LAB MANNUAL (R.A.

C)
 LAB MANNUAL

REFRIGERATION AND AIR CONDITIONING (LAB)

LAB #01
OBJECTIVE:
To study and draw the layout of refrigeration & air conditioning lab.

Theory:
A plant layout ideally invovles the allocation of space and arrangement of equipment in such
a manner that overall operating cost minimized.

Objectives:
 Efficient utilization of available floor space.
 Utilize labor efficiently.
 Reduce material handling cost.
 Provide enough production capacity.
 To ensure that work proceeds from one point to another without any delay.

Types Of Layout:
There are four main types of layout.
 Product/Line Layout:
If all the processing equipment and machines are arranged according to the sequence of
operations of the product, the layout is called product type of layout.
 Process/Functional Layout:
In this type of layout machines are not arranged according to the sequence of operations but are
arranged according to the nature or type of operations. This layout is commonly suitable for non
repetitive.
 Fixed Position Layout:
In this type of layout the major component remain in a fixed location other materials, parts, tools,
machinery, man power and other supporting equipment are brought to this location.
 Combination Layout:
In many manufacturing units several products are produced in repeated numbers with no
likelihood of continuous production combined layout followed. If the good features of all types
of layouts are connected a compromise solution can be obtained which will be more economical
and flexible.
LAB APPARATUS

1. Multi Heat Exchanger Trainer

2. Thermal Conductivity Of Building Materials
3. Free & Force Heat Convection Unit
4. Heat Conduction Study Bench
5. Jacket Vessel & Coil Type Heat Exchanger
6. Concentric Tube Heat Exchanger
7. Radiation Heat Transfer
8. Plate Type Heat Exchanger
9. Bench Top Cooling Tower H893
10. Absorption Refreigeration Demonstrator Unit
11. TH525 Air-To-Water Heat Pump
12. TH527 Refrigeration Trainer
13. TH520 Basic Refrigeration System
LAB#02
OBJECTIVE:
To study the household refrigeration unit.

Apparatus:
Basic refrigeration unit

Schematic diagram:

Theory: Refrigerator is a device used for refrigeration i.e. To maintain a system or body at a
temperature lower than that of its surrounding (atmospheric temperature). The system maintained at
lower temperature is known as refrigerated system.

Principle:
Refrigerator works on the principle of thermodynamics cycles and second law of
thermodynamics. Thermodynamic cycle is essentially a closed cycle in which the working substance
undergoes a series of processes and is always brought back to initial state. The vapour compression
refrigeration system (VCRs) is most commonly used in refrigeration. In a vapour compression
refrigeration system, refrigeration is obtained as the refrigerant evaporates by absorbing latent heat of
vaporization form evaporator (storage space) and liquid refrigerant converts into vapour.
The input to the system is in the form of mechanical energy required to run the compressor. Hence
these systems are also called as mechanical refrigeration systems. A wide variety of refrigerants can
be used in these systems as per different applications and capacities.

Construction and working:

A refrigerator consists of several components like compressor, condensers, expansion devices,
evaporator and some accessories for proper functioning like controls (temperature controlling devices),
filters, defrost system etc. For proper working of the device it is necessary to proper matching of all
the components as per the requirement and function. Every component performs their own function so
it is necessary to assemble all in proper sequence.

1. Compressor:
Compressor is the most important part in any refrigerator. Without it the working of refrigerator is not
possible. Compressor is a mechanical device which transfers mechanical energy to working fluids i.e.
Refrigerant. The function of the compressor is same as heart in human body i.e. Heart pump blood in
whole body same as compressor regulate the refrigerant in whole unit by increasing the pressure of the
working fluid i.e. Refrigerant. Refrigerant comes from evaporator into the compressor; the main
function of the compressor is to draw the refrigerant form evaporator so that low temperature and
pressure can be maintained in the evaporator to extract heat from refrigerated space. After that
compressor raises the pressure and temperature of the refrigerant to a level at which it can condense in
the condenser by rejecting heat.

Compressors used in refrigerators can be classified in two ways

a. Based on working principle
• Positive displacement type/reciprocating compressors
• Roto-dynamic type/centrifugal compressors

b. Based on arrangement of compressor motor

• Open type compressor
• Hermetic / sealed type
• Semi-hermitic/ semi-sealed type

2. Condenser:
Condenser is an important component of any refrigeration system. It is a type of heat exchanger. The
refrigerant enters into the condenser in a superheated state from the compressor as mention above. It is first
de-superheated and then condensed by rejecting heat to an external medium. The refrigerant may leave the
condenser as a saturated or a sub-cooled liquid, depending upon the temperature of the external medium
and design of the condenser. Condenser rejects the heat from working fluid (refrigerant) by means cooling
coils made up of copper into the atmosphere used in case of domestic refrigerator. Refrigerant comes from
compressor is at high temperature and pressure is cooled in condenser. After condensing refrigerant
goes into the expansion devices.

Based on the external fluid, condensers can be classified as:

a. Air cooled condenser
b. Water cooled condenser

3. Throttling/Expansion devices:
An expansion device is another basic component of a refrigeration system. The basic functions of an
expansion device used in refrigeration systems are to reduce the pressure of working fluid which comes
from condenser and goes into the evaporator. It also regulates the flow of refrigerant into the evaporator
and maintains the flow rate equal to the rate of evaporation in the evaporator. We can regulate and
control the temperature of refrigerator using expansion devices by varying the opening as per our
requirements.

Following are the some expansion devices are used in the refrigerator as per their requirement.

a. Hand Expansion Valve:

b. Automatic Expansion Valve
c. Thermostatic Expansion Valve

d. Capillary Tube

4. Evaporator:
It is the storage space or freezer. Refrigerant comes from throttling device enters into the
evaporator at very low temperature and pressure. In evaporator refrigerant goes through cooling coils.
In evaporator heat is absorbed by the refrigerant, due to this temperature of the refrigerant increases
and liquid refrigerant expands and converts into vapours after that this refrigerant goes to the
compressor. Evaporator works as a heat exchanger between storage space and cooling coils. This cycle
repeats continuously.

5. Refrigerants:
Refrigerants are the working fluids used in refrigerator and goes in a cyclic process and helps
in maintaining lower temperature in evaporator (freezer). When the refrigerant enters into the
evaporator, it absorbs heat from the storage space and evaporates. This process includes a phase
change process which maximizes the cooling effect. A good refrigerant must have some qualities
like it should be non-toxic, non-explosive, non-corrosive; non-inflammable and leakage should be
non-inflammable etc. Different refrigerants are used as per their requirements. For example: R-12 is
used in domestic refrigerator and water coolers.

Reference:

https://www.mech4study.com/2018/04/how-a-refrigerator-works.html
LAB#03
OBJECTIVE:
To study the heat pump (air to water).

Schematic Diagram:

Theory:

Heat Pumps (Air to Water):

The heat pumps take heat from external air and pass it to water in heating system. That means
that they not only fulfil heating requirements, but they also heat water. In this case, external air fulfils
the function of low-potential heat source, but its value significantly oscillates in the course of the
year. The main idea is to solve heating in the course of cold winter and spring and to provide cooling
in hot summer and warm autumn. We need maximal heating in frost era, but external air is the
coolest at that time. But current heat pumps are able to process cold air up to the value of −20 °C.
The heat pump may be designed in such a way so as to cover the complete heat consumption, but
more frequently it operates in bivalent operation with an auxiliary source. Usually it is an electric
heating element supporting the heat pump in case of severe frosts. But such a situation occurs just a
few days in the heating season.
How do the AIR – WATER Heat Pumps Operate:
The whole system consists of the external and internal unit. The external unit with evaporator
and fan is placed outside and it sucks ambient air. At that moment, liquid coolant is injected to the
external unit via the expansion valve. Flowing air heat is transferred to the coolant in the evaporator.
So its state changes to gas state. The coolant in gas state proceeds to the internal unit, concretely to
the compressor where it is pressed. While the coolant is pressed in the compressor, the pressure
increases and so increases the temperature.
In this way, the original low-potential heat of the coolant taken from the external air increases
to the level suitable for heating or water heating. The coolant of high temperature then proceeds to
the condenser and transfers heat to water of lower temperature there. In this way, the coolant is
cooled down and condensation occurs. Heated water that accepted heat from the coolant goes to
radiators or floor heating and emits the heat to a room. The condensed coolant passes via the sub-
cooling exchanger to the external unit and the whole cycle repeats.

1. Exchanger (high-pressure part), the gas cools down and condensates

2. Expansion valve, the liquid expands and cools down
3. Evaporator (low-pressure part), the liquid evaporates and changes its state to gas
4. Compressor, the gas is pressed and it heats up

Red section = high pressure

Blue section = low pressure
LAB#.04
OBJECTIVE:
To study the TH-520 basic refrigeration system.

Schematic Diagram:

THEORY:
A table top refrigeration system is used to investigate energy balance at compressor, condenser and
evaporator.

Both the condenser and evaporator used water cooled heat exchangers. Instruments are provided for
measurement of temperatures, pressures and cooling water flow rates. The system requires outside
water supply.

PROCEDURE:
Equipment Setup:

1. Connect the power cable to the power source.

2. Switch on the ELCB and circuit breaker.
Begin The Test:

1) Record the weight of the the filled water. Then, open the door of the cooling compartment and
fill the empty container with water.
2) Dip the thermocouple into the water and record the initial water temperature (Tw);
Note: the
temperature (Tw) are recorded by reading the temperature (Ts) with the same of thermocouple.
3) Switch on power switch (1) and set the temperature controller (2) to a required position such
as position “7”. Start the stopwatch.
4) The apparatus is allowed to run for another 20 minutes to start recording the data.
5) Record the following data:
• High side pressure, PH psi
• Low side pressure, PL
• Temperature ,T1,T2,T3,T4
• Water temperature ,T3
• Time ,t
• Power input (optional)
• Refrigerant flow rate (optional)
6) Record the data in item 5 every 10 minutes for another 3-5 times or until the water is freezing.

After completion of test:

1) Switch off power switch, ELCB and circuit breakers.

2) Disconnect the power cable from the power source.
3) Empty the water container.

Calculation:

Calculate and plot the data on a p-h diagram to obtain operating cycle.
 Pressure TEMPERATURE

Compre Compre Compre Compres Condenser Evaporator Cooling Condenser Evaporator

ssor ssor ssor sor Outlet Inlet Water Cooling Cooling COND. EVAP.
Inlet Outlet Inlet Outlet T3 T4 Inlet Water Water FLOW FLOW
Pressur Pressur T1 T2 (C) (C) T5 Outlet Outlet RATE RATE
e e (C) (C) (C) T6 QC QE
PL PH (C) L/Min L/Min
psi psi
1 50 175 25.4 87.8 44.7 15.5 32.6 40.5 24.5 3.2 3.2

2 47 160 25.4 86.2 41 14.6 32.6 37.1 24.2 4.8 3.2

3 46 150 25.6 85.9 39.8 14.1 32.6 35.5 24.3 6.4 3.2

1 42 165 28.2 88 42.8 12.7 32.5 39.6 28 3.2 4.8

2 43 155 27.9 89.1 40.7 13.3 32.6 37.6 28 4.8 4.8

3 42 150 27.9 88 39.8 12.8 32.7 35.8 27.7 6.4 4.8

1 44 165 29.5 91.3 43 12.9 32.6 39.5 28.7 3.2 6.4

2 43 155 29.3 90.9 41 12.4 32.8 37.2 28.3 4.8 6.4

3 42 150 28.9 90.4 39.5 12.1 32.7 35.4 28.1 6.4 6.4

4 50 175 25.4 87.8 44.7 15.5 32.6 40.5 24.5 3.2 3.2
LAB #05
OBJECTIVE:
To study basic components of air-conditioning system.

Theory:
The purpose of an air conditioner is to maintain a comfortable indoor environment.The comfort
is determined by a combination of 3 factors:
• Temperature.
• Humidity.
• Air Distribution.
For this reason, the main purposes of air conditioners are to:
• Control room temperatures (cooling/heating).
• Control room humidity levels (drying, humidifying).
• Optimise air flow (circulation, distribution).
• Clean the air (filtration).

Schematic Diagram:

An Air Conditioner Consists of Four Main Sections:

Evaporator:
An evaporator is basically a heat exchanger coil that’s responsible for collecting heat from
inside a room through a refrigerant gas. This component is known as the evaporator, and is where the
liquid refrigerant absorbs heat and evaporates to become gas.
Some of the most common refrigerant gases used in air conditioning systems include
hydrofluorocarbons or HFCs (like, R-410A) hydrochlorofluorocarbons or HCFCs (like, R-22) and
hydrocarbons (like R-290 and R-600A). It is this gas that actually absorbs the heat from the room and
travels to the the next component for further processing, which is…
Compressor:
As the name clearly signifies, this is where compression of the gaseous refrigerant occurs. It’s
located in the outside unit, i.e. the part that’s installed outside the house.

Condenser:
The condenser receives the vaporized refrigerant from the compressor, converts it back to liquid and
expels the heat outside. Needless to say, it’s also located on the outside unit of the split AC.

Expansion valve:
Also referred to as the throttling device, the expansion valve is located between the two sets of
coils (the chilled coils of the evaporator and the hot coils of the condenser). It keeps tabs on the amount
of refrigerant moving towards the evaporator.
LAB#06
OBJECTIVE:
To study the split AC and Window AC.

1) SPLIT AC
Schematic Diagram:

What is a Split Air Conditioner System?

A split air conditioner consists of an outdoor unit and an indoor unit. The outdoor unit is installed on
or near the exterior wall of the room that you wish to cool. This unit houses the compressor,
condenser coil and the expansion coil or capillary tubing. The sleek-looking indoor unit contains the
cooling coil, a long blower and an air filter.

The major parts and functions in a split air conditioning system.

Compressor – outdoors:
The electric pump, or heart of the system, that circulates the refrigerant in a closed loop
between the condenser and evaporator coils. Compressors come in more than one variety. According
to Consumer Reports™ “A reciprocating compressor is more trouble-prone than a scroll-type one,
they say. While pricier, scroll-type compressors do tend to be higher in efficiency and quieter than
reciprocating compressors. Most manufacturers offer both types of compressor.”

Condenser coil – outdoors:

A network of tubes filled with refrigerant that remove heat from the heated gas refrigerant
and convert the refrigerant into a liquid form again. The excess heat escapes into the outside air.

Fan – outdoors:
Pulls air through the condenser coil for heat dispersal.
Evaporator coil – indoors:
A network of tubes filled with refrigerant that remove heat and moisture from the air as the
refrigerant evaporates into a gas again.

Air handling unit – indoors:

The blower and related portion of the central air conditioning system that moves air through
the air ducts.

Drainage system and pan:

During the normal condensation process, an air conditioner produces a significant amount of
water as a by-product. In a central A/C system, there is a primary system of pipes, often made of
PVC, that carry this condensate water to the outside of the building.
This piping needs periodic flushing to prevent it from getting stopped up with the algae and
similar growth. At a minimum, this maintenance should be done by your service company during
your annual system tune-up. Your inside A/C system should have an emergency drain pan in case the
primary drain lines stop up. This pan usually comes equipped with an automatic cut-off switch that
turns your air conditioning system off when then pan fills up with water.
Otherwise, water will run out of the pan onto you ceiling or whatever is located below it. The
need to flush the drain lines is a prime example of how a little preventive maintenance can prevent a
major repair.

2) Window AC:

Window air conditioner is sometimes referred to as room air conditioner as well. It is the simplest
form of an air conditioning system and is mounted on windows or walls. It is a single unit that is
assembled in a casing where all the components are located.

Schematic Diagram:
Indoor Side Components

The indoor parts of a window air conditioner include:

 Cooling Coil with a air filter mounted on it. The cooling coil is where the heat exchange
happen between the refrigerant in the system and the air in the room.

 Fan Blower is a centrifugal evaporator blower to discharge the cool air to the room.

 Capillary Tube is used as an expansion device. It can be noisy during operation if installed
too near the evaporator.

 Operation Panel is used to control the temperature and speed of the blower fan. A
thermostat is used to sense the return air temperature and another one to monitor the
temperature of the coil. Type of control can be mechanical or electronic type.

 Filter Drier is used to remove the moisture from the refrigerant.

 Drain Pan is used to contain the water that condensate from the cooling coil and is
discharged out to the outdoor by gravity.

Outdoor Side Components

The outdoor side parts include:

 Compressor is used to compress the refrigerant.

 Condenser Coil is used to reject heat from the refrigeration to the outside air.

 Propeller Fan is used in air-cooled condenser to help move the air molecules over the
surface of the condensing coil.

 Fan Motor is located here. It has a double shaft where the indoor blower and outdoor
propeller fan are connected together.
LAB#.07

OBJECTIVE:
To study the various types of expansion devices.

Theory:

Hand Expansion Valve:

A hand expansion valve is a hand operated needle valve. The rate of liquid flow through the
valve depends on the pressure differential across the valve orifice and on the degree of valve
opening, the latter being manually adjustable.
This is suitable for use only on large systems where an operator is on duty and where the load on the
system is relatively constant (e.g., ice making plants and cold storages).
The main advantages of a hand expansion valve are its simplicity and low initial cost. Also, because
of its simple construction there is very little that can get out of order. The principle disadvantage is
that an operator must be available at all times to make the necessary adjustment to meet the changing
load conditions.

Automatic Expansion Valve:

The automatic expansion valve is a pressure-reducing device. It is activated by the evaporator
pressure which it keeps constant since the pressure of the refrigerant in the evaporator determines
evaporator temperature. Fig. 2 shows a schematic sketch of an automatic expansion valve.
It is a diaphragm-or bellows operated valve with the evaporator pressure acting on the lower
side of the diaphragm and atmospheric pressure plus adjustable spring pressure acting on the upper
side. As the compressor operates to remove the gas from the evaporator, reducing the pressure in the
evaporator and under the diaphragm, the adjusting spring pressure pushes diaphragm down. This
motion is transmitted through push rods (or by needle valve seat) to the valve needle, opening it
enough to allow more refrigerant to flow to the evaporator. As more Refrigerant in liquid enters the
evaporator, the pressure increases forcing the diaphragm upward and allowing the valve to close.
 A properly sized valve will pass enough liquid refrigerant to maintain constant temperature
and pressure condition. The automatic expansion valves find their greatest use in the systems with
relatively constant loads and in systems with only one evaporator coil.

Thermostatic Expansion Valve:

A thermostatic expansion valve is a throttling device which works automatically, maintaining proper
and correct liquid flow as per the requirements of the load on the evaporator.This valve finds a wide
application because of its adaptability to any type of dry expansion application, automatic operation,
high efficiency and ability to prevent liquid flood backs.
A thermostatic expansion valve performs the following functions:
• Reduces the pressure of liquid from the condenser pressure to evaporator pressure.
• Keeps the evaporator fully active.
• Modulates the flow of liquid to the evaporator according to the load requirement of the
evaporator so as to prevent flood back of liquid refrigerant to the compressor.
 The performance characteristics of thermostatic-expansion valves are most suitable for application
in air-conditioning and refrigerant plants. When the cooling load 'increases', the refrigerant evaporates at a
faster rate in the evaporator than the compressor can suck. As a result the pressure and degree of superheat
in the evaporator increase. The increase in superheat causes the valve to open more and to allow more
refrigerant to enter the evaporator. At the same time, the increase in suction pressure also enables the
compressor to delivery increased refrigerating capacity. When the cooling load 'decreases' the refrigerant
evaporates at a slower rate than the compressor can suck. As a result, the evaporator pressure drops and
the degree of superheat decreases. The valve tends to close and the compressor delivers less refrigerating
capacity at a decreased suction pressure. Thus the thermostatic-expansion valve, as opposed to the
automatic expansion valve, is capable of meeting varying load requirement.Most thermostatic expansion
valves are set for 5°C of superheat and are usually rated in tonnes of refrigeration.

CAPILLARY TUBE:
A capillary tube is a fixed restriction-type device. It is the simplest of the refrigerant flow
controls, consisting merely of a fixed length (from 0.5 m to 5 m) of small diameter (0.5 mm to 2.25
mm) tubing installed between the condenser and the evaporator, usually in place of the conventional
liquid line.The pressure drop through the capillary tube is due to the following two factors:
• Friction, due to fluid viscosity, resulting in 'frictional pressure drop'.
• Acceleration, due to the flashing, of the liquid refrigerant into vapour resulting 'momentum
pressure drop'.

The cumulative pressure drop must be equal to the difference in pressures at the two ends of the tube.
The flow through the capillary tube will, therefore, adjust so that the pressure drop through the tube
just equals the difference in pressures between the condenser and evaporator. For a given state of the
refrigerant, the pressure drop is directly proportional to the length and inversely proportional to the
bore diameter of the tube.
To obtain the desired flow and pressure drop a number of combinations of length and bore
are possible for a capillary tube. However, once a capillary tube has been selected, it will be suitable
only for design pressure drop. It cannot satisfy the flow requirements with changing condenser and
evaporator pressures. Even then the capillary tube is most commonly used in small refrigerators,
window type air-conditioners, water-coolers, etc.
Advantages:
• Capillary tube claims the following advantages:
 • Simplicity.
• Low cost.
• Absence of moving parts.

LAB#08
Objective:
To study the cooling tower.

Theory:
What is a cooling tower?
Cooling towers are a special type of heat exchanger that allows water and air to come in
contact with each other to lower the temperature of the hot water. During the cooling tower working
process, small volumes of water evaporate, lowering the temperature of the water that’s being
circulated throughout the cooling tower.
Cooling towers are an integral component of many refrigeration systems, providing comfort or
process cooling across a broad range of applications. They are the point in the system where heat is
dissipated to the atmosphere through the evaporative process, and are common in industries
such as oil refining, chemical processing, power plants, steel mills, and many different
manufacturing processes where process cooling is required. They are also commonly used to provide
comfort cooling for large commercial buildings including airports, office buildings, conference
centers, hospitals, and hotels.

Structure:
Cooling towers are the primary component used to exhaust heat in open recirculating cooling
systems. They are designed to maximize air and water contact to provide as much evaporation as
possible. This is accomplished by maximizing the surface area of the water as it flows over and down
through the tower structure.
Types of Towers:
Cooling towers are classified by the direction of air flow
(counter-flow or cross-flow) and the type of draft (mechanical or natural).

a. Mechanical Draft Towers:

Mechanical draft towers have air forced through the structure by a fan. The air flow can
be pushed through by fans located at the base of the tower (referred to as forced draft), or
pulled through by fans located at the top of the tower (referred to as induced draft). Induced
draft towers tend to be larger than forced draft units.

b. Natural Draft Towers:

Natural draft towers are designed to move air up through the structure naturally
without the use of fans. They use the natural law of differing densities between the ambient
air and warm air in the tower. The warm air will rise within the chimney structure because of
its lower density drawing cool ambient air in the bottom portion. Often times these towers are
very tall to induce adequate air flow, and have a unique shape giving them the name
“hyperbolic” towers.
 a. Cross-Flow Towers:
Cross-flow cooling towers are structured so that air flows horizontally across the
falling water. This design provides less resistance for the air flow, thereby reducing the fan
horsepower required to meet the cooling demand.
These towers usually feature gravity-fed water distribution decks that are either open
and uncovered, or that are covered to limit algae growth and debris from getting into the
distribution deck. Gravity-fed distribution decks have evenly spaced openings that the water
drops through to be spread across the tower fill.

b. Counter-flow Towers:
Counter-flow cooling towers have upward air flow that directly opposes the
downward flow of the water providing very good thermal efficiency because the coolest air
contacts the coolest water (in the bottom section of the tower structure).

Cooling Tower Applications:

Tradional HVAC heating and cooling systems are used in schools, large office buildings, and
hospital. On the other hand, Cooling towers are much larger than tradional HVAC systems and are
used to remove heat from cooling tower water systems in petroleum refineries, plants, natural gas
processing plants, petrochemical plants, and other industrial processes and facilites.