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OPERATING MANUAL
FOR
REFRIGERATION 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.com
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Title: Test on vapour compression test rig
Aim: To conduct the trial on Vapour Compression Test Rig
Prerequisites: Different types of refrigerants, thermodynamic processes and
working of VCC.
Objectives:
1. To Study various components and controls used in vapour compression
cycle (VCC).
2. To evaluate actual and theoretical COP of vapor compression cycle.
3. To Plot the actual refrigeration cycle on P-H chart.
Theory:
Test rig enables 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 immersed tube type evaporator. Separate pressure gauges are provided
to record suction and discharge pressure and digital temperature indicators
for various temperatures.
The calorimeter consists of an insulated stainless steel tank in which
evaporator tubes are fixed. The 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.
Principle of Operation:-
The refrigeration test rig works on vapour compression cycle. The
refrigeration (i.e. process of maintain 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
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condensation occurs at a high temperature and pressure. Thus it is possible
to transfer heat from an area of low temperature (in this case calorimeter) 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 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 evaporators where it absorbs heat from the
surrounding medium and evaporates. The compressor sucks the cold vapour
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.
Technical Specification of Refrigeration Test Rig:
Refrigerant : R-134
Compressor : Hermetically sealed (1/2 &2/3)
Air cooled : copper coil with fins & cooling
fan condenser
Expansion device : Thermostat expansion valve &
capillary tube
Evaporator coil : copper coil is immersed in water
tank
Electric heater : Immersion type 1.5Kw capacity
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Rota meter : for measuring liquid flow of
refrigerant
Energy meter : each for compressor & heater
Refrigerant : R-134
Dimer stat : 230 V , AC single phase
Pressure gauge : 1 No. each HP & LP
measurement
Thermometer : 4 No’s to measure condenser &
evaporator inlet & outlet
temperature
Supply : 230 volts, 50hz, 1 phase, ac.
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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, 50 Hz, and 1 phase supply to the unit.
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.
Observation Table:
Time Refrigerant Suction Discharge Refrigera Energy
Temperature Pressur Pressure nt Flow Meter
e Rate Reading
(hrs) T1 T2 T3 T4 T5 P1 (psi) P2 (psi) LPH sec
Where
T1= Suction Temperature
T2= Condenser Temperature
T3= Temperature after condenser
T4= Temperature before Evaporation
T5= Temperature of evaporator
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Sample Calculations:
1) Mass flow of water:-
Mass flow rate of liquid (Ml)= ------------ LPH
= -------------- KG/SEC
2) Actual Compressor work:-
------KW
3) Actual Refrigeration Effect:-
Actual Refrigeration Effect = Mw*Cpw*(T2-T3)
= ------------KW
4) Actual COP:-
5) Theoretical COP:-
From P-H chart of R-134a
h1= ------------ KJ/KG
h2= ------------ KJ/KG
h3= ------------ KJ/KG
h4= ------------ KJ/KG
Result Table:
Actual COP
Theoretical COP
Conclusion:
We can conclude that the theoretical COP is greater than the Actual
COP.
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Heat out
Condenser
3 flow of refrigerant
2
Expansion valve compressor
Work in
4 flow of refrigerant 1
Evaporator
Heat gain
Thermodynamic Process
From stage 1 to stage 2 work is put into compressor, thus
work = h2 – h1
From stage 2 to stage 3, heat is given off through the condenser, thus
qout = h3 – h2
From stage 3 to stage 4, the enthalpy of the refrigerant stays approximately constant,
h4 ~ h3.
From stage 4 to stage 1, heat is put into the system, thus
qin = h4 – h1 = h3 – h1
The coefficient of performance describes the efficiency the evaporator to absorb heat in relation to
the work put in, thus
COP = refrigeration effect / work input
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= qin / work = (h1 – h4) / (h2 – h1).
(H2 – H1) x m x 427
H.P. of unit = ------------------------------ HP
4500 x 4.18
(H1 – H4) m
Refrigerating cap in Ton = ---------------- Tons
50 x 4.184
PH Chart of R-134 a
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