REFRIGERATION SYSTEM COMPONENTS

There are four (4) main components of a refrigeration system, these are:

1.) Compressor
2.) Evaporator
3.) Condenser
4.) Expansion/Metering Device

In order for the refrigeration cycle to operate

successfully each component must be present
within the refrigeration system.

COMPRESSORS

Compressor is the considered the hearth of refrigeration system

responsible for circulating refrigerant inside the circuit, drawing it in as a
vapor at low pressure from the evaporator and then compressing it and
delivering it at higher pressure and temperature to the condenser.

It delivers the refrigerant vapor to the condenser at a pressure and

temperature at which the condensing process can be readily
accomplished, at the temperature of the air or other fluid (such as water)
used for condensing.

In other words it compresses the vapor refrigerant to condenser pressure with

a corresponding saturation or condensing temperature higher than the
temperature of the cooling medium in the condenser.

Types of Refrigeration and Air Conditioning Compressors

There are basically 5 types of refrigeration and air conditioning compressor

that are commonly used in the HVAC&R industry:

 Reciprocating
 Screw
 Rotary
 Scroll
 Centrifugal
1. Reciprocating Compressor

Reciprocating compressors adopt a volumetric compression system using pistons and work much like an
internal combustion engine. The pistons run up and down inside cylinders, producing suction and
compression of the refrigerant gas. Each cylinder has a suction valve for the gas refrigerant and a discharge
valve to deliver the gas to the condenser after having been compressed.

In general these are noisy compressors and create considerable vibrations that are felt around the entire
circuit.

Reciprocating compressors is divided into open, hermetic and semi-hermetic

1.1 Open Type Reciprocating Compressors

An open compressor is driven by an external power source, such as an electric motor, an engine, or a
turbine. The motor is coupled to the compressor crankshaft by a flexible coupling. Since the shaft protrudes
through the compressor housing, a seal is used to prevent refrigerant from leaking out of the compressor
housing.

This motor is cooled by air that is drawn in from the surrounding space. The heat removed from the motor
must still be rejected from the space, either by mechanical ventilation or, if the space is conditioned, by the
building’s cooling system.
1.2 Hermetic Reciprocating Compressors

Reciprocating compressors are called hermetic when the casing is welded, seals the motor within the
compressor housing and the cylinder heads cannot be accessed for inspection or maintenance.

1.3 Semi-hermetic Reciprocating Compressors

Similarly, the motor for a semi-hermetic compressor is also contained within the compressor housing and
is cooled by the refrigerant. The term “semi-hermetic” means that the sealed housing is designed to be
opened to repair or overhaul the compressor or motor.

2. Scroll Compressor

Similar to the reciprocating compressor, the scroll compressor works on the principle of trapping the
refrigerant vapor and compressing it by gradually shrinking the volume of the refrigerant. The scroll
compressor uses two scroll configurations, mated face-to-face, to perform this compression process.

The upper scroll, called the stationary scroll, contains a discharge port. The lower scroll, called the driven
scroll, is connected to a motor by a shaft and bearing assembly. The refrigerant vapor enters through the
outer edge of the scroll assembly and discharges the port at the center of the stationary scroll.
In scroll compressor is a hermetic type of compressor, refrigerant vapor
enters through the suction opening. The refrigerant then passes through
a gap in the motor, cooling the motor, before entering the compressor
housing. The refrigerant vapor is drawn into the scroll assembly where it
is compressed, discharged into the dome, and finally discharged out of
the compressor through the discharge opening.

Advantages of scroll compressors include relative small dimensions and

much lower weight than medium capacity reciprocating compressors.
Other benefits are low noise and reduced vibrations. High efficiency
versions of these compressors are also available fitted with inverters and
brushless DC motors. Scroll compressors are widely used in home and
commercial air-conditioning systems.
3. ROTARY COMPRESSORS (Rolling Piston)
4. Screw (or Helical Rotary) Compressors

Similar to the scroll compressor, the helical-rotary compressor traps

the refrigerant vapor and compresses it by gradually shrinking the
volume of the refrigerant. This particular helical-rotary compressor
design uses two mating screw-like rotors to perform the compression
process.

The rotors are meshed and fit, with very close tolerances, within the
compressor housing. The gap between the two rotors is sealed with
oil, preventing the compressed refrigerant vapor from escaping
through the mating surfaces. Only the male rotor is driven by the
compressor motor. The lobes of the male rotor engage and drive the
female rotor, causing the two parts to counter-rotate.

Refrigerant vapor enters the compressor housing through the

intake port and fills the pockets formed by the lobes of the rotors. As
the rotors turn, they push these pockets of refrigerant toward the
discharge port of the compressor.

In the air-conditioning industry, helical-rotary or screw compressors are most commonly used in water chillers
ranging from 70 to 450 tons [200 to 1,500 kW].
5. Centrifugal Compressors

The centrifugal compressor uses the principle of dynamic

compression, which involves converting energy from one form to
another, to increase the pressure and temperature of the refrigerant. It
converts kinetic energy (velocity) to static energy (pressure). The core
component of a centrifugal compressor is the rotating impeller. The
center, or eye, of the impeller is fitted with blades that draw refrigerant
vapor into radial passages that are internal to the impeller body. The
rotation of the impeller causes the refrigerant vapor to accelerate within
these passages, increasing its velocity and kinetic energy.

The accelerated refrigerant vapor leaves the impeller and enters the
diffuser passages. These passages start out small and become larger as
the refrigerant travels through them. As the size of the diffuser passage
increases, the velocity, and therefore the kinetic energy, of the
refrigerant decreases. The first law of thermodynamics states that
energy is not destroyed—only converted from one form to another.
Thus, the refrigerant’s kinetic energy (velocity) is converted to static
energy (or static pressure). Refrigerant, now at a higher pressure,
collects in a larger space around the perimeter of the compressor called
the volute. The volute also becomes larger as the refrigerant travels
through it. Again, as the size of the volute increases, the kinetic energy is
converted to static pressure.

In this example centrifugal compressor, refrigerant vapor is drawn into the compressor and enters the center
of impeller. This particular centrifugal compressor uses multiple impellers to perform the compression process
in stages. The impellers rotate on a common shaft that is connected to the motor.
In the air-conditioning industry, centrifugal compressors are most commonly used in prefabricated water
chillers ranging from 100 to 3,000 tons [350 to 10,500 kW].

II. EVAPORATORS

Evaporator is a heat exchanger that removes heat from the product, via the liquid refrigerant. The liquid or
wet refrigerant contained within the evaporator is boiling at a low-pressure and temperature.
Condenser is on the high pressure side of the refrigeration system.

To enable the transfer of heat, the temperature of the liquid refrigerant must be lower than the temperature
of the product being cooled. Once transferred, the liquid refrigerant is drawn from the evaporator by the
compressor via the suction line. When leaving the evaporator coil the liquid refrigerant is in vapour form.
Different types of evaporators are used in different types of refrigeration applications and accordingly they
have different designs. The evaporators can be classified in various ways depending on the construction of the
evaporator, the method of feeding the refrigerant, the direction of circulation of the air around the
evaporator, etc. Here we have classified the evaporators based on their construction.

Evaporator Construction
The evaporators used for the refrigeration and the air conditioning applications have different types of
construction depending on the application. Based on their construction the various types of evaporators are:
(1) Bare Tube Evaporator
(2) Plate Type of Evaporator
(3) Finned Evaporator
(4) Shell and Tube Evaporator

1.) Bare Tube Evaporators

The bare tube evaporators are made up of copper tubing or steel pipes.
The copper tubing is used for small evaporators where the refrigerant other
than ammonia is used, while the steel pipes are used with the large
evaporators where ammonia is used as the refrigerant. The bare tube
evaporators are used in very few applications.
Bare Tube Evaporators
2. ) Plate Type of Evaporators
In the plate type of evaporators the coil usually made up of copper or aluminum is embedded in the plate
so as so to form a flat looking surface. Externally the plate type of evaporator looks like a single plate, but
inside it there are several turns of the metal tubing through which the refrigerant flows. They are more rigid
as the external plate provides lots of safety. The external plate also helps increasing the heat transfer from
the metal tubing to the substance to be chilled. Further, the plate type of evaporators are easy to clean and
can be manufactured cheaply.

Plate Evaporators

3.) Finned-Tube Evaporators

The finned-tube evaporators are the bare tube type of

evaporators covered with the fins. When the fluid (air or water) to
be chilled flows over the bare tube evaporator lots of cooling
effect from the refrigerant goes wasted since there is less surface
for the transfer of heat from the fluid to the refrigerant. The fluid
tends to move between the open spaces of the tubing and does
not come in contact with the surface of the coil, thus the bare
tube evaporators are less effective.

The fins on the external surface of the bare tube evaporators

increases the contact surface of the of the metallic tubing with
the fluid and increase the heat transfer rate, thus the finned
evaporators are more effective than the bare tube evaporators.

The finned-tube evaporators are most commonly used in the air conditioners of almost all types like window,
split, packaged and the central air conditioning systems.
4.) Shell and Tube Evaporators
The shell and tube types of evaporators are used in the large refrigeration and central air conditioning
systems. The evaporators in these systems are commonly known as the chillers. The chillers comprise of large
number of the tubes that are inserted inside the drum or the shell. Depending on the direction of the
flow of the refrigerant in the shell and tube type of chillers, they are classified into two types: dry expansion
type and flooded type of chillers.

4.1 Shell and Tube Evaporators: Dry Expansion Type

In dry expansion chillers the refrigerant flows along the tube side and the fluid to be chilled flows along the
shell side. The flow of the refrigerant to these chillers is controlled by the expansion valve.

4.2 Shell and Tube Evaporators: Flooded Evaporator Type

In case of the flooded type of evaporators

the refrigerant flows along the shell side
and fluid (such as water) to be chilled flows
along the tube. In these chillers the level of
the refrigerant is kept constant by the float
valve that acts as the expansion valve also.
Shell and Tube Evaporators: Flooded Evaporator Type

III. CONDENSERS

Condenser is a heat exchanger that reduce the temperature and change the state of superheated
refrigerant from compressor to liquid by rejecting system (refrigerant) heat to a cooling medium (air or water).

Rejects sensible heat by desuperheating vapor refrigerant from the compressor and sub-cools refrigerant at
the outlet of the condenser. Condenser is on the high pressure side of the system.

Three main types of condensers: (1) Air cooled condensers; (2) Water cooled condensers; (3) Evaporative
condensers.

Air Cooled Condenser

Air cooled condensers are used in small units like household refrigerators, deep freezers, water coolers,
window air-conditioners, split air-conditioners, small packaged air-conditioners etc. These are used in plants
where the cooling load is small and the total quantity of the refrigerant in the refrigeration cycle is small.
2.) Water Cooled Condenser

Water cooled condensers: Water cooled condensers are used for large refrigerating plants, big packaged
air-conditioners, central air-conditioning plants, etc. These are used in plants where cooling loads are
excessively high and a large quantity of refrigerant flows through the condenser.

There are three types of water cooled condensers: tube-in-tube or double pipe type, shell and coil type
and shell and tube type. In all these condensers the refrigerant flows through one side of the piping while the
water flows through the other piping, cooling the refrigerant and condensing it.

TUBE-IN-TUBE. The tube-in-tube condenser is sometimes called a double pipe or coaxial condenser. Its name
reflects its design. A tube is placed within a larger tube and the ends of the larger tube are sealed. Water is
circulated through one of the tubes, while the refrigerant flows through the other.

SHELL AND COIL. The shell and coil condensers are used in system up to 50 TR capacity. The water flows
through multiple coils, which may have fins to increase the heat transfer coeficient. The refrigerant flows
through the shell.

Tube-In-Tube Condenser Shell and Coil Condenser

SHELL AND TUBE. In shell and tube condenser water runs inside tubes, while water runs inside shell.
WATER COOLED CHILLER DIAGRAMS
3.) Evaporative Condenser

Evaporative condensers are usually used in ice

plants. They are a combination of water cooled and air
cooled condensers. In these condensers the hot
refrigerant flows through the coils. Water is sprayed
over these coils. At the same time the fan draws air from
the bottom side of the condenser and discharges it from
the top side of the condenser. The spray water that
comes in contact with the condenser coil gets
evaporated in the air and it absorbs the heat from the
condenser, cools the refrigerant and condenses it.

IV. THROTTLING OR EXPANSION DEVICES

Throttling device is another vital part of all the refrigeration systems and air conditioning systems apart from
the compressor, condenser and the evaporator.

The throttling valve is fitted between the condenser and the evaporator. In the throttling valve the pressure
and the temperature of the refrigerant is reduced drastically and suddenly. Thus us it is the throttling valve
where the temperature of the refrigerant is reduced and it is then able to produce the cooling effect in the
evaporator of the refrigerator or the cooling coil of the air conditioner.

The throttling valve also controls the amount of the refrigerant that should enter into the evaporator
depending on the refrigeration load.

Some of the most commonly used types of throttling valves are:

1) Capillary tube
2) Constant pressure or automatic throttling valve
3) Thermostatic expansion valve
4) Float valve
Capillary Tube

Capillary tubes are the simplest of all refrigerant flow controls, with
no moving parts. They are normally consist only of a copper pipe,
diameter 0.5 to 1.5 mm and length 1.5 to 6 m. The decrease in
pressure of the refrigerant through the capillary depends on the
diameter of the capillary and the length of the capillary. The smaller is
the diameter and the more is the length of the capillary, the more is
the drop in pressure of the refrigerant as it passes through it.

Capillary tubes are fixed or non-adjustable metering devices that

means one cannot control the flow of the refrigerant through it as
one can do in the automatic throttling valves.

Capillary tubes can be found on small, high-volume commercial systems

such as household refrigerators, but can also be used for larger systems
if the operating conditions are relatively stable. The capillary tube is
vulnerable to clogging, which is why a filter drier and filter are normally
mounted before the inlet.

Capillary tubing is used for small refrigerating and air-conditioning systems like household refrigerators, water
coolers, deep freezers, window air-conditioners, split air-conditioners, small packaged air-conditioners etc.

Constant Pressure Expansion Valve or Automatic Expansion Valve

Constant Pressure Expansion Valve or Automatic

Expansion Valve
The constant pressure expansion valve keeps the
pressure inside the evaporator constant, hence the
name. The constant pressure valve maintains
constant pressure inside the evaporator no matter
what the load inside the evaporator is. It does not
allow the control of the flow of the refrigerant
through it even when lesser or more refrigerant is
required in the evaporator since the primary
function of the constant pressure valve is to
maintain constant pressure inside the evaporator.
Thermostatic Expansion Valve or TXV or TEV

Thermostatic expansion valve or TEV is one of the most commonly used throttling devices in the refrigerator
and air conditioning systems. The thermostatic expansion valve is the automatic valve that maintains proper
flow of the refrigerant in the evaporator as per the load inside the evaporator. If the load inside the
evaporator is higher it allows the increase in flow of the refrigerant and when the load reduces it allows the
reduction in the flow of the refrigerant. This leads to highly efficient working of the compressor and the whole
refrigeration and the air conditioning plant.

Thermostatic Expansion Valve

The thermostatic expansion valve performs following functions:

1.) Reduce the pressure of the refrigerant: The first and the foremost function of the thermostatic expansion
valve is to reduce the pressure of the refrigerant from the condenser pressure to the evaporator pressure
with corresponding refrigerant saturation (or evaporating) temperature lower than the product or space
to be cooled.

2.) Keep the evaporator active: The thermostatic expansion valve allows the flow of the refrigerant as per the
cooling load inside it. At higher load the flow of the refrigerant is increased and at the lower loads the flow
is reduced. The TEV constantly modulates the flow to maintain the superheat for which it has been
adjusted.

3.) Allow the flow of the refrigerant as per the requirements: This is
another important function of the thermostatic expansion valve. It
allows the flow of the refrigerant to the evaporator as per the load
on it. This prevents the flooding of the liquid refrigerant to the
compressor and efficient working of the evaporator and the
compressor and the whole refrigeration plant.

Beside the capillary tube, the thermostatic expansion valve is used

widely in the refrigeration and air conditioning systems. While the
capillary tube is used in the small domestic systems, the
thermostatic expansion valve is used in the systems of higher
capacities. It is commonly used in the industrial refrigeration plants,
high capacity split air conditioners, packaged air conditioners,
central air conditioners and many other systems.
Float Valve

The float valve is used as the throttling device in the large refrigeration systems. There are two types of float
valves: low side float valves and high side float valves.

Low Side Float Valves

The low side float type of the throttling valve is usually used in the shell and tube flooded type of the
refrigeration plants. It maintains the constant level of the liquid in the flooded evaporator irrespective of the
pressure and the temperature inside it.

High Side Float Valve

While in the low side float valve the float chamber is placed in the evaporator on low pressure side, in the high
pressure side float valve and the float chamber is placed on the high pressure side between the condenser
and the evaporator. In low side float valve the valve opens as the level of the refrigerant drops in the
evaporator, but in high side float valve the valve opens when the level of the refrigerant increases in the
chamber.
Other Components of Refrigeration System

A refrigeration system contains a minimum of four key components: compressor, condenser, metering device
or expansion device and evaporator. However, in practice the systems are much more complicated. A number
of components make the system more efficient, reliable or controllable, as shown in figure below. Many of
these components must be selected with care, because they can have a negative influence on the system if
they are incorrectly selected or mounted. The most important components are described below.

1.) FILTER-DRIERS

Filter-driers are devices used in a HVAC system that are a combination of

filter and dryer (or drier). A filter is used to remove any particle such as dirt,
metal or chips from entering the refrigerant flow control. The refrigerant
flow control device could be thermostatic expansion valve or simply a
capillary tube.

The filter is sometimes also referred to as a strainer. It is critical that these

particles are filtered out and prevented from going into the metering device.
It can cause blockage to the passage flow of the refrigerant in the expansion
valve and cause improper operation to the system.
A drier as its name imply is used to remove the moisture from the refrigerant. Sometimes it is also
referred to as dehydrator or dryer. It is necessary to remove moisture from the system otherwise it may
freeze inside the tube causing the flow of refrigerant to be restricted. The moisture will also cause the
formation of acids and sludge when in contact with oil in the system.

Types of Filter-Drier
There are basically two types in used today.
 Liquid Line Type
 Suction Line Type

Liquid Line Type is placed after the condenser coil and

before the expansion valve. The liquid refrigerant that
flows from the condenser to the expansion valve is
filtered from particles and moisture before entering it.

Suction Line Type is placed after the evaporator and

before the compressor. This device is used to protect
the compressor especially after any failure that
contaminates the system.
Motor failure in the compressor usually cause acid and
other contaminants to be introduced into the
refrigerant system hence it is important to have the
suction line filter dryer installed.

The Suction Line Filter-Drier method of cleaning up a system after a hermetic motor burnout is favored by
service technicians and recommended by manufacturers throughout the HVAC and refrigeration industry.
This method gives the most practical and positive protection of the new compressor, since the refrigerant
lubricant mixture is filtered and purified just before it returns to the compressor. It is important that all
contaminants remaining in the system be removed to prevent a repeat burnout of the new compressor.

Compressor motor burnout is a very specific mode of failure that may be caused by high temperatures in
the motor windings or discharge area of the compressor. High temperatures break down the motor
winding insulation, which may cause a loss of electrical resistance and result in a short to the ground or
even an open winding

Desiccant Materials Used in a Filter-Drier

The desiccant absorbs the moisture; desiccant material can be solid or liquid. The solid desiccant is silica
gel, activated alumina, zeolites, titanium dioxide whereas the commercial solid desiccant is activated
carbons, metal oxides and specially developed porous metal hydrides.

Silica gel is one of the best performing and commonly used materials in desiccant having its good long-
term stability. However, it is not a heat-resistant material and therefore is only adequate for low-
temperature systems only.

Today’s common driers are capsule charged with a solid desiccant such as activated alumina or zeolite with
acid absorbing capabilities and protect the valve orifice of the thermostatic expansion valve from damage
by fine debris.
2.) SIGHT GLASS

The sight glass is installed closest to the thermostatic

expansion valve so as to determine how much liquid is
present at the expansion valve and being drawn from the filter
drier; it can also be used to indicate the moisture content
present in the refrigerant.

An indication of only liquid means the system is correctly working while the presence of any gas bubbles
means the system is getting short of refrigerant.

Moisture indicating sight glasses have a colour indicator which changes colour when the moisture content
of the refrigerant exceeds the critical value.

Sight glass gives a more accurate reading in a horizontal position and shows up bubbles on the top of sight
glass/moisture indicator. In the vertical position, the refrigerant gas bubbles goes anywhere in the sight
glass/moisture indicator.
Commonly used materials for sight glass are brass metals and for ammonia, it’s steel or cast iron.

3. Liquid Receiver

Liquid receiver stores refrigerant when the system is operating at less

than maximum heat load and is generally designed so that receiver can
hold all of the system charges and still be no more than 80% full. This
allows you to pump down the entire system charge into the receiver
without danger of creating hydrostatic pressure (very high pressures
resulting from full liquid expansion) in the receiver. Receivers are
installed after the condenser.

The multi-position service valve at the outlet of the receiver is called a

“king valve” and can be used for refrigerant circuit access as well as
fully front seated (turned clockwise) for pump down.
4. Accumulator or Suction Accumulator

A suction accumulator is used to prevent liquid refrigerant flood-back to the compressor. Accumulators
are commonly used on heat pumps, transport refrigeration systems, low-temperature supermarket
refrigeration systems, and in any situation where liquid refrigerant is a concern.

The accumulator is installed in the suction line, close to the compressor. It usually is a vertical container
with top connections. An internal U-tube reaching down near the bottom is installed on the compressor
outlet connection so that the tube inlet is near the top of the container. This allows the accumulator to be
almost completely full before flood-back can occur.

A small hole is drilled in the U -tube near its lowest point. This hole allows controlled meter of any liquid
refrigerant or oil back to the compressor with a siphoning action. That hole is generally covered in a screen
to keep the hole from plugging and preventing oil return. Accumulators need to be kept clean and free of
debris or that screen at the bottom of the U-bend can potentially block as well which is why the
accumulator should be emptied and flushed when a system has a significant burnout or another type of
contamination event.

5. Oil Separator
The function of an oil separator is to separate oil from the hot gas in the discharge line and return it to the
compressor crankcase or to the oil reservoir in systems with multiple compressors.