test rig
Fig 4.10 refrigerent
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ENGINEERING
4.9 THERMOCOUPLE
Multi-point thermocouples are used to measure more than one temperature point
through a single access point. The sensor has multiple temperatures input along the length of
the sensor to calculate an accurate temperature profile.
Fig 4.11 Thermocouple
4.10 SWITCH
A switch responds to an external force to mechanically change an electric signal.
Switches are used to turn electric circuits ON and OFF and to switch electric circuits.
fig 4.12 switch
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ENGINEERING
CHAPTER 05
TOOLS REQUIRED
5.1 HAND TOOLS

5.1.1 SCREW DRIVER
A screwdriver is a tool, manual or powered, used for turning screws.
Fig 5.1.1 screw driver
5.1.2 DOUBLE ENDED SPANNER SET
It is suitable for loosening the nut at the beginning or locking the nut at
the end
Fig 5.1.2. double ended spanner set
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ENGINEERING
5.1.3 MEASURING TAPE
It is used for measuring dimensions, curved and angular surfaces up to an accuracy of

1.0 mm.
Fig 5.1.3 Measuring Tape
5.1.4 PAINT BRUSH
A paintbrush is a brush used to apply paint or ink
Fig 5.1.4 painting brush
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ENGINEERING
5.1.5 WIRE BRUSH
Wire brushes are an excellent choice for the removal of rust and oxidations,
paint, slag, weld splatter and other unwanted surface contaminants with angle
grinders, bench grinders or drills.
Fig 5.1.5 wire brush
5.1.6 SAND PAPPER
Sandpaper is produced in a range of grit sizes and is used to remove material from
surfaces, whether to make them smoother (for example, in painting and wood finishing), to
remove a layer of material (such as old paint), or sometimes to make the surface rougher (for
example, as a preparation for gluing).
Fig 5.1.6 sand paper
25
ENGINEERING
5.1.7 CLAW HAMMER
This is a hammer having steel head and wooden handle. The flat face of the head is
used to drive nails and the claw portion for extracting nails out of the wood.
Fig 5.1.7 Claw Hammer
5.1.8 BRAZING TORCH
Torch brazing, as the name implies, employs a hot gas torch on or near a joint to heat
the work pieces and melt the filler alloy being used to fill the gap
Fig 5.8 brazing torch
26
ENGINEERING
5.1.9 COMBINATION PLIER
It is used for holding small objects, twisting or turning, etc. Never use a combination
plier as a spanner.
Fig 5.1.9 Combination Plier
5.1.10 BALL PEEN HAMMER
It is helpful in hammering on curved surfaces.
Fig 5.1.10 Ball Peen Hammer
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ENGINEERING
5.1.11 CHIPPING HAMMER
It is used to remove slag from the welded joints.
Fig 5.1.11 Chipping hammer
5.1.12 HACK SAW
Hacksaw is used for cutting metal parts by sawing. It cut metal while pushed forward.
Fig 5.1.12 Hack saw
5.1.13 OPEN END SPANNER
It is used for tightening and loosening the nut and bolt.
Figure 5.1.13 Open end spanner
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ENGINEERING
5.1.14 WELDING ROD
A welding rod is a mineral- and metal-powder-coated metal rod. The rod has two
purposes: to provide filler metal to the workpiece and to conduct electric current to the arc
Fig 5.1.14 welding rod
5.2 POWER TOOLS REQUIRED

5.2.1 CIRCULAR SAW
Circular Saw Used for ripping, cross cutting, mitering, beveling, and grooving in large scale.
Fig 5.2.1 Circular Saw
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ENGINEERING
5.2.2 DRILLING MACHINES
A drilling machine, also called a drill press, is a powerful tool used to cut a round hole
into or through metal, plastic, wood, or other solid materials by turning and advancing rotary
drill bits into a workpiece.
Fig 5.2.2Drilling Machines
This drilling cutting tool (Drill Bit) is held in the drill press by a chuck and fed into the
work at variable speeds. The speed and feed should be set properly and coolant needs to be
provided for the desired finished part.
Fig 5.2.2 Drill Bit
30
ENGINEERING
5.2.3 WELDING MACHINE

Welding is a process of joining similar metals by application of heat with or without
application of pressure and with or without the use of filler metal.
Fig 5.2.3 Welding Machine
5.2.4 CENTER LATHE
The Centre Lathe. The Centre Lathe is used to manufacture cylindrical shapes from a range
of materials including; steels and plastics. We used for the cutting of the compressor for
internal view of the compressor
Fig 5.2.4 Centre lathe
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ENGINEERING
CHAPTER 6
COSTING
MACHINARY AND EQUIPMENT
SL NO ITEM RATE QTY AMOUNT
1 Drilling machine 20000 1 20000
2 Welding set 30000 1 30000
3 Grinder 5000 1 5000
4 Iron cutter 8000 1 8000
5 Wood cuter 3500 1 3500
6 Work bench 8000 1 8000
TOTAL 74500
Depreciation of machinery and equipment =10%
Depreciation of machinery and equipment per year =74500× (10÷100) = 7450
Depreciation of machinery and equipment per month = 7450 ÷ 12 =620.83 rs
FIXED CAPITAL INVESTMENT
SLNO ITEM AMOUNT
1 Machine and equipment 74500
TOTAL 74500
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ENGINEERING
AVERAGE DIRECT MATERIAL COST PER UNIT
SLNO ITEM RATE QTY AMOUNT
1 Working AC 5500 1 5500
2 Non-working AC 3500 1 3500
3 Thermocouple 3500 1 3500
4 Plywood 1100 1(8*4) 1100
5 Pressure gauge 350 2 700
6 Refrigerant R22 700 1 700
7 Energy meter 515 1 515
8 Square pipe 70 6mtrs 360
9 Paint 150 2 300
10 Wire 22 9mtrs 190
11 Switch 150 1 150
12 Varnish 120 1 120
13 Nut & bolt 100
14 Three pins 80 1 80
15 Washer 5 4 20
16 Insulation tape 10 1 10
TOTAL 16845
Total direct cost per unit = 16845
Expected order per month =5
Total direct cost per month = 5×16845 =84225 rs
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ENGINEERING
INDIRECT MATERIAL COST PER MONTH
SL NO ITEM RATE QTY AMOUNT
1 Cotton waste 80/kg 1 kg 80
2 Welding electrode 530/pc 2pc 1060
3 Cutting blade 15 20 300
4 Grinding wheel 40 4 160
5 Painting brush 1 30 30
6 Lpg gas 1 300 300
7 Brazing torch 1 150 150
8 Charging nipple 1 150 150
9 Washing soap 20 5 100
TOTAL 2339
MEASURING TOOL AND HAND TOOL
1 Steel rule 100 2 200
2 Spanner set 1000 1 1000
3 Try square 300 1 300
4 Scriber 80 2 160
5 Drill bit set 5000 1 5000
6 Measuring tape 250 1 250
7 Screwdriver 300 1 300
8 Personal protective 1000 4 4000

equipment
TOTAL 11210
36
ENGINEERING
Depreciation of measuring and hand tools = 23%
Depreciation of measuring and hand tool per year = 11210×(23÷100)=2578.3
Depreciation of measuring tool and hand tool per month =2578.3÷ 12= 214.8 rs
COST OF OFFICE EQUIPMENT AND FURNITURE
1 Chair 1000 3 3000
2 Table 3000 1 3000
3 Shelf 4500 1 4500
4 Fan 1500 2 3000
TOTAL 13500
Depreciation for office equipment and furniture = 20%
Depreciation of office equipment
and furniture per year =13500×(20÷100)=2700
Depreciation for office equipment and furniture per month = 2700÷12 = 225 rs
UTILITES PER MONTH
SLNO ITEM COST
1 Electric charge 3500
2 Water charge 500
3 Telephone bill 400
TOTAL 4400
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ENGINEERING
OVERHEAD EXPENSES PER MONTH
SL NO PARTICULARS AMOUNT
1 Rent for shed 2000
2 Travelling expenses 600
3 Insurance premium 500
4 First aid 400
TOTAL 3500
LABOUR AND ADMINISTRATION
SLNO NAME OF POST NO SALARY PER EXPENSES

MONTH
1 Supervisor 1 12000 12000
2 Skilled worker 2 8000 16000
TOTAL 28000
WORKING CAPITAL PER MONTH
SLNO ITEM AMOUNT
1 Direct material cost 16845
2 Indirect material cost 2339
3 Overhead expenses 4000
4 Labor and administration 28000
5 Utility 4400
TOTAL 55584
Working capital for 3 months =55584×3= 166752 rs
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ENGINEERING
DEPRECIATION
SLNO DEPRECIATION PERCENTAGE AMOUNT
1 Depreciation of machinery and 10% 7450

equipment
2 Depreciation of measuring tool 23% 2578.3

and head tool
3 Depreciation of office equipment 20% 3300

and furniture
TOTAL COST 13328.3
Total depreciation per year = 13328.3
Total depreciation per month = 13328.3 ÷12 =1110.9
Total depreciation per order = 1110.9÷5 = 222.18 rs
PROJECT COST
SLNO PARTICULARS AMOUNT
1 Fixed capital investment 74500
2 Working capital for 3 months 166752
3 Cost of office equipment and furniture 13500
4 Cost of measuring tool and hand tool 11210
TOTAL 265962
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ENGINEERING
AVERAGE MANUFACTURING COST PER ORDER
SLNO DESCRIPTION AMOUNT
2 Overhead cost 700
3 Labor cost 5600
4 Depreciation 222.18
TOTAL 23367.18
Expected order per month. = 5 No
Expected order per year. = 60 No
Average expense per order. =23367.18 rs
Sale price per unit =25000 rs
Profit per order. = 1632.82 rs
SOURCE OF FINANCE
SLNO SOURCE AMOUNT
1 Loan from bank at the rate of 11.2% interest 200000
2 Owns contribution 61962
TOTAL 261962
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ENGINEERING
INTREST PAYABLE PER MONTH
Loan amount =200000 rs
Payment duration. =3 year
Rate of interest. = 11.20% Annum
EMI. = 6576 rs
Total interest payable. =36401 rs
Interest payable per month. =1011.13 rs
Total payable. =236401 rs
BREAK EVEN ANALYSIS
FIXED COST PER MONTH
1 Rent for shed 2000
2 Insurance premium 500
3 Depreciation 1110.9
4 Labor and administration 28000
5 Loan repayment 1011.13
6 Travelling expenses 600
7 First aid 300
8 Utilities charge 4400
TOTAL 37922.03
Fixed cost per month =37922.03
Fixed cost per year =37922.03×12=455064.36 rs
41
ENGINEERING
VARIABLE COST PER UNIT
2 Indirect material cost 467.8
3 Other variable cost 4400
TOTAL 21712.8
BREAK EVEN POINT

Variable cost per unit =8236.8 rs
Fixed cost per year =455064 rs
Sale price per unit. =25000 rs
Break even point = fixed cost ÷(sale price per unit -variable cost per unit)
=455064 ÷ (25000-21712.8)
=138.4 units
There for the firm needed to produce 139 units in a year to breakeven.
42
ENGINEERING
CHAPTER 7
EXPERIMENTS
7.1 PERFORMANCE TEST ON THE AIR CONDITIONING TEST RIG

AIM : To determine the cop and specific refrigeration effect of a given air conditioning unit
APPARATUS : split air conditioner test rig.The unit bermetically sealed compression,
condenses, expansion valve and evaporater, pressure gauge, Thermocouple,Energy
meter,switch
PRINCIPLE:
Take h1,h2,h3 h4 From Ph chart

Specific Refrigeration effect, RE = h1-h4 kJ/kg
Specific work, work input to the compressor=w=h2-h1. kJ/kg
Co-efficient of performance, cop= RE / W
PROCEDURE :
1.Switch on the main board.Check Voltage It should be less than 190 Volt
2.Start the unit
3. Run the unit for half an hour and have the following readings
a) Suction pressure ie compressor inlet

b)Discharge pressure ie, compressor outlet
c) Compressor inlet temperature
d) Compressor outlet temperature
e)Condenser Outlet temperature
f) cold Air outlet temperature.
4.Switching off the unit
43
ENGINEERING
OBSERVATION
Trial Temperature Temperature Temperature Temperature Gauge Gauge
before after before of the cold pressure pressure
no compression compression throttling ₒ
air in C before after
in ₒ C in ₒ C in ₒ C compression compression
in kg/cm2 in kg/cm2
T2 T2 T3 T4 P1 P2
TABULATION
SL Specific Specific Specific Specific Specific Specific Coefficient
enthalpy enthalpy enthalpy enthalpy refrigerat work of
NO before after before after ion input in performance
compres compres throttling throttling effect in KJ/kg
sion sion in in KJ/kg
in KJ/kg in KJ/kg KJ/kg KJ/kg
h1 h2 h3 h4 RE W Cop
CALCULATION
Absolute pressure in bar = (gauge pressure in kg/cm2)×0.981
Pressure before compression, P1 = (gauge pressure in kg/cm2× 0.981)
Pressure after compression, P2 = (gauge pressure in kg/cm2 × 0.981)
Specific refrigeration effect, RE =h1-h4
Specific work input to the compressor, W = h2- h1

Coefficient of performance COP = RE/ W
RESULT :
Determine the cop and specific refrigeration effect of a given air conditioning unit
44
ENGINEERING
7.2 MEASUREMENT OF PSYCHROMETRIC PROPERTIES

AIM :
MEASUREMENT OF PSYCHROMETRIC PROPERTIES
OBJECTIVES:
At the end of this exercise you shall be able to

■ identify the psychometric lines
■ measure room DBT and WBT
■ find DPT, RH, moisture, enthalpy and specific volume
■ measure cooling with dehumidification
■ draw psychometric lines and process
REQUIREMENTS :
Psychrometer, Psychrometric chart
PROCEDURE :
1.Identify various psychrometric lines using psychrometric chart.

2.Measure room Dry Bulb Temperature using psychrometer.
3.Measure room Wet Bulb Temperature using sling psychrometer
4.Find the dew point temperature using psychrometric chart.
5. Find the Relative humidity using psychrometric chart
6. Find the moisture content using psychrometric chart
7.Find the enthalpy using psychrometric chart

8. Find the specific volume using psychrometric chart.
9. Town Measure cooling with dehumidification Measure the conditioned room dry bulb
temperature using psychometric.
10. And Measure the conditioned room wet bulb temperature using psychrometric chart,
11.sing DBT and WBT draw the psychrometric lines and process.
45
ENGINEERING
OBSERVATION
PROPERTIES INITIAL CONDITION FINAL CONDITION
DBT
WBT
DPT
RH
Moisture content
Enthalpy
Specific Volume
RESULT
Measured psychrometric properties at initial condition and final condition.
46
ENGINEERING
CHAPTER 08
CONCLUSION
We hope that AIR CONDITIONING TEST RIG that we have manufactured will be
use full for the college. It is very economical and very easy to operate. We come across several
practical difficulties during this project. We were able to tackle these problem. We could
change our courage to take up and implement any engineering changes
Air condition test rig explains about the working of air condition and find the cop of
air condition and also find the psychrometric properties .
We hope that we can proud of our effort so getting this project work completed While
doing this project we got involved in many techniques which all help us in future
47
ENGINEERING
CHAPTER 09
REFERENCE
[1] Paul Guyer. "An Introduction to Air Conditioning System Design" by, P.E, R.A., Fellow
ASCE, Fellow AEL
[2] Refrigeration and Air Conditioning", 3rd Edition, by C.P.Arora, The McGraw-Hill
Companies
[3] P. N. Ananthanarayanan, Basic Refrigeration and Air Conditioning McGraw-Hill, 2005.
[4] US Department of Energy. "History of Air Conditioning." https://energy.

gov/articles/history-air-conditioning/, 2017. Accessed: 10/10/2017
48
ENGINEERING
CHAPTER 10
PHOTOGRAPHS
49
ENGINEERING

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AIR CONDITION PROJECT REPORT

1.1 AIR CONDITIONING SYSTEM

1.2 WHAT IS AIR CONDITION

Air-conditioning is that process used to create and maintain certain temperature,

It's also used in industrial applications to ensure correct operation of equipment or

An air-conditioning system must be effective regardless of outside climatic conditions

Comfort air-conditioning on the other hand, as well as needing to satisfy personal

1.3 UNIT OF REFRIGERATION

Capacity of a refrigeration unit is generally defined in ton of refrigeration (TR). A ton

• This is equivalent to 3.5 kJ/s (3.5 kW) or 210 kJ/min.

● Maintain suitable humidity in all parts of a building.

1.5 LINE DIAGRAM FOR AIR CONDITION TEST RIG

Fig 1.1 Basic design for test rig

1.6 LINE DIAGRAM FOR NON WORKING AIR CONDITIONER

Fig 1.2 line diagram for non working AC

WORKING PRINCIPLE OF AIR CONDITON

2.1 VAPOR COMPRESSION REFRIGERATION SYSTEM

A vapor-compression refrigeration system is a system that uses liquid refrigerant in a

VAPOR COMPRESSION REFRIGERATION SYSTEM WORKING PRINCIPLE

The compression refrigeration cycle consists of circulating a liquid refrigerant through

2.2 TYPES OF AIR CONDITION

Central Air Conditioner.

Window Air Conditioner.

Smart Air Conditioner.

Ductless Mini-Split Air Conditioner.

Portable Air Conditioner.

Through-The-Wall Air Conditioner.

Geothermal Air Conditioner.

Evaporative Air Conditioner.

2.3 VAPOR COMPRESSION REFRIGERATION SYSTEM COMPONENTS

There are four main components in vapor compression refrigeration system.

Fig 2.0 working principle of AC

IN PROJECT WE CREATE WORKING AIR CONDITION TEST RING DISMANTLED

COMPONENTS OF AIR CONDITION

The function of the compressor is

• To draw the low-pressure refrigerant from the evaporator

• To compress the refrigerant and to raise its pressure and temperature

• To deliver the high-pressure refrigerant to the condenser

• To maintain continuous circulation of refrigerant through the refrigerating system

Compressors may be of three types:

• Rotary and Centrifugal

fig 2.1 non working compressor

Condenser is an important equipment located on the high pressure side of the

fig 2.2 non-working condenser

2.3.3 EXPANSION VALVE

An expansion device is an important component in a vapor compression system and is

IN OUR WORKING AIR CONDITION AND NON-WORKING AIR CONDITIONER

fig 2.3 non-working expansion valve

fig 2.4 non-working evaporator

2.4 P-V and T-S Diagram of Vapor Compression Refrigeration System:

Fig 2.5 P-V diagram

Fig 2.6 T-S diagram

2.5 WORKING OF VAPOUR COMPRESSION REFRIGERATION

2.6 C.O.P. OF VAPOR COMPRESSION REFRIGERATION SYSTEM:

The Coefficient of Performance (C.O.P) of a Simple Vapor Refrigeration

C.O.P. = (heat extracted or refrigerating effect)/Work done.

C.O.P. = (h2-h1)/(h3-h2) or C.O.P. = (h2-h4)/(h3-h2).

3.1 LIST OF PROCESSES FOR NON-WORKING AIR

3.2 LIST OF PROCESSES FOR WORKING AIR CONDITIONER