HVAC and Refrigeration
System
Introduction
Refrigeration deals with the transfer
of heat from a low temperature level
at the heat source to a high
temperature level at the heat sink.
Air conditioning for comfort
Refrigeration for process
Ton of refrigeration
The cooling effect produced is quantified as tons of
refrigeration.
1 ton of refrigeration = 3024 kCal/hr
heat rejected.
Conceptual view of a chilled-
water air-conditioning system
Typical Window Air Conditioner
Schematic of a Basic Vapor Compression
Refrigeration System
Vapour compression System
How do the chillers work ?
1. Boiling point of the water is a function of pressure. At atmospheric pressure water boils at 100 deg. C.
When maintained at high vacuum, water will boil and subcool itself. The boiling point of the water at
6 mmHg (abs) is 3.7 deg. C.
How do the chillers work ?
2. Lithium Bromide (LiBr) has the property to absorb water due to its chemical affinity. At higher
concentration and lower temperature LiBr absorbs water vapour (refrigerant vapour) very effectively.
How do the chillers work ?
3. As Lithium Bromide becomes dilute it loses its capacity to absorb water vapour. It thus needs to be
reconcentrated using a heat source. Heat source may be Steam or Flue gases or even Hot water.
Vapour Absorption Chillers: Types
Single effect steam fired (0.4 to 2 kg/cm2)
Steam Consumption for 200 TR = 8.5 Kg/hr/TR
Double effect steam fired (3 to 9 kg/cm2)
Steam Consumption for 200 TR = 4.5 Kg/hr/TR
Cost of m/c = Rs. 12000 to 15000 per TR
Low temperature hot water fired (75 – 100oC)
High temperature hot water fired (110 –
145oC)
Compressor Types
Centrifugal Compressors
•Centrifugal compressors are the most efficient
type when they are operating near full load.
•Centrifugal compressors have a single major
moving part - an impeller that compresses the
refrigerant gas by centrifugal force. The gas is
given kinetic energy as it flows through the
impeller. This kinetic energy is not useful in itself,
so it must be converted to pressure energy. This
is done by allowing the gas to slow down
smoothly in a stationary diffuser surrounding the
impeller.
Reciprocating Compressors
•The maximum efficiency of reciprocating compressors is
lower than that of centrifugal and screw compressors.
•Efficiency is reduced by clearance volume throttling losses
at the intake and discharge valves, abrupt changes in gas
flow, and friction.
Screw Compressors
Screw compressors, sometimes called “helical rotary”
compressors, compress refrigerant by trapping it in the
“threads” of a rotating screw-shaped rotor.
Scroll Compressors
•The gas is compressed between two
scroll-shaped vanes. One of the vanes
is fixed, and the other moves within
it. The moving vane does not rotate,
but its center revolves with respect to
the center of the fixed vane.
•This motion squeezes the refrigerant
gas along a spiral path, from the
outside of the vanes toward the
center, where the discharge port is
located.
Properties of Commonly
used Refrigerants
Properties of Commonly used Refrigerants
Boiling Vapor Vapor Enthalpy *
Freezing
Refrigerant Point ** Pressure * Volume * Liquid (kJ Vapor (kJ
Point (oC)
(oC) (kPa) (m3 / kg) / kg) / kg)
R - 11 -23.82 -111.0 25.73 0.61170 191.40 385.43
R - 12 -29.79 -158.0 219.28 0.07702 190.72 347.96
R - 22 -40.76 -160.0 354.74 0.06513 188.55 400.83
R - 502 -45.40 --- 414.30 0.04234 188.87 342.31
R-7 -33.30 -77.7 289.93 0.41949 808.71 487.76
(Ammonia)
* At -10 oC
** At Standard Atmospheric Pressure (101.325 kPa)
Performance Assessment
The specific power consumption kW/TR is a useful indicator of the
performance of refrigeration system. By messing refrigeration duty
performed in TR and the Kilo Watt inputs measured, kW/TR is
used as a reference energy performance indicator.
The refrigeration TR is assessed as TR = Q Cp (Ti – To) / 3024
Where TR is cooling TR duty
Q is mass flow rate of coolant in kg/hr
Cp is coolant specific heat in kCal /kg / 0C
Ti is inlet. Temperature of coolant to evaporator (chiller) in 0C.
To is outlet temperature of coolant from evaporator (chiller) in 0C.
COP
The theoretical Coefficient of Performance (Carnot),
COPCarnont - a standard measure of refrigeration
efficiency of an ideal refrigeration system- depends
on two key system temperatures, namely, evaporator
temperature Te and condenser temperature Tc with
COP being given as:
COPCarnot = Te / Tc - Te
This expression also indicates that higher COPCarnot is
achieved with higher evaporator temperature and
lower condenser temperature.
COP
COPCarnot is only a ratio of temperatures, and
hence does not take into account the type of
compressor. Hence the COP normally used in the
industry is given by
COP = Cooling Effect (kW)
Power input to compressor (kW)
where the cooling effect is the difference in
enthalpy across the evaporator and expressed as
kW.
Overall energy consumption
Compressor kW
Chilled water pump kW
Condenser water pump kW
Cooling tower fan kW
Overall kW/TR = sum of all above kW/ TR
Effect of Variation in Evaporator
Temperature on
Compressor Power Consumption
Evaporator Refrigeration Specific
Increase in
Temperature Capacity Power
kW/ton (%)
(0C) (tons) Consumption
5.0 67.58 0.81 -
0.0 56.07 0.94 16.0
-5.0 45.98 1.08 33.0
-10.0 37.20 1.25 54.0
-20.0 23.12 1.67 106.0
A 10C raise in evaporator temperature can help to save almost 3 % on power
consumption.
Effect of Variation in Condenser
Temperature on
Compressor Power Consumption
Condensing Refrigeration Specific Increase in
Temperature Capacity Power kW/TR
0
( C) (tons) Consumption (%)
26.7 31.5 1.17 -
35.0 21.4 1.27 8.5
40.0 20.0 1.41 20.5
Effect of Poor Maintenance on
Compressor Power Consumption
Specific Increase
Evap. Cond. Refrigeration
Power in
Condition Temp Temp Capacity
Consumption kW/Ton
(0C) (0C) (tons)
(kW/ton) (%)
Normal 7.2 40.5 17.0 0.69 -
Dirty 7.2 46.1 15.6 0.84 20.4
condenser
Dirty 1.7 40.5 13.8 0.82 18.3
evaporator
Dirty 1.7 46.1 12.7 0.96 38.7
condenser
and
evaporator
ENERGY SAVINGS OPPORTUNITIES
Cold Insulation
Building Envelop
Building Heat Loads
Process Heat Loads Minimisation
Flow optimization and Heat transfer area increase
to accept higher temperature coolant
Avoiding wastages like heat gains, loss of chilled
water, idle flows
Frequent cleaning / de-scaling of all heat
exchangers
Cold Insulation
Difference in temperature Heat ingress Exposed area per
between ambient and Kcal/m2/hr tonne of refrigeration
surface
5 35 86
10 73 41
15 113 27
20 154 19
Basis:
Ambient temperature - 35OC, emissivity – 0.8, still air conditions
Allowable heat ingress – 10 –15 Kcal/m2/hr
Thumb rules for cold Insulation
Chilled water pipe insulation (Provide 2 to 3 inch thickness)
Duct insulation (Provide 1 to 2 inch thickness)
Suction line refrigerant pipe insulation(Provide 2 to3 inch thickness)
Select the right Cooling Medium
Type of cooling Power Consumption
1. Cooling tower water 0.1 KW/TR
2. Chilled water System at 10oC 0.7 KW/TR
3. Brine System at -20oC 1.8 KW/TR
Order of preference
Cooling water ChilledWater Brine
Energy saving measures in A/c System
Comfort conditions: 25OC, 55 % RH
Minimize heat load through glass windows
Provide sun control film, Use double glass
Insulate roof top in A/C Building
Provide under deck insulation of 50 mm, Provide lawns at roof top
Optimize fresh air supply into a/c room
Conduct CO2 study to optimize fresh air quantity
10-15 cfm/person or 0.25 cfm/sq..ft as per ASHRAE
Minimise artificial lighting
Use natural lighting , 3.5 kw lighting consumes 1.0 TR load
Provide controls
install thermostat to control peak and base load
Provide VSD for AHU with return air temp.sensor-set at 25oC
Air tight the building envelop
prevent cold air leakage, Provide door closures
Avoid heat producing equipments inside the room
keep away UPS Battery , ovens, other loads
Efficient operation & maintenance
The suction Temperature, pressure delivery pressure of
compressors should be kept at optimum level
Ensure all indicators are working properly
Keep record of oil consumption
Condensers
Remove scale and algae and adopt suitable water treatment
Give periodic purging of non-condensable gases
Lesser the water temperature more the COP
Routine defrosting of Cooling coils
Stop condenser water pump when compressor not working
5OC rise in condensing temperature increases 10 % power
consumption
5OC rise in evaporating temperature increases 10 % power
consumption
Energy Savings in Refrigeration
systems
There are two broad ways by which
energy can be conserved
1. By decreasing the load
2. By optimising the refrigeration system
Energy saving measures in
refrigeration
Look for process modifications to reduce the cooling load
Use cooling water to remove the maximum heat before using chilled water
Provide VSD for condenser water pumps
to vary the cooling water flow to maintain 4oC difference across the condensers
Avoid primary pump operation
Normally two pumps are operation(Chilled water supply pump from cold well
and return water pump from hot well)
Modify to operate only return water pump
Provide VSD for efficient part load operation
Explore ‘Ice-bank’ system for Maximum demand reduction
Explore application of vapour absorption with cost economics
Replace old systems with modern energy efficient systems
End
