“Maintenance ofvapor compressionrefrigeration

Test Rig”

A
Minor Project Report
Submitted
in partial fulfillment
For the award of the Degree of
Bachelor of Technology

in Mechanical Engineering
2015-2019

Submitted To SUBMITTED BY

Dr. Deepak Paliwal Omprakash choudhary

(Head of Department)
Mechanical Engineering (15egime084)
GITS, Udaipur

Department of Mechanical Engineering

Geetanjali Institute of Technical Studies, Dabok, Udaipur
Dec-2018
 CERTIFICATE

This is to certify that the minor project report entitled “ Maintanace of vapour compression
refrigeneration” for the award of Degree inMechanical Engineering at Rajasthan Technical
University (Kota) has been prepared and submitted by Mr Dr Deepak Paliwal (Enrollment No.
15egime084) as per the guidelines under my supervision and guidance.

Dated: 31-10-2018

Under the Guidance by

Supervisor Name:Dr. Deepak Paliwal Head of Department

(Department of Mechanical Engineering)
 STUDENT DECLARATION

We hereby declare that the minor project entitled " Maintenance of vapour compression
refrigeration" is the work done by us during the academic year 2018-2019 and is submitted in
partial fulfillment of the requirements for the award of Four Year Degree in MECHANICAL
ENGINEERING from RAJASTHAN TECHNICAL UNIVERSITY (KOTA).

Omprakash Choudhary
(15egime084)
 ACKNOWLEDGEMENT

Success is epitome of hard work, cogency for fulfilling the mission, indefatigable perseverance and
most of all encouraging guidance and Steering.

It gives us an immense pleasure to express our gratitude to Supervisor name, Assistant

Professor/Associate Professor/Professor of Department of Mechanical Engineering for his esteemed
guidance and able supervision during the course of the project. His constant encouragement and co-operation
made this project a success.

We are especially thankful to Dr Deepak Paliwal, for providing the necessary facilities to carry out
the work successfully.

We are also thankful to our head of department, Dr. Deepak Paliwal for needful support whenever
required during execution of our project.

Omprakash Choudhary

(15EGIME084)
 ABSTRACT

Energy requirement for refrigeration and air conditioning applications bears a huge share of total energy
consumption around the world. Since, thermal comfort plays a very important role on the health, working
efficiency and activities of all living beings, especially, temperature and humidity. In the excessively hot
climates it is necessary to reduce the temperature and humidity whereas in the cold climate there is a need to
increase the temperature. When the temperature drops below thermal comfort level, especially in the winter
season, the heating systems are employed. In some countries, where the atmospheric temperature is very
low, natural heating like solar energy is not sufficient, the heat pump and fuel fired systems are proven to be
suitable heating devices. In hot climates, thermal comfort achieved through the use of air conditioning
systems.

.
 LIST OF FIGURES

Figure Figure Title Page No.

No
1
2
2
 LIST OF TABLES

CHAPTER Title Page No.

1 Vapor Compression Refrigeration
2 Working principle of VCRS
3 Evaportor and maintenance
4 Practical view
CHAPTER 1
Introduction:
1.1 Vapor Compression Refrigeration:
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 of buildings and automobiles. It is also used in domestic and commercial
refrigerators, large-scale warehouses for chilled or frozen storage of foods and meats, refrigerated trucks and
railroad cars, and a host of other commercial and industrial services. Oil refineries, petrochemical and
chemical processing plants, and natural gas processing plants are among the many types of industrial plants
that often utilize large vapor-compression refrigeration systems.

1.2 Refrigeration:
Refrigeration may be defined as lowering the temperature of an enclosed space by removing heat
from that space and transferring it elsewhere. A device that performs this function may also be called an air
conditioner, refrigerator, air source heat pump, geothermal heat pump or chiller (heat pump).
The vapor-compression uses a circulating liquid refrigerant as the medium which absorbs and
removes heat from the space to be cooled and subsequently rejects that heat elsewhere.

Fig 1.1: Vapor-compressionrefrigeration

1.3 Working Principle of Vapor CompressionRefrigeration System:

The Vapor Compression Refrigeration Cycle involves four components: compressor, condenser,
expansion valve/throttle valve and evaporator. It is a compression process, whose aim is to raise the
refrigerant pressure, as it flows from an evaporator.

1.4 Study of components:

Main component list of vaporCompression Refrigeration
S.No. Component Specification
Name

1. Compressor 1/4 HP; Hermetically sealed.

2. Condenser Forced convection air cooled.

3. Condenser fan Axial flow type.

4. Drier/ filter Molecular sieve type.

5. Expansion device Capillary tube.

6. Evaporator Direct expansion type. Shell & Coil type provided.

7. Accumulator Copper / M.S. shell suction line accumulator provided.

8. Refrigerant R-134 A.

9. Pressure 2 nos. dial type pressure gauges; one for suction and the
indication other for discharge pressure.

10. Temperature Multi-channel LED digital temperature indicator.

indication

11. Refrigerant flow Glass tube rotameter.

indication

12. Operating Main switch & piano type switches for compressor &
switches heater.

13. Calorimeter Stainless steel: SS-304 tank with nitrile foam insulation.

14. Amp. Meter Provide for Compressor and Heater.

15. Voltmeter 220-240 Volts, 50 Hz, 1 phase.

16. ON/OFF Switches To ON/OFF Condenser fan, Compressor, Solenoid valve,

Heater, Agitator motor etc.

17. Suction Gauge Measure the Suction rate of Refrigerant

18. Discharge Gauge Measure the Discharge rate of Refrigerant.

19. Dimmer To regulate the range of temperature.

20. Liquid line Copper pipe in which the refrigerant is flow in liquid form.

21. Discharge line Copper pipe which carry out the refrigerant from
Compressor.

22. Suction line Copper pipe which carry the refrigerant in Comp.
23. By-pass valve This provide the By-pass path for vapor form of refrigerant.

24. Base Platform To mount all device or components

Fig.1.2:Vapour compression cycle

CHAPTER 2
2.1 Working principle of VCRS
Description of major and main components:

1.Condenser
2.Compressor
3.Evaporator
4.Expansion Valve

2.2 Condenser:

Figure: Condenser unit

 Fig.2.2: Condensor

Condensation changes gas to a liquid form. Its main purpose is to liquefy the refrigerant gas sucked
by the compressor from the evaporator. As condensation begins, the heat will flow from the condenser into
the air, only if the condensation temperature is higher than that of the atmosphere. The high-pressure vapor
in the condenser will be cooled to become a liquid refrigerant again, this time with a little heat. The liquid
refrigerant will then flow from the condenser to a liquid line.

2.3 Compressor:

Fig.2.3: Compressor
The compressor’s use is to pull the low-temperature and low-pressure vapor from the evaporator, through a
suction line. Once the vapor is drawn, it will be compressed. This will cause the vapor’s temperature to rise.
Its main function is to transform a low-temperature vapor in to a high-temperature vapor, to increase
pressure. Vapor is released from the compressor into a discharge line.
CHAPTER 3

3.1 Evaporator:

Fig.3.1: Evaporator

Fig.3.1.1: Evaporator
An evaporator is used to turn any liquid material into gas. In this process, heat is absorbed. The evaporator
transfers heat from the refrigerated space into a heat pump through a liquid refrigerant, which boils in the
evaporator at a low-pressure. In achieving heat transfer, the liquid refrigerant should be lower than the goods
being cooled. After the transfer, liquid refrigerant is drawn by the compressor from the evaporator through a
suction line. Liquid refrigerant will be in vapor form upon leaving the evaporator coil.

3.2 Expansion Valve:

Fig.3.2: Expansion Valve

Commonly placed before the evaporator and at the end of the liquid line, the expansion valve is
reached by the liquid refrigerant after it has been condensed. Reducing the pressure of the refrigerant, its
temperature will decrease to a level below its atmosphere. This liquid will then be pumped into the
evaporator.
 Component Name

Compressor
Problem : 1. Leakage in discharge and suction valves
2. Leakage from the relief valve
3. Overheating of Discharged Air
4. Wrong setting of compressor auto cut-in and cut-out (too close)
Maintenance: 1) Clean air filter.
2) Check un-loader operation.
3) If belt is provided for driving cooling water pump, check its tightness.
4) Intercooler cleaning

Condenser
Problem:
Maintenance : 1. Fouling of the tube surfaces
2. Tube or tubesheet fouling due to shell fish or debris
3. Circulating water in-leakage.
4. Excess ambient air in-leakage

Condenser fan

Drier/ filter
Function: 1. Bi-flow filter driers
2. Ensure fast and effective adsorption of moisture as well as organic.
3. The filter’s shell is UL approved for PS/MWP up to 46 bar/667 psig
4. Available with solder (cu-plated steel) and flare connections
5. No dirt released by reversing the flow direction

Expansion device

Evaporator

Accumulator
Maintenanace 1. Accumulator being check of over section.
2. Ther are proper cleaned.

Refrigerant
Maintance 1

Pressure indication
Maintenance 1. Low Pressure or LP cut off
2. High pressure or HP cut off

Temperature indication
Maintenance 1. Check temp. Meter proper working.
2. All o0ver sectuion cleaning 0 proper.

Refrigerant flow indication

Maintenance 1. Indication meter chech proper working
2. No leakage of the over sectuion.
Operating switches
Maintenance 1. Operating switches are properly working.
2. Switches being contrlled components.

Amp. Meter
Maintenance 1. Amp. Meter are properly working.
2. Cleaning surface area.

Voltmeter
Maintenance 1. Volt meter check working.
2. Cleaning of surface.

ON/OFF Switches
Maintenance 1. ON/OFF switch are full working .
2. Eletercitry are connnected.

Suction Gauge

Discharge Gauge

Dimmer

Liquid line
Maintenance 1. Liquid line no leakage.
2. All over surface area be cleaned.

Discharge line
Maintenance 1. Discharge line being no leakage
2. Full surface cleaning area

Suction line
Maintenance 1. Suction line surface area be cleaning.
2. In their no leakage.

By-pass valve
Maintenance 1. By pass valve lubricants
2. Most of valve working

Base Platform
Maintenance: 1. Finishing surface
2. No leakage of surface
CHAPTER 4

4.1 AIM: To study the performance of the refrigeration test Ring (Water Chiller).

4.2 CONTENT:

1. Product Description

2. Product Specification

3. Principle of Operation

4. Operating Procedure

5. Observation Table

6. Standard Values and Formulae

7. Calculations

8. Results
4.3 Product Description:

Test Rig enables students to study and understand Vapour Compression Cycle, its components, principle
and working. All the components are mounted on rigid steel frame. The trainer consists of a hermetically
sealed compressor; forced convection air-cooled condenser, filter / drier, flow meter, expansion device and
shell & coil type evaporator. Separate pressure gauges are provided to record suction and discharge
pressures and digital temperature indicators for various temperatures.

The refrigerant used is R-134a, which is environment friendly.

The calorimeter consists of an insulated stainless steel tank. The evaporator tubes are made of refrigerated
grade annealed copper tubes. This is a direct expansion type evaporator. The heat absorbed by the
refrigerant is balanced by heater input. The heater is immersion type resistive water heater. The
calorimeter temperature can be set by a digital thermostat. Adequate safety devices such as HP/LP cut-out,
heating thermostat, and overload protection for compressor are incorporated to prevent any malfunctioning
of the system.
1. Product Specifications:

 Capacity : 500 watt at rated test conditions.

 Refrigerant : R-134 a

 Compressor : Hermetically sealed

 Condenser : Forced convection air cooled

 Condenser fan motor : Induction type

 Drier / filter : Dry all make

 Expansion device : Capillary tube

 Refrigertant flow : Rota meter

 Hp/lp cutout : Provided

 Pressure indication : Pressure guage, 2nos provided

 Energy meter : L & t make,

 Temprature control of the calorimeter : Automatic by temperature controller

  Evaporator for refrigeration test rig : Shell and coil type, direct expansion coil

 Temperature indication : Digital led

 Insulation for water tank : Puff
 Supply : 230 volts, 50hz, 1 phase, ac.

 Construction : Main body: 18 g CRCA, powder

coated.

Calorimeter: SS 304.
Principle of Operation:

The Refrigeration Test Rig works on vapour compression cycle. The refrigeration (i.e. process of maintaining a closed space temperature below ambient
temperature) is accomplished by continuously circulating, evaporating and condensing a fixed supply of refrigerant in a closed system. Evaporation occurs at
a low temperature and low pressure while condensation occurs at a high temperature and pressure. Thus it is possible to transfer heat from an area of low
temperature (in this case evaporator) to an area of high temperature (the surroundings).
The compressor pumps the low-pressure refrigerant from the evaporator through the accumulator, increases its pressure, and discharges the high-pressure gas
to the condenser. The accumulator prevents liquid refrigerant entering the compressor. In the condenser, the refrigerant rejects its heat to the surroundings by
passing air over it. At that pressure, the refrigerant loses its latent heat and liquefies. Then the refrigerant passes through the drier/filter where any residual
moisture or foreign particles present, these are plugged. The flow of refrigerant into the evaporator is controlled by expansion device where its pressure and
consequently temperature is lowered to the saturation temperature at the corresponding pressure. The low temperature refrigerant enters the evaporator where
it absorbs heat from the surrounding medium and evaporates. The compressor sucks the cold vapours and the cycle repeats.
The required instrumentation is provided to measure the various parameters at different points. This includes pressure gauges, temperature indicators and
controller, energy-meters, heater for applying load and flow meter to measure the refrigerant flow.
2. Operating Procedure:

Put the machine in the proper position where its level is horizontal and it is well ventilated. The machine must have at least 1.5 meters clearances
from all sides.
Give 230 volts, 50Hz, and 1 phase supply to the unit.
Incoming cable should be adequate size (at least 4 sq. mm) to prevent overheating of it.
The electrical point should have a MCB of 16 Amps rating.
 Ensure proper earthing.
Fill the water tank with clean water.
Start the compressor by putting the switch ON.
Also switch on the heater; it will start automatically at set point.
Control the water flow to heat exchanger around 3 LPM.
Record all the readings as per the observation table.
Calculate the results as per the procedure mentioned. At various points.
3. Observation Table:

Date Current of Machine in Amp. :

Capacity Voltage of Machine :

REFRIGERAN WATER PRESSUR

T TEMP. E
TEMP.
Wate
(0C) Kg/cm2 Refrigera
Energy
TIME r (0C) Meter
in Hrs Flow Heate nt Flow
Reading for
r T1 T2 T3 T4 Inlet ˚C P1 P2 L/Hr 10 Pulses t
Rate
On/Of Outlet Suctio Discharge sec
In f T5 ˚C n

L/S T6

On
 Off

T1 = Discharge gas temperature

T2 = Temperature after condensation T3 = Temperature

after expansion
T4 = Suction gas temperature

P1 =

Average

suction

pressure in

bar P2 =

Average

discharge

pressure in

bar

Absolute suction pressure =

suction gauge pressure+
barometric pressure

Absolute discharge
pressure= discharge
gauge pressure+
barometric pressure
4. Standard Values and Formulae:

 Standard Barometric Pressure = 1.013 bar = 1.013 x 105 N /m2

 Density of Water =
1000 kg / m3
=
 Specific Gravity of R-134a at 400 C 1.14

 1 Ton of Refrigeration effect = 3516 Watts = 3.51 kJ / s

 1 bar = 14.5 psig

 Specific heat of water = 4.2 kJ/kg K

  Density of Air at 250C = 1.1 kg/m3

 Gas Constant of Air = 287kg/kJ K

 1 KWHr = 3600
4.5 Calculations:

The Objectives of experiment are

To evaluate the cooling capacity in Watts & in Tons of the system.
To evaluate actual and theoretical C.O.P. of Vapour Compression Cycle.
To plot the actual Refrigeration Cycle on P-H chart.
To study various components and controls used in Vapour Compression Cycle.

Average refrigerant temperatures at salient points: T4 =

Suction gas temperature =

T1 = Discharge gas temperature=

T2 = Temperature after condensation= T3 =

Temperature after expansion=

P1 = Average suction pressure in bar P2 = Average

discharge pressure in bar

Absolute suction pressure = suction gauge pressure+ barometric pressure Absolute

discharge pressure= discharge gauge pressure+ barometric pressure

4.6 Theoretical C.O.P.

Theoretical Coefficient of performance = n /w

Where n = Theoretical refrigeration effect = (h1-h4)= kj/kg w= Theoretical

compressor work = (h2-h1) = kj/kg

Accordingly, the Enthalpies of refrigerant at salient points are

h1=enthalpy of refrigerant at inlet of compressor

h2= enthalpy of refrigerant at outlet of compressor

 h3=enthalpy of refrigerant after condensation h4=enthalpy

of refrigerant after expansion = h3

4.7 Actual C.O.P.

1. Actual Refrigeration Effect in kw = M X Cp X Dt

Where M=Mass Flow Rate of water in kg/s; Cp=Specific heat of water=4.2KJ/KgK(Constant);

Dt=Difference between T5 & T6.

2. Compressor Work W = (10 X 3600)/ (t X 3200 ) kW

3. Actual COP = Actual Refrigeration Effect/ Actual Compressor Work

4.8 Results:

 apacity of the system = ------ Watts = -------- TR

Actual COP = Theoretical COP =
4.9 PRECAUTIONARY NOTE

The plant should not be left with water in the tank when not in use.
Do-not tamper with the temperature as well as the pressure settings.

Objectives:
1. To assess the performance of the vapor compression cycle as a refrigerator and as a heat pump and
its dependence on various parameters.

2. To learn how to use the equipment to measure temperature at various test points and the flow rates
for liquids and gases.

3. To checkout defects in Vapor compression refrigeration test rig.

4. To maintenance of Vapor compression refrigeration test rig.