SUPERVISED INDUSTRIAL TRAINING

at HVACR System (Direct Fired Vapor Absorption Chiller/Heater) and

Installation of New DF Vapor Absorption Chiller/Heater

Session: 2017-2021
Mubashir Shehzad
2017-BT-MECH-713

Department of Mechanical Engineering

Mechanical Engineering and Technology Program
Muhammad Nawaz Sharif
University of Engineering and Technology, Multan Pakistan
 CERTIFICATE
This report entitled “SUPERVISED INDUSTRIAL INTERNSHIP REPORT” is going to approve by
the Department of Mechanical Engineering & Technology Muhammad Nawaz Sharif University of
Engineering & Technology Multan in partial fulfilment of the, Bachelor’s degree in Mechanical
Engineering Technology is hereby approving.

Name: Mubashir Shehzad

Enrollment #: 2017-BT-MECH-713
Sr. No. Industry (full name) Starting Date Ending Date Duration
1 Arslan Poultry 09-10-2020 20-06-2021 32 Weeks
Rahim Yar Khan

Miss Misbah Niamat

In-charge Tours and Internships,
Mechanical Engineering Department.

Miss Sania Azam

Head of Mechanical Engineering Department
 ABSTRACT
There are two basic types of gas absorption chillers:
Absorption systems and gas engine driven chiller systems. This project report deals
specifically with gas absorption systems. These guidelines are intended to be a step forward a
comprehensive approach to design specifications, which encompasses the full range of efficiency
options for all types industries.
This advanced project report is based on careful evaluation and analysis of gas absorption
cooling to determine when it is appropriate, how it is best implemented, how cost effective it is, and
how its energy savings are described. These guidelines describe efficiency measures that are more
advanced than standard practise, yet still cost effective in all, or select markets. Design reports are
used by individuals and organisations interested in making industries more energy efficient. It should
be remembered that this project document deals primarily with the comparison of a single efficiency
measure and its baseline. This means that the analysis assumes that all other features of the building
are fixed. This is done primarily for clarity of the analysis, and allows one to focus on the advantages
and economics of the single measure.

i
Dedication
Click here to enter text
 ACKNOWLEDGEMENTS
I express my sincere gratitude to Ali Raza (Site Supervisor) for providing me an opportunity
to work and for his constant guidance and timely suggestions throughout. I am also thankful to Mr.
Shafqat Abbas (Manager Technical) for their valuable guidance and advice.
Finally, I thank all my professors and friends for their support and encouragement without which
this Supervised Industrial Training would not have been possible.

Name: Mubashir Shehzad

Enrollment No: 2017-BT-MECH-713
Department of Mechanical Engineering Technology
MNS University of Engineering and Technology,
Multan
TABLE OF CONTENTS
ABSTRACT i
ACKNOWLEDGEMENTS iii
TABLE OF CONTENTS v
LIST OF FIGS vii
LIST OF TABLES ix
LIST OF EQUATIONS Xi
LIST OF ABBREVIATIONS xiii
Chapter No: 01 17
Company Profile 17
1.1 Company Background 17
1.2 Philosophy 18
1.3 Vision and Mission 18
1.4 Engineering 18
1.5 Training 19
1.6 Future Development 19
Chapter No: 02 20
Introduction of Absorption Chiller 20
2.1 Introduction 20
2.2 Literature Survey 20
2.3 Basic Principle of Absorption Chiller 21
2.3.1 Basic Principle of all Refrigeration and Air Conditioning Plants 21
2.4 How Absorption Chiller Works 21
2.4.1 Basic Principle of Absorption Cooling Machine 22
2.5 Types of Absorption System 24
2.5.1 Single Effect Absorption System 24
2.5.2 Double Effect Absorption System 24
2.5.3 Triple Effect Absorption System 25
2.6 Efficiencies 26
2.7 Advantages and Limitation of Using Absorption Chiller 26
2.7.1 Non-energy Benefits 26
2.7.2 Recent Improvements to Absorption Chiller 26
2.7.3 Limitation 27
Chapter No: 03 28
History and Status 28
3.1 History 28
3.2 Standards and Ratings 30
3.2.1 Coefficient of Performance 30
3.2.2 Integral Part Load Value 31
3.2.3 Applied Part Load Value 32
3.3 Economics/Cost Efficient 32
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3.3.1 Energy Rate and Billing Structure 32
3.3.2 Operating Characteristics 33
3.3.3 Estimating Annual Energy Savings 33
3.4 Size of Absorption Systems 33
3.4.1 High Pressure Steam Fired Vapor Absorption Chiller 33
3.4.2 Low Pressure Steam Fired Vapor Absorption Chiller 34
3.4.3 Hot water Driven Vapor Absorption Chiller 34
3.4.4 Direct Fired Vapor Absorption Chiller 35
3.5 Equipment Manufacturer 35
3.6 List of Equipment Installation 36
Chapter No: 04 37
Design Analysis 37
4.1 Overview 37
4.2 Energy Savings 38
4.3 Cost Efficient 38
4.4 Effective Use of waste heat from Diesel Genset to run AC Plant 39
4.4.1 Analysis of Performance of Vapor Absorption Chiller System 40
4.5 Design Analysis Graphs 42
4.5.1 Using Graphs 42
4.5.2 Annual Energy Cost Savings Graphs 43
Chapter No: 05 44
Installation of Chiller/Heater 44
5.1 Requirements to Maintenance during Installation 44
5.2 Requirements to Machine Room 44
5.3 Installation of Chiller/heater 45
5.3.1 Installation of Assembled Chiller/heater 45
5.3.2 Installation of unit of chiller/heater from split parts 45
5.4 Adjustment of Levelness of Chiller/heater 46
5.5 Insulation of Chiller/heater 46
Chapter No: 06 47
Test Operation of New Installed Chiller/Heater 47
6.1 External Visual Inspection 47
6.1.1 Chiller insulation must be correctly fitted 47
6.1.2 Insulation Checks 47
6.2 Solution Charge 47
6.2.1 Precautions 47
6.2.2 Procedure 47
6.3 Electrical Checks 48
6.3.1 Check the motor insulation Resistance 48
6.3.2 Measuring the Insulation Resistance 48
6.3.3 Precautions 48
6.3.4 Procedure 48
6.4 Initial Control Board and Inverter Settings 49
6.5 Damper Setting and Valve Position 49
6.5.1 Damper Setting 49
6.5.2 Check valve opening status and switch position 49
6.6 Purging of Chiller/Heater 49
6.6.1 Ballast Valve is Closed before Starting 49
6.6.2 Bubble Test 49
6.7 Burner and Fuel Piping 49
6.7.1 Leak Test for Gas Piping and Adjustment of Burner 49
6.8 Function Test 50
6.9 Operation of Chiller/Heater 50
6.9.1 Gas Fired 50
6.9.2 Oil Fired 50
6.9.3 Test Operation for Cooling 50
6.9.4 Operation and Data Record 50
6.9.5 Absorbent Sampling 50
Chapter No: 07 51
Check List 51
7.1 External Visual Inspection 51
7.2 Verify field wiring and wiring of palladium cell heater 51
7.3 Check of insulation resistance of motors 52
7.4 Check of control board safety and switch settings 52
7.5 Check of purge pump 52
Chapter No: 08 53
Conclusion and Future Recommendation 53
8.1 Conclusion 53
8.2 Future Recommendation 53
References 54
LIST OF FIGURES
Figure No Name page No
1.1 Schematic of the Principle of an absorption chiller 22
1.2 Schematic cycle of Double effect Absorption Chiller 23
1.3 Single-Effect Absorption Refrigeration Chiller 24
1.4 Double-Effect Absorption Refrigeration Chiller 25
1.5 Tripple-Effect Absorption Refrigeration Chiller 25
3.1 Absorption Chiller Market Conditions 28
3.2 High Pressure Steam Fired Vapor Absorption Chiller 34
3.3 Low Pressure Steam Fired Vapor Absorption Chiller 34
3.4 Hot Water Driven Vapor Absorption Chiller 35
3.5 Direct Fired Vapor Absorption Chiller 35
3.6 Industry-wise Ton Refrigeration(TR) Installation 36

ix
LIST OF TABLES
Table No Table Name page No
1.1 Typical Value of Electric Chiller and Absorption Chiller 26
3.1 Cost Benefit Analysis of Vapor Absorption Chiller 29
3.2 Cost Benefit Analysis of Reciprocationg Chiller 30
3.3 IPLV Calculation Assumptions 31
3.4 High Pressure Steam Fired Vapor Absorption Chiller 33
3.5 Low Pressure Steam Fired Vapor Absorption Chiller 34
3.6 Hot Water Driven Vapor Absorption Chiller 34
3.7 Direct Fired Vapor Absorption Chiller 35
4.1 Cities Used for Cooling Analysis 37
4.2 Building Type and Size 38
4.3 Cooling Equipment Type Based on Size 38
4.4 Cooling Equipment Efficiencies 39
4.5 Cooling Potential Based on Engine Rating 42

xii
LIST OF EQUATIONS
Equation No Equation page No
3.1 Integral Part Load Value Equation 31
LIST OF ABBREVIATIONS
DF Direct Fired
LiBr Lithium bromide
COP Coefficient of Performance
LTHE Low Temperature Heat Exchanger
HTHE High Temperature Heat Exchanger
HP High Pressure
LP Low Pressure
DCC Double Condenser Coupled
CFC
HCFC
VFD Variable Frequency Driver
TR Ton of Refrigeration
FY Final Year
IPLV Integral Part Load Value
APLV Applied Part Load Value
O&M Operation and Maintenance
HVACR Heat Ventilation and Air Conditioning and Refrigeration
CDD Cooling Degree Day
SIR Saving to Investment Ratio
LCC Life Cycle Cost
CHPC Combined Heating Power and Cooling

xv
1 No Chapter:

Company Profile
Xperts Electromechanical Engineering Solutions
1.1 Company Background: (PVT) Ltd Established in January, 2018. Xperts
Electromechanical Engineering Solutions (PVT) Ltd has gone
from strength to strength. In the founding year the owners
used their enhanced knowledge & skills to build a business
based on superb technical ability, outstanding customer
service and a desire to build a business that would grow and
succeed in the retail market place. This happened because of
the regular re-investment back into the business, creating the
perfect conditions to provide a solid financial base from which
the company could expand.
Xperts Electromechanical Engineering Solutions has
started its operations from a single room was located in one of
the most densely populated parts of the Lahore. In order to
meet the customer’s needs & provide more value-added
products with quality services at reasonable cost & quality
services, As Xperts Electromechanical Engineering Solutions
(Pvt.) Ltd. is working on the philosophy of “Continuous
Improvement & Development”, we continually work on
updated manufacturing & design set-up with well-trained team
of Engineers.
By identifying a need in the market place for
contracting services that could be ‘bought’ in, Xperts
Electromechanical Engineering Solutions (Pvt.) Ltd. created
the platform from which to develop the business further.
Existing refrigeration companies had gone through a
challenging period and the use of sub-contract engineers
allowed Xperts Electromechanical Engineering Solutions
(Pvt.) Ltd. to maximize revenues during this period. An
opportunity to provide integrated design solutions, installation
works, reactive service and planned maintenance for the
refrigeration, HVAC and electrical services of an ever-
expanding customer estate.
Building on the success of the contracting services
provided, Xperts Electromechanical Engineering Solutions
(Pvt.) Ltd. soon identified an opportunity to encompass
innovative design solutions with a focus on plant noise and
physical constraints on site. The company can now provide a
complete selection of standard and individually designed plant
solutions to meet with end users’ needs. Xperts
Electromechanical Engineering Solutions (Pvt.) Ltd. is also
proud to have a training & testing facility - developed as an
identified need to train engineers professionally to the
exacting standards expected by end users and to give the
engineers the knowledge of new and ever-changing
developments within the refrigeration and air conditioning

17
industry.

18
1.2 Philosophy:
Our philosophy is based on long term partnership with our customers, working together as a
team, to make our work better, easier and more efficient. The commitment of the company is to
provide our customers optimized solutions, offering the lowest life cycle costs with cutting - edge
products. We also commit our customers dedicated support and services from the design stage until
the replacement of the products.

1.3 Vision and Mission:

 Vision:
The world and the market are changing very fast, which lead us to adapt our products
and processes to meet the latest requirements and regulations. Our strategy is based on
continuous developments on environment friendly and indoor air quality solutions.
Innovation, sustainability and minimum life cycle costs are the key aspects considered
when designing new solutions.
 Mission:
A dynamic, diverse and growth XEES delivering ethical and competitive outsourcing
solutions for our customers through a network of professionals ensuring rewards to our
stakeholders while fulfilling our corporate social responsibilities.

1.4 Engineering:
Xperts Electromechanical Engineering Solutions (Pvt.) Ltd. is proud to offer the following
Engineering disciplines as part of its portfolio of services offered to our clients:
 Refrigeration system design
 Refrigeration contracting services
 Air Conditioning design & installation
 Ventilation & extraction design and installation
 Reactive service provision
 Planned maintenance provision
 Electrical installation works & design
 Electrical compliance
 Refrigeration commissioning provision
 RO Plant installations, Services and supply of all chemicals of RO Plant
 Repairs & Maintenance of all types of Absorption & Electrical Chillers
 Supply of all types of Absorption Chillers Chemicals (Lithium Bromide Solutions,
Inhibitors, Octyle Alcohols, etc.)
 Inline Filtration of Absorption Chillers lithium bromide Solution.
 Supply of Spare parts of Absorption & Electrical Chillers.
Since the company was founded Xperts Electromechanical Engineering Solutions (Pvt.) Ltd.
has gained valuable experience within the following fields for the customers detailed as either a
contractor or supplier of services and equipment.
1.5 Training:
Refers to educational activities within a company created to enhance the knowledge and
skills of employees while providing information and instruction on how to better perform specific
tasks. Xeespl has good instructors for On-Site Training which is a flexible and cost-effective solution
that allows you to train maximum number of employees at a minimal expense to your organization.
On-Site Training is ideal if you have a group of people, would like to customize the content, or need
a consistent message across a global team.

1.6 Future Development:

Xperts Electromechanical Engineering Solutions (Pvt.) Ltd. is very proud of its heritage and
of the customers who have enjoyed the services and skills that the company have provided to them
over the years. Xperts Electromechanical Engineering Solutions (Pvt.) Ltd. has an extremely focused
attitude towards the future and that is reflected in its commitment to developing skills within the
business to shadow changes within the marketplace. This has allowed the business to stay one step
ahead with regard to refrigerant. Xperts Electromechanical Engineering Solutions (Pvt.) Ltd. is
always looking at new technologies as they enter the market place allowing them to communicate
effectively with customers and offer them best possible advice for their own estates.
Xperts Electromechanical Engineering Solutions (Pvt.) Ltd. continues to develop the unique
range of packaged refrigeration solutions which it manufactures to provide the very best in
engineering practice and sensible thinking towards noise impact and containment, space planning
constraints and the key driver of reduced energy consumption.
Xperts Electromechanical Engineering Solutions (Pvt.) Ltd. aspires to be the very best in the
market sectors in which it operates and will always push the envelope to achieve greater things as
time moves forward.
2 No Chapter:

Introduction of Absorption Chiller

2.1 Introduction:
Today’s world is facing two most important environmental problems. They are the energy
crisis and the greenhouse effect. Scientists are working on how to eradicate these problems. Most of
the today’s innovations are based on this fact. Lithium-Bromide and water driven absorption
refrigeration cycle is a burning example of this concept, which not only helps in minimizing the
fossil fuel usage, hence the reduced CO2 gas emission but also utilizes the low-grade heat from
various industries and data centres.
The vapour absorption refrigeration cycle or the absorption refrigerator is a closed loop cycle
that uses low grade heat (waste heat) to provide cooling or refrigeration. It is different from the
conventionally used vapour compression refrigerator in the sense that it works on chemical energy
rather than electrical energy. The absorption refrigerator uses a chemical substance as the absorbent
which absorbs the refrigerant in the absorber and the waste heat is being used to recover the
refrigerant free absorbent and enable it to be reused. (Ammonia + water) and (Lithium-bromide +
water) are the two commercially used working pairs for this kind of refrigerators with their
operability limitations.
In this report, simulation analysis and working of an absorption refrigeration system using the
LiBr + water working pair has been carried out, where water works as refrigerant and LiBr works as
absorbent. The efficiency of this refrigerator is around 1.0 and from the simulation work, the
optimized cycle’s coefficient of performance (COP) has been found out to be 1.0065. This work also
attempts to find out the economic evaluation of this system in comparison to vapour compression
refrigeration cycle. The project work revels that installing an absorption refrigeration system for low
grade heat recovery is beneficial than the vapour compression refrigeration cycle. This thorough
investigation of this commercially used absorption refrigeration system may pave the way to carry
out similar exercise using some novel working pairs to be used in near future.

2.2 Literature Survey:

In the early twentieth century, vapour absorption refrigerators were used extensively taking
ammonia and water as working pairs, but due to the easy availability of electricity and developments
of vapour compression refrigeration cycle, decreased the use of absorption refrigerators. The
outcome of less efficiency is another factor for its minimal use. But still now-a-days, these
refrigerators may find their usage depending on the availability of low-grade heat, solar and
geothermal energy.[1]
A. Yokozeki [1] has first done the modelling of vapour absorption refrigeration using
equation of states. He has considered various refrigerant-absorbent pairs, mainly two conventionally
available pairs i.e., LiBr+water and ammonia+water. Though the development of this kind of
absorption refrigeration system have been carried out since 1932, but this kind of complete
thermodynamic study and computer-based modelling has made other scientists and researchers to
study the different aspects and behaviours of these kinds of working pairs. He has done large number
of experiments to find out the cycle performance of these kinds of refrigerators so that the
temperature, pressure, concentration and enthalpy data have been easily found out.
 In recent developments of thermal engineering, refrigeration technology plays an important
role in their industrial applications. But as far as the COP is concerned, it has always posed
challenges to the researchers in enhancing the efficiencies of these systems. The most popular
refrigeration and air conditioning system at present is the conventional vapour compression systems.
These systems are popular because of their inexpensiveness and reliability. However, these systems
require high grade energy i.e., mechanical or electrical energy for their operations necessitating
depletion of fossil fuel, hence CO2 emission. Besides, it has been found out that the conventional
refrigerants used in these refrigerators are harmful towards environments and cause ozone layer
depletion. Hence the logical alternative is obviously the vapour absorption refrigerator system which
mainly uses low grade heat energy for the operations and acts as a saviour of thermal pollution. The
most interesting thing of these refrigerators is that, they are environment friendly which is the need
of this hour.[2] S. Kaushik has done the analytical work on absorption refrigeration systems to find
out the COP values [2]. He has done most of his works on LiBr+water system and found out all the
state point enthalpy values experimentally

2.3 Basic Principle of Absorption Cooling:

2.1.1 The two basic principles on which all air conditioning and refrigeration plants
operate are:
 When a liquid evaporates, it absorbs heat and when it condenses it gives up that heat. This
heat is called the latent heat of evaporation and latent heat of condensation respectively.
 Boiling point of liquid a pressure i.e., boiling point decreases if pressure decreases and vice
versa
The absorption cooling works on the affinity of some pairs of chemicals to dissolve in one
another. For example, lithium bromide solution has affinity towards water, water has affinity towards
ammonia etc. this affinity depends on two factors – temperature and the concentration of the
solution.

2.4 How an Absorption Chiller Works:

In vapour absorption chillers, a low pressure (vacuum) is maintained in the evaporator. At
this pressure the refrigerant boils at very low temperature. This boiling causes the refrigerant to
absorb the heat from the medium being cooled, thus lowering the temperature. On absorbing the
heat, the refrigerant gets vaporized. The refrigerant vapours thus formed tend to increase the pressure
in the vessel. This will in turn increase the boiling temperature and the desired cooling effect will not
be obtained. So, it is necessary to remove the refrigerant vapours from the vessel. A liquid having
affinity towards the refrigerant vapour is sprayed in the absorber which absorbs the vapour and
maintains the low pressure in the shell.
As the absorbent absorbs the refrigerant vapor, it becomes dilute & losses its capacity to
further absorb refrigerant vapours. To maintain continuous cycle, it is essential that the absorbent is
enriched to its original level of concentration and the refrigerant vapours are condensed to the liquid.
This is achieved by pumping the dilute solution continuously from absorber to the generator. In the
generator the addition of heat boils off the refrigerant from the absorbent and the absorbent regains
its original level of concentration. The re-concentrated absorbent returns to the absorber to resume
the absorption process. The refrigerant vapour released in the generator flows to the condenser. In
the condenser cooling water is circulated through the coils, which picks up the heat carried by the
refrigerant vapour and vapour condenses back to the liquid phase. The condensed liquid is returned
back to the evaporator thus completing the absorption cycle.
2.4.1 Basic Components of an Absorption Chiller/Heater:
The basic Principle of an absorption cooling machine may be illustrated with Figure 1.1. In
its simplest design the absorption machine consists of the following components:
 Evaporator
 Condenser
 Absorbers
 Generators
 Solution heat exchangers
 Hermetically Sealed pumps

Figure 1.1 schematic of the principle of an absorption cooling machine

In an absorption cycle chiller, the absorber, the solution pump and the generator in
combination, instead of a mechanical vapour compressor, effects compressing the refrigerant vapour.
Vapour generated in the evaporator is absorbed into a liquid absorbent in the absorber. The absorbent
that has taken up refrigerant, spent or weak absorbent, is pumped to the generator where the
refrigerant is released as vapour. Which vapour is to be condensed in the condenser? The regenerated
or strong absorbent is then led back to the absorber to pick up refrigerant vapour anew. Heat is
supplied to the generator at a comparatively high temperature and rejected from the absorber at a
comparatively low level, analogously to a heat engine. The words “thermo chemical compressor”
have actually been used in specialised literature to describe the function of the generator and
absorber half of the absorption cycle.
Refrigerant and absorbent in an absorption cycle form what is called a working pair, many
pairs have been proposed through the years but only two of them have widely used: ammonia
together with water as absorbent and water together with a solution of lithium bromide as absorbent.
The ammonia water pair is mostly found in refrigeration applications, with low evaporation
temperatures, below 0 Deg C. the water – lithium bromide pair is widely used for air conditioning
applications, where it is not necessary to cool below 0 Deg. the pressure levels in ammonia and water
are usually above the atmospheric pressure and while the water – lithium bromide machines
generally operate in partial vacuum.
 The heat flows in the basic cycle are the following:
 Heat is supplied, and cooling is produced, at a low temperature level.
 Heat is rejected in the condenser at an intermediate temperature level.
 Heat is rejected from the absorber, also at an intermediate level.
 Heat is supplied to the generator at a high temperature level.
The basic cycle illustrated in Fig1.1 may be modified in several ways. One is to utilise all
possible opportunities from heat recovery within the cycle in order to improve the heat economy
within the cycle. For example, it is customary to heat exchange the streams of weak absorbent
leaving the absorber with the regenerated or strong absorbent that is led back into the absorber.
When all heat recovery opportunities that can reasonably be used have been incorporated into the
design of a machine, one obtains a cooling coefficient of performance of approximately 0.7 for the
water – lithium bromide system and approximately 0.6.
Further improvements may be obtained if one cascades more efficiently the high temperature
heat available to power the generator. The so-called double- effect systems incorporate two
generators- absorber blocks that are staged, see figure 2.2, in order to utilise the heat supplied more
or less twice. Heat is supplied at 170 Deg C to the first generator and heat rejected by the
corresponding condenser is used to power the second generator at a lower level, the temperature 100
Deg C of a single effect machine according to Figure 1.2. The co-efficient of performance of such a
system with water-lithium bromide as working pair may be 1.2, which is significantly better than the
C.O.P of 0.7 of the single-effect systems. It is not double of the single-effect because of imperfect
heat exchange between streams of solutions, to some extent, and because the heat of vaporisation of
the refrigerant is necessarily larger when it evaporates from a solution than when it evaporates from a
pure liquid.

Figure
1.2

Schematic cooling cycle of Double effect Absorption Chiller

2.5 Types of Absorption System:
Absorption chillers are generally classified as
2.3.1 Single Effect Absorption Chiller
2.3.2 Double Effect Absorption System
2.3.3 Triple Effect Absorption Systems
In direct –fired units, the heat sources can be gas or some other fuel that is burned in the unit.
Indirect – fired units use steam or some other transfer fluid that brings in heat from a separate source,
such as boiler or heat recovered from an industrial process. Hybrid systems, which are relatively
common with absorption chillers, combine gas systems and electric systems for load optimisation
and flexibility.

2.5.1 Single Effect Absorption Chiller:

The single-effect “cycle” refers to the transfer of fluids through the four major components of
the refrigeration machine- Evaporator, Absorber, Generator and Condenser, as shown in the pressure
– temperature diagram in figure 1.3. Single – effect LiBr/H2O absorption chillers use low pressure
steam or hot water as the heat source. The water is able to evaporate and extract heat in the
evaporator because the system is under a partial vacuum. The thermal efficiency of single – effect
absorption system is low.
Although the technology is sound, the low efficiency has inhibited the cost competitiveness
of single – effect systems. Most new single-effect machines are installed in applications where waste
heat is readily available. Single –effect chillers can be used to produce chilled water for air-
conditioning and for cooling process water, and are available in capacities from 10 to 1500 tons.

Figure 1.3 Single – Effect Absorption refrigeration cycle

2.5.2 Double Effect Absorption System:

The desire for higher efficiencies in absorption chillers led to the development of double-
effect LiBr/H2O systems. The double effect chiller differs from the single-effect, in that there are
two condensers and two generators to allow for more refrigerant boil –off from the absorbent
solution. Figure 1.4 shows the double effect absorption cycle on a pressure – temperature diagram.
The higher temperature generator uses the externally supplied steam to boil the refrigerant from the
weak absorbent. The refrigerant vapour from the high temperature generator is condensed and the
heat produced is used to provide heat to the low temperature generator.
 Figure 1.4 Double – Effect Absorption refrigeration cycle

These systems use gas fired combustors or high-pressure steam as the heat source. Double-
effect absorption chillers are used for air-conditioning and process cooling in regions where the cost
of electricity is high relative to natural gas. Double-effect absorption chillers are also used in
applications where high-pressure steam, such as district heating, is readily available.

2.5.3 Triple Effect Absorption System:

The triple-effect cycles are the next logical improvement over the double-effect:
Triple-effect absorption chillers are under development, as the next step in the evolution of
absorption technology. Figure 2.5 shows the triple-effect absorption cycle on a pressure-temperature
diagram. The refrigerant vapour from the high and medium temperature generators is condensed and
the heat is used to provide heat to the next lower temperature generator. The refrigerant from all
three condensers flows to an evaporator where it absorbs more heat.

Figure 1.5 Tripple Effect Absorption Cycle

Two different triple-effect absorption chiller cycles are capable of substantial performance
improvements over equivalent double-effect cycles. One uses two condensers and two absorbers to
achieve the triple effect. A second, the double condenser coupled (DCC) triple-effect, uses three
condensers as well as a third condenser sub cooler.
2.6 Efficiencies:
Efficiencies of absorption chillers are described in terms of coefficient of performance
(COP), which is defined as the net refrigeration effect by the net heat input. Single – effect
absorption chillers have COPs of approximately 0.6-0.8 out of an ideal Since the COPs are less than
one, the single-effect chillers are normally used in applications that recover waste heat such as waste
steam from power plants or boilers. Double- effect absorption chillers have COPs of approximately
1.0 out of an ideal while not yet commercially available, protype triple effect absorption chillers 1.0.
have calculated COPs from 1.4 to 1.6. The COP metric is also applied to electric chillers. However,
since COP is based on site energy, it is not good for comparing gas and electric chiller efficiencies. A
better metric is the resource COP, which accounts for the source to site efficiency of the fuel,
accounting for electricity generation and transmission losses. Fig 1.6 shows typical values for both
electric chillers and absorption chillers.

Table 1.6 Typical values of electric chillers & Absorption Chillers

Chiller Site COP Source to Site Factor Resource COP
Electric 2.0-6.1 0.27 0.54-1.65
Absorption 0.65-1.2 0.91 0.59-1.1

2.7 Advantages and limitations of using Absorption chillers:

The primary energy benefit of gas cooling absorption system is reduction in operating costs
by avoiding peak electric demand charges and time of day rates. The use of gas absorption chillers
eliminates the high incremental cost of electric cooling. Natural gas cooling systems have greater
resource efficiency than similar to electric systems. Typical electricity generation and distribution
results in an approximately 65% - 75% loss in the initial energy resource of fuel. In contrast, only
about 5% to 10% of the fuel resource is lost with a gas system. Additionally, electricity costs per
Kwh are typically three to four times the cost per Kwh for electricity, so the cost of a unit of
output(refrigeration) can often be lower with an absorption system. Utilising waste heat that would
otherwise be unused greatly increases the cost effectiveness of the systems, compared to consuming
gas directly.

2.7.1 Non-energy Benefits:

 Eliminations of the use of CFC and HCFC refrigerants
 Quiet, vibration free operation
 Lower pressure systems with no large rotating components
 High reliability and low maintenance

2.7.2 Recent Improvements to absorption chillers:

Since the 1960’s, several improvements have been made to absorption chiller, which include:
 Automatic purge systems eliminating the need for manual purging and lowering the potential
for corrosion.
 Faster system response due to the use of elect controls and solution concentration sensing
 Electronic controls and sensors that make crystallisation of the chiller far less likely than in
the past.
 Absorption chillers can provide water temperature as low as 3.5 Deg C allowing for the use
of reduced air flow and duct size in delivery systems.
2.7.3 Limitation:
 Cost is the primary constraint on the widespread adoption of absorption chiller systems. The
low thermal efficiency of single effect absorption systems has made them non-competitive
except in situations with readily available free waste heat. Even double effect systems are
non-cost effective in many applications. Although absorption chillers can be quite
economical in the right situation, their exact economics must be worked out on a project-by-
project basis.
 Absorption systems also require greater pump energy than electric chillers. The size of
condenser water pump is generally a function of the flow rate per unit cooling capacity. They
require cooling tower capacities approximately 1/3 greater than electric chillers of the same
size.
3 No Chapter:

History and Status

3.1 History:
Absorption systems have been used in air – conditioning applications for over 50 years.
Ammonia – water absorption equipment was found to be well suited for large capacity industrial
applications that required low temperature for process cooling. In the late 1950’s the first working
double-effect lithium bromide – water absorption chiller was built. Lithium bromide –water
absorption equipment is currently used to produce chilled water for space cooling and can also be
used to produce hot water for space heating and process heating.
In the 1960’s the natural gas industry was very effective in promoting this alternative to
electric – driven cooling. Absorption cooling and gas absorption chillers were successfully marketed
on the basis of lower operating costs, and better system performance. Counteracting this, innovations
in compressors, electric motors and controls increased the performance and decreased the cost of
electric cooling systems. Additionally, and perhaps more importantly, the gas crunch of the seventies
curtailed gas cooling promotion and forced prospective buyers to remain with conventional electric
systems. Since 1987 when the Montreal Protocol first came into existence many issues surrounding
electric cooling including the use of CFC refrigerants and electric utility rates, have become
increasingly complicated. Coincident with these electric cooling issues, gas costs have remained
relatively stable while the technology itself has improved.
Indian absorption chiller market for FY 06-07 is estimated at 350 nos and valued at Rs.106 cr
with total TR capacity installed at 70,000
 The total chiller market in India is estimated at 7,000 units and valued at Rs.1800 crores.
 The Indian absorption chiller market is largely driven by industrial process cooling
application.
 Natural gas equipment accounts for 8 to 10 % of the market for larger chillers and this
number is expected to grow.
As a result of rising electric rates and the increased efficiency, reliability and accessibility of gas
equipment Figure 3.1 shows the Absorption cooling market conditions from 2019 – 2027.
Figure 3.1 Absorption chiller market conditions
Table No. 3.1 Cost Benefit analysis of Vapour Absorption Chiller

OPERATIONAL COST ANALYSIS

Description Value Units
Capacity 200 RT
Type of Energy Steam
Specific Steam Consumption 4 Kg/hr-RT
Total Steam/hr 800 Kg/hr
Daily Operation 22 Hrs.
Total Steam Consumption/day 17600 Kg
Cost of Steam 0.6 Rs/Kg
Total Cost of energy/day 10560 Rs.
Power req for M/c per day 85 KW
Cost of Power 4.5 Rs/KW
Cost of Power req for M/c 383 Rs.
Total Operating Cost per day 10943 Rs.
Total Cost of operation per year 3994242 Rs.
Maintenance Cost 25000 Rs.
Total Operational Cost 4019242 Rs.
CAPITAL COST ANALYSIS
Equipment Cost 2683000 Rs.
Description Rate 80%
Description Amount 2146400 Rs.
Saving in Corporate Tax@35% 751240 Rs.
Effective Cost 1931760 Rs.
Table No. 3.2 – Cost Benefit analysis of Reciprocating chillers

OPERATIONAL COST ANALYSIS

Description Value Units
Capacity 200 RT
Type of Energy Electricity
Specific Elec Consumption 0.7 Kg/hr-RT
Total Elec/day 140 Kg/hr
Daily Operation 22 Hrs.
Total Elec Consumption/day 3080 Kg
Cost of Energy 4.5 Rs/Kg
Total Cost of energy/day 13860 Rs.

Total Operating Cost per day 13860 Rs.

Total Cost of operation per year 5058900 Rs.
Maintenance Cost 40000 Rs.
Total Operational Cost 5098900 Rs.
CAPITAL COST ANALYSIS
Equipment Cost 2100000 Rs.
Description Rate 25%
Description Amount 525000 Rs.
Saving in Corporate Tax@35% 183750 Rs.
Effective Cost 1916250 Rs.

3.2 Standards and Ratings:

Currently there are no state or federal standards that regulate gas absorption cooling systems.
However, there are several metrics that are used to define absorption chiller efficiency, including:
3.2.1 COP
3.2.2 IPLV
3.2.3 APLV

3.2.1 Co-efficient of Performance (COP):

The performance of absorption system equipment is usually rated in terms of COP, defined as
the cooling output, or refrigeration effect in BTU, divided by the energy input, in BTU. This same
metric is applied to electric chillers, but since it is based on site energy, it is not good for comparing
gas and electric chiller efficiencies. Gas absorption chillers, as well as electric chillers, are rated to
Air conditioning and refrigeration Institute ARI-550-92 conditions as listed below:
Chilled water conditions:
 44 deg F chilled water supply temperature
 54 deg F chilled water return temperature
 2.4 GPM/ton chilled water flow
Water cooled condensers:
 85 deg F condenser water supply temperature
 95 deg F condenser water return temperature
 3.0 GPM/ton condenser water flow
Air cooled condensers:
 95 deg F air supply
 20 deg F temperature differential between air supply and condensing refrigerant
 deg F refrigeration system loss to the condenser

3.2.2 Integrated Part Load Value (IPLV):

Another measurement of chiller efficiency is integrated part Load Value, IPLV. It is an
industry standard for calculating an annual COP based on a typical load profile and the part load
characteristics of chillers. It was originally conceived as part of ANSI/ASHRAE standard 90.1
(standard for energy Efficient design of New Non-residential and High-rise Residential buildings) in
response to need for directly comparing manufacturer’s part load data. The method assumes that the
chiller operates at a specific part load for a specific number of hours during the year. According to
the following equation:

Table 3.3 IPLV Calculation Assumptions:

Chiller Load Chilled Water Return Mfgr rated COP Part Load Hours
(%) Temperature (F) (%)
100 85 A 1
75 78.75 B 42
50 72.5 C 45
25 66.25 D 12

COP ratings A, B, C, and D at each part load condition are obtained from the chiller
manufacturer and should be derived from actual chiller tests. Note that the calculation allows for a
2.5 Deg C reduction in the entering cooling water temperature for every 10% drop in cooling load. A
lower entering cooling water temperature corresponds to part load (reduced) cooling demand, that
results from a drop in ambient temperature. Although LPLV is a useful way to compare different
manufacturer’s chiller models, it probably doesn’t represent actual operating conditions. For
applications where cooling load is not significantly affected by ambient temperature conditions, (e.g.,
when cooling load is dominated by internal gains) this estimate of part load performance may not
provide accurate results. Chiller performance should be modelled to actual building load profiles
tailored to site- specific ambient conditions.
3.2.3 Applied Part Load value (APLV):
The applied Part Load value, APLV is calculated using the same IPLV formula, except that
actual chilled and condenser water temperatures and flow rates are used. The advantage of using the
APLV over the IPLV, is that this rating more closely approximates actual operating conditions
imposed on the chiller. The disadvantage is the additional performance data that needs to be
collected.

3.3 Economics/cost effectiveness:

The table no. 3.3 shows the economics of absorption systems vs. electric chillers. They are driven
by the additional investment cost and several factors influencing operating cost, including:
 Relative costs of the electricity and gas, and their billing structures.
 Relative performance characteristics.
 Operating characteristics.
 Relative maintenance costs.
The first three factors are discussed in the following sections and combined to produce estimates
of annual energy savings. Annual operating savings include an energy component and a comparison
of O & M costs.

3.3.1 Energy rates and billing structure:

Energy rates and billing structures have major impact on economic evaluations of gas versus
electric cooling equipment. Energy rates include:
 Electric demand, Rs/Kw
 Electric energy, j/Kwh
 Gas Energy rate, Rs/MMBtu (or therms)
It is essential that the complete utility rates and rate structures are used for an accurate economic
analysis. Utility rate structures may include one or more of the following:
Block rates: The electric block rates may be in terms of kWh, with different rates for various
levels of energy consumption. It may also be stated in kWh per kw of demand. In this case kWh rate
is function of demand. A lower demand typically results in a large allowed amount of kWh at a
lower rate. A high demand results in a smaller amount of kWh before the higher rate kicks in.
typically, although not always, the unit price per kWh increases as demand increases.
Time of use rates: The electric rate may vary depending on the time of day. The time of use rate
is typically described in terms of on-peak and off peak and sometimes partial peak.
Ratchets: The electric rate may include a demand which allows for a variation on how the
demand kW is defined.
Seasons: Some utilities have different summer and winter rates.
Taxes: Applicable taxes and franchise fees, which can be over 10% in many areas.
Special rates: For gas cooling equipment or special load-management electric rates are
sometimes available. Using average electric and gas cost is rarely adequate to capture the cost of
operating cooling equipment, especially when the rate structure includes demand charges or
declining blocks. The marginal electric price for cooling has a larger demand component relative to
usage, which drives up the unit price. The details of the actual electric rates must be considered in the
total analysis of chiller system operating costs.
3.3.2 Operating Characteristics:
Operating schedules for building types vary. For example, HVAC equipment for office
buildings generally are operated approximately 10-12 hours per day, five days per week. Equipment
in hospitals will operate near full load for much of the day and at reduced, but still significant load
for the remainder of the day. Annual energy savings need to be large enough to overcome higher
initial costs from gas- engine driven chillers to be cost effective. Annual energy savings will be a
function of the operating schedule. An operating schedule that has a significant number of hours
where the equipment runs at part load, favours gas engine-driven chillers because of their excellent
part load performance.
However, operating schedules that require equipment to run at full load for relatively few
hours and not at all for most hours will result in too little annual energy savings to realize an
acceptable payback for most business requirements.

3.3.3 Estimating annual Energy savings:

To estimate the annual energy savings, the performance characteristics of each chiller
alternative must be carefully compared. The customary approach to analysing chiller economics has
been to employ” equivalent full load hour” methodology. Equivalent full load Hours (EFLH)Are
defined as the total cooling load supplied over the cooling load duration) ton/hour0 divided by the
cooling equipment capacity (tons0. Part load operation is modified to obtain the equivalent of
running at full load. While this method does not reflect the efficiency of part load operation, it does
simplify economic comparison.
Since the economics of gas cooling are highly dependent on operating hours, accurate
analysis requires a detailed building simulation. A comprehensive analysis should be done with an
hourly simulation model, such as DOE-2, HAP or TRACE, which predicts when, where and how
much cooling is required for the building.

3.4 Sizes of Absorption systems:

The following commercially proven absorption cooling systems, ranging in size from 40TR
to 2500TR are widely available in the market.
These systems come as stand-alone chillers or as chillers with integral heating systems. The
following sections provide manufacturer specific information and examples of installations.

3.4.1 High Pressure Steam Fired Vapour Absorption Chiller:

Table 3.4 High Pressure Steam fired Vapour Absorption Chiller
Refrigeration Capacity 150 TR to 2500 TR (525 KW to 8775 Kw)
Chilled water in/out 12/7 Cͦ
Cooling Water in/out 32/37.5 Cͦ
Steam Pressure 8Kg/cm^2.g
 Figure 3.2 High Pressure Steam fired Vapour Absorption Chiller

3.4.2 Low Pressure Steam Fired vapor Absorption Chiller:

Table 3.5 Low Pressure steam fired Vapour Absorption Chiller:
Refrigeration Capacity 95 TR to 1460 TR (333 KW to 5125 Kw)
Chilled water in/out 12/7 Cͦ
Cooling Water in/out 32/37.5 Cͦ
Steam Pressure 1.5Kg/cm^2.g

Figure 3.3 - Low Pressure steam fired Vapour Absorption Chiller

3.4.3 Hot Water Driven Absorption Chiller:

Table 3.6 Hot water driven Vapour Absorption chiller:
Refrigeration Capacity 45 TR to 360 TR (158 kW to 1,264 kW)
Chilled water in/out 12/7 Cͦ
Cooling Water in/out 31/39 Cͦ
Hot Water in/out Temperature 81/86 Cͦ
 Figure 3.4 Hot water driven Vapour Absorption chiller

3.4.4 Direct Fired Absorption Chiller:

Table 3.7 Direct Fired driven Vapour Absorption Chiller:
Refrigeration Capacity 45 TR to 360 TR (158 kW to 1,264 kW)
Chilled water in/out 12/7 Cͦ
Cooling Water in/out 32/37.5 Cͦ
Fuel Natural Gas, LPG, Furnace Oil, Kerosene, HSD etc.

Figure 3.5 Direct Fired driven Vapour Absorption Chiller

3.5 Equipment Manufacturers:

There are several manufacturers of absorption chillers, including:
 Carrier Absorption chillers- 100 TR – 1500 TR
 York Absorption Chillers – 100 TR – 1500 TR (Single-effect systems only)
 TRANE (USA) Absorption Chillers – 100 TR to 2000TR
 THERMAX (INDIA) – former licensee of Sanyo – 40 TR – 2500 TR
 EBARA (JAPAN) – 50TR – 2500 TR
 VOLTAS (INDIA) - 100 TR – 2000TR
 BROAD (CHINA) Absorption chillers – 50 TR to 3000
 Yazaki (JAPAN), Small capacity units only – 50TR to 250TR
  McQuay (USA) Absorption Chillers.
 SANYO (JAPAN) Absorption systems.
The list is certainly not exhaustive. Daikin (Japan) withdrew from the absorption cycle field
in the 1980’s, but it seems from recent reports that some activities have been taken up again. In
addition to these in the list, there are manufacturers that supply large units for Industrial use e.g.,
Hitachi Shipyard (Japan). Most Absorption systems based on the water – lithium Bromide working
pair is designed for air cooling applications. For historic reasons capacities are given in US RT
(refrigeration tons), one US ton of ice per hour, in literature from manufacturers. One RT
corresponds to 3.516KW cold production.

3.6 List of Equipment Installations:

Absorption cooling equipment is available for the following facilities *:
 Hotels
 Commercial buildings
 Education centres
 Hospitals
 Super markets
 Pharmaceutical companies
 Refineries & Petrochemicals
 Chemicals
 Electronics
 Engineering Industries
 Thermal Power Plants
 Dairy and confectioneries

Figure No 3.6 Industry wise TR Installation

4 No Chapter:

Design Analysis
4.1 Overview:
 Absorption chillers were compared to the following chiller options:
 Standard efficiency electric – screw or centrifugal
 High efficiency electric screw or centrifugal
 Indirect – fired single effect absorption system
The analysis is structured to provide “typical” values that can be used as a screening tool
during schematic design of a building or as guidance on equipment efficiency code bodies. The
results of a detailed energy and rates analysis for seven building types in ten cities, have been
distilled to a series of graphs.
The cities and buildings are representative of the range of climates and building occupancies
where gas cooling options would be used. The list of cities, sorted by cooling degree day(CDD) is
provided in Figure 4.1. information on building type and size are provided in Figure 4.2. The
economic analysis is of course dependent upon gas and electric rates. Building description and city
specific utility rates are provided the appendix.
The results are graphed for various gas rates and various electric rates. Due to The
complexities of the interactions between fuel type usage and utility rates. It was not possible to
develop “typical” gas to electric cost results. These graphs can be used, as will be shown by example
in the following chapter to determine relative increase in gas consumption and relative decrease in
electric consumption, when comparing a gas chiller to an electric chiller. The results of separate fuel
type analysis can then be combined to provide a complete picture of the savings opportunities.

Table 4.1 cities used for cooling analysis:

City CDD 50
San Francisco 2.833
Chicago 2.941
Washington DC 3.473
Los Angeles 4.77
Atlanta 5.083
San diegeo 5.223
New Delhi 3.221
River Side 5.295
Miami 9.474

Table 4.2 shows the building types included in the analysis, along with the building size in
square feet, and the cooling equipment sizes represents the variation in cooling load for the cities
analysed. The sizing of the cooling plant follows ASHRAE 90.1R ECB guidelines with a 20% over
sizing margin.
Table 4.2 Building type and size:
Type Size (Sq. Ft) Cooling (Tons)
Medium Office 49000 100-143
Large Office 160000 408-573
Hospital 272000 384-519
Hotel 315000 645-891
Out-patient Clinic 49000 90-111
Secondary School 50000 90-205
Large Retail 164000 165-393

As shown in table 4.3, the type of electric equipment, either screw or centrifugal, used as a
comparison, was dependent on size. table 4.4 shows the standard and high efficiencies assumed for
the various types of chillers.

Table 4.3 Cooling Equipment Type Based on Size:

Size (Tons) Type

100-300 Screw
>300-600 Screw
>800 Centrifugal
Because of the complexities and individual nature of Hybrid systems, results of any hybrid
systems analysis cannot be generalized. They were therefore intentionally not included in this
analysis. However, if the results indicate that a gas absorption chiller is cost effective, or even
marginally not cost effective, a hybrid system under the same conditions, will typically be cost
effective.

4.2 Energy Saving:

Energy savings were calculated using detailed DOE-2.1E building simulation models. The models
provide comprehensive data on energy use and savings. The modelling included a complete
comparison of system components, including auxiliary equipment such as cooling towers, fans and
pumps.
The graphs in the figure 4.1 present the energy savings for watch of the cities for a range of marginal
gas and electrical prices. The graphs present the annual energy cost savings, in rupees per year,
versus the marginal cost of gas, in rupees per therm, or the marginal cost of electricity in rupees per
kWh. The marginal energy cost, gas or electric, is calculated as energy cost savings, in rupees
divided by energy savings in therms or kWh. The marginal cost accounts for varying rates that may
apply based on total usage.

4.3 Cost Effectiveness:

Cost effectiveness is based on the calculation of the savings to investment ratio (SIR), SIR is
defined as the Life Cycle Cost (LCC) savings, in dollars, divided by the incremental measure cost
per unit capacity, in rupees per ton capacity, as shown in the following equation:
SIR = LCC Savings/Incremental Cost (4.1)
The SIR uses an investment model over the life of the equipment rather than the simplistic
and short-range perspective of simple payback.
The LCC savings describe the present worth of the energy cost savings over the life of the
investment. If the LCC savings are greater than the incremental cost, then the SIR will be greater
than one and the measure is assumed to be cost effective. Savings to investment ratios (SIR’s)
indicate the cost effectiveness of the equipment selection depending upon several factors including:
 Building type
 Equipment,
 Climate,
 Utility rate, and
 Scalar ratio.
Specific equipment cost information is provided in the Appendix. Additional first costs for
absorption systems were applied to the cost-effectiveness model, including:
 Additional cooling tower capacity add Rs450 -Rs750/Ton
 Additional boiler capacity adds Rs300 – Rs750/Ton
Another element of the first cost for gas absorption chillers is the potential savings from
interactions with other building elements. For example, installing a gas absorption chiller may reduce
the building’s electric service drop and load centre. These savings could be significant, but are not
included due to the variability between installations.
A scalar ratio is a mathematical simplification of life cycle costing (LCC) analysis. The scalar
ratio is a single term that combines discount rate, period of analysis, fuel escalation and other factors.
The first-year savings are multiplied by the scalar to arrive at the life cycle savings. In technical
terms, the scalar ratio represents the series present worth multiplier.
Table 4.4 Cooling Equipment Efficiencies:
Standard Efficiency High Efficiency
Equipment Type & Size
COP KW/Ton COP KW/Ton
Electric Screw <150 Tons 3.8 0.93 4.45 0.79
Electric Screw =150-300 Tons 4.2 0.84 4.90 0.72
Electric Centrifugal >300 5.2 0.68 6.01 0.58
Single Effect Absorption 0.60 5.86
Double Effect absorption 1.0 3.51

4.4 Effective Utilisation of waste heat from Diesel Genset to Run Air conditioning
Plant:
Load shedding is a common practice everywhere due to increased load power stations.
Industries depending heavily on electrical energy are the most affected ones. Industries are
encouraged to have their own captive power stations. Diesel generating sets are the most common
captive power stations. The exhaust gases of these gensets have a very large amount of heat (about
700 Degree Celsius at full load), which is wasted, can be effectively exploited. Waste heat of coolant
(about 120 Degree Celsius) from diesel gensets, equipped with evaporative cooling system can also
be exploited. The waste heat of exhaust gas & coolant so exploited can run a central air-conditioning
plant based on Vapour Absorption Chiller.
The present case study(theoretical) shows that a 30TR Vapour Absorption chiller based
central air conditioning plant can be run by tapping waste heat of the exhaust (14.5TR) and coolant
heat(15.5TR) of 125 HP genset. The practical implementation of such vapour absorption chillers by
number of companies like THERMAX India Ltd, Kaltimex, etc are reported. Such system with
combined heating & power (CHPC) is the need of time for conservation of the energy.
Key words:
Waste heat Utilisation, vapour absorption chiller, Gensets, Air conditioners, CHPC (combined
heating power & cooling)
Nomenclature:
P = Pressure
T = Temperature
ƺ = Concentration by weight
h = Specific Enthalpy
f = Specific Rich Solution Circulation
q = Heat transfer per unit Mass
D = Mass of Vapor Distilled from Generator
4.4.1 Analysis of Performance of the Vapour Absorption chiller System (case study for
125HP Genset):
 Diesel Genset Details
1. Rated Power output of Engine Considered = 125 Hp
2. Break Hp of Engine = ¾ X 125 = 93.75 kW
3. Heat Loss along with exhaust = 93.75 kW
4. Heat lost to coolant (latent heat) = 75kW
 Vapour Absorption Chiller Details:
Operating Conditions: for a water- lithium bromide chiller water plant for air conditioning
are as follows:
 Generator Temperature = 105 ° C
 Condenser temperature = 45 ° C
 Chilled – water Temperature = 5 ° C
 Absorber temperature = 45 ° C
 Temperature of Solution entering Generator = 95 ° C
Thermodynamic Calculations:
Condenser & Generator Pressure
P K = 71.9 mm Hg (At 45 ° C)
Flash Chamber & Absorber Pressure
P o = 6.54 mm Hg (At 5 ° C)
4.4.1 A Thermodynamic Conditions:
State 1: Saturated Condition state at
P = 71.9 mm of Hg & t = 91 ° C
x Li Br2 = 0.63 (From h - x Diagram)
h1 = -50 kj/kg
Rich Solution Concentration of Water
x = 1 - x Li Br2 = 1 - 0.63 = 0.37
State 2: Saturated Condition state at
P = 71.9 mm of Hg & t = 105 ° C
x Li Br = 0.67 (from h - x Diagram)
 h1 = -22 kj/kg
Poor Solution Concentration of Water
x = 1 - x Li Br2 = 1 - 0.67 = 0.33
State 4:
t = 45 ° C x Li Br2 = 0.63
h 4 = -140 kj/kg
The Enthalpy is read against temperature and composition. It may be noted that point 4
represents a sub cooled state at 6.54 mm of Hg pressures.
State 4 a: Assume the same as 4
Specific solution circulation rates
f = 1 – 0.33 / 0.37 - 0.33 = 16.75 kg/kg of vapour
f - 1 = 15.75 kg/kg of vapour
State 3: energy balance of liquid – liquid heat exchanger specific solution
circulation rates
f (h1 – h4) = (f –1) (h2 – h3)
h3 = h2 - [ f (h1 – h4) / (f – 1)]
= -22 – 16.75(-50+140) / 15.75 = -118 kj/kg
State 5: It is the water vapour at 71.9 mm Hg pressure and 105 ° C temp.at these
conditions it represents a superheated state. The enthalpy of vapour
above the reference state of saturated water at 0 ° C can be found either
from steam tables or from the empirical relation.
h = (250 + 1.88t) kj / kg
using the later procedure
h = 2501 + 1.88(105) = 2698 kj / kg
State 6: Saturated water at 45 ° C
h6 = 4.1868 (45) = 188.4 kj / kg
State 7:
P = 6.54 mm of Hg & t = 5 ° C (liquid + water)
h7 = h6 = 188.4 kj / kg
State 8:
P = 6.54 mm of Hg & t = 5 ° C (saturated vapor )
h8 = 2501 + 1.88(5) = 2510 kj / kg
4.4.1 B Refrigerating Effect:
qo = h 8 - h 7 = 2510 – 188.4 = 2321.6 kj / kg
Heat is added in the generator per unit mass of vapour distilled
qb = h5 – h2 + f (h2 – h1)
= 2698 – 22 + 16.75 (-22 + 50)
= 3189 kj / kg of vapour
Coefficient of Performance:
COP = qo / qb = 2321.6 / 3189
= 0.728
4.4.1C Water Vapour distilled, D:
Heat available for vapour generation from Exhaust gas system of Diesel Genset
= 0.75 X 93.75
= 70 kW
Heat available for vapour generation from cooling system of
Diesel Genset = 70 + 75 = 145 kW
D = [ 145 kj/s] / [ 3189 kj / kg of vapour]
D = 145 / 3189 X 2321.6 kj/s
= 105.56 kW
= 105.56 / 3.516 [ 1 TR = 3.516 kW]
= 30 TR
With increased natural gas availability and ever widening demand supply gap for
power, commercial / industrial users are shifting towards self-generation to meet their ever-
increasing power needs. Industries are utilizing the tri-generation systems which utilizes the
waste heat from the engine Exhaust directly along with the jacket water to generate
chilled/Hot water to cater to the Air conditioning / process cooling / Heating requirements.
Following table shows cooling potential based on engine rating. (Data from
Thermax Ltd.)
Table 4.5: Cooling Potential based on Engine rating
Cooling Capacity on Exhaust + Jacket
Engine Rating (KW)
Water (USRT)
300 100-110
500 175-200
1000 300-350
1500 425-500
2000 525-600

4.5 Design Analysis Graphs:

4.5.1 Using Graphs:

The following graphs that describe the performance of gas absorption chillers in a
variety of cities and building types. As described earlier, these graphs were developed from
DOE-2.1E runs done for representative prototype buildings using the actual utility rate
structures currently published for each city.
4.5.2 Annual Energy Cost Savings Graphs:
Two sets of energy cost savings are calculated for each building type. One is for a
range of marginal gas costs and a fixed marginal electric cost. The other is for a range of
marginal electric costs on a fixed marginal cost. The top graph in figure 4.7 is typical of the
annual energy cost savings Vs marginal cost graphs. The bottom graph is same for the same
conditions showing the energy cost savings Vs marginal costs. These particulars are for the
medium office building type prototype. The comparison is between a gas absorption chiller
and a standard efficiency electric chiller.
The vertical y-axis shows the annual energy cost savings, between the base equipment
and the gas Absorption Chiller. As shown on the top graph, as gas prices increase, the energy
savings associated with an absorption chiller decrease. Conversely, as electric prices
increase, savings from the Absorption Chiller increases, as shown in the bottom graph.
5 No Chapter:

Installation of Chiller/Heater
5.1 Requirements to Maintenance during Installation:
For chiller/heater tested in the Company, customer should pay attention to check the
chiller/heater for its air tightness, observe the vacuum of internal space of chiller/heater by Macleod
gauge. During storage and installation of chiller/heater, customer is required to observe the vacuum
conditions of chiller/heater. Observe the vacuum conditions daily. Information about the change of
reading of pressure gauge should be given to the service engineer of Company. Abnormality of
chiller/heater, observed by the service engineer of Company, should be corrected by the customer
under his guidance and technical manual.
During shipping, handling and installation, chiller/heater should be protected from man-made
damage and unauthorized operation of valves and instruments. In order to protect the chiller/heater
from leaks, the personnel are forbidden to climb the chiller/heater by the piping and valves. Control
panel, electric instrument and wiring should be protected from damage, control panel is not allowed
be opened and wiring be removed by uncertified operator. Protection means from dampness and rain
should be adopted.
All the outlet openings of chiller/heater should be covered to protect it from ingression of
dirty and foreign matter. With original openings covered and protections provided chiller/heater
should be covered by a tarpaulin, but not plastic sheeting (which will permeate damp and speed up
its corrosion), when it is left in the open air. Chiller/heater or its parts, stored for long time in the
room or in the open air, should be covered carefully.
Box with bulk of parts is recommended to store at dry and safe place to ensure its intact.

5.2 Requirements to Machine Room:

1. Machine room should be designed in accordance with the provisions of fire-fighting rules for
buildings, design rules for gas and oil fuel supply system, and other standards and
specifications.
2. Machine room should be provided with good ventilation and lighting facility. Discharge fans
should be installed with air change rate of 6-10 times in hour to meet the needs of
combustion, heat dissipation and safety.
3. Temperature in the room should be kept in the limits of 5-40℃, and humidity less than 90%.
4. Machine room should be supplied with power voltage of 380VAC±10%, and without
accidental failure of power.
5. Machine room is provided with perfect drain system. Machine room should be constructed
against fire and water flood.
6. Machine room with gas-fired chiller/heater should be provided with gas leakage detection
and warning device, which should be designed with perfect functioning in the installed
positions, and interlocked with air discharging fans and gas quick shut-down valves.
7. Machine room should be arranged in such a way, that the chiller/heater is accessible to
handling, install, maintain, repair, replace the parts and modernize chiller/heater. Space and
height should be reserved for handling and transport the chiller/heater.
8. Minimum space with the dimensions shown in the Table2-1 should be reserved. Space for
changing tubes should be provided in axial direction from any one side of chiller/heater.
Chiller/heater can be installed with the ends against window or door for pulling the leaking
tubes.
 9. Machine room should be designed with due considerations of its vibration and noise to the
surrounding rooms, and provided with good sound isolation, attenuation and vibration
absorbing means.
10. Machine room should be able to carry the total weight of whole package of chiller/heater and
its auxiliary equipment such as water pumps during their operation.
11. Machine room should be equipped with locks and screens for doors and windows to protect
from the entrance of unauthorized people.
12. Machine room should be provided with tools, spare parts and materials for maintenance of
chiller/heater and systems.

5.3 Installation of Chiller/heater:

The foundation for chiller/heater should be designed to carry the chiller/heater with operation
weight. as static load, because of its stable operation and minor vibration. The foundation should
be raised from the floor with dimensions in accordance with installation drawings provided by
our Company. During installation the transportation rack should be removed. The installation
work of chiller/heater is essential to its successful operation, especially the levelness should be
ensured, though the installation of chiller/heater is not so complicated.
In general, the chiller/heater is installed in the machine room, but it can be installed outside it,
if the conditions not allowed. But the unit cannot be installed in the open air, when the lowest
circumstance temperature in the year is less than 5℃. When installed outside the room, means
should be taken to protect the chiller/heater body, control panel, measuring and control
instrument, burner and piping valves from rain, wind, corrosion and heat dissipation.
Chiller/heater should be installed with consideration of daily operation, and provision of space
for withdraw of heat transfer tubes from any end of chiller/heater. In the meantime, it can be
installed with one end oriented to the window. Drainage should be provided around the
chiller/heater and covered with perforated plate made from cast iron.
Before positioning the chiller/heater on the fundament, which should be cleaned from dirty,
be kept level and with dimensions in accordance with the design requirements. On the support
area of fundament, hard rubber plates with area bigger than supporting foot and thickness of
about 10mm should be covered.

5.3.1 Installation of Assembled Chiller/heater:

During installation of chiller/heater, it should be handled carefully with steel ropes placed on
the marked area. Every steel rope should have capacity to carry whole weight of chiller/heater.
Chiller/heater should be handled with care to be protected from damage of any parts. The position of
contact of ropes with the chiller/heater should be adjusted to avoid the damage of parts, such as small
diameter pipes, connecting wires and instrument. Chiller/heater should be handled in horizontal
position with slow movement in order to be protected from drop of unit owing to deviation of centre
of gravity, when solution in chiller/heater is moved. Chiller/heater should be lowered with all feet
contacted with the surface of floor or fundament.
After positioning of chiller/heater on the fundament, the longitudinal and transversal
levelness should be checked. Two holes on the both sides of tube plates of evaporator-absorber are
provided, and should be on the same level with deviation less than 1/1000. Chiller/heater can be
raised at one end by crane or two jacks at each side of unit, and long steel spacer can be inserted
between the foot and fundament, if the levelness of unit is not in the prescribed limits.

5.3.2 Installation of unit of chiller/heater from split parts:

Separation of chiller/heater into split units impairs vacuum of chiller/heater, and causes its
corrosion. Chiller/heater tested in the works, should be separated close to the machine room, and
handled into the machine room to be tested for refrigeration operation as quickly as possible.
 For split chiller/heater, its installation is basically the same as for assembled unit of
chiller/heater. The main difference is: the separated parts should be put at their own fundament, lined
up for connections, checked for longitudinal and transversal levelness, and welded together, if it is
separated into two parts. Or the lower shell should be put on the fundament, checked with
longitudinal and transversal levelness; then the upper shell should be put on the lower shell, lined up
for connection, checked for longitudinal and transversal levelness, and welded together with lower
shell. Afterwards, the high-pressure generator should be put on the fundament, lined up for
connections, checked for longitudinal and transversal levelness, and welded together with the other
parts, if the chiller/heater is separated into three parts. Cautions should be taken to prevent the
welding from ingression of slag and scales into the unit. Welded chiller/heater should be checked
again for levelness. Installed unit should be evacuated, and checked for air tightness.

5.4 Adjustment of Levelness of Chiller/heater:

Method of checking the levelness of unit usually is done by level or with transparent plastic
hose and water as follows:
1. As shown in the Figure 5.1, transparent plastic hose is hanged close to the level reference
holes, and charged with water.
2. Water lever in one end of hose is kept to the centre of one reference hole. Water level in
another end of plastic hose should be at same height with the centre of another reference hole,
adjusting the height of chiller/heater at another end by crane or other means. The longitudinal
levelness of installed chiller/heater equals to the difference of water level in two ends divided
by the distance between the tube plates. Chiller/heater is kept in the limits of levelness, which
should be less than 1/1000, by insertion of long steel spacer at the lower end.
3. The transverse levelness is adjusted in the same manner by placing the plastic hose along the
tube plate.

5.5 Insulation of Chiller/heater:

When the chiller/heater is installed and checked for air tightness, the following parts should
be insulated:
Thermal insulation locations: high pressure generator (~160 ℃), high temperature heat
Exchanger (~160℃), low pressure generator (~90℃), low temperature heat exchanger (~90℃), and
relevant pipes between them. Pipes connected with high pressure generator are at 160℃, others at
90℃.
Cold insulation locations (~7℃): evaporator water pan, evaporator water chamber end
covers, piping before and after refrigerant pump.
Thickness of thermal insulation layer: 70mm for locations of surface temperature 160℃ and
40mm for locations of surface temperature 90℃. Thermal insulating material: super-fine glass fiber
felt, rock wool felt, or material with similar property. Thickness of cold insulation layer: 30mm.
Cold insulating material: polyethylene foam plastics, or material with similar property. Cold
insulating material shall not absorb water, and no gas can be pass through. Joints shall be sealed by
adhesive tapes.
Thermal/cold insulation construction: welding shall not be conducted on the chiller/heater,
electric circuits shall not be damaged, and sight glass, temperature-measuring tubes, valves and
drainage cocks shall not be covered.
6 No Chapter

Test Operation of New Installed Choller/Heater

6.1 External Visual Inspection:
The items below must be accessible after fitting the insulation:
 Changeover valves, dampers, service valves and sight glasses.
 Temperature sensors and pressure gauges should be replaceable.
 Bar-thermometers need to be inserted into the wells provided on water headers and solution
pipes.
 Evaporator headers should be removable.
 Inspection window for the high temperature generator should be removable.

6.1.1 Chiller insulation must be correctly fitted:

The following positions should not be insulated.
 The motor section of the refrigerant pump
 The rupture disk.
 The rupture disk on the high temperature generator.

6.1.2 Installation checks:

 There should not be any rust on the chiller/heater.
 Flange and bolted connections should not be loose.
 There should not be any liquid leakage from the chiller/heater.
 Ensure that the chiller/heater components are not damaged.
 Ensure that no chiller/heater components are missing.
 Ensure that wiring and piping are not damaged.

6.2 Solution Charge:

6.2.1 Precautions:
 Solution shall be charged at the site for multiple-piece shipment unit.
 Make sure that the vacuum of the Chiller/heater is sufficient.
 The refrigerant must be charged just before running the chiller/heater.

6.2.2 Procedure:
Refer to figure 5 and 7 and to exhibit A.
1. Prepare solution containers.
2. Operate the vacuum pump.
3. Open V1 and V3.
4. Charge the absorbent first and then charge the refrigerant.
5. Charge one-third each of the absorbent from SV3, SV4 and SV8.
 6. Connect a vacuum hose to the service valve and attach a copper tube at the other end of the
hose, and put the copper tube into the container. Be sure that the copper tube does not touch
the bottom of the container)
7. Open the service valve.
8. When the solution starts to be drawn into the chiller/heater, make sure not to let air leak into
the chiller/heater.
9. Before the container is empty, tilt it so that no air enters the tube.
10. When the container is almost empty, bend the rubber vacuum hose with both hands to ensure
that no air enters and quickly insert it into the next container.
11. Repeat steps 8. to 10. until all containers have been emptied.
12. Close SV3, SV4 and SV8.
13. After that, to charge the refrigerant from SV3.
14. Once the required amount of solution has been charged, make sure SV3, SV4 and SV8 have
been closed tightly.
15. Remove the rubber vacuum hose from SV3, SV4 and SV8, and put the caps on the service
valves.
16. Close V1 and V3.
17. Stop the purge pump.

6.3 Electrical check

The electrical specifications must comply with the control panel nameplate data. Check the field
wiring and the palladium cell heater wiring. Refer to exhibit F and the specification drawings.

6.3.1 Check the motor insulation resistance:

Always ensure that the motors are disconnected from the wiring before carrying out this check. The
standard value is 10 MΩ minimum. The insulation resistance of the absorbent pump No.1, No. 2 and
the blower motor should be measured at the secondary terminals of each magnetic contactor.

6.3.2 Measuring the insulation resistance

Measure the insulation resistance of absorbent pumps, refrigerant pump and purge pump using the
following equipment:
 500 V d.c. megger
 Screwdriver

6.3.3 Precautions
The insulation resistance should be 10 MΩ minimum. Be sure to perform this measurement at the
seasonal maintenance and after pump replacement.

6.3.4 Procedure:
 Switch off the power supply during the work. Make sure to turn off the circuit breaker
(MCBM).
 Disconnect the three wires (U1, V1, W1) connected to the inverter of absorbent pump No. 1.
 Connect the earth wire of the megger to the earth terminal in the control panel.
  Measure the insulation resistance of each motor at the following terminals on the control
panel and at the wires disconnected.
For positions measured with the megger see Fig. 8:
- Absorbent pump (terminals): U1/V1/W1
- Absorbent pump (terminals): U2/V2/W2
- Refrigerant pump (terminals): U3/V3/W3
- Purge pump (terminals): U4/V4/W4
 Record the measured values.
 Remove the earth wire.

6.4 Initial control board and inverter settings

 Time setting.
 Turn on the backup battery on the control board.
 Check the control board parameters.
 Check the inverter parameters.

6.5 Damper setting and valve position:

6.5.1 Damper setting

Refer to exhibit J.

6.5.2 Check valve opening status and switch positions

The position of each valve and switch is different for each operation.

6.6 Purging:

6.6.1 Ensure the gas ballast valve is closed before starting the purge pump:
During operation of the purge pump, the gas ballast valve should be opened. However if the
valve is opened too far, purge pump oil may spill from the oil charge port.

6.6.2 Bubble test

Before conducting the bubble test, purge the chiller/heater for at least one hour. The gas ballast
valve should be closed during the bubble test. Please refer to the table in the chapter 1.12.1 "Bubble
test".

6.7 Burner and fuel piping

6.7.1 Leak test for gas piping and adjustment of burner

 For gas pipe leaks and leaks at the seat of each valve refer to the burner operation and
maintenance manual.
 To prepare for burner adjustment refer to the burner operation and maintenance manual.
 To adjust the main burner, refer to exhibit K or exhibit L.
6.8 Function test:

6.9 Operation:

6.9.1 Gas-fired
 Check that the smoke pipe, draught regulator, chimney top and chimney are all in good
condition.
 Turn on the main power and the main gas valve. Adjust the burner link in accordance with
the burner installation and operation instructions to keep the exhaust gas within the standard
combustion value.
 Change to automatic normal operation.

6.9.2 Oil-fired
 Check that the smoke pipe, draught regulator, chimney and chimney top are all in good
condition.
 Turn on the main power and the main oil valve. Adjust the burner link to keep the exhaust
gas within the standard combustion value.
 Change to automatic normal operation.

6.9.3 Test operation, cooling:

Before starting the chiller/heater, check the valve opening and the damper position. Refer to
exhibit J. Usually the units are factory adjusted, but for on-site assembly or first operation the
following adjustments should be made. These are only possible, if the cooling load is more than 50%
of the rated capacity.

6.9.4 Operation and data record:

Record data three times at 10-to-15-minute intervals at stable operating conditions.
Tools required to record operation data
 Thermometer
 Pressure gauge
 Stop watch
 Exhaust gas analyser
 Smoke tester
 Solution sampling tool
 Gravimeter
 Concentration table as attached

6.9.5 Absorbent sampling:

 Sampling should be carried out as follows:
 Sampling of diluted solution
 Sampling from SV4, located on absorbent pump 1 outlet
 Solution should be sampled twice. The sample quantity is 100 ml. The second sample should
be used for analysis.
7 No Chapter:
7.1 visual inspection:
Check List
 Lower shell................................................................................Not damaged < > Damaged < >
 Upper shell.................................................................................Not damaged < > Damaged < >
 High-temperature generator.......................................................Not damaged < > Damaged < >
 Heat exchangers.........................................................................Not damaged < > Damaged < >
 Burner........................................................................................Not damaged < > Damaged < >
 Fuel piping.................................................................................Not damaged < > Damaged < >
 Evaporator headers....................................................................Not damaged < > Damaged < >
 Absorber headers.......................................................................Not damaged < > Damaged < >
 Condenser headers.....................................................................Not damaged < > Damaged < >
 Control panel.............................................................................Not damaged < > Damaged < >
 Absorbent pump 1 and isolation valves.....................................Not damaged < > Damaged < >
 Absorbent pump 2 and isolation valves.....................................Not damaged < > Damaged < >
 Refrigerant pump and isolation valves......................................Not damaged < > Damaged < >
 Strainer of absorbent pump 1 outlet..........................................Not damaged < > Damaged < >
 Temperature sensors (11 sensors).............................................Not damaged < > Damaged < >
 High temperature generator solution level electrodes...............Not damaged < > Damaged < >
 Generator pressure switches......................................................Not damaged < > Damaged < >
 Generator pressure gauge..........................................................Not damaged < > Damaged < >
 Purge unit (diaphragm valves, liquid trap)................................Not damaged < > Damaged < >
 Chilled water flow switch..........................................................Not damaged < > Damaged < >
 Cooling water flow switch (option)...........................................Not damaged < > Damaged < >
 Refrigerant blow-down valve....................................................Not damaged < > Damaged < >
 Purge tank pressure sensors.......................................................Not damaged < > Damaged < >
 Palladium cells and heater.........................................................Not damaged < > Damaged < >

7.2 Verify field wiring and wiring of palladium cell heater:

 Cooling water pump interlock...................................................Not damaged < > Damaged < >
 Chilled water pump interlock....................................................Not damaged < > Damaged < >
 Ventilation fan interlock............................................................Not damaged < > Damaged < >
 Run/stop remote signal..............................................................Not damaged < > Damaged < >
 Stop indication...........................................................................Not damaged < > Damaged < >
 Operation indication..................................................................Not damaged < > Damaged < >
 Alarm indication........................................................................Not damaged < > Damaged < >
 Chilled water pump..................................................................Not damaged < > Damaged < >
  Cooling water pump..................................................................Not damaged < > Damaged < >
 Ventilation fan...........................................................................Not damaged < > Damaged < >
 Cooling mode indication...........................................................Not damaged < > Damaged < >
 Heating mode indication............................................................Not damaged < > Damaged < >
 Feedback indication...................................................................Not damaged < > Damaged < >
 Earth connection........................................................................Not damaged < > Damaged < >
 Wiring of palladium cell heater.................................................Not damaged < > Damaged < >

7.3 Check of motor insulation resistance:

Standard: more than 10 MΩ
 Absorbent pump: MΩ...................Good < > Not good < > Repaired < > Replaced < >
 Refrigerant pump: MΩ..................Good < > Not good < > Repaired < > Replaced < >
 Purge pump: MΩ.........................Good < > Not good < > Repaired < > Replaced < >
 Burner blower motor: MΩ...........Good < > Not good < > Repaired < > Replaced < >

7.4 Check of control board safety and switch settings:

 Generator pressure switch (63GHH): kPa/MPa
 Generator pressure switch (63GHL): kPa/MPa
 Purge tank pressure sensor (69PR): kPa
 Absorption pump 2 thermal relay (51A2): A
 Refrigerant pump thermal relay (51R): A
 Purge pump thermal relay (51P): A
 Gas pressure switch: mbar
7.5 Check of purge pump:
 No water in liquid trap: Yes < > No < >
 Oil quality: Clean < > Not clean < >-->Replace oil (or contains water)
 Oil quantity: Good < > Not good < > -->Add new oil up to the centre of mirror or remove oil.
 Direction of rotation: Good < > (as arrow on V-belt cover) Not good < > -->Replace two
power supply wires.
8 No Chapter:

Conclusion and Future Recommendation

8.1 Conclusion:
For successful completion of this work, caution has been taken while doing the flow sheet
construction and property method selection. From this project, it can be concluded that COP of the
system is dependent on the evaporator and generator temperature. With suitable adjustment of the
temperatures in these blocks can optimize the COP value and this can be seen from the chapter 4. It
can be found out that, the COP of LiBr + water-based absorption refrigeration system is higher than
that of ammonia + water-based system. There are some demerits in this system like the
crystallization, corrosion and leakage problems which need to be given serious consideration,
because they can pose limitation on operating conditions of this system, hence limiting the COP of
the cycle.
Recently, ionic liquid + water-based absorption refrigeration system has been proposed,
which is much costlier than the LiBr + water-based system. In this project, economic feasibility has
also been checked by taking a simple basis. When compared with the conventional vapour
compression refrigeration system, it can be visualized that, the LiBr+water system has an annual
average profit of around Rs. 7500/- which is the clear indication of economic profitability of this
system. Moreover, the LiBr + water system doesn’t harm the environment and uses the waste heat
which could otherwise affect the nature.

8.2 Future Recommendation:

The simulation studies have been done in a very simple way of choosing heater blocks for
most of the components. As COP calculation is our main purpose, this selection is fine, but if
detailed designing is needed, then other blocks like heats etc. can be used. There is a much-required
work needed for the improvement in crystallization property either by inclusion of other salts or by
using anti-crystallizers, though it was not included in the scope of the present project. Hence the
future scope lies in the improvement of anti-crystallinity property. Other thermodynamic properties
can also be found out like mass transfer coefficient, mass flux, heat flux, heat transfer and
effectiveness of each component. A detailed comparative study can be done taking LiBr+water,
ammonia-water and ionic liquid + water, so that economic feasibility can be easily determined.
 References
1. A. Yokozeki, (2005). "Theoretical Performance of Vapor Absorption System." 80: 383-399.
2. Kaushik, S. (Feb, 2014). "Thermodynamics Analysis of Vapor Absorption Refrigeration
System and Calculation of COP." International Journal of Research in Applied Sciences and
Engineering Technology 02.
3. Elsevier (April, 2009). "Energy Conversion and Management." 50(04).
4. Jung-In-Yoon, E. (2005). "Heat and Mass Transfer Characteristics." International Journal of
Heat and Mass Transfer 48.
5. S¨ozen, M. Ozalp. (2003). "Performance improvement of absorption refrigeration system
using triple-pressure-level." Applied Thermal Engineering 23(13).
6.