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INSTRUCTION MANUAL

FOR

VAPOUR COMPRESSION
REFRIGERATION CYCLE TEST RIG

Manufactured by:

ROORKEE EQUIPMENT & MODELS L PVT TD

Factory : C-18 Ram Nagar Industrial Area, Ram Nagar
Roorkee Distt-Haridwar,
Roorkee-247 667.
Email: rempvtltd@yahoo.in , remtender007@gmail.com
Website: www.rempvtltd.co

OBJECT
1. To study vapour compressor cycle
2 To calculate the C.O.P. of unit
3. To calculate cooling capacity
4. To calculate H.P. of unit

SPECIFICATION :-
1. Compressor: Hermetically Sealed
2. Condenser: Air Cooled, made of copper coil and aluminum fin
Expansion Device : Capillary tube and thermostatic expansion valve
3. Evaporator: Immersed Type (Refrigeration Grade Copper Tube)
4. Refrigerant : R 134-a
5. Energy Meter : For Compressor
6. Pressure Gauge: For Suction & Discharge
7. Digital Temperature Indicator : 4 Channel
8. Temperature sensor (Thermocouple )
9. Ammeter
10. Voltmeter
11. Filter/Drier

THEORY :

The unit is based on vapour compression principle. The refrigerant after

evaporation removes the heat from the brine solution to convert in vapour
stage. The brine solution further takes the heat from the water placed in
water tank which converts into Ice. The brine is used because the freezing
point of brine solution is very low. The unit is based on vapour compression
cycle which is explained as below :

EVAPORATOR:

The liquid refrigerant from the condenser at high pressure is fed through a
throttling device to an evaporator at a low-pressure. On absorbing the heat

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to be extracted from media to be cooled, the liquid refrigerant boils actively
in the evaporator and changed state. The refrigerant gains latent heat to
vaporize at saturation temperature/pressure and further absorbs sensible
heat from media to be cooled and gets fully vaporized and super-heated.
The pressure and temperature in the evaporator can be determined by the
“Temperature-Pressure Relation chart” Table 1.

COMPRESSOR:

The compressor is known as the heart of the refrigeration system. It pumps

the refrigerant vapour in refrigeration in refrigeration cycle as the heart
pumps blood in the body The low temperature, pressure, superheated
vapour from the evaporator is conveyed through suction line and
compressed by the compressor to a high pressure, without any change in
gaseous state and the same is discharged into condenser. During this
process heat is added to the refrigerant and known as heat of compression.
The compressor should have a compression ratio to raise the pressure of
refrigerant to such a level that the saturation temperature of the discharged
refrigerant is higher than the temperature of the available cooling medium,
to enable the super-heated refrigerant to condense at normal ambient
condition.

CONDENSOR :

The heat added in the evaporator and compressor to the refrigerant is

rejected in condenser at high temperature/high pressure. This super-heated
refrigerant vapour enters the condenser to dissipate its heat in three stages.
First on entry the refrigerant losses its super-heat, it then losses its latent
heat at which the refrigerant is liquidified at saturation temperature
pressure. This liquid losses its sensible heat, further and the refrigerant
leaves the condensers as a sub-cooled liquid.

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The heat transfer from refrigerant to cooling medium (air or water) takes
place in the condenser. The sub-cooled liquid from condenser is collected in
a receiver (wherever provided) and is then fed through the throttling device
by liquid line to the evaporator.

THROTTLING DEVICE:

The high pressure liquid from the condenser is fed to evaporator through a
throttling device which should be designed to pass maximum possible liquid
refrigerant to obtain a good refrigeration effect. The liquid should be
properly sized to have minimum pressure drop.

The throttling device is a pressure-reducing device and a regulator for

controlling the refrigerant flow. It also reduces the pressure from the
discharge pressure to the evaporator pressure without any change of state
of the liquid refrigerant.

The types of Throttling Devices are :

• Capillary tubes

The most commonly used throttling device is the Capillary Tube .The
capillary is a copper tube having a small dia.-orifice and is selected, based
on the system design, the refrigerant flow rate, the operating parameters
(such as suction and discharge pressures), type of refrigerant, capable of
compensating any variations/fluctuating in lead allowing only liquid
refrigerant to flow to the evaporator.

VAPOUR COMPRESSION REFRIGERATION CYCLE DIAGRAM (Mollier

Diagram)

Earlier the state of the refrigerant in various parts of the refrigeration

system, along with the pressure, temperatures etc. have been covered. It is
now necessary to understand the individual thermodynamic processes that
make up the cycle and also understand the effect of change in a particular

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part of the cycle on the overall complete cycle. These aspects are greatly
simplified by the use of proper charts and diagrams, in which the process,
and the complete cycle can be graphically represented for different
conditions.

There are two types of representation in use which are :

1. The pressure-enthalpy (Ph) diagram - also known as the Mollier

Diagram.

2. The temperature-entrophy diagram.

Of these the pressure-enthalpy (Ph) diagram is more commonly used and is

explained hereunder.

Mollier Diagram :

The Mollier of pressure-enthalpy (Ph) diagram for a refrigerant is a graph

with a number of curves from which various properties of the refrigerant
under different conditions or phases can be read.

The curves are drawn by using the values taken from thermodynamic tables
of the refrigerant, both at saturation and super-heated conditions. The
pressure are represented on he ordinate (left vertical line) and the enthalpy
(total heat content) in Btu/lb. are taken on abscissa (bottom horizontal line).

Since pressure and temperature have definite relation at saturation, the

horizontal pressure lines can also represent constant temperatures and the
diagrams are also termed as temperature-enthalpy diagram. The charts
include a curve which indicates saturation line showing different states of
refrigerants.

The chart is divided into three areas, which are separated from each other:

(a) Saturated liquid

(b) Saturated vapour

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(c) The area in between the two having a mixture of liquid and vapour.

Processes

1. Points falling on the left side of saturated liquid curve represent

sub-cooling.
2. Points on the right side of saturated vapour curve represent super-
heating.
3. The horizontal distance between the two curves represent difference
in enthalpy level between saturated vapour and liquid at specific
pressure and is equal to Latent Heat of Vaporization at the saturation
pressure/temperature.

For known values of saturation pressures on high side and low side (Ph)
diagram or Mollier Diagram is shown in Figure.

For simplification only saturated pressures are assumed. Four processes in

refrigeration cycle are explained below :

(a) Compression : In compressor (vertical 1,2 on diagram) the

compression is assumed as adiabatic (constant enthalpy). No heat is
added or subtracted to the refrigerant vapour from outside. The
vapour is saturated at the beginning and end of compression. In actual
practice, the vapour are super-heated at beginning and end of
compression - shown in dotted line 1’-2’.
The temperature and pressure of refrigerant vapour is raised during
compression.

(b) Condenser: In condenser (horizontal line 2-3 on diagram)- the

condensation of refrigeration takes place at constant pressure. The
drop in enthalpy (total heat content) is equal to latent heat of
condensation (or vaporization) at saturation pressure. The process is
shown by line 2-3 on diagram. The liquid at point 3 is saturated. In
actual practice, the vapour is super-heated at beginning o'

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 condensation and sub-cooled at end of condensation. The process is
shown by line 2'2-2'2. The refrigerant change its state from vapour to
liquid in this process.

(c) Throttling: In Throttling Device (shown by line 3-4 in diagram)

this is an adiabatic process, the pressure drop occurs is refrigerant at
constant enthalpy - i.e. no heat transfer occurs between refrigerant
and outside. The refrigerant is saturated liquid point 3 and mixture of
vapour and liquid at point 4. For sub-cooled liquid the process is shown
by dotted line 3'4'.
(d) Evaporation : In Evaporator (shown by line 4-1 in diagram) the
evaporation of liquid refrigerant takes place at constant pressure. The
refrigerant gains latent heat from surrounding medium to be cooled.
The refrigerant is saturated vapour at end of evaporation at point 1.
The net refrigerating effect is obtained by projection of 1 and 4 on line
0-x i.e. 91-04. In actual cycle, taking sub-cooling of liquid refrigerant in
condenser and super-heating of refrigerant vapour in evaporator, the
net refrigerating effect would be 01-04'. It is seen to obtain bette
refrigerating effect, sub-cooling in condenser and super-heating in c\
r.porator i: essential.
Summary:

From Mollier diagram the following are known :

• Sequence of various process involved in the refrigeration cycle.

• Refrigerating effect, compression, condensation, throttling.
Following can be computed from Mollier diagram:

• Refrigerating effect.
• Heat equivalent of work done in compression
• Pressure drop in throttling device
• Coefficient of performance and power requirements
• Efficiency of refrigeration cycle

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• Power consumption on EER
OPERATING PROCEDURE
1. Switch 'ON' the main board. Check voltage. It should not be less than
190 volt.
2. Close the digital Rota meter valves.

3. Open the hand stuff off valves

4. Start the unit. Start the compressor.

5. Check down the readings of the various pressure gauges. Absence of

any reading will indicate the blockage of pipe line or leakage of gas.
6. Run the unit for 5 to 6 hours and note following readings :

(a) Suction pressure i.e. Compressor inlet

(b) Discharge pressure i.e Compressor outlet
(c) Compressor inlet temperature
(d) Compressor outlet temperature
(e) Condenser outlet temperature
8. Switch 'OFF' compressor then switch 'OFF1 the main board.
IMPORANT CAUTIONS :

1. Check the voltage. It should not be less than 200/240 volts. Single
phase 50 Hz AC supply.

2. Wherever the compressor is switch 'OFF ’, do not switch 'ON' the

compressor before five minutes interval.
3. Avoid sudden opening/closing of the hand shut off valve in the line to
prevent float hunting and possible glass tube leakage or breakage. For
this our company will not responsible for replacement of the
Rotameter.

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OBSERVATION AND CALCULATIONS
Temperature before compression i.e. Suction Temp T 1 = 23°C
Temperature after compression i e. Discharge Temp T 2 = 72 °C
Temperature after condenser T3 = 37°C
Temperature after expansion T4 = 20°C
Final temperature of water placed in tank T5 =

Initial reading of energy meter = KWh

Final reading of energy meter = KWh

Mass of refrigerant flow m = kg/min.

Gauge pressure before compression P11 = 20 PSI

i.e. suction pressure

P1'PSI
Absolute suction pressure P1 = ———— +1 = 2.4 kg/cm2
14.22

Gauge pressure after compression P2 = 240 PSI

i.e. Discharge pressure
P21 PS!
Absolute Discharge pressure = -———-+1 = 17.8 kg/cm2
14.22

From PH Chart of R314 a

Take P1 T1 Calculate H1 = 420 KJ/kg

Take P2 T2 Calculate H2 = 450 KJ/kg

P3 T3 Calculate H3 = 260 KJ/kg

As evaporation is constant enthalpy process

So H3= H4

Refrigerating effect = H1 – H4 KJ/kg.

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Work done by compressor = H2 – H1 KJ/kg.

Refrigerating effect
COP = ——————————-—-
Work done by compressor

H1- H4
C O.P = ———-
H2-H1

(H2-H1) x m x 427
H.P. of unit = ————————— H.P.
4500 x 4.184

(H1 – H4) m
Refrigerating cap in Ton = —-———-- Tons
50 x 4.184

1. C.O.P. Of Plant = Refrigeration effect

Work Done by Compressor

420-260
----------= 5
450-420

2. Refrigeration Capacity in Ton

= (Hl-H4)x m = Tons
50 x 4.18

(160) x m
= ---------------= 0.3 ton
50 x 4.18
m= 0.39 kg/min

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3. H.P. of Unit

(H2-H1) x m x 427
= ----------------------- HP
4500 x 4.18

(30) x 0.39 x 427

= ----------------------= 0.27 HP
4500 x 4.18

Vapour compression cycle

Heat out

Condenser

3 flow of refrigerant
2
Expansion valve compressor
Work in

4 flow of refrigerant 1

Evaporator

Heat gain

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