Refrigeration system with Refrigeration chamber Introduction Identifying faults in refrigeration systems requires comprehensive knowledge. This knowledge also includes the design and purpose of the individual components. This apparatus helps to acquire this knowledge. The components of a refrigeration circuit with refrigeration and refrigeration chambers are arranged clearly in the trainer. Solenoid valves enable the individual or parallel operation of the evaporators in the chamber. The circuit is equipped with a combined pressure switch for the delivery and intake side of the compressor. The refrigeration chamber features an evaporation pressure controller. The effect of the evaporation pressure controller on the overall process is being examined. An inner heat exchanger in the inlet of the evaporator is used for super cooling the refrigerant to increase the efficiency of the process. At the same time the intake gas is supetheated. An electric defrost heater is available to defrost the freezing chamber. The simulation of 18 different faults, e.g. faulty solenoid valves or faulty relays, is provided for. ‘The process schematic at the trainer offers a quick overview. Signal lamps in the process schematic indicate the operating state of selected components. Relevant measured values are recorded by sensors. The measured values can be read on digital displays. At the same time, the measured values can also be transmitted directly to a PC via USB. The data acquisition software is included, The most important pressures are additionally indicated with manometers directly at the trainer. The software enables the representation of the cyclic process in the log p-h diagram. The well-structured instructional material sets out the fundamentals and provides a step-by-step guide through the experiments, Fig, 1- Refrigeration System with Refrigeration ChamberRefrigeration System ‘The basic ‘refrigeration system components include compressor, condenser, evaporators, expansion devices, filter/Drier, sight glass and check valve and a refrigerant gas filled the system. Compressor ‘A hermetically sealed compressor, housing a motor and a reciprocating compressor assembly in the same welded body, which is common in most of the small refrigerators and air conditioners, has been used. The compressor receives the low pressure gaseous refrigerant from the evaporator/s exit and compresses it to the desired high pressure for feeding into the condenser inlet as superheated gas. Condenser The air cooled type condenser with a fan is made up of copper tubing with aluminum fins for efficiently removing heat from the hot refrigerant at high pressure, The first part of the condenser coil’ removes superheat of the refrigerant gas and cools it to liquid phase, while the second part connected to the first part; sub cools the liquid refrigerant to discharge it as a high pressure sub cooled liquid. Specifications of the condenser used are: Air cooled type with fan Expansion Device Capillary Tube expansion device/s, made up of a long minute bore capillary in the form of a coil is used to reduce the liquid refrigerant pressure due to friction and area reduction, The liquid refrigerant received from the condenser is expanded in the capillary coil/s to the evaporator pressure for feeding into the evaporator/s as low pressure cold liquid. Evaporator Evaporator is made up of copper tubing with aluminum fins, which receives sub cooled liquid refrigerant from the expansion device and heats it by absorbing heat from the cold chamber of refrigerated space. The low pressure refrigerant, because of its low pressure boils in the evaporator tubing and is vaporized to gaseous phase, leaving the evaporator as supetheated gas for feeding to the compressor. In the present system two evaporators, one for the refrigerator compartment and the other for the freezer compartment have been used. The refrigerant coming out from the second evaporator is delivered to the compressor suction line through a check valve for avoiding backflow and maintaining appropriate pressures. ‘quid Receiver A liquid receiver is fitted in the liquid refrigerant line to receive and store sufficient liquid for supply to the capillary expansion device. It ensures that only liquid refrigerant shall enter the capillary for proper expansion, and it also prevents the liquid accumulation in the condenser for its efficient operation, Specifications of the liquid receiver used are: HFC R134aFilter/Drier ‘A capsule shaped filter/drier unit is installed in the liquid refrigerant tine before the expansion device inlet for reducing the water content of the refrigerant and straining the fine debris of the drying agents included in the drier, Specifications of the filter/drier used are: Sight Glass A sight glass is fitted in the liquid refrigerant line, after the filter/drier, which gives a visual indication of the presence of liquid refrigerant quantity. In normal system operation, the sight glass shows only liquid. However if bubbles are seen in the sight glass, it is an indication of the shortage of refrigerant in the system; due to leakage ete. Check Valve Check valve or non-return valve allows only unidirectional flow of refrigerant from the colder evaporator for maintaining the differential pressures in the two evaporators. Refrigerant Refrigerant is the working fluid used in vapor compression system, which is capable of absorbing heat from the air or commodities stored in the refrigerator or freezer compartments, while ‘passing through the evaporator and rejecting the~ heat to the atmosphere, while passing through the evaporator. The refrigerant boils at low temperature in the evaporator coils because of the lowering -of its boiling point at low pressure after expansion and after absorbing heat in the evaporator it turns into supetheated gas. The boiling point of the refrigerant is increased with the increase of pressure due to compression, due to which it rejects heat during passage through condenser tubing and ‘turns into liquid." Specifications of refrigerant used are: Control System Components and Instruments Thermostat A thermostat is a device that monitors the temperature of a system component and at a preset maximum or minimum value generates an electrical control signal to operate a switching device, In the present system two thermostats have been used for monitoring the temperatures of the refrigerator and freezer compartments, which selectively operate switching devices at pre-set temperatures to stop refrigerant supply to the respective evaporators by blocking the refrigerant path with a solenoid valve and shutting down the compressor. ‘Temperature Gauge A temperature gauge is a device that continuously monitors and measures the temperature of a system component. In the present system a number of temperature gauges have been used for monitoring and measuring temperature of various system components as shown in the refrigeration circuit diagram.Note: Digital thermometer range is up to 70°C Pressure Gauge A pressure gauge is an instrument for continuously monitoring and measuring the pressure of the working fluid in a fluid line, In the present system two pressure gauges have been used, which measure the pressure of the refrigerant before entering the compressor and after leaving the compressor. Voltmeter The volt meter is installed to monitor the electric circuit voltage during the system operation, Ammeter Ammeter is installed to monitor the circuit during the system operation, ireuit Breaker The circuit breaker is provided to shut down the system in case of a malfunctioning. Caution It is highly advisable to keep the switch panel locked and the switches should be operated by the instructor/operator only in the prescribed manner. In no case the students should be allowed to operate the switch, Precautions 1. Compressor. Evaporator Fan and Condenser Fan should be ON at the time observations are recorded. Keep all hand shut OFF valves tight close until not required, Do not touch the copper tubing because it may cause leakage of refrigerant from the system, Run the system quite some time before take reading, The system should not switch OFF immediately after once switched ON, If digital temperature gauge reading reaches 50 oC, note the reading The values of all observations are dependent on the ambient temperature and the fault duration. dawsRefrigeration Circuit Diagram ConolVahe ——experson Vole Fenraperator Compressor Convol vale Fig 1: Refrigeration Circuit Diagram The coefficient of performance or COP (sometimes CP) of a heat pump is a ratio of heating or cooling provided to work required. Higher COPs equate to lower operating costs. The COP may exceed 1, because, instead of just converting work to heat (which, if 100% efficient, would be a COP of 1), it pumps additional heat from a heat source to where the heat is required. For complete systems, COP should include energy consumption of all auxiliaries. COP is highly dependent on operating conditions, especially absolute temperature and relative temperature between sink and system, and is often graphed or averaged against expected conditions The equation is: Where «Qs the heat supplied to or removed from the reservoir. + W isthe work consumed by the heat pump.The COP for heating and cooling are thus different, because the heat reservoir of interest is different. When one is interested in how well a machine cools, the COP is the ratio of the heat removed from the cold reservoir to input work. However, for heating, the COP is the ratio of the heat removed from the cold reservoir plus the input work to the input work: +0 COPheating = 2h [eels Where + Qcis the heat removed from the cold reservoir. + Qiris the heat supplied to the hot reservoirEXPERIMENT 5 Objective To observe the effect of blocked evaporator Air path or fan failure on refrigeration process. Apparatus Refrigeration system with Refrigeration Chamber Theory ‘An evaporator is used in an air-conditioning system to allow a compressed cooling chemical, such as R-22 (Freon) or R-410A, to evaporate from liquid to gas while absorbing heat in the process. It can also be used to remove water or other liquids from mixtures. The process of evaporation is widely used to concentrate foods and chemicals as well as salvage solvents. In the concentration process, the goal of evaporation is to vaporize most of the water from a solution which contains the desired product. In the case of desalination of sea water or in Zero Liquid Discharge plants, the reverse purpose applies; evaporation removes the desirable drinking water from the undesired product, salt. One of the most important applications of evaporation is in the food and beverage industry. Foods or beverages that need to last for a considerable amount of time or need to have certain consistency, like coffee, go through an evaporation step during proce: ‘Types of Evaporators ‘Natural/forced circulation evaporator: Natural circulation evaporators are based on the natural circulation of the product caused by the density differences that arise from heating. In an evaporator using tubing, after the water begins to boil, bubbles will rise and cause circulation, facilitating the separation of the liquid and the vapor at the top of the heating tubes. The amount of evaporation that takes place depends on the temperature difference between the steam and the solution. Problems can arise if the tubes are not well-immersed in the solution. If this occurs, the system will be dried out and circulation compromised. In order to avoid this, forced circulation can be used by inserting a pump to increase pressure and circulation. Forced circulation occurs when hydrostatic head prevents boiling at the heating surface. A pump can also be used to avoid fouling that is caused by the boiling of liquid on the tubes; the pump suppresses bubble formation. Other problems are that the residing time is undefined and the consumpt is very high, but at high temperatures, good circulation is easily achieved Falling film evaporato1 This type of evaporator is generally made of 4-8 m (13-26 ft) tubes enclosed by steam jackets. The uniform distribution of the solution is important when using this type of evaporator. The solution enters and gains velocity as it flows downward. This gain in velocity is attributed to thevapor being evolved against the heating medium, which flows downward as well. This evaporator is usually applied to highly viscous solutions, so it is frequently used in the chemical, food, and fermentation industries. 1g film (Long Tube Vertical) evaporat In this type of evaporator, boiling takes place inside the tubes, due to heating made (usually by steam) outside the same. Submergence is therefore not desired: the creation of water vapor bubbles inside the tube creates an accessional flow enhancing the heat transfer coefficient. This type of evaporator is therefore quite efficient, the disadvantage being to be prone to quick scaling of the internal surface of the tubes. This design is then usually applied to clear, non-salting solutions. Tubes are usually quite long, typically 4+ meters (13+ ft). Sometimes a small recycle is provided. Sizing this type of evaporator is usually a delicate task, since it requires a precise evaluation of the actual level of the process liquor inside the tubes. Recent applications tend to favor the falling-film pattern rather than rising-film. Climbing and falling-film plate evaporators have a relatively large surface area, The plates are usually corrugated and are supported by frame. During evaporation, steam flows through the channels formed by the free spaces between the plates. The steam alternately climbs and falls parallel to the concentrated liquid. The steam follows a co-current, counter-current path in relation to the liquid. The concentrate and the vapor are both fed into the separation stage where the vapor is sent to a condenser. This type of plate evaporator is frequently applied in the dairy and fermentation industries since they have spatial flexibility. A negative point of this type of evaporator is that itis limited in its ability to treat viscous or solid-containing products. There are other types of plate evaporators, which work with only climbing film. Procedure Turn the main power supply including Compressor, Condenser Fan and Evaporator Fan ON. After 15 minutes take the readings of temperatures and pressures. Then OFF the Evaporator Fan or block the way of air to the Evaporator After 5 minutes take the readings of temperatures and pressures, ‘Then compare the results by calculating COP.Readi and Calculations: ‘Normal Conditions Faulty Condition ‘Ambient Temp CC) 25 m4 Chamber Temp. CC) 16.7 115 Pressure before Compression (bar) 1s 1 Pressure alter Compression (bar) 5 3 Pressure before expansion (bar) 84 74 Pressure after Expansion (bar) 2 1 Temp after Compression °C) 40 26.3 ‘Temp before Compression (°C) 4 “85 ‘Temp before expansion °C) 38 34 Temp afier Expansion (°C) 1 24 COP 4.698 6.133HFC-134a Pressure-Enthalpy Diagram (SI Units) = -20°C temperature Pressure (MPa) 400 Enthalpy (kJ/kg)Sampl ¢ Calcalakin a Far Normal Condition Frem Ph-gragh : hy = 394 7onl/Iy he = 4.204 ug lyzhy = 256. 24 KI} Hg We kintw -thel 2 aS cop = hichy = 34-10-2607 h. -hy 424-200-307 fc - 46738 | For Fully lenditror ; hy = BABU ng hy xhy = AHO ES/1q We tow thet Te COP = hi-ty _ SO/9 — 220 I —hy YT 343 0p = bP 20 Ha!Comments and Conclusions: The solution containing the desired product is fed into the evaporator and passes across a heat source, The applied heat converts the water in the solution into vapor. The condenser condenses the separated vapor, then the vacuum or pump provides pressure to increase circulation. The process of evaporation is widely used to concentrate foods and chemicals as well as salvage solvents, We have observed that, If the fanis not running, unplug the refrigerator and remove the evaporator fan cover. In many cases the problem is do to the fact that the evaporator fan cannot operate freely due to an ice buildup on the fan blades.