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Study The Thermal Performance of A Refrigeration System Equipped with

Variable Speed Compressor and Different Controllers
Thesis · August 2020

DOI: 10.13140/RG.2.2.25160.24321
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Republic of Iraq
Ministry of Higher Education
& Scientific Research
University of Wasit
Study The Thermal Performance of

A Refrigeration System Equipped with Variable
Speed Compressor and Different Controllers
A Thesis
Submitted to the College of Engineering
Wasit University in Partial Fulfillment of the Requirements
for the Degree of Master of Science in
Mechanical Engineering
Refrigeration and Air-Conditioning
By
Ahmed Hamed Hassani
B.Sc. in Mechanical Engineering 1995
Supervised by
Asst. Prof. Dr. Alaa Al-Badri
2020 AD 1441 AH
‫بِســــــــــــــ ِم ٱ ه َِّلل ٱ هلر ۡح َٰـ ِن ٱ هلر ِح ِي‬
‫(‪)١‬‬ ‫ۡس ۡرب ّ ِۡك ٱ ه َِّلي ۡخلۡ ۡق‬ ‫ٱق ۡرٱ بِٱ ِ‬
‫سا ۡن ِمن عۡلۡق (‪)٢‬‬ ‫ۡخلۡ ۡق ٱۡل ۡن‬
‫ِ‬
‫ٱق ۡرٱ ۡو ۡرب ُّ ۡك ٱ َۡلل ۡر ُم (‪ )٣‬ٱ ه َِّلي عۡ ه َّۡل بِٱل ۡق ِۡ‬
‫َّل (‪)٤‬‬
‫سا ۡن ۡما لۡم يۡع َّۡل (‪)٥‬‬ ‫عۡ ه َّۡل ٱ ِۡلن ۡ‬
‫ۡصدق هللا ال ۡع ُيل ال ۡعظي‬

‫سورة العلق (‪(٥-١‬‬
Examination Committee Certification
We are the members of the examining committee certify that after

reading the thesis entitled "Study the thermal performance of a
refrigeration system equipped with variable speed compressor and
different controllers" and examining the student (Ahmed Hamed
Hassani) in its content. We think it meets the standard and it is
adequate for the award of the Degree of Master of Science in
Mechanical Engineering Refrigeration and Air-Conditioning.
Prof. Dr. Asst. Prof. Dr.

Mushtaq I. Hasan Abdul Salam D. M. Hassen
/ / 2020 / / 2020
(Chairman) (member)
Lect. Dr. Asst. Prof. Dr.

Ahmed A. Yassen Alaa R. Al-Badri
/ / 2020 / / 2020
(member) (Supervisor)
Prof. Dr.
Ali N. Hillo
/ / 2020
Dean of the College of Engineering
Supervisor Certification
I certify that the thesis entitled ″ Study the thermal performance of

a refrigeration system equipped with variable speed compressor and
different controllers″ by ″ Ahmed Hamed Hassani″ has been
prepared and written under my supervision at Wasit University/ College
of Engineering as partial fulfillment of the requirements of the degree of
the master of sciences in (Mechanical Engineering) Refrigeration and
Air-Conditioning.
.
Asst. Prof. Dr. Alaa R. Al-Badri
. College of Engineering
Wasit University
/ / 2020
Linguistic Certification
I certify that I have read this thesis entitled ″Study the thermal
performance of a refrigeration system equipped with variable speed
compressor and different controllers″ by ″ Ahmed Hamed Hassani″
and I examined the language of the thesis and in my opinion, it’s
adequate as a thesis for the degree of Master of Engineering
Technology.
Asst. Dr. Radwan M. Aljuhashy
College of Engineering
Wasit University
/ / 2020
Dedication
To ALLAH “Greatest Creator”
To the Prophet of ALLAH “Mohammed” and his pure immediate family
To All Believers in the World
To all who helped and taught me in completing this research
I dedicate this modest endeavor …
Ahmed Hamed Hassani

Acknowledgments
In advance, I thank ALLAH for his support and for giving me the
patience to prepare this research carefully
Also, I extend my sincere thanks, gratitude, all respect, and appreciation,
to Asst. Prof. Dr. Alaa R. Al-Badri for their unlimited support during the
research period
I would like to extend my thanks and appreciation to my family for their
patience and unlimited support
Ahmed Hamed Hassani

Table of Contents
Abstract
A variable speed compressor with different controlling methods is

employed to improve the performance of the refrigeration and air
condition systems by reducing energy consumption. In this thesis, the
performance of the variable speed chilled water refrigeration system with
an electronic expansion valve (EEV) was studied. The effect of changing
the compressor speed and valve opening on the performance and
stability of the system was investigated. The speed of the compressor
was controlled depending on the change in the evaporator product cold-
water temperature with the first control loop. The second loop was used
to regulate valve opening to keep refrigerant superheat (DS) in its setting
value. Two new controlling methods were presented to control the EEV
opening that achieved optimum performance at different operation
conditions. The first method considered the DS was a variable value
between 6.5 and 8.5°C which is estimated by an empirical equation
depending on the compressor speed and the evaporator inlet water
temperature with two control loops. The coupling effect between the two
loops (compressor speed and valve opening) decreases system stability
and performance. This was solved with a second control method with
only one controlling loop to control the compressor speed while the EEV
opening was estimated directly by the empirical equation which is
related to the cooling load. For each controlling method, PI, PID, P-
fuzzy, P+D-fuzzy, and PD-fuzzy controllers were considered.
Comparison results showed high stability for the DS with a reduction in
the response oscillation about 15% with the variable DS method and
35% with the direct EEV opening method compared to the constant DS
at 7°C method. The DS response stability is affected the product cold
I
Table of Contents
water temperature response and system coefficient of performance

(COP) which increases about 7% with variable DS method and 18% with
direct EEV opening method compared to constant DS. Energy
conservation was about 30% with the PD-fuzzy controller which was the
best controller compared to the On/Off method.
The performance of the controlled system was examined at steady-

state operation by changing the evaporator and condenser inlet water
temperatures at a constant cooling load. Increasing the inlet water
temperature of the condenser from 25 to 33°C decreases the COP of the
system by about 42% due to the increase in the pressure ratio and
compressor speed. The COP of the system increases about 6.5% with
increasing the inlet water temperature of the evaporator from 15 to 19°C
at constant cooling load and condenser temperature. The last tests were
by changing the cooling load, evaporator inlet water flow rate, and
condenser temperature to examine the controllability of the system at
transient responses. The results showed good stability and at high
performance with the direct EEV opening method to control the EEV
and with the PD-fuzzy controller to control the speed of the compressor.
II
Table of Contents
Table of Contents
Abstract I
Table of Contents III
Nomenclature VII
Chapter One
Introduction and Background
1.1 Introduction 1
1.2 Motivation for the current study 1
1.3 Refrigeration cycle 2
1.4 Controlling capacity methods 4
1.5 System improvement work 6
1.5.1 Improving system equipment 6
1.5.2 Improving system control 8
1.6 VSRS applications 10
1.7 VSRS advantages 11
Chapter Two
Literature Review
2.1 Introduction 12
2.2 General performance 12
2.3 Refrigerant superheat 17
2.4 Controlling method 20
2.5 Scope of previous work 33
2.6 Aim of this study 34
III
Table of Contents
Chapter Three
Theoretical Analysis
3.1 Introduction 35
3.2 Refrigeration cycle with variable speed compressor 35
3.3 Refrigerant flow rate 36
3.4 Design of heat exchangers 37
3.4.1 Water-side heat transfer coefficient 38
3.4.2 Refrigerant side heat transfer coefficient 44
3.4.2.1 Single phase region 44
3.4.2.2 Two-phase region 43
3.4.3 Tube length 45
3.5 Refrigerant charge 46
3.6 Control algorithms 48
3.6.1 On/Off controller 49
3.6.2 High/Low controller 55
3.6.3 PI-controller 54
3.6.4 PID-controller 52
3.6.5 P-Fuzzy Controller 53
3.6.6 P+D Fuzzy Controller 65
3.6.7 PD-fuzzy Controller 63
Chapter Four
Experimental Rig
4.1 Introduction 68
4.2 System equipment 74
IV
Table of Contents
4.2.1 Compressor 72
4.2.2 Electronic expansion Valve 73
4.2.3 Evaporator and condenser 75
4.3 Measuring instruments 77
4.3.1 Temperature sensors 77
4.3.2 Pressure transducers 79
4.3.3 Refrigerant flow meter 84
4.3.4 Water flow meter 82
4.3.5 Power meter 83
4.4 Data acquisition 83
4.5 System operation 85
4.6 Uncertainty analysis 95
Chapter Five
Results and Discussion
5.1 Introduction 97
5.2 Manual operation performance 98
5.2.1 Compressor speed and EEV opening effects 455
5.2.2 Refrigerant superheat 106
5.2.3 Two loops with variable superheat controlling method 140
5.2.4 Coupling effect 142
5.2.5 Single loop Controlling method 144
5.2.6 Controllers Tuning 118
5.3 Automatic control operation 122
V
Table of Contents
5.3.1 Controlling methods comparison 123
5.3.2 Controllers comparisons 129
5.3.3 Comparison with conventional controllers 134
5.3.4 Performance comparisons 133
5.4 Controlled system performance 137
5.4.1 Steady state performance 137
5.4.2 Transient performance 142
Chapter Six
Conclusions and Recommendations
6.1 Conclusions 147
6.2 Recommendations 149
References
References 155
Appendices
(A) Programs 158
(B) Experimental results 163
(C) Tuning tables and figures 167
VI
Nomenclature
Nomenclature
Symbol Definition Unit

ac Cross-sectional area (m2)
C Specific heat (J/kg.°C)
d Copper tube diameter (m)
D PVC cylinder diameter (m)
Dh hydraulic diameter (m)
f Frequency (Hz)
G Mass flux of the water (kg/s.m2)
h Convection heat transfer coefficient (W/m2.°C)
H Enthalpy (J/kg)
K conduction heat transfer coefficient (W/m.°C)
L Length (m)
Mass flow rate (kg/s)
N Compressor speed (rpm)
P Pressure (bar)
Pch Distance between two terns of the coil (m)
Pr Prandtl number
Pr,cr Critical pressure ratio of the refrigerant
Q Amount of heat transferred (W)
Re Reynolds number
T Temperature (°C)
t Time (s)
U Overall heat transfer coefficient (W/m2.°C)
V Volume (m3)
v Specific volume (m3/kg)
W Energy (W)
x Dryness fraction of the refrigerant mixture
VII
Nomenclature
Greek symbols
Symbol Definition
Δ Difference between set and measured value
volumetric efficiency
Dynamic viscosity of the water (kg/m.s)
Density (kg/m3)
stander deviation
Subscripts
Symbol Definition
comp Compressor
con Condenser
eq Equation
ev Evaporator
f Fluid
i Inlet, inner
l Liquid
m Mean
n Net volume
o Outlet, outer
r Refrigerant
sat saturation
set Set value
suc Suction side
v Refrigerant vapor
1 Evaporator output point
2 Condenser input point
3 Condenser output point
4 Evaporator input point
VIII
Nomenclature
Abbreviations
Symbol Definition
A/C Air Conditioning system
AC Alternating Current
ANN Artificial Neural Network
BLDC Brushless Direct Current motor
COP Coefficient Of Performance
DC Direct Current
DS Degree of refrigerant Superheat
DX Direct expansion
EER Energy Efficiency Ratio
EES Engineering Equation Solver
EEV Electronic Expansion Valve
FLC Fuzzy Logical Controller
HVAC Heating, Ventilation and Air Condition systems
kd Controller derivative gain
ki Controller integral gain
kp Controller proportional gain
MIMO Multi-Input and Multi-Outputs controller
NTC Negative Temperature Coefficient
P proportional controller
PD Proportional Derivative controller
PI Proportional Integral controller
PID Proportional Integral Derivative controller
PVC Polyvinyl chloride
R125 Pentafluoroethane
R134a Tetrafluoroethane
R22 Chlorodifluoromethane
R32 Difluoromethan
R410a Mixture of 50% R32 and 50% R125
ST Electronic Expansion valve steps
TEV Thermostatic Expansion Valve
VFD Variable Frequency Drive
VRFs Variable Refrigeration Flow systems
VSC Variable Speed Compressor
VSRs Variable Speed Refrigeration systems
IX
Chapter One
Introduction and
Background
Chapter One Introduction
Chapter One
Introduction and Background
1.1 Introduction
The refrigeration system works to absorb heat from space and rejected
it to surrounding according to the principle of a simple vapor
compression cycle [1]. The compressor compresses the refrigerant vapor
from evaporator (at low pressure) to condenser (at high pressure) by the
compression process that consumes about 80% of the total system power
[2]. Conventional refrigeration systems are working at a single speed
compressor with the On/Off controlling method that results in high
power consumption at partial load conditions [3]. Variable speed
compressors can regulate the compressor speed depending on the
thermal load that could lead to reducing power consumption at high
performance. In this chapter, the motivations of this study were
presented, a review for capacity controlling methods was sorted, and
then equipment enhancement and controlling methods are reviewed.
Finally, applications and advantages of variable speed compressor
systems are presented.
1.2 Motivations for the current study
The International Energy Agency provided statistics about the growth

of air-conditioners (A/C) units. In the period between 2010 and 2018,
sold A/C units increased by about 40% from 1.3 million to 1.8 million
A/C units respectively. It is expected that the growth will reach 5.6
1
million units in 2050 with a rate of 10 new A/C units sold every second
in the world as shown in Figure (1-1) [4].
Million A/C solid units

1.5
0.5
0
2010 2011 2012 2013 2014 2015 2016 2017 2018
year
Figure (1-1): Number of AC sold units in the hot zone at each year [4].
Air-conditioning systems consumed about 40-50% of electrical energy

production which may increase CO2 emission from power plants that
affects global warming [5]. From these effects, designers are facing two
challenges to designing more efficient A/C systems with low power
consumption; increasing the number of A/C units and its operation
period.
1.3 Refrigeration cycle
The working principle of variable speed refrigeration and heat pump

systems depend on the vapor compression cycle as shown in Figure (1-2)
[6]. Which consists of:
 Compressor: A mechanical equipment that is working to

compress the refrigerant vapor from evaporator at low pressure to the
condenser at high pressure and the temperature. The compressor speed in
2
variable speed refrigeration systems can be regulated by using a control

panel depending on the thermal loads.
Figure (1-2): Refrigeration cycle.
 Condenser: A heat exchanger condenses refrigerant vapor into a

liquid at high pressure by rejecting heat to the surrounding.
 Expansion valve: A throttling device reduces the refrigerant
cycle pressure between condenser (high pressure) and
evaporator (low pressure) and regulates the refrigerant flow rate
by changing its orifice opening. In variable speed compressor
systems, the electronic expansion valve (EEV) is used.
 Evaporator: A heat exchanger works to evaporate the
refrigerant liquid at low pressure by absorbing heat from the
surrounding then converting it to a superheated vapor, which
returns to the compressor.
Variable speed refrigeration systems are equipped with a control

panel, which is an electronic board, used to control both compressor
speed and the EEV opening depending on the thermal load and operating
conditions.
3
The compressor speed and the valve opening could affect the
refrigerant flow rate and compression ratio, which are reflected by
refrigeration capacity and power consumed by compressor as shown in
Figure (1-3). The increase in the compressor speed increases the
refrigerant flow rate and compression ratio, consequently, the power
consumption will be higher. The refrigeration effect decreases with the
increasing pressure ratio due to the behavior of the saturation line curve.
For these reasons, the coefficient of performance will increase at low
compressor speed [7].
Low speed
High speed
Qe,L W,L
Qe,h W,h
Figure (1-3): Effect of compressor speed change on the refrigeration cycle [7].
1.4 Controlling capacity methods
Designers of the refrigeration system depend on the maximum load to

select system equipment, but with continuous system operation to obtain
4
the set conditions, refrigeration capacity must be regulated depending on

thermal load [8], which can be achieved in different ways:
 Start and stop: A conventional controlling method that is used for

single speed refrigeration systems. Compressor at On/Off operation
frequently is depending on the thermostat signal. Cooling effect will
be 100% at compressor running and 0% at stop, which increases
temperature fluctuation and power consumption.
 Cylinder unloaded: This method is used with multi cylinders
compressors refrigeration systems by lifting the suction valve that
leads to no compression case.
 Multiple compressors: This method is used for high capacity
systems by running the compressors sequentially depending on the
thermal load. The advantage of this method is the low startup
current and the “standby” capacity provided.
 Hot gas bypass: A little hot compression vapor is bypass back into
the suction pipe to reduce the system capacity. Low current is
required when system startup is the most advantage of this method
and can be used for low capacities. Overheated compressor cylinder
is a drawback of this method, especially at part load condition.
 Speed control: In the previous methods, compressor still operates at
maximum speed which means high power consumption. Variable
speed compressors (VSC) with variable frequency drive (VFD) are
the best for the power reduction with high system performance. Low
startup current with VFD occurs at low compressor speed. Thus, the
VSC is still the best method for thermal systems.
5
1.5 System improvement work
Conventional refrigeration systems are controlled by On/Off

compressor operation to maintain the thermal load. For the variable
speed technology, compressor speed is regulated depending on the
thermal load. For example, in air conditioning systems when room
temperature reaches a set point, compressor speed decreases and
continues running with a certain minimum speed depending on this load.
In the following, system improvement in terms of equipment and
controlling methods are discussed.
1.5.1 Improving system equipment
The refrigeration capacity can be regulated by changing the

refrigerant flow rate that depends on compressor speed. Compressors
consume about 80% of the total power required in refrigeration systems
and 20% are consumed by the fans [9]. Rotary and scroll compressors
are more efficient in variation speed than reciprocating compressors due
to lubrication and vibration problems, especially at low speed. With a
new version of variable speed compressors, twin cylinder rotary
compressors are more efficient at low speed and the refrigeration system
will be more flexible to any disturbance [10]. Figure (1-4) shows
different types of variable speed compressors.
6
Figure (1-4): Different types of variable speed compressors [10].
Compressor speed can be regulated directly by changing its frequency

to meet the required load by using an inverter driver [11]. AC-current
can be converted to three phases DC-current by the inverter with a
constant voltage to frequency ratio [12] as shown in Figure (1-5).
Figure (1-5): Basic configuration of variable speed drive [12].
EEV regulates the refrigerant flow rate and the pressure ratio by
changing the orifice opening to keep the degree of refrigerant superheat
at a set point. The refrigerant degree of superheat (DS) is defined as the
temperature difference between the refrigerant vapor temperature at the
7
evaporator outlet (Tev,ro) and the saturation refrigerant temperature

(Tev,sat) at evaporator pressure [1].
(1-1)
1.5.2 Improving system control
Conventional refrigeration systems with single-speed compressors are

controlled by a thermostat with On/Off operation method to keep the
temperature approximately at desired values. Intelligent controllers are
required to control both compressor speed and EEV opening depending
on the thermal load at optimum operating conditions [13]. These
controllers have sensors to control system equipment and a
microprocessor which results in an additional cost and complications to
the system. Variable speed refrigeration systems with EEV, controlling
system have two loops as shown in Figure (1-6):
 The first loop controls compressor speed to match variable

thermal loads depending on the temperature difference between
sensor reading and set value.
 The second loop controls EEV opening to maintain DS at the
desired value depending on the difference value in DS between
the temperature sensor reading and the DS set value.
8
Compressor control loop
Tev,wo
Tw,set - compressor
inverter compressor
+ controller Product
ΔTw cold water
temperature
The
refrigeration
chill water
system
Refrigerant
ΔDS superheat
DS set + EEV EEV
-
EEV
controller driver
DS
EEV control loop
Figure (1-6): Two controlling loops of the VSRs [13].
Conventional controllers are used for variable speed refrigeration

systems VSRs with an acceptable response and low cost as compared
to intelligent controllers which have a high accuracy [13]. VSRs are
rated as high order systems with time delay [14] for that reason fuzzy
controllers are widely used to control these systems. Controllers that
were used with VSRs can be summarised in a diagram as shown in
Figure (1-7).
controllers
convensional intelligent
Adaptive
On/Off High/Low PID fuzzy ANN
PID
Figure (1-7): VSRs controllers classification [14].
9
1.6 VSRS applications
Refrigeration systems are widely working at part load condition, thus

the aim of power saving will be achieved using variable speed
compressors which increases coefficient of performance (COP). For that
reason, many applications used VSC as follow:
 Modern Refrigerator: High performance and low room

temperature fluctuation are the benefits of using variable speed
compressors in addition to long working life.
 Direct expansion (DX) air conditioning systems: Continuous
dehumidification at low compressor speed was the best advantage
in these systems in addition to the power saving.
 Variable Refrigerant Flow systems (VRFs): This technology
provides the ability for several indoor units to operate with only
one outdoor unit of the system. VRF systems can either be for
cooling or heating. The speed of the compressor is regulated with
respect to the thermal capacity which depends on room
temperature.
 Variable speed chillers: These are used for a large capacity of the
system to reject heat from the working fluid (water). With the
new technology, power saving reaches 30% in addition to low
noise and increasing heat exchangers' effectiveness at low
compressor speeds.
10
1-7 VSRS advantages
Refrigeration systems with variable speed compressors are widely used

in industrial and residential sectors, in spite of high cost and
complications, but with many advantages, as follows:
 Significant reduction in power consumption due to decreasing the

compressor speed and pressure ratio at partial load conditions.
 Less power is required at compressor startup operation by using
inverter technology and EEV.
 Increasing system COP at partial loads due to low power consumed
by compressor at low speeds.
 Increasing the stability of the system that depends on the DS value
by using EEV in the VSRs instead of the conventional expansion
devices.
 Low fluctuations in room temperature by using VSRs as compared
to single speed compressor systems.
 At low speeds, compressor vibration and noise will decrease.
 A short time is required to bring the set temperature, which is
because of a high speed compressor, runs.
 Continuous dehumidification prosses in inverter air-conditioning
systems, on the contrary in conventional systems, in off-period
condensed water on evaporator fins will be evaporated.
 The working life of compressor increases at low-speed operation
due to low friction losses and low temperature of electrical coils.
11
Chapter Two
Literature Review
Chapter Two Literature Review
Chapter Two
Literature Review
2.1 Introduction
The concept of variable capacity control was proposed before more

than 40 years ago [15]. Theoretical studies were concentrated on the
general system performance because of the high cost of experimental
works. Thus, most of this literature suggested a mechanical solution to
control refrigerant flow in refrigeration systems at partial load conditions
[8]. In this chapter, a review of literature is classified into three sections
(general performance, refrigerant superheat, and system control
principles) and then the aim of this study is presented.
2.2 General performance
The first study, in this review, was by Cohen et al. [15], to improve
the air conditioning system by using a variable-capacity compressor.
Energy conservation was only at seasonal operation conditions because
of a partial load. Where the compressor will be more efficient at low
capacities due to the decrease in both mechanical frictional losses and
also cycle pressure compression ratio at low capacities. Energy
conservation from 28% to 35% was achieved by using the thermostatic
expansion valve (TEV) instead of a capillary tube. Energy saving was
due to low torque required at startup compressor and few On/Off cycles
at seasonal base calculations.
12
Shimma et al. [16] used a variable frequency drive VFD with an air
conditioning (A/C) system. This technique improved the system COP
20% to 40% depending on the controlling method at low demand
conditions. At low compressor speed, the thermal efficiency of both
evaporator and condenser increased and also the power consumption
decreased. Their experimental results showed that using the PI controller
to control compressor speed resulted in good response and less
oscillation in the room temperature as compared to the On/Off method.
The effect of the compressor speed variation and EEV opening on the
power consumption and refrigeration capacity in cooling chiller systems
was numerically investigated by Koury et al. [17]. Their results of the
numerical simulation showed that when compressor speed was
increased, the COP will be decreased because of higher power
consumption in spite of the increase in refrigeration effect. An increase
in the EEV opening will increase the COP too with a limit of safety for
compressor operation. This simulation presented a relationship between
compressor speed and EEV opening which achieves maximum system
performance.
Hogqi et al. [18] compared a reciprocating and scroll variable speed

compressor of the A/C system. The disadvantages of the reciprocating
compressors were high vibration, high noise, a limitation for operation at
lower frequency, and lubrication problems. They found the scroll
variable speed compressor was more efficient than the reciprocating
compressor and it is more suitable for variable speed refrigeration
systems.
13
Li et al. [11] compared the reciprocating and scroll variable speed

compressors of the A/C system and studied the effect of the voltage to
frequency ratio (v/f ) on the compressor performance. For reciprocating
variable speed compressors, their results showed that there was a
lubrication problem at low speed and high level of vibration and noise at
high speed. Thus, the scroll compressor was more flexible to variable
speed conditions than reciprocating compressors at the same working
conditions. In addition, the ratio v/f must be kept constant to avoid the
overheating in compressor coils caused by high currents.
Chang et al. [19] developed a numerical design program to calculate

the optimum geometrical scroll compressor parameters (scroll extended
angle, the thickness of the scroll wrap and the height of this wrap) and
compared between direct current brushless (BLDC) motor and
conventional alternating current (AC) motor. They found the
improvement in the COP which was about 2~9% by using the BLDC
scroll compressors.
The improvement of the inverter systems was achieved by using

modified equipment and intelligent controllers Chen et al. [20]
presented a refrigerator-freezer with a variable BLDC reciprocating
compressor and a microcontroller which depended on the temperature
difference as a function to the change in the frequency of the compressor
motor. Their results showed that energy-saving in winter and in summer
was 34% and 22% respectively due to differences in thermal loads.
The effects of operating conditions on system power consumption for

a water chiller system with R410a refrigerant were investigated by
Aprea et al. [21] for cooling and heating modes. They compared
14
constant frequency reciprocating compressor and variable frequency

scroll compressor with different temperature sets for the evaporator and
condenser at a variable water mass flow rate for a constant thermal load.
Their experimental results showed higher energy consumption by using a
constant speed compressor at all operating conditions. The effect of
decreasing evaporation temperature increased power consumption and
also at increasing condenser temperature.
Cecchinato [22] examined a chiller package system with three types

of scroll compressors (constant speed, variable speed, and both). Their
experimental results showed that the energy efficiency ratio (EER) for
all three scroll compressors decreased with increasing cooling load, also
the EER of inverter compressor was the best at partial demand. It could
be shown that the full variable speed compressor with inverter drive is
more suitable for a good performance at different operating conditions.
Energy conservation in both cooling and heating modes was

investigated by Adhikari et al. [23]. Four different kinds of Heating and
Ventilation Air Condition systems (HVAC) were working as heat pumps
(water to water borehole, water to water wells, air to water, and air to
air). Based on the heat exchanger working principles, the four HVAC
systems were compared to a low energy building condition by using a
variable and constant speed compressor at the different climatic zones
among one year. Their results were showed that the variable speed
compressor could save about 18% of power consumption and the COP
was 3.7, besides, the saving at the heating mode was greater than cooling
one.
15
The performance of the inverter room air conditioner at heating and

cooling mode was investigated by Huang et al. [24]. The effect of the
amount of refrigerant charge, compressor speed, EEV opening, and fan
speed of both condenser and evaporator were in considerations. By using
a mathematical model based on air enthalpy change, they were
concluded that the optimum refrigerant charging process must be at
cooling mode with intermediate conditions. In addition, the COP
decreased with increasing compressor speed, and for each compressor
speed, there is a certain fan speed at the optimum COP. Furthermore, the
COP slightly increased with the increasing refrigerant degree of
superheat which is inversely proportional to the EEV opening.
Lago et al. [7] studied the effect of compressor speed on EEV

opening for the A/C system to achieve the maximum COP. Their
experimental results showed that at each compressor speed, there is an
EEV opening value that achieved maximum COP for refrigeration
systems with a variable speed compressor.
A different study was presented by Watcharapongvinij et al. [25],

to compare single and variable speed compressor (VSC). Their results
showed that, under certain conditions, a cooling system with a single
speed compressor was more efficient at night compared to a variable
speed compressor. More power was consumed at night from the VSCs
due to the continuous compressor operation at no-load condition, while a
conventional system was stopped. On the contrary, in the daytime, VSCs
were more efficient than constant speed systems. For that reason, the
VSCs must be turned off at no-load condition.
16
The HVAC system is designed at maximum load conditions, but

when the system runs at partial loads, the conventional refrigeration
systems will be at On/Off operation that results in more power
consumption. Schibuola et.al [26] studied the A/C system for two rooms
with different loads along one year at cooling and heating mode. Their
experimental results showed energy saving can increase 38.9% by using
a variable speed driver for both the compressor and fans compared to
single speed equipment.
Tu et al. [27] developed a dynamic model to control a variable

refrigerant flow system (VRFs) including a variable speed compressor,
EEV, and sub-cooler. The effect of coupling between compressor speed
and EEV opening on the performance and stability of the VRFs was
studied. They found the optimum energy efficiency ratio (EER) was at a
narrow EEV opening under the part-load condition. The narrow EEV
opening affected the amount of the refrigerant in the subcool case at a
certain compressor speed that led to increasing the refrigeration capacity.
2.3 Refrigerant superheat
Refrigerant superheats affect system stability, coefficient of

performance, and the compressor saving for a variable speed
refrigeration system. Superheat control is a difficult task due to the
nonlinearity of the VSRs response and with time delay. A high DS value
leads to low COP but it saves the compressor against damage from liquid
drops. The EEV opening affects the stability of the system at high DS
values that results in a continuous fluctuation in temperature and
pressure that is defined as hunting [28].
17
Lei et al. [29] presented a simulation study for a chiller cooling

system with a variable speed compressor and variable expansion valve.
This study showed that the expansion valve closing at high compressor
speed results in a higher decrease in the refrigerant flow rate as
compared to the closing at low compressor speed. One of the important
results of this study, the degree of superheat was not constant at a certain
value, but it decreases with increasing the compressor speed.
Rasmussen et al. [30] converted the DS controlling method to a

referred variable that directly controls the linear system depending on the
evaporation temperature and the design characteristics to release an EEV
controlling equation. A new method for the DS indirect controlling value
was submitted which depended on the evaporator's inherent
characteristics and the refrigeration mass flow rate instead of its working
points. The advantages of these methods were fast response with high
accuracy and also it was simple to control. Their experimental results
showed a high equivalence between the new method and conventional
controllers PID with more stability at the disturbance.
The stability of HVAC systems with the VSC depends on the degree
of the superheat set value, this was discussed by Deng et al. [31] using
an EEV and thermostatic expansion valve (TEV). Their results stated
that for each cooling load there is a minimum stable degree of
superheating where the system operates without hunting and the DS set
value increases when the cooling load increases. This means that the DS
is a function of compressor speed, evaporator temperature, and the EEV
opening.
18
Xia et al. [32] studied the DX A/C system which was modeling with
a VSC and EEV to examine the effect of DS value on the stability of the
system by adding the temperature sensor equation to the EEV controller
which depended on the time delay of the sensor reading. Their
simulation results showed that slowing down of the DS controlling
signal by increasing the sensor thermal resistance could lead to stability
in the system. Furthermore, when the mixture-vapor point moved
towards the evaporator exit at the high compressor speed or low fan
speed causes hunting. The latter is defined as excessive fluctuations in
the refrigerant temperature at the evaporator exit.
The phenomenon of hunting is one of the drawbacks in the VSRs

because it leads to reduce operation safety and high power consumption.
In variable speed compressor systems, hunting is very common due to
changes in compressor speed and EEV opening. Xia et al. [33] studied
the effect of evaporator temperature and compressor speed on the degree
of refrigerant superheat by examining the R410a DX system with an
EEV controlled by a PI controller. Their experimental results showed
that the none linearity between the EEV opening and refrigerant mass
flow rate could lead to more chance of being hunt especially at low
compressor speed or at low evaporating temperature.
The sensing dynamic characteristics of temperature sensors in both

TEV and EEV have an impact on the operation stability. Increasing the
sensor‟s thermal resistance leads to the stable operation of the system
due to delays in the sensor controlling signal. Xia et al. [28] developed a
dynamic model for the DX A/C system with a variable speed compressor
and EEV to study the effect of the EEV sensor thermal resistance on the
stability of the system. Their results showed that the increasing speed of
19
the compressor can cause a high chance for hunting at a large cooling
capacity, and also by decreasing the sensor thickness.
2.4 Controlling method
Several studies focused on the controlling method to control the

refrigeration capacity and the degree of refrigerant superheat. The
conventional refrigeration and heat pump systems used an On/Off
method to control the single speed compressor while the degree of
superheating was controlled by a thermostatic expansion valve. The
variation in the cooling capacity by using variable speed compressors
equipped with an electronic expansion valve requires intelligent
controllers to achieve optimum performance. The non-linearity of the
system thermal characteristics and the time delay in the DS response
make that the VSRs is considered as a high order control system [33] in
addition to the cross-coupling effect between the compressor speed
variation and EEV opening.
Zhu et al. [34] controlled the degree of refrigerant superheat of the

DX system at the end of the evaporator by a PID-fuzzy controller, which
was suitable for enhancement of evaporator characteristics. Their results
showed a stable response with less time required to reach the study state
as compared to the conventional PID controller.
The integral term in the PI-fuzzy controller decreases the steady-state

error in the static response of a linear system, but a cooling system with a
variable speed compressor is dynamic with time delay and a high order
system. The fuzzy controller with the integral term was investigated by
Kolokotas et al. [35] for the HVAC system with a variable speed
compressor. A system response comparisons between PID-fuzzy, PD-
20
fuzzy, adaptive PD-fuzzy, and On/Off controllers were made using

Matlab Simulink. They found the error integration term in the PID-fuzzy
controller increased system oscillation which led the system to consume
more power as compared to the PD-fuzzy controller. A new adaptive
PD-fuzzy controller was presented with a variable scale that resulted in
the best performance compared to other suggested controllers.
When the scroll compressor runs at low speed the pressure ratio and
the friction losses decrease, and consequently, this results in low power
consumed by the compressor. Binneberg et al. [2] compared three
compressor speed controlling methods (On/Off, high/low, and full
controlling method) for a household refrigerator. Their experimental
results showed the reduction in the compressor power consumption was
about 21% with a high/low controller and 30% at the full controlling
method as compared to the On/Off controller. In addition, the power-
saving decreases with increasing the speed of the compressor.
Aprea et al. [36] presented a comparative study between two A/C

refrigeration systems. The first was a variable speed reciprocating
compressor with a fuzzy controller to control the frequency of the
compressor between 30 and 50 Hz. The second was a constant frequency
50 Hz compressor with an On/Off thermostatic controller. Experiments
were performed with evaporator temperatures -5, 0, and 10ºC in summer
and winter. Their comparison results between the two controllers showed
that power saving increased with increasing the evaporator temperature.
One of the advantages of a variable speed compressor in a DX A/C

system is the continuous dehumidification of moist air. Re-evaporation
of the condensed water occurs when the compressor stopped in the
21
On/Off controlling method which is one of the drawbacks of single

speed A/C refrigeration systems. Xu et al. [37] compared two
controlling methods On/Off and high/low for both the compressor speed
and supply fan for the DX cooling system. They found with the
high/low controller, the humidity ratio decreased, the indoor air
temperature was stable, and the energy saving was higher compared to
the On/Off controlling method. Furthermore, the high/low controlling
method was simple in the structure and cheaper than the other intelligent
controllers.
To decrease the humidity ratio of moist air by cooling, air

temperature should be decreased below the dew point temperature. This
sometimes results in overcooling and then the air must be reheated
before supply it to the room. This process may require more energy
consumption. For DX A/C system, Qi et al. [38] presented a new
controlling method with a variable speed compressor and supply fun
using multi-input and multi-outputs controller (MIMO) to control the
humidity ratio and dry bulb temperature. This method depended on two
feedback signals of dry bulb temperature and humidity ratio as inputs to
the controller. Their experimental results showed a good performance of
the system by using the new controlling method, also the temperature
and humidity ratio were at desired values with a stable response.
The variation of the compressor speed affects directly the

refrigeration capacity, and indirectly the degree of refrigerant
superheating. Thus there is a cross-coupling between the EEV opening
and compressor speed controlling loops. Hua et al. [39] presented a new
PI controlling method for the EEV controller by adding the compressor
speed value as a feed-forward signal to the EEV controller. They found
22
the new PI controller was more stable response in the DS compared to

the conventional PI controller. The controller index was less about than
10 % where this parameter can be determined by the following equation:
Controller index = ∫ ( ) (2-1)
Soyguder et al. [40] compared between conventional PID, PD-fuzzy,

and PID-fuzzy controllers using MATLAB software to control a cold air
mass flow rate entering to two different temperature rooms conditioned
by the DX A/C system. The adaptive PID controller gains kP, ki, and kd
were changed by fuzzy rules which depended on temperature difference
and its rate of change. Their numerical results showed that the PID-fuzzy
controller is better than other controllers to reduce the steady-state error
and settling time.
The chiller system is widely used in cooling applications. In recent

years, these systems have been equipped with a variable speed
compressor and EEV. The controlling method plays a primary role in the
power saving process. Ekren et al. [13] compared three types of
controllers PID, fuzzy, and Artificial Neural Network (ANN) to control
the cold water temperature and degree of refrigerant superheat of 2 tons
of refrigeration chiller system. This chiller system was equipped with a
variable speed scroll compressor, electronic expansion valve, and R134a
as a refrigerant. Their results appeared that the PID controller was more
stable in controlling Two and DS from the fuzzy and ANN controllers.
But the ANN was better in saving power from PID and fuzzy controllers
about 8.1% and 6.6% respectively, on another hand, hardware and
software costs of the ANN controller were very expensive as compared
with the PID controller which is still used in most cooling applications.
23
The dynamic behaviors of the evaporator at different temperatures

affect cooling system's efficiency of VSRs. Auguto et al. [41] developed
a PID controller using adaptive controller gains (kp, ki, and kd) with
respect to the temperature of the evaporator to control the EEV of
variable speed chiller system with the refrigerant R134a. Their
experimental results indicated that the adaptive PID-controller response
was more effective in controlling the DS at different operation
conditions with an acceptable percentage error up to 8~10%.
Qi et al. [42] developed a new feed-forward EEV controller to

control the DS by using compressor and supply fan speeds as input
signals to the EEV controller. They found by a comparison between a
conventional PID and the new improved controller pointed to better
performance with higher efficiency and stability that achieved with the
new controlling method.
The amount of refrigerant charge affects the working pressures of the

condenser and evaporator which directly influence system efficiency.
Filho et al. [43] developed an adaptive PD-fuzzy controller. Weight
values of this controller are changed with respect to the absolute mean
error in the outlet cold water temperature from the chiller system. They
found, for a chiller system, the effect of increasing the refrigerant charge
on the performance was investigated. The increase in refrigerant charge
led to an increase in compressor power consumption and its temperature
that negatively affects the COP. Reduction in power consumption was
about 17.5% with a new controlling method as compared to the On/Off
controller.
24
The cooling system performance was improved by Ali [44]. It was

conducted by using two fuzzy logic controllers to control room
temperature and humidity ratio by changing the compressor and supply
fan speeds for the DX A/C system. The difference in room temperature
and rate of change of this difference were used as inputs to the fuzzy
compressor controller. The output was compressor speed. For the
humidity controller, the inputs were the difference in room temperature
and the humidity ratio, and the output was the supply fan speed. Their
simulation results with the Matlab tool showed that the new fuzzy
controller was highly efficient in reducing power consumption at any
disturbance.
Li et al. [45] presented a simulation study to control a cooling tower

fan speed by using an extremum seeking control scheme which depends
on the optimization of power consumption for both cooling tower and
variable speed screw compressor of a chiller system with the EEV. they
found the increasing tower fan speed leads to decrease the power
consumption of the compressor. For this controlling method, the
reduction in total power consumption was about 5.7% at changing inlet
water temperature of evaporator and about 0.32% at changing ambient
temperature.
Afzali [46] studied a model of a refrigeration system with the VSC

and EEV which were controlled by four improved PID-fuzzy controllers
for (compressor, (condenser and evaporator fans) and also the EEV). The
new controllers consisted of the PD-fuzzy and (integrator of the output
from the PD-fuzzy) to a composition of the output controlling signal.
The new controllers were compared to the On/Off controlling method for
(power consumption, temperature distribution, and COP). His simulation
25
results pointed to good performance with the new PID-fuzzy controllers.

Also, the effect of compressor speed variation on the total performance
of the system and equipment was reviewed in this study. System
efficiency was increased at low compressor speed.
The integral term in a fuzzy controller uses to remove response

offsets for a static system, but for the dynamic and high-order system
during a transient response, it will beat high fluctuations due to an
integral operator. A comparison between conventional-PID and fuzzy-
PID controllers was presented by Vidal et al. [47], on a prototype of a
chiller system. Their Simulation results with MATLAB software showed
that the system's response was faster and more stable with the PID-fuzzy
controller at different disturbance operation tests.
Jaafar [48], combined between conventional PID and fuzzy

controllers by using MATLAB. Five types of fuzzy controlling methods
(PD-fuzzy+I, PI-fuzzy+D, PD-fuzzy + PI-fuzzy, P-fuzzy+ID, and P-
fuzzy+I-fuzzy+D-fuzzy) were used to control the speed of compressor of
the HVAC system. His simulation results displayed increasing in rising
time and settling time by using hybrid fuzzy logic and PID controller and
also there was decreasing of overshot and transient response.
A time delay of the EEV working was one of the important reasons
for the unstable operation in variable speed compressor systems. This
delay comes from (stepper coil of the EEV, controller loop, and the
sensors of the feedback signal). Varchmin et al. [49] developed a new
PI controlling method with a forwarding signal of compressor speed and
evaporation temperature to control the DS in a variable speed chiller
system with R134a. Their results showed that there was more stability
26
with a fast response for the new controller compared with the previous
one.
Kianfar et al. [50] proposed a new cascade DS controlling method

by two loops with only one evaporation temperature sensor. The first
loop controlled the refrigerant DS and the second loop controlled the
two-phase flow evaporating length by regulating the refrigeration mass
flow rate. Their simulation results were achieved by using the new
controlling method for both loops. This showed robustness against
uncertainties and disturbances.
One of the advantages of DX A/C systems with a variable speed

compressor is controlling the moisture content. The coupling effect
between a compressor and supply fan loop was weakened by Xu et al.
[51]. A different strategy was used by changing the compressor and
supply fan speed to control wet and dry bulb temperatures respectively,
with a PD-low fuzzy logic controller which was modified by the theory
of weights. Their experimental results of the DX variable speed scroll
compressor with the EEV demonstrated that the air temperature and
moisture content were at high accuracy with a simplified controller
structure at all controllability tests.
A good controlling method for the EEV depends on increase the

mixture (vapor and liquid) of the refrigerant inside the evaporator, which
increases the cooling efficiency of the evaporator. Panoeiro et al. [52]
presented a new adaptive PID controller with Artificial Bee Colony
controlling method. The adaptive PID controller gains kp, ki, and kd can
be regulated depending on the evaporating temperature which was
changed from -5 to 10°C. Their simulation results showed a good DS
27
response with small overshoot, low study state error without hunting
effect, and fast reach to set value at different evaporating temperatures.
Prsic et al. [53] studied the effects of evaporator static characteristics

and the EEV on the degree of refrigerant superheat for a chiller system
with R410a refrigerant. Their numerical results displayed that the high
limit of the DS value was depended on the stability of the system to
avoid hunting and that low DS limit was depended on the evaporator
inlet water temperature to maintain the compressor. Friction inside the
EEV will be affected by the signal delay in time response and noise from
temperature sensors that led to hunting. The stability of the system was
improved by using a describing function that depended on a static
characteristic of the EEV to generate the controlling signal effect.
Jeon et al. [54] presented a procedure to design a fuzzy controller of

a refrigeration system. The effect of changes in the input memberships
scale for error and the rate of change in error in addition to the sampling
time on the response were studied. Their simulation and experimental
results showed that the system was more stable with decreasing the
membership scale of the error but the response became slow. Increasing
the membership scale of the rate of change the error leads to a fast
response with low dumping. Finally, the response will be faster with
decreasing its sampling time, but with more fluctuations.
For a DX system, Xia et al. [55] used an ANN controller to evaluate

the optimum DS set value which was found within the range between
4~7°C depending on the compressor speed, supply fan speed, and the
evaporator inlet air temperature. Their experimental results were
compared with a conventional controlling method at constant DS=6.
28
Controllability tests showed an improvement in the temperature response

with a higher COP which was about 1.2%. The system with variable DS
set value was more stable and without hunting as compared to the
constant DS controlling method.
The nonlinearity of the DS response to the EEV opening was

investigated by Yan et al. [56] to develop an adaptive PI controller
depending on the evaporator operating conditions. Proportional gain kp
and time constant were functions of the evaporator fan speed in the DX
variable-speed A/C system. Their experimental controllability tests
showed that the response of the DS with the adaptive PI controller was
more stable and faster than the On/Off method. Table (2-1) presents a
fast summary of these literatures.
Table (2-1): Summary of the literature.
General performance
The authors The methodology Their results
Cohen et al. They Improved the A/C system Energy conservation from 28% to
[15] by using a variable-capacity 35% was achieved by using the
(1974) compressor with TEV. TEV instead of a capillary tube.
Shimma et They used a VFD with a PI- The system COP was improved
al. [16] controller to control the from 20% to 40% compared to
(1985) compressor speed of an A/C. the on/off controlling method.
They studied the effects of the An increase in the EEV opening
Koury et al.
compressor speed variation and will increase the COP too with a
[17]
EEV opening on the limit of safety for compressor
(2001)
performance of a VSC chiller. operation.
They compared a reciprocating The scroll compressor was more
Hogqi et al.
and scroll variable speed suitable s than the reciprocating
[18]
compressor for a variable speed compressor with low noise and
(2002)
A/C system. vibration.
They studied the effect of the The ratio v/f must be kept
Li et al.
voltage to frequency ratio (v/f ) constant to avoid the overheating
[11]
on the A/C system with VSC. in compressor coils caused by
(2002)
high currents.
They compared direct current The improvement in the COP was
Chang et al.
brushless (BLDC) motor and about 2~9% by using the BLDC
[19]
conventional alternating current scroll compressors.
(2002)
(AC) motor.
29
They studied a refrigerator- The energy-saving in winter and

Chen et al.
freezer with a variable BLDC summer was 34% and 22%
[20]
reciprocating compressor and a respectively.
(2002)
microcontroller
They presented the effects of The Decreasing evaporation
Aprea et al.
operation conditions on the temperature increased power
[21]
chiller system with R410a with consumption and also at
(2006)
scroll VSC. increasing condenser temperature.
They examined a chiller package The VSC with inverter drive was
Cecchinato
system with three types of scroll with a good performance and
[22]
compressors (constant speed, high EER at different operating
(2010)
variable speed, and both). conditions.
Adhikari et They compared between VSC The VSC could save about 18%
al.[23] and CSC for different types of of power consumption and the
(2012) HVAC system as a heat pump. COP was (3.7).
They studied the effects of The refrigerant charging must be
Huang et al.
refrigerant charge, compressor at cooling mode and for each
[24]
speed, EEV opening, and fans compressor speed, there was a fan
(2014)
speed on the A/C system. speed with the best COP.
Lago et al. They presented a relationship At each compressor speed, there
[7] between compressor speed and is an EEV opening value that is
(2016) EEV opening for A/C system. achieved maximum COP.
Watcharap. They compared single and At no-load conditions, the single
et al. variable speed compressors of speed system was more efficient
[25] (2017) the A/C system. than VSCs.
Schibuola They studied the performance of The energy saving was increased
et.al[26], the A/C system with VSC at by about 38.9% by using a VSD
(2018) different loads along one year. for both the compressor and fans.
They investigated the coupling The optimum EER was at a
Tu et al.
between compressor speed and narrow EEV opening under the
[27]
EEV opening on VRFs. part-load condition that achieved
(2018)
the subcooling phase.
Refrigerant superheat
They studied the effect of EEV The degree of superheat was not
Lei et al.
opening and compressor speed constant at a certain value, but it
[29]
on the DS of a variable speed decreases with increasing the
(2005)
chiller system. speed of the compressor.
They developed the EEV A high equivalence between the
Rasmussen
controlling method depending new method and conventional
et al. [30]
on the evaporator temperature of controllers PID with more
(2006)
a refrigeration system. stability at the disturbance.
Deng et al. They compared the effect of DS The stability of the system was
[31] on the stability of A/C between depended on the DS value which
(2008) EEV and TEV. was not constant.
They examined the effect of the Increasing the sensor thermal
Xia et al.
temperature sensor resistance of resistance could lead to more
[32]
the DS on the stability of the stability and slowing down the
(2016)
A/C system. control signal of the EEV.
30
They studied the effects of The nonlinearity of the EEV

Xia et al. evaporator temperature and opening could lead to more
[33] compressor speed on the DS of a chance of being hunt especially at
(2017) DX system with an EEV and low compressor speed or at a low
refrigerant R410a. evaporating temperature
They investigated the effect of The increasing speed of the
Xia et al. the compressor speed variation compressor can cause a high
[28] and the EEV sensor thermal chance for hunting at a large
(2019) resistance on the stability of the cooling capacity, and also by
DX A/C system. decreasing the sensor thickness.
Controlling method
They compared the PID fuzzy Their results were a stable
Zhu et al.
controller and PID conventional response with less time required
[34]
controller to control the EEV of to reach the study state as with
(2000)
the DX system. the fuzzy controller.
They investigated The fuzzy Error integration term in the PID-
Kolokotas et
controller with an integral term fuzzy controller increased system
al. [35]
for the HVAC system. oscillation as compared to the
(2001)
PD-fuzzy controller.
They compared three controlling The reduction in the power
Binneberg et methods (On/Off, high/low, and consumption was about 21% with
al. [2] full controlling) for a household a high/low controller and 30% at
(2002) refrigerator. the full controlling method as
compared to the On/Off controller
They studied the effect of The power-saving increased with
Aprea et al.
increasing the evaporator increasing the evaporator
[36]
temperature on the A/C system temperature and with a fuzzy
(2004)
with a fuzzy controller. controller.
They compared two controlling With the high/low controller, the
Xu et al. methods On/Off and high/low humidity ratio decreased and the
[37] for the DX cooling system. energy saving was higher
(2008)
compared to the On/Off.
They used multi-input and A good performance by using the
Qi et al.
multi-outputs controller MIMO, also the temperature and
[38]
(MIMO) to control the humidity humidity ratio were at desired
(2008)
ratio and dry bulb temperature values with a stable response.
They presented a new PI The new PI controller showed a
Hua et al. controlling method by adding more stable response in the DS
[39] the compressor speed value as a compared to the conventional PI
(2009) feed-forward signal to the EEV controller with decreasing about
controller. 10% in the controlling index.
Soyguder et They compared PID, PD-fuzzy, The PID-fuzzy controller was
al. [40] and PID-fuzzy controllers using better than other controllers to
MATLAB software to control an reduce the steady-state error and
(2009)
A/C. settling time.
Ekren et al. They compared three types of The ANN was the better in saving
[13] controllers PID, fuzzy, and power from PID and fuzzy
31
(2010) Artificial Neural Network controllers about 8.1% and 6.6%

(ANN) to control the cold water respectively, in spite of the high
temperature and DS of a chiller. cost of the ANN controller.
They developed an adaptive PID The new controller response was
Auguto et al.
controller depending on Tev to more effective in controlling the
[41]
control the EEV of a variable DS at different operation
(2010)
speed chiller system. conditions with error 8~10%.
They developed a PID with Better performance with higher
Qi et al. feed-forward by using efficiency and stability was
[42] compressor and supply fan achieved with the new controlling
(2010) speeds as input signals to the method as compared to a
EEV controller. conventional PID.
They developed an adaptive PD- A reduction in power
Filho et al.
fuzzy controller by changing its consumption was about 17.5%
[43]
weight values to control the with a new controlling method as
(2011)
chiller system. compared to the On/Off controller
He used two fuzzy logic The fuzzy controller was highly
Ali
controllers to control room efficient in reducing power
[44]
temperature and humidity ratio consumption at any disturbance
2012
for the DX A/C system. with a reduction in humidity ratio.
They used extremum seeking The reduction in power
Li et al.
control scheme for the fan and consumption was about 5.7% at
[45]
compressor speeds of a chiller changing the inlet water
(2012)
system with the EEV. temperature of the evaporator.
He studied a model of a The high performance was with
Afzali
refrigeration system with the PD-fuzzy controller compared to
[46]
VSC and EEV controlled by the PID. Also, the system efficiency
(2014)
PID-fuzzy controller. was increased at low loads.
Vidal et al. They compared between The response was faster and more
[47] conventional-PID and fuzzy-PID stable with the PID-fuzzy
(2013) controllers for a chiller system. controller at different disturbance.
He combined conventional PID The rising time and settling time
Jaafar
and fuzzy controllers by using were increased by using fuzzy
[48]
MATLAB for the HVAC compared to PID controller and
(2013)
system. the overshot was decreased too.
They used a compressor speed More stability with a fast
Varchmin et
and Tev as a forward signal to response was with the new
al. [49]
control the DS of a VSC chiller controller compared as compared
(2014)
system with a new PI controller. to the conventional PI-controller.
They proposed a new cascade The new controller showed
Kianfar et al.
DS controlling method by two robustness against uncertainties
[50]
loops with only one evaporation and disturbances.
(2014)
temperature sensor.
Xu et al. They used a modified PD-low The air temperature and moisture
[51] fuzzy logic controller to weaken content were at high accuracy at
(2015) the coupling effect for an A/C. all controllability tests.
Panoeiro et They used an adaptive PID The DS response was with low
al. [52] controller with an Artificial Bee study state error and without
32
(2016) Colony to control the EEV. hunting effect at different sets.

They studied the effects of The high limit of the DS value
Prsic et al. evaporator static characteristics was related to the stability of the
[53] and the EEV on the DS for a system and the low DS limit was
chiller system. to maintain the compressor.
They presented a procedure to The system was more stable with
design a fuzzy controller for an decreasing the membership scale.
Jeon et al.
A/C system. The effect of the response will be faster with
[54]
sampling time and membership decreasing its sampling time, but
scale was in consideration. with more fluctuations.
They used an ANN controller to The system with variable DS set
evaluate the optimum DS set value was more stable and the
Xia et al.
value depending on the COP was increased by 1.2% as
[55]
compressor speed, supply fan compared to the constant DS
speed, and Tev controlling method.
They developed an adaptive PI The response of the DS with the
Yan et al. controller depending on the adaptive PI controller was more
[56] evaporator operating conditions stable and faster than the On/Off
of the A/C system. method.
2.5 Scope of previous work
Refrigeration systems have evolved much by using variable speed

compressors and EEV technologies. Thus, intelligent controlling
methods are required to control the speed of the compressor and valve
opening. The refrigeration systems with variable speed compressors are
high order controlling systems with time delay. The value of the degree
of refrigerant superheat plays the main role in the stability of the system
which cannot be taken as constant. More of the controlling methods for a
variable speed refrigeration system depended on two controlling loops to
control the compressor speed and EEV opening. The stability of the
system is affected by the coupling between the two controlling loops.
There is no experimental study about using the fuzzy logic controller for
variable speed chiller refrigeration systems with R410a as a refrigerant.
33
2.6 Aim of this study
The objective of this study is to investigate the performance for water

chilling refrigeration system equipped with a variable speed compressor,
the EEV, and the refrigerant R410 as a working fluid with different kinds
of controllers and control methods. For this aim, the study has been
structured as the following:
1. Studying the effect of compressor speed and EEV opening on

the system performance at different evaporator and condenser
temperatures at manual operation.
2. Determination of the optimum degree of refrigerant superheats
relation with system variables at different operating conditions.
3. Developing a new controlling method to control the EEV at high
system stability depending on the optimum DS.
4. Comparison between different types of controllers ( high/low,
PID, and fuzzy) with different controlling methods to control
compressor speed and EEV opening.
5. Study the performance of the system at the dynamic and steady-
state operation with the new controlling method.
34
Chapter Three
Chapter Three Theoretical Analysis
Chapter Three
3.1 Introduction
In this chapter, the design and calculations of heat exchangers are

presented depending on the maximum compressor cooling capacity for
one ton of refrigeration capacity using Engineering Equation Solver
(EES) software. Then, calculations of the amount of R410a refrigerant
are stated. Finally, a review of controllers‟ types for compressor speed
and EEV opening is given.
3.2 Refrigeration cycle with variable speed compressor
The refrigeration system works according to the vapor compression

cycle and consists of four basic components which are a compressor,
condenser, expansion valve, and evaporator. The difference between
single and variable speed compressor cycles is in the refrigerant flow
rate in the cycle and also in the pressure ratio between the pressures of
the condenser and evaporator of the system which will be reflected in the
refrigeration capacity. This difference is due to the variation of the
compressor speed that will affect refrigerant mass flow rate which
changes from time to time and it will not be constant. Increasing
compressor speed leads to an increasing pressure ratio between
condenser and evaporator which can also be regulated by an expansion
valve, as shown in Figure (3-1).
35
condenser
High speed 3 2
Expanssion valve
Low speed
r
sso
pre
com
4
Pressure (bar)
1
evaporator
Enthalpy (kJ/kg)
Figure (3-1): Refrigeration cycle at high and low compressor speed.
3.3 Refrigerant flow rate
The design of the heat exchanger depends on the amount of

refrigerant flow in the cycle which is related directly to the compressor
speed. The refrigerant mass flow rate can be calculated from the
following equation [29]:
̇ (3-1)
Where the compressor speed depends on the frequency as follows:
(3-2)
The volumetric efficiency is defined as:
(3-3)
Where:
36
̇ Refrigerant mass flow rate (kg/s).

Compressor volumetric efficiency.
Compressor speed (rev/s).
Compressor swept volume per revolution (m3/rev).
Refrigerant vapor suction specific volume (m3/kg).
Compressor net output volume per revolution (m3/rev).
Compressor motor frequency (Hz).
Compressor electrical coil poles.
For the present work, the net displacement volume of the variable
speed compressor was 15 cm3/rev with volumetric efficiency 0.85 from
the manufacturer's information. By substituting equation (3-3) in (3-1),
the calculated mass flow rate was 0.023 kg/s at the maximum
compressor speed of 180 Hz with 220 V and 6 poles. The value of
is determined from the refrigerant R410a tables at evaporator
pressure and temperature 7 bar and 10°C respectively.
3.4 Design of heat exchangers
Two shells and coil heat exchangers are used as evaporator and
condenser. The refrigerant R410a flows inside the coil of the copper tube
and exchanges heat with cold water, which flows through a shell. The
shell consists of three concentric PVC cylinders (insulation cylinder,
outer cylinder, and inner cylinder) with diameters of 15.3, 12.7, and 10.2
cm respectively, as shown in Figure (3-2).
37
Water path
Di Refrigerant path
Do
Dc Pch
dto
Insulation cylinder
Figure (3-2) Shell and tube coil heat exchanger.
The design process depends on the copper tube length of the

evaporator and condenser, which relates to the amount of heat transfer
between the refrigerant and water. The heat transfer calculations depend
on the convection heat transfer coefficient for both the refrigerant and
water. The refrigerant convection heat transfer coefficient is calculated
based on the refrigerant phase (vapor, mixture of liquid and vapor, or
liquid) inside the copper tube. Thus, the coil tube length is the
summation of lengths for all flow regions phases inside the tube.
3.4.1 Water-side heat transfer coefficient
For the evaporator and condenser, water flows between two

concentric cylinders over the copper coil [57]. For the external flow on a
helical coil, Incropera and Dewitt suggested the following experimental
38
correlation [58] to determine the convective heat transfer coefficient for

the turbulent flow:
* + (3-4)
Where:
Convection heat transfer coefficient of water-side (W/m2.°C).
Water Reynolds number.
Water Prandtl number.
Water conduction heat transfer coefficient (W/m.°C).
Water-side hydraulic diameter (m).
Reynolds number can be calculated from the following equation:
(3-5)
Where:
Mass flux of the water (kg/s.m2).
Dynamic viscosity of the water (kg/m.s).
̇
(3-6)
Where:
̇ Water mass flow rate (kg/s).
Cross-sectional area of water flow (m2) which calculated from
the equation:
[( ) (( ) ( ) )]
(3-7)
Where:
Outside diameter of water shell cylinder (m).

Inside diameter of water shell cylinder (m).
39
Center diameter of the water shell cylinder (m).

Outside diameter of the refrigerant copper tube (m).
(3-8)
And to calculate the hydraulic diameter from the following equations
[57]:
(3-9)
Where:
The net volume of the water flowed through one turn (m3).
Length of one turn of the coil tube (m).
(3-10)
Where:
Volume trapped between two tubes of the shell for one turn (m3).
The volume of the copper tube in the one turns (m3).
( ) (3-11)
Where:
Distance between two turns of the coil (m).
(3-12)
( ) (3-13)
(( ) ) (3-14)
In the present work, the convective heat transfer coefficients for

condenser and evaporator were equal to 1743 W/m2.°C and 1850
W/m2.°C respectively which were determined using the EES software.
All thermodynamic properties for the refrigerant and water were
40
calculated by the EES program, and for more details about the code for
calculations can be seen in appendix (A).
3.4.2 Refrigerant-side heat transfer coefficient
Inside the condenser tubes, vapor refrigerant is condensed by rejecting

heat to the water. During a condensation process, refrigerant phase
change occurs from superheated vapor to a liquid phase. The refrigerant
boils in the evaporator by absorbing heat from the water. During this
process, liquid refrigerant evaporates in a phase change process. There
are two heat transfer coefficients for each exchanger: the first coefficient
is for the single-phase state (liquid or vapor) and the second one is for
the two-phase state (a mixture of saturated vapor and liquid).
Calculations of refrigerant single and two-phase heat transfer
coefficients are described in the following sections.
3.4.2.1 Single phase region
For single-phase refrigerant fluid state (liquid or vapor), the heat

transfer coefficient can be calculated using the following correlation:
[59],
(1+3.455( )) ( ) (3-15)
Where:
Convection heat transfer coefficient of the refrigerant fluid
(vapor or liquid). (W/m2.°C).
Reynolds number of the refrigerant fluid.
Prandtl number of the refrigerant fluid.
Inside diameter of the refrigerant copper tube (m).
41
Conduction heat transfer coefficient of the refrigerant fluid

(W/m.°C).
Where Reynolds number and Prandtl are calculated from:
(3-16)
(3-17)
̇
(3-18)
Where:
Refrigerant fluid mass flux (kg/m2.s).
Dynamic viscosity of the refrigerant fluid (kg/m.s).
Specific heat at a constant pressure of the refrigerant fluid
(J/kg.°C).
̇ Refrigerant mass flow rate (kg/s).
The length of the tube for the single-region can be calculated by solving
the conservation of energy law equations for the refrigerant-side and the
water-side [57].
̇ ( )
(3-19)
̇ ( )
(3-20)
( )
(3-21)
(3-22)
42
( ) ( )
( )
(3-23)
( )
The amount of heat transferred between the refrigerant and water

through the single-phase region (W).
Refrigerant enthalpy at the inlet to the single-region (J/kg).
Refrigerant enthalpy at the outlet from the single-region (J/kg).
Specific heat at constant pressure for the water (J/kg.°C).
Inlet water temperature inlet to the single-region (°C).
Outlet water temperature from the single-region (°C).
Overall heat transfer coefficient of the single region (W/m2.°C)
Logarithmic mean temperature difference.
copper tube length for the vapor region (m).
The same equations were used to calculate the tube length of the
condensing refrigerant liquid region (LC,3).
3.4.2.2 Two-phase region
For a mixture of the refrigerant vapor and liquid inside circular tubes
with R410a as a refrigerant, Vu et al. [60] modified the Shah equation
form the experimental work to the following equation:
(3-24)
∫ *( ) ( ) +
Where:
Convection heat transfer coefficient of the refrigerant mixture
region (W/m2.°C).
Refrigerant Reynolds number base on the liquid phase
properties.
43
Refrigerant Prandtl number base on the liquid phase properties.

Conduction heat transfer coefficient of the refrigerant liquid
(W/m.°C).
Dryness fraction of the refrigerant mixture.
Critical pressure ratio of the refrigerant.
(3-25)
(3-26)
̇
(3-27)
(3-28)
All the thermodynamic properties of the refrigerant are calculated at
saturation conditions (constant pressure and temperature). By solving the
equation (3-24) for (x) with the boundary from 0 to 1 for condenser and
from 0.3 to 1 for the evaporator to calculate the convection heat transfer
coefficient. The length of the tube for the mixed-region can be calculated
by solving the conservation of energy law equations for the refrigerant-
side and the water-side [57].
̇ ( ) (3-29)
( ) ( ) (3-30)
̇ ( ) (3-31)
( ) ( ) (3-32)
Where:
44
Refrigerant enthalpy at the inlet to the mixed-region (J/kg).

Refrigerant enthalpy at the outlet from the mixed-region (J/kg).
Refrigerant copper tube length in the mixed-region (m).
Specific heat at constant pressure for the water (J/kg.°C)
Wall copper tube temperature (°C).
Refrigerant saturation temperature (°C).
Water outlet temperature from the mixed-region (°C).
Water mean temperature of the mixed-region (°C).
Water inlet temperature to the mixed-region (°C).
(3-33)
3.4.3 Tube length
The evaporator can be divided into two regions (mixed and vapor)
depending on the refrigerant thermodynamic state while the condenser
consists of three regions (vapor, mixed, and liquid), as shown in Figure
(3-3).
subcool mixture superheat
3 Condenser 2
Pressure
Expansion
Valve
4 Evaporator 1
mixture superheat
Enthalpy
Figure (3-3): Refrigeration cycle with refrigerant phase regions .
45
The total length of the tube is the sum of all the lengths of each
region for both the evaporator and condenser which can be calculated by
solving the previous equations by using the EES software. The
evaporator and condenser program can be seen in appendix (A) which is
summarized with the two flowcharts. The result of the calculations for
the evaporator copper tube length was 6 m and for condenser was 9 m.
Table (3-1) reviews all the calculation results for the evaporator and
condenser.
Table (3-1): Reviews of calculations for evaporator and condenser.
Parameter Unit Evaporator Condenser

Water convection H.T.C (W/m2.°C) 1743 1850
2
Refrigerant mixed convection H.T.C (W/m .°C) 23078 11962
Refrigerant vapor convection H.T.C (W/m2.°C) 1635 4564
Refrigerant liquid convection H.T.C (W/m2.°C) / 5714
Mixed region tube length (m) 4.26 6.14
Vapor region tube length (m) 1.63 2.05
Liquid region tube length (m) / 0.85
Total coil length (m) 6 9
Number of turns (turn) 16 24
Coil height (cm) 35 50
Refrigerant copper tube diameter (mm) 9.5 9.5
The total height of the exchanger (cm) 55 70
3.5 Refrigerant charge
R410a was a refrigerant that is used in the experimental rig which is

a zeotropic mixture of equal mass ratio of refrigerants R32 and R125.
R410a has zero Ozone Depletion Potentials with thermal properties
46
similar to those of R22. The higher volumetric cooling capacity of

R410a as compared to R22 and the better thermal exchange properties
made the refrigeration system with R410a are more efficient also to the
higher density of the vapor at the suction side [61]. The condensing and
evaporating pressures are at high levels as compared to those of R22
which lead to high-pressure equipment required.
The amount of refrigeration fluid was calculated depending on the

amount of the refrigerant phase at each side of the cycle. The vapor
phase was at the evaporator and compressor, which was evaluated by
calculating the volumes of evaporator and compressor by the flowing
equation:
*( ) ( )+ (3-34)
The liquid phase side of the refrigerant was at the condenser and
filter drier which is evaluated by calculating the volume of these parts
from the flowing equation:
*( ) ( )+ (3-35)
Results from the two equations were about 550 g of R410a that is
required for the experimental rig. R410a was calibrated before using it in
the laboratory with the standard table of R410a thermal properties.
Comparison between three types of R410a (SEASON, UISZL, and
GALAXY) with the standards by measured the saturated pressure at a
temperature range from -30°C to 40°C and the results appear in Figure
(3-4).
47
24
20
saturated pressure (bar)

16
12
Standard
SESON
4
UISZL
GALAXY
0
-40 -30 -20 -10 0 10 20 30 40 50
saturated temperature (°C)
Figure (3-4): Comparison of R410a refrigerants.
3.6 Control algorithms
The process was controlled to maintain the output value from the
system at its desired limits. The refrigeration systems with a variable
speed compressor and EEV can be operated with different controlling
methods and controllers by using two control loops. The first control
loop was for control compressor speed which depends on the difference
in the produced cold water temperature (ΔTw) and the second control
loop was for controlling the EEV opening which depends on the
difference in the degree of refrigerant superheating (ΔDS), as shown in
Figure (1-6) in chapter one.
48
The outlet cold water temperature from the evaporator is regulated

by changing the refrigerant mass flow rate in the cycle which is related
to the speed of the compressor. This speed depends on the frequency of
the inverter drive which is controlled by the output analog voltage signal
in the range 0 to 5 volts from the controller to the compressor‟s driver.
The difference in the water temperature can be calculated from the
equation:
(3-36)
The degree of refrigerant superheat can be controlled by changing

the refrigerant flow through the EEV which depends on the valve
opening. The amount of the difference in the DS can be calculated from
the equation:
(3-37)
(3-38)
Where is the saturation temperature of refrigerant vapor through

the evaporator which is calculated by saturation tables of R410a at the
evaporator pressure.
Different types of controllers can be used in the refrigeration cycle

which are equipped with variable speed compressor and electronic
expansion valve EEV such a proportional, integral, and derivative
controller (PID) and also the fuzzy controller. The amount of the voltage
signal outlet from the controller should be added or subtracted from the
privies value of the driver signal. The controllers' types which are tested
with the experimental system to control the compressor speed and the
EEV opening can be summarized as follows:
49
3.6.1 On/Off Controller
The first was the On/Off controller, which is considered as a

reference in the current work for the comparison process with the other
controllers used in the experimental work. In this study, when the cold
water temperature reaches the desired value minus one, the compressor
will be stopped and after this temperature raises higher than the desired
value with plus one, so the compressor will be operating at a maximum
speed 3600 rpm. The EEV opening value was constant at 180 steps when
the compressor On or Off. The block diagram of this controller can be
seen in Figure (3-5).
Tev,wo
IF (ΔTw) > (+1) refrigerant
Tw,set - THEN (Vc=0)
IF (ΔTw) < (-1) inverter compressor
+ Product
THEN (Vc=5)
ΔTw cold water
temperature
The
refrigeration
chill water
system
Refrigerant
refrigerant superheat
EEV
Steps=180 the EEV
driver
Figure (3-5): Block diagram of the On/Off controller.
3.6.2 High/Low controller
The simplest controlling method for variable speed refrigeration

systems is the High/Low method. The compressor will be within a
continuous operation process at two speed limits, 3600 rpm at high
speed, and 1200 rpm at low speed. When the difference in the cold water
temperature is (+1), the compressor speed will be at the low-speed
50
operation. While at the deference (-1), it will be raised to the high-speed

operation. The EEV opening will be 180 steps at the full speed and 70
steps at minimum speed. The block diagram of this controlling method
can be seen in Figure (3-6).
Tev,wo
IF (ΔTw) > (+1) THEN
ΔTw Vc refrigerant
Tw,set - (Vc=1.7) AND (step=75) compressor
+ IF (ΔTw) < (-1) THEN (Vc=5)
inverter
Product
AND (step=180)
cold water
temperature
The
refrigeration
chill water
system
steps
Refrigerant
refrigerant superheat
EEV
the EEV
driver
Figure (3-6): Block diagram of high/low controller
The On/Off and High/Low controllers required only one loop to

control the compressor speed while the EEV opening will depend
directly on the value of this speed.
3.6.3 PI-controller
The proportional and integral (PI) controller is widely used in

variable speed refrigeration systems VSRs because of the simplicity of
its structure and low cost in addition to acceptable performance. The
speed of the compressor and EEV opening are controlled by the PI-
controller in separate loops as shown in Figure (3-7).
51
PI compressor
controller
Tev,wo Kp
Tw,set - ΔTw Vc Mr
+ inverter compressor
+ Product
Ki 1/S cold water
temperature
The
refrigeration
chill water
PI EEV
system
controller
Kp Refrigerant
DS set + ΔDS step EEV Mr superheat
+ the EEV
- driver
Ki 1/S
DS
Figure (3-7): Block diagram of the PI-controller.
The output signal from the PI-controller is calculated from the

equation (3-39) which consist of the summation of the two terms:
 A proportional term is the main effect to reduce the error from

multiply the difference value by the proportional gain (kp).
 An integral term reduces the steady state error by multiply the

time integral of the change in the difference value with the integral
gain (ki).
( ) ( ) ∫ ( ) (3-39)
Each controller gain ( ) and ( ) values determined by the tuning

process which is discussed in chapter five.
52
3.6.4 PID-controller
The derivative term in the PID controller is to reduce sudden changes

in the controlled signal by multiplying the derivative gain (kd) by the rate
of the change in the error which is combined with the proportional and
derivative terms.
( )
( ) ( ) ∫ ( ) (3-40)
The variable speed refrigeration systems with the PID-controller are

somewhat unstable as compared to the systems with the PI-controller
because the VSRs are high-order systems with time delay and at a
continuous change in operating conditions [14]. The block diagram of
the PID controller can be seen in Figure (3-8).
PID compressor
controller
Tev,wo Kp
Tw,set - ΔTw Vc Mr
Ki 1/S + inverter compressor
+ Product
Kd S cold water
temperature
The
refrigeration
chill water
PID EEV controller system
Kp
Refrigerant
ΔDS steps Mr superheat
DS set + EEV
Ki 1/S + the EEV
- driver
Kd S
DS
Figure (3-8): Block diagram of the PID-controller.
53
3.6.5 P-Fuzzy controller
The Fuzzy Logical Controller (FLC) was introduced in 1965 by Lotfi

Zadeh which is very similar to the human mind and it is widely used to
control the non-linear systems [46]. The FLC deals with the measured
value from the sensors and does not require a mathematical model to
represent the system, the FLC consists of three main parts fuzzification,
rules, and defuzzification as shown in Figure (3-9).
Input output
Fuzzification Rules Defuzzification
Figure (3-9): Main part of the fuzzy controller [46].
 Fuzzification: it is a process used to change the input real values to

a linguistics value (low, normal, high, and very high) depending
on the input values.
 Rules: it is using to relate and combine the inputs and outputs

linguistics values by (IF-AND-THEN) rules which depend on the
expert experience.
 Defuzzification: it is used to change the output linguistics values

from the rules to the crisp output values which can be used in the
controlled system as an output signal.
The fuzzification and the defuzzification are described by

membership functions as shown in Figure (3-10) which consist of:
54
 Weights of the segments which are represented on the X-axis as

values of the inputs or outputs corresponding to the linguistics
value.
 The degree of the membership which is represented by the amount

of the agreement with the true value on the Y-axis with a set of
values between 0 and 1.
Linguistic variables
-5Tw -4Tw -3Tw -2Tw -1Tw 0Tw +1Tw +2Tw +3Tw +4Tw +5Tw
Degree of membership
0.8
0.6
0.4
0.2
0
-2 -1.6 -1.2 -0.8 -0.4 0 0.4 0.8 1.2 1.6 2
Segment weights
Figure (3-10): Membership function components of the fuzzy controller.
The output signal value from the fuzzy controller is affected by:
 Increasing the number of segments will increase the response

smoothing from the controller.
 The value of the weight affects the controller output signal

value which represents the main action of the controller.
 The membership shape affects the relationship function

between the input and output which may be linear or
nonlinear, as shown in Figure (3-11).
55
0.6
change in V
0.4
-2 -1.6 -1.2 -0.8 -0.4 0 0.4 0.8 1.2 1.6 2

0.2
TW difference
error TW
0
-5V -4V -3V -2V -1V 0V+1V +2V +3V +4V +5V -4 -2 0 2 4
-0.2
-0.4
-0.6
0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 -0.05 -0.1 -0.15 -0.2 -0.25 -0.3 -0.35 -0.4 -0.45 -0.5
output voltage
0.6
change in V
0.4
-2 -1.6 -1.2 -0.8 -0.4 0 0.4 0.8 1.2 1.6 2
0.2
TW difference
error TW
0
-5V -4V -3V -2V -1V 0V+1V +2V +3V +4V +5V -4 -2 0 2 4
-0.2
-0.4
-0.6
0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 -0.05 -0.1 -0.15 -0.2 -0.25 -0.3 -0.35 -0.4 -0.45 -0.5
outout voltage
Figure (3-11): Linear and non-linear relation between the inputs and outputs.
For the present work, the design of membership input and output
functions was achieved by using the fuzzy system designer which is an
accessory tool with LabVIEW software as shown in Figure (3-12).
Figure (3-12): fuzzy system designer program front panel.
56
Rules of fuzzy controller present as a logical statement depending on

the logical names of the inputs and outputs, for example:
IF “ΔTw” (+5Tw) THEN “ΔV” (+5V)

IF “ΔTw” (+4Tw) THEN “ΔV” (+4V)
 .
 .
IF “ΔTw” (-5Tw) THEN “ΔV” (-5V)
Table (3-2) showed the rules of the P-fuzzy compressor and EEV
controllers.
Table (3-2): Rules of the P-fuzzy compressor and EEV controller

Compressor controller EEV controller
ΔTw ΔV ΔDS Δstep
+5 Tw +5 V +5 DS +5 ST
+4 Tw +4 V +4 DS +4 ST
+3 Tw +3 V +3 DS +3 ST
+2 Tw +2 V +2 DS +2 ST
+1 Tw +1 V +1 DS +1 ST
0 Tw 0V 0 DS 0 ST
-1 Tw -1 V -1 DS -1 ST
-2 Tw -2 V -2 DS -2 ST
-3 Tw -3 V -3 DS -3 ST
-4 Tw -4 V -4 DS -4 ST
-5 Tw -5 V -5 DS -5 ST
Where (+5Tw, +4Tw,…….., -4Tw, and -5Tw) represent the

linguistics inputs corresponding to the difference values in the water
temperature from high to low difference respectively as shown in Figure
(3-13). The (+5V, +4V,…….., -4V, and -5V) represent the linguistics
outputs corresponding to the change values in the compressor controlled
voltage from high to low voltage change respectively as shown in Figure
(3-14).
57
-5Tw -4Tw -3Tw -2Tw -1Tw 0 +1Tw +2Tw +3Tw +4Tw +5Tw
input (ΔTw)
Figure (3-13): P-fuzzy compressor controller input membership function
-5V -4V -3V -2V -1V0 +1V+2V +3V +4V +5V

output (ΔV)
Figure (3-14): P-fuzzy compressor controller output membership function.
Also for EEV P-fuzzy controller (+5DS,….., -5DS) represent the

linguistics inputs corresponding to the difference value in the degree of
superheat from high to low difference respectively as shown in Figure
(3-15).
-5DS -4DS -3DS -2DS -1DS 0 +1DS +2DS +3DS +4DS +5DS
input (ΔDS)
Figure (3-15): P-fuzzy EEV controller input membership function.
58
The (+5 ST,…, -5 ST) represent the linguistics outputs

corresponding to the change values in the EEV controlled steps from
high to low steps change respectively as shown in Figure (3-16).
-5ST -4ST -3ST -2ST-1ST 0 +1ST+2ST +3ST +4ST +5ST

output (Δsteps)
Figure (3-16): P-fuzzy EEV controller output membership function.
The values of all these weights can be evaluated by the tuning

process in chapter five. Figure (3-17) shows the block diagram of the P-
fuzzy controller for the two controlling loops for the compressor and the
EEV that are used in the LabVIEW.
P-fuzzy
Compressor controller
Tev,wo
Tw,set - compressor
inverter compressor
+ controller Product
0-5 V 30-180
ΔTw refrigerant cold water
signal Hz
temperature
The
refrigeration
chill water
P-fuzzy system
EEV controller
50-520 A,B.C.D Refrigerant
ΔDS steps refrigerant superheat
DS set + EEV EEV coils
-
the EEV
controller driver
DS
Figure (3-17): Block diagram of the P-fuzzy controller.
59
3.6.6 P+D Fuzzy controller
The controlled signal from the P+D fuzzy controller consists of

the summation of the two fuzzy controller signals, the proportional fuzzy
controller output signal, and the derivative fuzzy controller output as
shown in Figure (3-18).
P-fuzzy controller
+ Error value e +
- +
system
Set value Output 2 The total Output
controllers value
D-fuzzy controller output
The rate of
change in ee
d /dt Output 1
the error
Figure (3-18): P+D fuzzy controller structure diagram.
For the compressor controlling loop, the rate of change in water

temperature difference value can be calculated from following equation:
( ) ( )
(3-41)
And For the EEV controlling loop, the rate of change in DS

difference value can be calculated from the following equation:
( ) ( )
(3-42)
Where ( ) is the sampling time which it is the time between two

reading at ( ) and ( ) and in the experimental system was 1s.
60
Fuzzy memberships function for the compressor controller consists

of two parts, the error in cold water temperature function and the rate of
change the error function as shown in Figures (3-19).
-5Tw -4Tw -3Tw -2Tw -1Tw 0Tw +1Tw +2Tw +3Tw +4Tw +5Tw -5dTw -4dTw -3dTw -2dTw -1dTw 0dTw +1dTw +2dTw +3dTw +4dTw +5dTw
Input 1 the difference in cold water temperature Input 2 the rate of change of the difference in cold water temperature
-5V -4V -3V -2V 0V +2V +3V +4V +5V -5V -4V -3V -2V 0V +2V +3V +4V +5V
Output 1 the ganged in the compressor controller voltage signal Output 2 the ganged in the compressor controller voltage signal
Figure (3-19): P+D fuzzy membership functions of the compressor controller.
The rules for each fuzzy controller can be shown in the table (3-3)
which the same of the P-fuzzy controller in the form of „IF-THEN‟ for
the two parts of the controller:
Table (3-3): Rules of the P+D fuzzy compressor controller.

P-fuzzy compressor controller D-fuzzy compressor controller
ΔTw ΔV 1 d(ΔTw)/dt ΔV2
+5 Tw +5 V +5 dTw +5 V
+4 Tw +4 V +4 dTw +4 V
+3 Tw +3 V +3 dTw +3 V
+2 Tw +2 V +2 dTw +2 V
+1 Tw +1 V +1 dTw +1 V
0 Tw 0V 0 dTw 0V
-1 Tw -1 V -1 dTw -1 V
-2 Tw -2 V -2 dTw -2 V
-3 Tw -3 V -3 dTw -3 V
-4 Tw -4 V -4 dTw -4 V
-5 Tw -5 V -5 dTw -5 V
61
The EEV P+D fuzzy controller consists also of two parts, the
difference and the rate of changing the difference in the DS which the
membership functions can be seen in Figure (3-20).
Figure (3-20): Membership functions of the P+D fuzzy EEV controller
The rules of the two parts of the P+D fuzzy controller depend on the
„IF-THEN‟ base which can be seen in the table (3-4) and the values of
all the linguistics variables can be fined by tuning process in chapter (5).
Table (3-4): Fuzzy rules of the EEV controller

P-fuzzy EEV controller D-fuzzy EEV controller
ΔDS Steps change1 d(ΔDS)/dt Steps change2
+5 DS +5 ST +5 dDS +5 ST
+4 DS +4 ST +4 dDS +4 ST
+3 DS +3 ST +3 dDS +3 ST
+2 DS +2 ST +2 dDS +2 ST
+1 DS +1 ST +1 dDS +1 ST
0 DS 0 ST 0 dDS 0 ST
-1 DS -1 ST -1 dDS -1 ST
-2 DS -2 ST -2 dDS -2 ST
-3 DS -3 ST -3 dDS -3 ST
-4 DS -4 ST -4 dDS -4 ST
-5 DS -5 ST -5 dDS -5 ST
The block diagram of the P+D fuzzy controller for the compressor loop
and EEV loop can be seen in Figure (3-21).
62
P+D fuzzy
Tev,wo 0-5 V 30-180 refrigerant
P-fuzzy signal Hz
ΔTw e 1
Tw,set - +
compressor
+
+ inverter
Product
D-fuzzy cold water
ee 2 temperature
d /dt
The
refrigeration
chill water
P+D fuzzy system
EEV controller
P-fuzzy 50-520 A,B.C.D Refrigerant
DS set + ΔDS e 1 + steps EEV coils refrigerant superheat
- + the EEV
driver
D-fuzzy
ee 2
DS d /dt
Figure (3-21): Block diagram of the P+D fuzzy controller.
3.6.7 PD-Fuzzy controller
The PD-fuzzy controller has two inputs which are the error and the
rate of changing the error values and with one output is the controlled
signal as shown in Figure (3-22).
PD-fuzzy controller
+ Error value e
-
Set value ee system
d /dt Output value
The rate of
change in the error
Figure (3-22): PD-fuzzy controller diagram.
The main difference between P+D and PD-fuzzy controllers is in the

output controlling signal which is depending on one compound rule for
decision in PD-fuzzy controller unlike P+D fuzzy which depends on two
63
separate rules. The rate of change in the error for the water temperature
and the DS can be calculated from the equations (3-41) and (3-42)
respectively. The compressor speed PD-fuzzy controller has two inputs,
the difference in the cold water temperature out from the evaporator and
the rate of the change this difference, and one output was the change in
the voltage signal of the inverter drive which regulates the compressor
speed. The membership function of the PD-fuzzy compressor controller
can be seen in Figure (3-23).
First input (ΔTw)
-5dTw -4dTw -3dTw -2dTw -1dTw 0dTw +1dTw +2dTw +3dTw +4dTw +5dTw
Second input d(ΔTw)/dt
-5V -4V -3V -2V -1V 0V +1V+2V +3V +4V +5V

Output (ΔV)
Figure (3-23): Membership function of the PD-fuzzy compressor controller
64
The rules of the PD-fuzzy controller are consisting of the summation of

the two inputs in the form of “AND” and one output as the following
formula:
IF “ΔT” (+5Tw) AND “d(ΔTw)/dt” (+5dTw) THEN “ΔV” (+5V).
The rules table of the PD-fuzzy controller showed in the table (3-5).
Table (3-5): Compressor PD-fuzzy controller rules
Input (ΔTw)
- - - - -
ΔV +5Tw +4Tw +3Tw +2Tw +1Tw 0Tw
1Tw 2Tw 3Tw 4Tw 5Tw
+5dTw +5V +5V +5V +5V +5V +5V +4V +3V +2V +1V 0V
+4dTw +5V +5V +5V +5V +5V +4V +3V +2V +1V 0V -1V
+3dTw +5V +5V +5V +5V +4V +3V +2V +1V 0V -1V -2V
Input d(ΔTw) / dt
+2dTw +5V +5V +5V +4V +3V +2V +1V 0V -1V -2V -3V
+1dTw +5V +5V +4V +3V +2V +1V 0V -1V -2V -3V -4V
0dTw +5V +4V +3V +2V +1V 0V -1V -2V -3V -4V -5V
-1dTw +4V +3V +2V +1V 0V -1V -2V -3V -4V -5V -5V
-2dTw +3V +2V +1V 0V -1V -2V -3V -4V -5V -5V -5V
-3dTw +2V +1V 0V -1V -2V -3V -4V -5V -5V -5V -5V
-4dTw +1V 0V -1V -2V -3V -4V -5V -5V -5V -5V -5V
-5dTw 0V -1V -2V -3V -4V -5V -5V -5V -5V -5V -5V
All values of the linguistic variables can be evaluated by the tuning

process in chapter five. The EEV PD-fuzzy controller output step value
also depended on the difference in the degree of superheating (DS) and
the rate of the change this difference as two inputs to the controller and
with only one output the change value in the EEV steps. The
65
membership functions of the PD-fuzzy EEV controller can be seen in

Figure (3-24).
-5DS -4DS -3DS -2DS -1DS 0DS +1DS +2DS +3DS +4DS +5DS
First input (ΔDS)
-5dDS -4dDS -3dDS -2dDS -1dDS 0dDS +1dDS +2dDS +3dDS +4dDS +5dDS
Second input d(ΔDS)/dt
-5ST -4ST -3ST -2ST-1ST0V+1ST+2ST +3ST +4ST +5ST

Output (Δstep)
Figure (5-24): Membership function of the PD-fuzzy EEV controller.
The rule of the PD-fuzzy controller for the EEV comes with the flowing
formula:
IF “ΔDS” (+5DS) AND “d(ΔD)/dt” (+5dDS) THEN “Δstep” (+5ST)
The rules table of the PD-fuzzy controller for EEV controller is shown
in the table (3-6).
66
Table (3-6): EEV PD-fuzzy controller rules.
ΔDS
Δstep
+5DS +4DS +3 DS +2 DS +1 DS 0 DS -1 DS -2 DS -3 DS -4 DS -5 DS
+5 dDS +5ST +5ST +5ST +5ST +5ST +5ST +4ST +3ST +2ST +1ST 0ST
+4 dDS +5ST +5ST +5ST +5ST +5ST +4ST +3ST +2ST +1ST 0ST -1ST
+3 dDS +5ST +5ST +5ST +5ST +4ST +3ST +2ST +1ST 0ST -1ST -2ST
+2 dDS +5ST +5ST +5ST +4ST +3ST +2ST +1ST 0ST -1ST -2ST -3ST
+1dDS +5ST +5ST +4ST +3ST +2ST +1ST 0ST -1ST -2ST -3ST -4ST
d(ΔDS) / dt
0 dDS +5ST +4ST +3ST +2ST +1ST 0ST -1ST -2ST -3ST -4ST -5ST
-1 dDS +4ST +3ST +2ST +1ST 0ST -1ST -2ST -3ST -4ST -5ST -5ST
-2 dDS +3ST +2ST +1ST 0ST -1ST -2ST -3ST -4ST -5ST -5ST -5ST
-3 dDS +2ST +1ST 0ST -1ST -2ST -3ST -4ST -5ST -5ST -5ST -5ST
-4 dDS +1ST 0ST -1ST -2ST -3ST -4ST -5ST -5ST -5ST -5ST -5ST
-5 dDS 0ST -1ST -2ST -3ST -4ST -5ST -5ST -5ST -5ST -5ST -5ST
All linguistic variables of the PD-fuzzy EEV controller rules table

can be evaluated by the tuning process in chapter five. Figure (3-25)
shows the block diagram of the PD-fuzzy controller of the two
controlling loops.
PD fuzzy
Tev,wo 0-5 V 30-180 refrigerant
signal Hz
Tw set - ΔTw e
inverter compressor
+ Product
d /dt cold water
ee temperature
The
refrigeration
chill water
system
50-520 A,B.C.D Refrigerant

DS set + ΔDS e steps EEV coils refrigerant superheat
-
the EEV
driver
d /dt ee
DS
PD fuzzy
EEV controller
Figure (3-25): Block diagram of the PD-fuzzy controller
67
Chapter four
Experimental Rig
Chapter Four Experiment Rig
Chapter Four
Experimental Rig
4.1 Introduction
This chapter provides a description of the main equipment and drivers
that were used in the rig. Methods of attaching and working sensors and
instruments were explained. It can indicate how the system functions by
using the LabVIEW program with different controlling methods were
presented. Finally, an uncertainty analysis was presented.
The experimental rig is a prototype for a one-ton chiller refrigeration

system with R410a as a refrigerant. The variable speed compressor and
EEV were used with two heat exchangers to exchange heat between the
refrigerant and water. Four pressure and temperature sensors were used
to determine the refrigerant properties at the four main points of cycle 1,
2, 3, and 4. Refrigerant and water flow rates were measured by flow
meters. Data acquisitions with LabVIEW are used to read and record all
sensors' data and also to control compressor speed and EEV opening.
Different controlling methods and controllers are designed to control the
system with two or one control loops depending on the temperature
sensor reading. An auxiliary system is used to provide operating
conditions of the inlet water temperature to the evaporator and condenser
which consist of two 60L tanks with three water pumps and an electrical
heater. The return hot water from the condenser is cold by radiator and
fan which its speed is regulated by the controller depending on the hot
tank temperature. The electrical heater and the circulation water pump
are used to maintain the cold tank temperature at desired limits. The
sketch diagram of the experimental system is shown in Figure (4-1) and
the photos in Figure (4-2).
68
T T
F 1 P T P T
2
a
d e b
4 T P T P 3
F
T
T c f
F
a- Variable speed compressor

b- Condenser
c- EEV
d- Evaporator
e
e- Control and measurement unit
f- Filter dryer
g- Condenser water tank
i
h- Evaporator water tank
i- Hot water cooler
j- Water pump
k- Electrical heater T T
j
F Flow meter
T Temperature sensor
h g
k
P Pressure sensor
. Figure (4-1): Experimental rig diagram.
69
Front view Back view
2 d 2
1 d
b
4
a b
3 4 e
e g a
c
g f
Top view 2
d
3
c
g e g
4
f h
b
a
1
g-Pressure sensor
a- Compressor d- Control unit
b- EEV e- Refrigerant flow meter h- Temperature sensor
c- Filter dryer f- Water flow meter
Figure (4-2): Instruments of the refrigeration system.
70
All tubes and heat exchangers were thermally insulated to minimize

the heat transfer with the surrounding. The pressure drop in the
refrigerant tubes of the evaporator and condenser was neglected.
4.2 System equipment
The refrigeration cycle consists of four main equipment (compressor,

condenser, expansion valve, and evaporator). The refrigerant R410a is
compressed to the condenser to rejected heat to the water at high
pressure with phase-change from vapor to liquid. The expansion valve
works to reduce pressure and regulate refrigerant flow depending on the
valve opening. Then, the refrigerant inters to the evaporator to absorb
heat from the water at low pressure with phase-change from liquid to
superheated vapor. Then, the refrigerant returns to the compressor as
3 condenser 2
Expanssion valve
r
sso
pre
com
Pressure (bar)
4 evaporator 1
Enthalpy (kJ/kg)
Figure (4-3): Vapor compression refrigeration cycle.
71
The specification and method of running each requirement were

summarized as follows:
4.2.1 Compressor
The variable speed compressor was manufactured by the GMCC
refrigeration compressors company, which is ATM150D43TFZ model.
This model consists of twin rotary cylinders with total displacement
volume 15 cm3/rev and 1 ton of refrigeration capacity, as shown in
Figure (4-4).
Refrigerant
reservoir
coil
core
cylinders
Figure (4-4): GMCC variable speed compressor.
The electrical motor compressor is a brushless direct current

(BLDC) with three-phase (UVW) and 220 V. The speed of the
compressor can be regulated by changing the frequency of the three
phases from 0 to 180 Hz that is controlled by using a variable frequency
driver (VFD) which was suitable for BLDC motor model INVERTIK-E3
as shown in Figure (4-5).
72
Figure (4-5): Compressor driver.
The Invertek driver regulates the frequency of compressor phases

(UVW) which will lead to change the rotational speed of the compressor
motor depending on an analog voltage signal from 0 to 5v from the
controller as shown in Figure (4-6).
controller
0-5 v
Variable
speed
BLDC driver compressor
S U
Variables
R (V)
V
T (F) W
Input 3-phase output 3-phase
(pwm)
380 v 0-220 v
Figure (4-6): Variable frequency drive connection diagram.
4.2.2 Electronic Expansion Valve
The EEV was selected depending on the one-ton refrigeration capacity

of the compressor of type Danfoss (ETS 6-08) as shown in Figure (4-7).
73
Paramagnetic core
coil
orifice
Inlet
body
outlet
Figure (4-7): Electronic expansion valve.
The valve opening can be changed depending on the needle rotor

rotation which is affected by a 4-pools stepper motor coil by changing
steps pulse from step 50 as a minimum value to step 520 for a maximum
opening. Each step is equal to 45°/rev from the EEV revolution shaft.
The EEV driver regulates coil steps by a 12v pulse for each coil
depending on the input pulse signal 5v from the controller as shown in
Figure (4-8).
Figure (4-8): EEV driver connection.
74
4.2.3 Evaporator and Condenser
The evaporator and condenser are a shell and coil heat exchangers
used to exchange heat between water and refrigerant which flow inside
the (3/8”) copper coil tube as shown in Figure (4-9).
3/8" copper tube
water path
5" outer cylinder
w
6" insulation cylender
t flo
g eran
ri
ref
ow
ter fl
wa
Figure (4-9): Heat exchanger construction.
Each heat exchanger consists of three concentric PVC cylinders (4”

inner cylinder, 5” outer cylinder, and 6” insulation cover cylinder), the
copper tube was coiled around the 4” inner cylinder and water flow
around it between inner and outer cylinders as shown in Figure (4-10)
75
a a 6” insulation cylinder
b 5” outer cylinder
c 4” inner cylinder
a
b
c b
c
Figure (4-10): Evaporator and condenser used in the experimental rig.
Design calculations for both evaporator and condenser were presented

in chapter three and table (4-1) shows a summary of these calculations.
Table (4-1): Dimensions of the evaporator and condenser.
Item evaporator condenser
Insulation cover cylinder diameter (cm) 15.25 15.25

Outer cylinder diameter (cm) 12.7 12.7
Inner cylinder diameter (cm) 10.16 10.16
Copper tube diameter (mm) 9.5 9.5
Number of turns (turns) 16 25
Height of the coil (cm) 35 50
The exchanger hight (cm) 55 70
The inlet water to the evaporator and condenser was pumped by two
liquid centrifugal pumps with drivers. A variable speed pump can be
regulated depending on the input voltage signal from 0 to 5 V from the
controller to the driver as shown in Figure (4-11).
76
Water flow from the pump
0-1 utpu
2v t
o
DC
12v put
in
DC
0-5 v
signal
Figure (4-11): Water pump and its driver.
4.3 Measurement instruments
The experimental rig is equipped with many measurement devices,

for example at each point (1, 2, 3, and 4); pressure and temperature
sensors are connected. Sensors data are sent to the “LabVIEW” program
by the data acquisition “Labjak-T7 pro”. All these sensors and meters
have been calibrated in the control laboratory.
4.3.1 Temperature sensors
The eight temperature sensors were used in the experimental rig are
type Negative Temperature Coefficient (NTC) thermistor with value 10
kΩ to measure refrigerant and water temperatures with a temperature
range from -50 to 120°C. The thermistor was placed in direct contact
with the fluids as shown in Figure (4-12).
77
Figure (4-12): Water and refrigerant temperature sorceress direct connections.
All those sensors were calibrated with respect to NTC-10 kΩ which
was pr-calibrated with a fixed error of about 0.28°C. The results of the
calibration process appear in the table (4-2).
Table (4-2): Calibration results of temperature sensors

Sensor Fixed error Calibration equation Random error
(°C) (°C) (°C)
NTC1 0.3387 T1 = 0.9984 T1' + 0.2195 0.05215
NTC2 0.2841 T2 = 1.0005 T2' + 0.1455 0.03779
NTC3 0.2954 T3 = 0.9974 T3' + 0.1785 0.04768
NTC4 0.2874 T4 = 0.998 T4' + 0.0205 0.051317
NTC5 0.3235 T5 = 1.0005 T5' + 0.0316 0.04165
NTC6 0.3241 T6 = 1.0175 T6' - 0.4948 0.03415
NTC7 0.2874 T7 = 1.0083 T7' - 0.068 0.04875
NTC8 0.3071 T8= 1.0186 T8' - 0.5674 0.05071
78
The electrical circuit diagram of the NTC sensors can be seen in

Figure (4-13). The voltage potential on the NTC thermistor was
measured by the data acquisition.
Figure (4-13): NTC electrical circuit diagram.
The temperature value can be calculated by using a voltage value of

data acquisition in the flowing equation [62]:
(4-3)
( )
Where: , , and is the voltage value.
4.3.2 Pressure transducers
Four pressure sensors are used at selected four points in the

experimental rig to measure the pressure of the refrigerant. The range of
readings, which were given by sensors, was 0 to 40 bar type HYXC that
was found to be suitable for refrigerants as shown in Figure (4-14). All
79
sensors were calibrated in the control laboratory with respect to a pre-

calibrated pressure gage with a fixed error about 0.25 bar. The
calibration process results were presented in table (4-3).
Table (4-3): Pressure sensors calibration results.

(bar) (bar) (bar)
P1 0.25 P1 = 8.0552 v + 0.1308 0.071146
P2 0.25 P2 = 8.0634 v + 0.1227 0.072725
P3 0.25 P3 = 8.0577 v + 0.1114 0.064842
P4 0.25 P4 = 8.0505 v + 0.0457 0.083273
Figure (4-14): Pressure sensor.
The pressure value was calculated by measuring the sensor output

voltage 0 to 5 v by using data acquisition from the following equation by
the manufacture:
(4-4)
Where ( ) is measured pressure in bar and ( ) is the output voltage

from the sensor in volt.
80
4.3.3 Refrigerant flow meter
The refrigerant flow meter was located between the condenser and the
expansion valve after the dryer filter to measure the refrigerant liquid
volumetric flow rate. The flow meter was from the McMillan company,
which is a model (S-114-7). It was suitable for the refrigerant (R410a) at
flow ranges 0.2 to 2 L/min as shown in Figure (4-15).
Figure (4-15): Refrigerant flow meter.
The flow rate value in (mL/s) was calculated by measuring voltage

output from the meter with data acquisition following equation by the
manufacturer:
̇
(4-5)
Where ( ̇ ) is the volumetric flow rate of the refrigerant R410a in

(mL/s) and ( ) is voltage output from the flow meter in (v) measured
by the data acquisition. The McMillan flow meter was calibrated by the
manufacturer with a fixed error of 0.325 mL/s.
81
4.3.4 Water flow meter
The water flow rate was measured by using two flow sensors before
water enters the condenser and evaporator. It is AICHI type and
OF05ZAT model at a flow range 5 to 600 L/h as shown in Figure (4-16).
Figure (4-16): The water flow meter
The water flow meter was calculated by computing the number of

pulses at each second by the data acquisition with the following
empirical equation by the manufacture:
̇ (4-6)
̇
Where ( ) is a water volumetric flow rate in (mL/s) and ( ) is a
number of pulses measured by a data acquisition in (pulse/s). Water flow
meters were calibrated in the control laboratory by recording the time
required to fill a 5 liters dram at different flow ranges, the results of
calibration appear in table (4-4).
82
Table (4-4): Water flow meters calibration results.

(mL/s) (mL/s) (mL/s)
Water flow con. V 6.6523 Hz - 0.9527
0.9977 1.574384
Water flow ev.
1.0587 V 6.6512 Hz - 0.6996 1.94568
4.3.5 Power meter
The amount of power consumed in the system was measured by a

YIGEDIANQI meter and YG889-9SY model. A (power, voltage,
current, and frequency) digital 3-phase meter is shown in Figure (4-17).
The power input value to the system was recorded directly to the
LabVIEW front panel.
Figure (4-17): The 3-phase power meter.
4.4 Data acquisition

LabJack T-7 Pro is a data acquisition and the control panel in the
experimental rig. All sensors reading were collected by using the
LabVIEW-2018 software, which is installed in a laptop, were connected
83
to LabJack by a USB cable as shown in Figure (4-18). LabVIEW can be

used to control the speed of the compressor and valve opening by a
voltage analog signal 0 to 5 V from LabJack to the drivers.
Figure (4-18): Data acquisition.
The analog input pins of the LabJack connection and digital output
pins are viewed in the table (4-5) that used in the control panel of the
experimental rig.
Table (4-5): Data acquisition connection pins.
pin sensor measured

AIN0 NTC1 refrigerant temperature at point 1
AIN4 NTC5 water temperature at point 1
84

AIN8 P1 refrigerant pressure at point 1
AIN12 mr refrigerant flow meter
DAC0 Speed compressor speed output (0-5)v
DAC1 Pump water pump motor output (0-5)v
FIO0 mw,e evaporator water flow meter (pulse)
FIO1 mw,c condenser water flow meter (pulse)
FIO2 Relay Invertek relay on/off
FIO3 A-coil coil A of the EEV driver
FIO4 B-coil coil B of the EEV driver
FIO5 C-coil coil C of the EEV driver
FIO6 D-coil coil D of the EEV driver
4.5 System operation
LabVIEW is a system engineering application software used to

measure and control systems by using a graphical programming
approach. The application consists of two windows a front panel and a
block diagram [63]. All readings of sensors in the system and the
calculated properties appear in the front panel window as values and
graphs so make sure the system is in a steady-state operation as shown in
Figure (4-19).
85
start subcooling Compressor speed Refrigerant properties Pressure sensor reading
Chapter Four
Temperature sensors
response
86
EEV opening and DS
response
COP
COP response
Controller selection Controlling method selection

(manual, on/off, High/ Tw set Constant DS=7 EEV opening Refrigerant flow
Low, PI Variable DS by equation
input (steps) meter
PID, P-fuzzy, P+D-fuzzy, Direct EEV opening
PD-fuzzy)
Figure (4-19): LabVIEW front panel of the experimental system

Experiment Rig
The block diagram of the experimental system can be seen in the

appendix (A-4). It contains the graphical language program of the
experimental operating system which was summarized by the following
flow chart in Figure (4-20).
At first step, the EEV will be opened for full scale at step 520 to start
the operation from a specific value and then run the compressor at the
maximum speed 3600 rpm for 120s to expel deposited oil in system
parts. During these 120s, the EEV will be gradually closed from step 520
to step 180 which was the best opening at the maximum speed. The
advantages of the full EEV opening are to reset the EEV and also
decrease the pressure difference between the high side (condenser) and
the low side (evaporator) which leads to a decrease in the initial torque
required by the compressor.
At each main refrigeration cycle points 1, 2, 3, and 4, there are

measured values of temperature and pressure, in addition, the
calculations of the thermodynamic properties of refrigerant R410a can be
seen in the front panel window. Also, all the data which measured and
calculated in the front panel are saved as table data by the LabVIEW
software that can be opened in the Microsoft Excel program.
Depending on water temperature sensors data, cooling and heating

effects are calculated. The coefficient of performance (COP) is
computed depending on the power meter reading and cooling effect
calculations.
87
start
 Full opening the EEV at 520 step.

 Run the compressor at max. speed for 120s.
 Run the water pumps.
 Decreasing the EEV opening to 180 step at
step by step during the 120s .
Input set cold water temp.

Tw,set
Chose compressor speed controller:

PI, PID, P-fuzzy, P+D fuzzy, PD- fuzzy
Chose the control method of EEV opening:

Constant degree of superheat DS at 7 °C with controller.
By equation for variable DS with controller.
Direct control by equation EEV opening.
 Read temperatures (Tr1, Tr2, Tr3, Tr4, Tw1,Tw2,Tw3, Tw4)

 Read pressure sensors (P1, P2, P3, P4).
 Read water and refrigerant flow meters.
 Read the power meater
Calculate (Qe, Qc, COP)

NO
NO Tw,set > Tw4 YES NO DS set > DS YES
Increase the Decrease the Decrease the EEV Increase the EEV
compressor speed compressor speed opening opening
Press stop
YES
END
Figure (4-20): Flow chart of the operation system.
88
Controllers are used to making the outlet cold water temperature of

the evaporator at set values by controlling the speed of the compressor
and the EEV opening. The front panel window is provided with an
option to select the controlling method from the seven suggested
methods (manual, On/Off, High/Low, PI, PID, P-fuzzy, P+D fuzzy, and
PD-fuzzy). The controlling signal from the controller depends on the
difference between the set and reading value from the sensors.
Refrigerant thermodynamic properties were computed by using
“COOLPROP” that is an accessory software with LabVIEW depending
on the temperature and pressure sensors' values. System reading and
computed parameters are updated every one second which is defined as
sampling time. Table (4-6) shows LabVIEW front panel parameters used
in the system.
Table (4-6) LabVIEW front panel parameters
parameter Description Unit

Tw1 Evaporator inlet water temperature. °C
Tr1 Evaporator outlet refrigerant temperature. °C
Pr1 Evaporator outlet refrigerant pressure. bar
hr1 Evaporator outlet computed refrigerant enthalpy at Tr1 kJ/kg.°C
and Pr1
Tsat1 Evaporator outlet computed refrigerant saturated °C
temperature at Pr1.
Tw2 Condenser outlet water temperature. °C
Tr2 Condenser inlet refrigerant temperature. °C
Pr2 Condenser inlet refrigerant pressure. bar
hr2 Condenser inlet computed refrigerant enthalpy at Tr2 kJ/kg.°C
and Pr2.
Tw3 Condenser inlet water temperature. °C
Tr3 Condenser outlet refrigerant temperature. °C
Pr3 Condenser outlet refrigerant pressure. bar
hr3 Condenser outlet computed refrigerant enthalpy at Tr3 kJ/kg.°C
and Pr3.
89
Tsat3 Condenser outlet refrigerant saturated temperature °C

computed at Pr3.
r3 Condenser outlet refrigerant liquid density computed kg/m3
at Tr3 and Pr3.
Tw4 Evaporator outlet water temperature. °C
Tr4 Evaporator inlet refrigerant temperature. °C
Pr4 Evaporator inlet refrigerant pressure. bar
hr4 Evaporator inlet refrigerant enthalpy computed at Tr4 kJ/kg.°C
and Pr4.
DS Degree of refrigerant superheat outlet from evaporator °C
calculated from (DS= Tr1-Tsat1).
Tw,set Set cold water temperature interred by the user. °C
Subcool Amount of the subcooling in the condenser outlet °C
refrigerant temperature calculated (sub cool= Tr3-Tsat3).
Vw,e Evaporator water measured volumetric flow rate. mL/s
Vw,c Condenser water volumetric flow rate. mL/s
Vr Refrigerant volumetric flow rate. mL/s
r Refrigerant mass flow rate calculated from ( r= r3 Vr) g/s
Vc Compressor speed calculated from controlling loop. rpm
EEVopen EEV opening calculated from controlling loop. step
Wc Compressor measured power consumption. W
Qc Condenser heat rejected calculated from (Qc=Cpw ρw W
Vw,c ( Tw2- Tw3))
Qe Cooling effect calculated (Qe=Cpw ρw Vw,e( Tw1- Tw4)) W
COP Coefficient Of Performance calculated from (COP= Qe /
/ W c)
4.6 Uncertainty analysis
Uncertainty in final results indicates the amount of deviation from a

true value [64]. Measurement devices have a fixed error, which is related
to the manufactures, and a random error that results from the effects
during the measurement process. The fixed error was reduced by a
calibration process for all sensors and meters and also, the random error
was identified from the experimental results in the control and
90
measurement laboratory at steady state conditions. Uncertainty (δR) in

the result (R) can be calculated in terms of fixed and random errors from
equation (4-7) [65].
[∑ ( ) ∑( ) ] (4-7)
The two terms of the summation in equation (4-7) refer to contribution
of fixed and random errors. Where ( ) is the partial derivative of
result (R) to measurand ( ), (n) is measurands number, and ( ) and

( ) are the values of fixed and random errors respectively. Multi-
samples uncertainty analysis is a method that used to calculate the
random error ( ) from equation (4-8) [66]:
(4-8)
Here, “t” can be found from “Student‟s (t) distribution” depending on
the number of samples (N), which in this study was N=60 and t=2
corresponding to the confidence level 95%. ( ) is the stander deviation
for the chosen samples. Table (3-7) shows the calculation results of the
fixed and random error for used instruments.
Table (4-7): Instruments fixed and random error.
Sensor Unit fixed error ( ) random error ( )

Tr1 °C 0.3387 0.05215
Tr2 °C 0.2841 0.03779
Tr3 °C 0.2954 0.04768
Tr4 °C 0.2874 0.051317
Tw1 °C 0.3235 0.04165
Tw2 °C 0.3241 0.03415
Tw3 °C 0.2874 0.04875
Tw4 °C 0.3071 0.05071
91
Pr1 bar 0.25 0.077115

Pr2 bar 0.25 0.069273
Pr3 bar 0.25 0.071484
Pr4 bar 0.25 0.068327
̇ mL/s 0.9977 0.24787
̇ mL/s 1.0587 0.2872
̇ mL/s 0.3254 0.607
Vc rpm 7.5 5.24
power W 5 5.643
Refrigeration capacity is calculated from the waterside by equation

[67]:
( ̇ ) ̇ ( ) (4-9)
Here, ( ) is the density of water in (kg/m3) and ( ) is water specific

heat in (kJ/kg.°C).
Uncertainty value is calculated from the equation (4-10).
[( ̇ ) ( ̇ ) ( )
̇ ̇
( ) (4-11)
( ) ( ) ( ) ]
The values of fixed error ( ̇ , , ) and the random

error ( ̇ , , ) are estimated from a table (4-7) and the
derivative result for each variable is:
̇
( ) (4-12)
̇ (4-13)
( ) ̇ (4-14)
92
Heat is dissipated from refrigerant to water by the condenser that

calculated from the following equation [67]:
( ̇ ) ̇ ( ) (4-15)
Uncertainty value in ( ) is calculated from equation (4-16).
[( ̇ ) ( ̇ ) ( )
̇ ̇
( ) (4-16)
( ) ( ) ( ) ]
The values of fixed error ( ̇ , , ) and the random

error ( ̇ , , ) are estimated from table (4-7) and the
derivative result for each variable is:
̇
( ) (4-17)
̇ (4-18)
( ) ̇ (4-19)
The coefficient of performance COP was another final result from the
current study which depends on temperature sensors, water flow meter,
and the reading of the power meter. The COP was calculated from
equations [3]:
̇ ( )
( ̇ ) (4-20)
Where (W) is the power consumed by the system which measured by a

power meter, so the uncertainty equation will be as follow:
93
[( ) ( ) ( ̇ )
̇
( ̇ ) ( ) ( ) (4-21)
̇
( )
( ) ( ) ]
The values of fixed error ( , ̇ , , ) and the

random error ( , ̇ , , ) are estimated from table (4-
7) and the derivative of each variable is:
̇
( )
(4-22)
( )
̇ (4-23)
̇
(4-24)
̇
(4-25)
There are another two empirical equations that will appear in chapter
five in order to determine the degree of the refrigerant superheat (DS)
and EEV opening which were a function to the compressor speed (Vc)
and to inlet water temperature to the evaporator (Tw1) as follows:
( ) ( ) ( )
(4-26)
( )
( )
( )
(
( )
)
(4-27)
( ) ( )
* ( ) ( )+
94
Uncertainty for the DS and EEV equations is calculated for (4-26)

and (4-27) equations as follow:
[( ) ( ) ( )
( ) (4-28)
( ) ]
[( ) ( ) ( )
( ) (4-29)
( ) ]
The values of fixed error ( , ) and the random error ( ,

) are estimated from the table (4-7) and the derivative result for
each variable is:
(4-30)
(4-31)
( ) ( )
( )
[
(4-32)
( ) ( )
* ( ) ( )+
]
95
( ) ( )
( )
[
(4-33)
( ) ( )
* ( ) ( )+
]
Uncertainty values were calculated at the steady-state conditions for

different cooling loads that appeared in the table (4-7).
Table(4-9): Uncertainty calculation results.
parameter Uncertainty value Uncertainty [%]

Qe (W) 120 ~ 225 6 ~ 7.5
Qc (W) 190 ~ 280 5~7
COP 0.065 ~ 0.09 5~6
DSeq (°C) 0.072 ~ 0.16 1.2 ~ 2
EEVeq (step) 2.22 ~ 3.6 1.9 ~ 2.8
96
Chapter Five
Results and Discussions
Chapter Five Results and discussion
`
Chapter Five
Results and Discussion

5.1 Introductions
In this chapter, the results of the experimental work are presented.
First, system performance under manual operation was examined to
determine the optimum refrigerant superheat value at different operation
conditions. The EEV controlling method was improved to reduce the
coupling between the EEV opening and compressor speed. And then
gain parameters for suggested controllers are obtained by a tuning
process. This enables investigation of the effect of suggested controllers
on the system performance and on the refrigerant superheat under the
automatic controlling operation. Finally, the refrigeration system with a
variable speed compressor (VSC) and EEV was examined with the
improved controlling method at steady state and dynamic operating
conditions that can be summarized with Figure (5-1).
Experimental work
Manuel operation Automatic operation
1- Effects of EEV closing and compressor 1- Controlling methods and controllers

speed at different Te an Tc comparisons
2- optimum DS value and DS equation with

2- Steady state performance.
two control loops.
3- optimum EEV opening and EEV equation

3- Transient performance
with single control loop.
4- controllers tuning PI, PID, P-fuzzy, P+D

fuzzy, PD-fuzzy.
Figure (5-1): Experimental work procedure diagram.
97
`
The compressor speed, EEV opening, changes in the water
temperature, and its mass flow rate for both evaporator and condenser
were taken into consideration.
5.2 Manual operation performance
Performance is the ability of a system to achieve goals [68]. The

speed of the compressor has an impact on the refrigerant flow rate in the
cycle; consequently, it will affect the refrigeration capacity. Also, the
EEV is working as the main part of variable speed refrigeration systems
to regulate the degree of refrigerant superheat at desired values and to
maintain the pressure ratio at optimum working levels.
To study the effects of increasing inlet water temperatures of the

condenser and evaporator on the system performance and the relation
between compressor speed and EEV opening, the experimental
workflow was by 45 experiments at manual EEV closing from the step
250 to the step 60 for each constant compressor speed range 1200, 1800,
2400, 3000, and 3600 rpm with different evaporator inlet water
temperatures 14, 17, and 19°C and also condenser inlet water
temperatures 25, 29, and 33°C. For each experiment, temperature,
pressure, and flow meters are recorded and also the COP is calculated at
each second by the LabVIEW program and then collected data are drawn
to study the response and performance of the system, which can be seen
a sample for one experiment in Figure (5-2).
At constant compressor speed and inlet water temperatures of the

evaporator and condenser, closing the EEV led to increasing the pressure
of the condenser that achieved refrigerant in the subcool phase. More
closing the EEV resulted in hunting which can be defined as “the
98
`
phenomena of the oscillation of certain system operating parameters
such as the degree of refrigerant superheat, refrigerant mass flow rate
and evaporating pressure” [32]. The optimum operation of the variable
speed refrigeration system depends on the amount of refrigerant
superheat outlet from the evaporator. The degree of superheating affects
both refrigerants‟ subcooling and systems‟ stability. The optimum
performance condition for 45 experiments has been selected and their
results have been sorted as shown in appendix (B-1).
optimum performance
0 250 500 750 1000 1250 1500 1750 2000
12
subcool (°C)
9
6
3
3°C
130
12
DS (°C)
11 Hunting
10
9
8
3.2
COP
3.0
2.8
2.6
2.4
Q ev (w)
2600
2500
2400
940
power (w)
930
920
910
900
890
Tcon,ri (°C)
75
70
65
30
Pc (bar)
29
28
27
26
25
Pe (bar)
6.0
5.5
5.0
250
EEV opening
200
(step)
150
100
50
0 250 500 750 1000 1250 1500 1750 2000
time (s)
Figure (5-2): Effects of EEV closing at condener temprature 29 and

evaporator temprature 17 at compressor speed 3000 rpm.
99
`
5.2.1 Compressor speed and EEV opening effects
At constant inlet water temperatures of evaporator and condenser

which were 17 and 29°C respectively, sensors data were sorted at steady
state operation from the optimum performance, the results which are
shown in appendix (B-2). The collected data was drawn as figures to
show the effects of closing the EEV at a different range of compressor
speed on the system performance while the other parameters were
constant.
Figure (5-3) shows the effect of the EEV closing on the refrigerant
flow rate at each compressor speed. The refrigerant mass flow rate was
directly proportional to the compressor speed and also to the EEV
opening. Increasing the speed of the compressor leads to increases the
displacement volume per minute that will be result increasing the
refrigerant flow rate. The EEV closing will be lead to decreases the
valve orifice that decreases the refrigerant flow through it.
18
17
16
15
Mr (g/s)
14
13
1200 (rpm)
12
1800 (rpm)
2400 (rpm)
11 3000 (rpm)
3600 (rpm)
10
40 60 80 100 120 140 160 180
EEV open (steps)
Figure (5-3 o e i g si e versus refrigera t mass f ow rate r) with five

different compressor speeds at manual operation.
100
`
Figure (5-4) shows the effect of the EEV closing on the evaporator
pressure which decreases with the EEV closing. In addition, the
evaporator pressure (Pev) decreases with increasing the speed of the
compressor, both effects were due to the starving of the evaporator tube
from the refrigerant (a small quantity of refrigerant).
8.5
1200 (rpm)
1800 (rpm)
2400 (rpm)
8.0 3000 (rpm)
3600 (rpm)
7.5
Pev (bar)
7.0
6.5
6.0
60 80 100 120 140 160 180
EEV open (steps)
Figure (5-4): EEV opening size versus evaporator pressure (Pev) with five different
compressor speeds at manual operation.
Figure (5-5) shows the effects of the EEV closing on the condenser
pressure (Pcon). The pressure of the condenser increases with increasing
the speed of the compressor at the constant EEV opening because of
trappings the refrigerant charge in pipes of the condenser. In addition,
the pressure Pcon increases with the EEV closing at a constant
compressor speed for the same reason.
101
`
34
1200 (rpm)
1800 (rpm)
32 2400 (rpm)
3000 (rpm)
3600 (rpm)
30
Pcon (bar)
28
26
24
22
40 60 80 100 120 140 160 180 200
EEV open (steps)
Figure (5-5): EEV opening size versus condenser pressure (Pcon) with five different
Figure (5-6) shows the effect of the EEV closing on the refrigerant
superheat which was increases at constant compressor speed and
decreases with increasing the compressor speed at a constant EEV
opening. EEV closing leads to a decrease refrigerant flow to the
evaporator which leads to increasing refrigerant superheat. The
refrigerant flow increases with increasing the speed of the compressor
that results in decreases refrigerant superheating.
11
1200 (rpm)
1800 (rpm)
10 2400 (rpm)
3000 (rpm)
3600 (rpm)
9
8
DS (°C)
4
40 60 80 100 120 140 160 180 200
EEV open (steps)
Figure (5-6): EEV opening size versus DS at different compressor speeds.
102
`
The amount of a degree refrigerant subcooling is directly
proportional to the compressor speed. At a constant compressor speed,
the EEV closing leads to increase subcool phase due to increase the Pcon
as shown in Figure (5-7). Increasing condensing pressure leads to
increase the refrigerant saturation temperature that affects the amount of
heat transfer to water. Increasing the speed of the compressor will be
affected directly by increasing the condenser pressure too.
13 1200 (rpm)
1800 (rpm)
2400 (rpm)
11
3000 (rpm)
3600 (rpm)
9
subcool (°C)
-1
40 60 80 100 120 140 160 180 200

EEV open (steps)
Figure (5-7): EEV opening size versus refrigerant subcool with five different
compressor speeds.
Compressor power consumption is directly proportional to the

compressor speed and it is also affected by the EEV opening. Closing the
EEV leads to increase the pressure ratio that results in increased power
consumption at a constant compressor speed as shown in Figure (5-8).
103
`
1300
1200
1100
1000
900
Power (W)
800
700
600 1200 (rpm)

1800 (rpm)
500 2400 (rpm)
3000 (rpm)
400 3600 (rpm)
300
40 60 80 100 120 140 160 180 200
EEV open (steps)
Figure (5-8): Compressor power consumption versus EEV opening with variable
compressor speeds at manual control.
Increasing compressor speed increases the refrigeration capacity (Qe)

due to increasing the refrigerant flow and at a constant EEV opening will
be lead to increasing the condenser pressure that affects the refrigerant
subcooling. Also at constant compressor speed closing the EEV leads to
increase the Qe due to increases the pressure ratio that effects the subcool
phase too, more closing the EEV decreases the refrigerant flow to the
evaporator that decreases Qe as shown in Figure (5-9).
3200
3000
2800
2600
Qe (W)
2400
2200
1200 (rpm)
2000 1800 (rpm)
2400 (rpm)
1800 3000 (rpm)
3600 (rpm)
1600
40 60 80 100 120 140 160 180 200
EEV open (steps)
Figure (5-9): Refrigeration capacity(Qe) versus EEV opening with variable

104
`
Figure (5-10) shows the effect of the EEV opening on the Coefficient
Of Performance (COP) of the experimental system. The COP increases
at low compressor speed due to decreasing compressor frictional losses
and also the pressure ratio between Pcon and Pev which results in decrease
compressor power consumption. The COP increases by closing the EEV
at each speed due to increase the degree of the refrigerant liquid
subcooling outlet from the condenser. More closing the EEV led to a
decrease in the COP value due to decreasing in the refrigerant flow to the
evaporator.
5.5
1200 (rpm)
1800 (rpm)
5.0 2400 (rpm)
3000 (rpm)
3600 (rpm)
4.5
4.0
COP
3.5
3.0
2.5
2.0
40 60 80 100 120 140 160 180 200
EEV open (steps)
Figure (5-10): EEV opening size versus coefficient of performance (COP) with five
different compressor speeds at manual control.
The results show that the system is affected by the speed of the
compressor and EEV opening, thus the optimum operation (achieve
subcooling and avoid hunting), occurs at a certain value of the EEV
opening with respect to the compressor speed at constant inlet water
temperature to the evaporator and condenser.
105
`
5.2.2 Refrigerant Superheat
The degree of refrigerant superheat plays an important role in a good

performance and stability of refrigeration systems equipped with a
variable speed compressor. To determine the suitable constant value of
the DS, several values were examined with a P-fuzzy controller for both
the compressor and EEV. The experimental results show that decreasing
DS value to 5°C led to lower the degree of refrigerant subcooling that
decreases the system COP, and on the contrary, increasing the DS value
to 8°C resulted in hunting. The EEV opening affected the degree of the
refrigerant superheating and also on the pressure ratio between the
condenser and evaporator, opening the EEV will lead to decreasing the
condenser pressure which results in a low amount of subcooling in the
refrigerant outlet from the condenser. Figure (5-11) shows the effects of
DS value on the subcooling and stability of the system.
18
DS set
16
acceptable DS hunting
DSmeasured
14 sub cool DS=8
12
10
DS (°C)
8
DS=6 DS=7 DS=7
6
Acceptable subcoll
Acceptable subcoll
4 DS=5
2
0
low subcool
-2
200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
time (s))
Figure (5-11): Effects of the DS value on the subcool and system stability at
automatic control operation.
106
`
For the optimum operation conditions, the DS in the variable speed
refrigeration systems is not constant at a certain value. This concept was
presented by previous researches [29], [30], [33], [53], and [55].
The effect of the inlet water temperatures of the evaporator and

condenser on the DS value at each compressor speed was investigated by
the previous 45 experiments. The optimum DS values were collected in
the table (5-1) at different operation conditions. From the results in this
table, the relation between the degree of superheating and the operating
conditions were identified. The DS value changes from 6.5 to 8.5°C
depending on the compressor speed and evaporator inlet water
temperatures at optimum operation conditions (achieve subcool and
avoid hunting).
Table (5-1): Optimum DS from the 45 experiments (°C).

Inlet water temperature (°C) Compressor speed (rpm)
Condenser Evaporator 1200 1800 2400 3000 3600
25 14 8.53 8.32 8.15 7.76 7.52
25 17 8.01 7.81 7.65 7.41 7.02
25 20 7.51 7.32 7.10 6.82 6.55
29 14 8.55 8.34 8.17 7.77 7.54
29 17 8.03 7.83 7.67 7.43 7.04
29 20 7.53 7.34 7.12 6.84 6.57
33 14 8.59 8.38 8.11 7.80 7.58
33 17 8.07 7.78 7.57 7.47 7.08
33 20 7.57 7.38 7.16 6.88 6.51
107
`
The experimental results showed at a constant evaporator inlet water
temperature (Tev,wi), the effect of variation condenser inlet water
temperature (Tcon,wi) on the DS was insignificant at with each constant
compressor speed which was summarized in Figures (5-12)d, (5-12)e,
and (5-12)f. At constant Tev,wi increasing compressor speed decreases the
DS due to increasing the refrigeration capacity by increasing the
refrigerant flow rate, as shown in Figures (5-12)a, (5-12)b, and (5-12)c.
Increasing condenser inlet water temperature results in increases
condenser pressure and at a constant compressor speed and EEV
opening, the DS will be constant. The optimum DS values at constant
condenser temperature were inversely proportional to the Tev,wi at each
compressor speed due to the increase in the evaporator pressure (Pev).
Increasing Pev leads to an increase in the refrigeration effect and at
constant cooling load, the DS will be decreased. In both cases, the DS
value was inversely proportional to the compressor speed to avoid
hunting at high speeds. In fact, the influence of the inlet water
temperature of the condenser on the degree of superheat is included in
the compressor speed. Increasing condenser temperature results
increases the pressure of the condenser which leads to a decrease in the
amount of the refrigeration capacity and therefore more refrigerant could
flow by increasing the speed of the compressor.
108
`
9 9
8 8
DS / °C
DS (°C)
7 7
(a) Tcon,wi=25 (d) Tev,wi=14

6 6
13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 34
Tev,wi (°C) Tcon,wi / °C
9 9
8 8
DS / °C
DS / °C
7 7
(b) Tcon,wi=29 (e) Tev,wi=17

6 6
13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 34
Tev,wi / °C Tcon,wi / °C
9 9
8 8
DS / °C
DS / °C
7 7
(c) Tcon,wi=33 (f) Tev,wi=20

6 6
13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 34
Compressor speed: ♦1200 □1800 ▲2400 ●3000 Δ3600 (rpm)
Figure (5-12): Effect of the condenser and evaporator inlet water temperature on the
DS at different compressor speed.
109
`
Also, at low compressor speed increasing condenser pressure (Pcon) is
required to achieve the subcool phase by decreasing the EEV opening
that increases the DS, as shown in Figure (5-13).
33 11
(a) Tev,wi=17°C (b) Tcon,wi=29°C
10
31
9
29
Pcon (bar)
Pev (bar)
27 7
1200 (rpm) 1200 (rpm)
1800 (rpm) 6 1800 (rpm)
25 2400 (rpm) 2400 (rpm)
3000 (rpm) 5 3000 (rpm)
3600 (rpm) 3600 (rpm)
23 4
24 26 28 30 32 34 13 15 17 19 21
Tcon,wi (°C) Tev,wi (°C)
Figure (5-13): Effect of the condenser and evaporator inlet water temperature on its
pressures at different compressor speed.
Experimental results proved that the degree of refrigerant

superheating was a function of the compressor speed and the inlet water
temperature of the evaporator.
5.2.3 Two loops with variable superheat controlling method
The optimum values of the DS were sorted at different evaporators‟

water inlet temperature with the absence of the condenser temperature
effect as shown in table (5-2).
Table (5-2): Optimum DS (°C) at each compressor speed and evaporator inlet water
temperature.
Evaporator inlet water Compressor speed(rpm)

temperature (°C)
1200 1800 2400 3000 3600
14 8.5 8.3 8.1 7.8 7.5
17 8 7.8 7.6 7.4 7
20 7.5 7.3 7.1 6.8 6.5
110
`
The DS is a function of evaporator inlet water temperature and
compressor speed as shown by the surface plain in Figure (5-14).
8.25
8.00
6.400
7.75
6.650
DS (°C)
7.50 6.900
7.150
7.25
7.400
7.00 7.650
7.900
6.75
8.150
6.50 8.400
1500
2000
20
sp
2500 19
e
18
ed
3000 17
16
(rp
15 (°C)
m)
3500 14 T ev,wi
Figure (5-14): Degree of the superheat surface relation.
And the fitting surface equation to the DS surface plot is:
( ) ( ) ( ) (5-1)
Here; ( ) is the inlet water temperature of the evaporator in (°C),

and ( ) the compressor speed in (rpm). The error value in the DS
equation (DSeq.) was about 0.14°C and the validation with the
experimental results shown in Figure (5-15).
111
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10
DS predicted value (°C)

8
4
4 5 6 7 8 9 10
DS experimental value (°C)
Figure (5-15): DS equation validation with the experimental results.
The DS-equation is used with the LabVIEW-2018 tool to determine

the set value of the (DS) in which the controller of the EEV controls
valve opening is depending on operating conditions, as shown in Figure
(5-16).
Tev,wo
ΔTw Vc(t)
+-
Compressor Compressor
Compressor
controller driver
Tw set Product
Cold water
system
temperature
DS(t) ΔDS refrigerant

superhea
EEV EEV
DS(Tev,wi,Vc) + EEV
- controller driver
Figure (5-16): Control block diagram with variable DS controller.
5.2.4 Coupling effect
A variable speed compressor of refrigeration systems with an

electronic expansion valve has two controlling loops to control the speed
of the compressor and the EEV opening as shown in chapter one in
112
`
Figure (1-6). The compressor control loop depends on the difference in
cold water temperature as a feedback signal input to the compressor
controller in the first control loop. While the difference in DS was the
feedback signal of the EEV controller in the second control loop. The
two control loops are to control the refrigerant flow that enters the
evaporator which affects the DS and Tev,wo values.
The effect of the speed of the compressor on the DS was shown in

Figure (5-5). At a constant EEV opening, increasing the speed of the
compressor leads to an increase in the DS value due to evaporator
starving from the refrigerant. The EEV opening affects the cold water
temperature (Tev,wo), at constant compressor speed, decreasing EEV
opening leads to decrease the evaporation temperature that is reflected
on the Tev,wo as shown in Figure (5-17). The speed of the compressor
affects Tev,wo, and the DS, and also the EEV opening affects the DS and
Tev,wo. This coupling between the two controlling loops affects the
working stability of each controller especially the EEV controller [27].
14
1200 (rpm)
1800 (rpm)
2400 (rpm)
13 3000 (rpm)
3600 (rpm)
12
Tev.wo (°C)
11
10
9
40 60 80 100 120 140 160 180 200
EEV opening ( steps)
Figure (5-17): Effect of the EEV opening on the (Tev,wo) at each compressor speed.
113
`
The DS is directly affected by the EEV opening and also it is a
function to the speed of the compressor and the inlet water temperature
of the evaporator, as mentioned earlier in the section (5.2.3).
To solve this coupling; only one control loop will be used to control
the compressor speed, and the EEV opening which was controlled by a
direct digital controlling method depending on the empirical relationship
that connected the EEV opening to the compressor speed and the
evaporator inlet water temperature (Tev,wi) as a forward signal.
5.2.5 Single loop controlling method
The direct EEV opening controlling method depends on the

prediction of the EEV opening that achieves the best performance
depending on the experimental data at different operating conditions.
The optimum EEV opening, as mentioned earlier, is the value that

achieves a subcool phase and avoids hunting. The recorded data for the
45 experiments was at optimum operating conditions for each case
which can be seen in the appendix (B-4) and the optimum value of the
EEV opening collected in the table (5-3).
Table (5-3): Optimum EEV opening (step) at different operation conditions
Inlet water Temp. to Compressor speed (rpm)

condenser evaporator 1200 1800 2400 3000 3600
25 14 60 70 90 105 120
25 17 65 85 105 135 155
25 20 75 115 125 165 185
29 14 60 70 90 105 120
29 17 68 90 108 138 158
114
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29 20 70 110 125 160 180
33 14 60 70 90 105 120
33 17 70 90 110 140 160
33 20 80 110 123 160 180
From table (5-3), the effect of increasing condenser inlet water

temperature Tcon,wi, at each constant water inlet temperature of the
evaporator Tev,wi, was negligible as shown in Figure (5-18a).
200 200
(a) Tev.wi=17°C (b) Tcon.wi =29°C
EEV opening (steps)
EEV opening (steps)

150 150
100 100
50 50
1200 1800 2400 1200 1800 2400
3000 3600 ---------- 3000 3600 ----------
0 0
24 26 28 30 32 34 13 14 15 16 17 18 19 20 21
Tcon.wi (°C) Tev.wi (°C)
Figure (5-18): Effect of evaporator and condenser water inlet temperature on the
EEV opening.
At each constant Tcon,wi, the effect of Tev,wi on the optimum EEV

opening value was clear in Figure (5-18b).
Increasing the inlet water temperature of the evaporator increases

the evaporator pressure and refrigerant flow due to increases suction
refrigerant density, and at constant compressor speed, the EEV opening
will be increased to allow the refrigerant inters to the evaporator that
results in decreasing the DS value.
From the experimental results, the EEV opening was a function to

the inlet water temperature of the evaporator and the compressor speed
and from the table (5-3) the optimum EEV opening values were selected
115
`
at each compressor speed and the inlet water temperature of the
evaporator that appear in the table (5-4).
Table (5-4): Optimum EEV opening (steps) at each speed and (Tev,wi).
Evaporator inlet water compressor speed (rpm)

temperature (°C) 1200 1800 2400 3000 3600
14 60 70 90 105 120
17 68 90 108 138 158

20
75 110 125 160 180
The surface relation-ship of the EEV opening was presented as a

function of the speed of the compressor and water inlet temperature of
the evaporator. It appears in Figure (5-19).
50.00
65.00
80.00
160
95.00
110.0
140 125.0
g (step)
140.0
120 155.0
EEV openin
170.0
100
20
80 19
18
60
)
(° C
17
16
wi
1500
ev,
2000
T
15
spee 2500
d (rp 3000
m) 14
3500
Figure (5-19): The surface relation of the EEV opening.
116
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And the surface fitting equation to Figure (5-19) is:
( )
( )
( )
(
( )
)
(5-2)
( ) ( )
* ( ) ( )+
Where: is the evaporator inlet water temperature in (°C)
is the compressor speed in (rpm).
The error value in the EEV equation was about 4.64 steps and the
validation with the experimental results is shown in Figure (5-20).
170
EEV opening predicted value (steps)
150
130
110
90
70
50
50 70 90 110 130 150 170
EEV opening experimental value (steps)
Figure (5-20): The EEV opening equation validation.
The controlling block diagram is shown in Figure (5-21) which was

used in the LabVIEW tool with only one controlling loop to control the
speed of the compressor and with the direct equation to control the EEV
opening.
117
`
Tev,wo
- ΔTw Compressor Compressor Vc(t)

+ controller driver
Compressor
Tw set Product
Cold water
temperature
system
EEV
Open (Tev,Vc)
driver
EEV
Figure (5-21): The control block diagram with one controller.
5.2.6 Controllers tuning

Tuning is defined as the process to determine the optimum controller
gains [69] which, in this study, was performed by the trial and error
method. The controller of the compressor speed was tuned at the first
step while the EEV was controlled by a direct equation, and then the
EEV controller was tuned in the second step. The operation stability of
the system is related to the change in the degree of the refrigerant
superheating that depends on the speed of the compressor and evaporator
(product cold water) temperature. Appendix (C) presents tables and
figures for tuning test results of controllers under consideration.
The proportional integral (PI) controller has two gains which are kp
and ki. The results of the tuning process are presented in Figure (5-22).
Here, the changes in the degree of superheat and cold water temperature
with time are demonstrated. Six tests were performed to find the most
stable operation of the system. Test variables are presented in table (1) 0f
appendix (C). By comparison, among these six tests, the stable operation
of the compressor and the EEV with PI-controller is obtained with test
three (kp=0.02, ki=0.002) and test six (kp=0.8, ki=0.01) respectively.
118
`
20
18
Tev,wo (°C)
16
Tw set
14 test 1
stable test 2
test 3
12
stable test 4
test 5
10 test 6
8
DS (°C)
0 100 200 300 400 500 600 700 800 900 1000
time (s)
Figure (5-22): Tuning process test results for the PI controller.
The tuning process for the proportional integral derivative (PID)

controller was performed with six tests (different values of gains) which
relied on the results of the PI controller. A comparison between all these
tests is shown in Figure (5-23). PID gains tuning parameters can be seen
in the table (2) of appendix (C).
26
test 1
24
test 2
Tev,wo (°C)
22 test 3
test 4
20 stable test 5
18 test 6
16
14
12
10
stable
8
DS (°C)
100 200 300 400 500 600 700 800 900 1000
time (s)
Figure (5-23): Tuning process test results for the PID controller.
119
`
The most stable system response was at test number three with gain
values of kp=0.025, ki=0.00002, and kd=0.00001 for the compressor, and
was at test number six with gain values of kp=0.6, ki=0.02, and kd=0.01
for the EEV PID controller.
The tuning process of the fuzzy controller was performed by

changing weights corresponding to the linguistic variables of input and
output membership function for each controller. Comparison results
between tests for the two controllers are shown in Figure (5-24). The
most stable system response was at test number six for both the
compressor and EEV controllers and the membership weights value can
be seen in the table (3) of appendix (C).
14
Tev,wo (°C)
stable
12
10
6
Tw set
DS (°C)
test 1
4 test 2
stable test 3
2 test 4
test 5
test 6
0
0 100 200 300 400 500 600 700 800 900 1000
time (s)
Figure (5-24): Tuning process test results for the P-fuzzy EEV controller.
The proportional plus derivative fuzzy controller tuning process for

the compressor and EEV controllers were performed at five tests with
different membership weights.
120
`
14
13
Tev,wo (°C)
12
11
10
9
stable
8
7
DS (°C)
6
test(1)
5
test(2)
4 test(3)
test(4)
3
test(5)
2
0 100 200 300 400 500 600 700 800 900 1000
time (s)
Figure (5-25): Tuning process test results for the P+D fuzzy compressor controller.
A comparison of results between these five tests for the two

controllers is shown in Figure (5-25) for compressor and EEV
controllers. The most stable system response was at test number two
with membership function weights which can be seen in the table (4) of
appendix (C) for the two controllers.
Previous tuning results of the P+D fuzzy controller were useful to

facilitate the tuning process of the PD-fuzzy controller. The tuning
process was performed with three tests at different weights for each
controller (compressor and EEV) which can be seen in the table (5) of
appendix (C). A comparison of results between the three tests is shown
in Figure (5-26) for the two controllers.
121
`
14
13 stable
Tev,wo (°C)
12
11
10
8
stable
7
6 test 3
DS (°C)
test 1
5
test 2
4 test 3
test 1
3 test 2
test 3
2
0 100 200 300 400 500 600 700 800 900 1000
time (s)
Figure (5-26): Tuning process test results for the PD fuzzy controller.
5.3 Automatic control operation
The system is now ready to operate under different controlling

methods and controllers. The best controller and controlling method
were determined by the comparison process. Finally, the system
performance was compared to the On/Off controlling method which was
considered as a reference in this study. It should be noted that all
comparisons were at the same different system excitement conditions
(start-up from Tev,wi at 20°C to bring the set cold water temperature
Tev,wo of 10°C and then reduce the set temperature to 9°C after that
return to 10°C in set cold water temperature Tw,set). Results, which were
gained during the comparison, were drawn as figures of response for
each product cold water temperature and the refrigerant superheat.
122
`
5.3.1 Controlling methods comparison
Three controlling methods were used to control the EEV opening:
1- Constant value for refrigerant superheats at 7°C (DS7).

2- Variable value for the degree of superheat by Equ. (5-1), (DSeq).
3- Direct EEV opening by equation (5-2) with a single loop (EEVeq).
These controlling methods are used with the suggested five
controllers (PI, PID, P-fuzzy, P+D fuzzy, and PD-fuzzy) in the
experimental rig. Two controlling loops used the suggested controllers
with DS7 and DSeq methods while only one loop with the EEVeq method.
At first, the PI-controller was compared with different controlling

methods at the same test conditions. Figure (5-27) shows the DS
comparison response from the EEV controller at constant DS value 7°C
which was at high oscillation as compared to the variable DS eq response.
Using the EEVeq with the PI-controller DS response was at acceptable
stability.
14
DSset
DS7
12 DSeq
EEVeq
10
DS (°C)
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-27): DS response comparison between three controlling

methods with PI-controller.
123
`
(DSset) indicates the variable DS value which was calculated from

equation (5-1) depending on the compressor speed and Tev,wi. The
response comparison for the product cold water (Tev,wo) can be seen in
Figure (5-28) which appeared the EEV equation controlling method was
stable.
14 Twset
DS7
13 DSeq
EEVeq
12
Tev.wo (°C)
11
10
8
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-28): Tev,wo response comparison between three controlling
methods with PI controller.
The second comparison was with the PID-controller which is used to

control the compressor speed and the EEV opening. The derivative term
in the PID-controller increases the amount of error and overshoots in the
DS response. The DS response was more stable with a direct EEV
opening equation (EEVeq) compared to the adaptive DS equation (DSeq)
as shown in Figure (5-29).
124
`
14
DS7
DSset
12 DSeq
EEVeq
degree of superheat °C
10
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-29): DS comparison between three methods with PID-controller.
System response in terms of Tev,wo use PID controllers is shown in

Figure (5-30). PI and PID are conventional controllers and suitable to
control first-order linear systems and also deal with the principle of
processing based on the actual existence of the error value which leads to
an increase in the oscillation in response signal.
14
Twset
DS7
13
DSeq
Cold water temperature (°C)
EEVeq
12
11
10
8
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-30): Tev,wo response comparison between three controlling methods with
PID-controller.
The variable speed refrigeration systems are considered to be high
order systems with a time delay. In the case of using intelligent
125
`
controllers as a fuzzy controller, the DS response was more stable as
shown in Figure (5-31) especially with the EEVeq method.
14
DSset
DS7
degree of super heat (°C)
12
DSeq
EEVeq
10
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-31): DS response comparison between three controlling methods with P-
fuzzy controller.
The EEVeq controlling method gives a good indication of how a

fuzzy controller can do to get Tev,wo as shown in Figure (5-32).
14
Twset
DS7
13
DSeq
EEVeq
12
11
10
8
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-32): Tev,wo comparison response between three controlling methods with
P-fuzzy controller.
126
`
The rate of change term in the error value of the D-fuzzy controller
predicts error before it occurs, therefore, the oscillation in the DS
response will be decreased as shown in Figure (5-33) by using the EEVeq
with the P+D fuzzy controller.
14
DSset
DS7
12 DSeq
EEVeq
10
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-33): DS response comparison response between three controlling methods
with P+D fuzzy controller.
Figure (5-34) shows that the fast Tev,wo response with low oscillations
by using the direct EEV opening controlling method.
14
Twset
13 DS7
DSeq
EEVeq
12
11
10
8
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-34): Tev,wo comparison response between three controlling methods with
P+D fuzzy controller.
127
`
The best response to disturbance was appeared by the PD-fuzzy

controller. The derivative effect in this controller was helpful to increase
the response stability of the DS due to taking the pre-action to create a
control signal, especially with the EEVeq as shown in Figure (5-35).
14
13 DSset
12
DS7
DSeq
11
EEVeq
10
3
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-35): DS comparison between three controlling methods with PD- fuzzy
controller.
The response of Tev,wo with the PD-fuzzy controller to control the

compressor speed was faster with the low osculation as shown in Figure
(5-36).
128
`
14
Twset
13 DS7

DSeq
EEVeq
12
11
10
8
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time(s)
Figure (5-36): Tev,wo response comparison between three controlling methods with
PD-fuzzy controller.
The outcome of these comparisons was “variable DS make the

system at the stable response as compared to constant DS and the new
controlling method have the best response in DS and Tev,wo“. Variable
speed refrigeration systems stability depends on the DS value and with
DSeq to suggest this variable value depending on the operation conditions
the response was way off hunting. The one controlling loop, which was
used with the EEVeq , was the direct cause of the system's stability, thus
this controlling method was used in the system for the next comparisons.
5.3.2 Controllers comparison
The EEVeq controlling method results of the previous comparisons

were sorted for the five suggested controllers and drawn. The DS
response was more stable and with low osculation with the PD-fuzzy
controller as compared to the controllers as shown in Figure (5-37).
129
`
14 DSset
PI
12 PID
degree of superheat (°C)

P-fuzzy
P+D fuzzy
10 PD fuzzy
2
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-37) DS response comparison between the five controllers with EEV-
equation.
The DS stability was due to the PD-fuzzy controller which was used
to control the compressor speed that affects indirectly the DS value by
changing the refrigerant flow rate.
The Tev,wo response was the fastest and at high stability with the PD-
fuzzy controller to control the compressor speed as shown in Figure (5-
38). The response stability was due to the reduction in the coupling
effect from the DS controlling loop which was controlled by the direct
EEVeq.
14
Twset
PI
13 PID
P-fuzzy
cold water temperature (°C)
P+D fuzzy
12 PD fuzzy
11
10
8
0 200 400 600 800 1000 1200 1400 1600 1800 2000
time (s)
Figure (5-38): Tev,wo response comparison between the five controllers with EEVeq.
130
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The rate of change term in the error value of the PD-fuzzy controller
predicts error before it occurs and therefore the oscillation in response
will be decreased, and also, the controlling signal depends on the
coupling between the two inputs (error and the rate of change this error)
to make the right decision by the fuzzy-rules.
5.3.3 Comparison with conventional controllers
The new controlling method (PD-fuzzy controller to control the

compressor speed and with the direct EEVeq to control the expansion
valve with a single control loop) was compared to conventional
controllers (On/Off and High/Low) at different operating conditions. For
this comparison, the experimental data were taken for 3000s. This time
period was divided into three equal parts. Startup from 20°C which was
the evaporator inlet water temperature (Tev,wi) to bring the set water
temperature 10°C, and then the set temperature decreased to 9°C, and
finally, return set temperature to 10°C as shown in Figure (5-39).
14
On/Off
Tw set
13
High/Low
cold water temperature (°C)
PD-fuzzy + EEVeq
12
11
10
7
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
time
Figure (5-39): Tev,wo response comparison between the (on/off, high/low, and PD-
fuzzy with EEV-eq.) controllers.
131
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Obvious differences can be seen among the responses of the three
controllers for the cold water temperature and also for the degree of
superheating as shown in Figure (5-40). It can be concluded that the
intelligent controlling method is more reliable than conventional
methods to bring the system in a stable condition. This may justify
adding extra cost for intelligent controllers as they require an application
of high technology. .
30
On/Off
25 High/Low
PD-fuzzy+EEVeq
20
15
10
0
0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000
time
Figure (5-40): DS response comparison between the (On/Off, High/Low, and PD-
. fuzzy with EEVeq) controllers.
The results of these comparisons were summarized with the

following points:
 The system was more stable with the new controlling method due
to using only one controlling loop for the compressor speed.
 The DS response was at high stability with the EEV equation

controlling method and with high performance.
 The PD-fuzzy controller was the best, especially with the EEVeq
controlling method.
 Intelligent controllers are suitable for variable speed systems.
132
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5.3.4 Performance comparisons
The results of previous comparisons for the suggested controllers and

with different controlling methods were compared to the On/Off method
which was considered as preference. The first comparison was for the
stability of the system by comparison the summation of the absolute
value for the error in Tev,wo and also in the DS value which is defined as a
controlling index that is calculated from the following equations.
( ) ∑| | (5-3)
(5-4)
( ) ∑| |
Figure (5-41) shows a comparison in the summation of the absolute

error which was 581 with the new controlling method (PD-fuzzy and
EEVeq) compared to the On/Off method which means the system
response was at high accuracy for Tev,wo.
2000
in cold water temperature (°C)
Summation of absolute error
1500
1000
500
0
PI PID P-fuzzy P+D-fuzzy PD-fuzzy
on/off 2070
high/low 1608
DS=7 790 830 729 707 682
Ds.eq 755 767 718 690 652
EEV.eq 695 722 645 608 581
Figure (5-41): Comparison in summation of the absolute difference in Tev,wo between

suggested controllers and also controlling methods.
133
`
A better response of the system was from the DS with the EEVeq
method in a one controlling loop. The improvement of the DS stability
was about 90% with the PD-fuzzy controller to control the compressor
speed which indirectly affects the DS response (compared On/Off
method) as shown in Figure (5-42). The EEVeq method increases the DS
response stability about 30~50 % which compared the constant DS7
method with the used controllers.
3000
Summation of absolute error
in degree of superheat (°C)
2500
2000
1500
1000
500
0
on/off 2757
high/low 1707
DS=7 697 706 619 555 525
Ds.eq 664 683 607 498 326
EEV.eq 480 524 437 352 240
Figure (5-42): Comparison in summation of the absolute difference in DS between

suggested controllers and also controlling methods.
Increasing the oscillation of the system will be reflected in the power

consumed by the system. Figure (5-43) shows the power saving was
30.6% with the new controlling method compared to the On/Off method.
134
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35
30
25
power reduction (%)

20
15
10
0
high/low 13.35
DS=7 21.89 21.03 25.36 25.60 27.58
Ds.eq 25.78 25.21 28.50 29.21 30.00
EEV.eq 28.01 27.57 28.94 29.43 30.63
Figure (5-43): Percentage reduction in power consumption with respect to the

On/Off controller.
One of the most important indications of a good performance is the

energy efficiency ratio (EER) which is defined as the ratio between the
refrigeration capacityin (Btu/h) to the power consumed in (W) of the
system.
( )
(5-5)
( )
( )
( ) (5-6)
(5-7)
The experimental comparison results showed that the new

controlling method has the highest value for suggested controllers and
the maximum enhancement was about 88% in the EER for PD-fuzzy
controller as shown in Figure (5-44). The system efficiency was
increased at partial load conditions with low speed of the compressor.
135
`
14
Average EER (Btu/h.W)

12
10
8
6
4
2
0
P+D-
PI PID P-fuzzy PD-fuzzy
fuzzy
on/off 7.17
high/low 8.63
DS=7 9.69 9.28 10.13 11.05 11.74
Ds.eq 10.44 10.07 11.12 11.33 12.32
EEV.eq 11.60 10.99 12.49 13.00 13.51
Figure (5-44): EER comparison for suggested controllers and controlling methods.
The other indicator for the good performance is the power required
for each refrigeration tone, which calculated from the equation:
( )
( ) (5-8)
( )
And ( ) ( )
The highest reduction was about 47% with the new controlling
method as compared to the On/Off method as shown in Figure (5-45).
50
Power per one Ton reduction (%)
40
30
20
10
0
P+D-
PI PID P-fuzzy PD-fuzzy
fuzzy
high/low 17
DS=7 26.06 22.79 29.29 35.19 38.95
Ds.eq 31.37 28.81 35.58 36.75 41.83
EEV.eq 38.24 34.78 42.62 44.88 46.97
Figure (5-45): Percentage reduction in the power per one Ton with respect to On/Off
controller.
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5.4 Controlled system performance

The experimental system was examined under dynamic and steady
state operations to show the performance of the system at different
external conditions. Only one loop was used to control the speed of the
compressor with the PD-fuzzy controller depending on the difference in
the product cold water temperature, and the EEV was directly controlled
by the suggested equation depending on the compressor speed and the
inlet water temperature of the evaporator.
5.4.1 Steady state performance

These tests were achieved at constant cooling load and steady state
system operation with the new controlling method. During these
experiments, the inlet water temperature of the evaporator was increased
at three steps 15, 17, and 19°C at each constant inlet water temperature
of the condenser (Tcon,wi) 25, 27, 29, 31, and 33°C. The constant cooling
load was achieved by keeping the difference between Tev,wi, and Tev,wo at
7°C in the constant state for the three evaporator water temperature sets
(8,15), (10,17), and (12,19)°C. The performance was studied by the
effects of increasing the Tcon,wi in five steps on the COP, DS, r, Pev, and
Pcon for each Tev,wi 15, 17, and 19°C. The effect of increasing the inlet
water temperature of the evaporator on the refrigeration cycle with the
refrigerant R410a is shown in Figure (5-46).
137
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Te (19-12)
Te (15-8)
Pressure (bar)
Qe W
Qe W
Enthalpy (kJ/kg)
Figure (5-46): Effect of increasing cold water temperature on the R410a cycle p-h
diagram at constant Tcon,wi=25°C.
The flow of the refrigerant is regulated by the compressor speed and

also the EEV opening to maintain the refrigeration capacity at a constant
level. The effects of increasing the inlet water temperature of the
condenser on the R410a refrigeration cycle can be seen in Figure (5-47).
Automatic control maintained the system at constant cooling load by
regulating the compressor speed and the EEV opening at different
operation conditions.
138
`
Tc (33)
Tc (25)
Pressure (bar)
Qe W
Qe W
Enthalpy (kJ/kg)
Figure (5-47): Effect of increasing condenser water temperature on the R410a cycle
at constant Tev,wi=17°C.
Figure (5-48) demonstrates that the increase in Tcon,wi leads to

increase the refrigerant flow by increasing compressor speed to maintain
refrigeration capacity at the constant value which is decreased from
increasing condenser pressure. Increasing Tev,wi has impacts on
increasing the refrigerant flow due to increasing the refrigeration vapor
density at the compressor suction line and also volumetric efficiency,
although decreasing of the speed of the compressor. The volumetric
efficiency increases with decreasing the compression ratio which
decreased with increasing the evaporator pressure [29].
̇
(5-6)
*( ) + (5-7)
Here, is a clearance volume of the compressor and is its

displacement volume.
139
`
32 14
Refrigerant density (Kg/m )

13
Refrigerant flow rate (g/s)

30
12
11
28
10
9
26
(Tev,wo ,Tev,wi) (8-15) 8 (Tev,wo ,Tev,wi) (12-19)

(10-17) (12-19) (10-17) (8-15)
24 7
24 26 28 30 32 34 24 26 28 30 32 34
Condenser inlet water temperature (°C) Condenser inlet water temperature (°C)
Figure (5-48): Refrigerant density and flow versus (Tcon,wi) at the three sets of (Tev,wi).
Increasing Tcon,wi results to increase the condenser pressure (Pcon)

while the evaporator pressure (Pev) almost constant which results in
increased power consumption due to increasing the compression ratio in
addition to increasing the speed of the compressor.
8.5 33
condenser pressure (bar)
Evaporator pressur (bar)
8.0 31
7.5 29
7.0 27
6.5 25
(Tev,wo ,Tev,wi) (8-15)
(Tev,wo ,Tev,wi): (8-15)
(10-17) (12-19)
(10-17) (12-19)
6.0 23
24 26 28 30 32 34 24 26 28 30 32 34
Figure (5-49): Evaporator and condenser pressure versus (Tcon,wi) at the three sets of
(Tev,wi).
At constant Tcon,wi increasing Tev,wi could lead to increasing the

pressure of the evaporator while the pressure of the condenser remains
constant due to increasing the EEV opening which decreases the
compression ratio and then decreases power consumption as shown in
Figure (5-49).
140
`
The degree of superheating decreases with increasing Tcon,wi due to
increasing the EEV opening that is related to the compressor speed as
8.0 120
(Tev,wo ,Tev,wi): (8-15)
(10-17) (12-19)
7.8
110
EEV open (step)

7.6
100
DS (°C)
7.4
90
7.2
80
7.0
(Tev,wo ,Tev,wi) (8-15)
(10-17) (12-19)
6.8 70
24 26 28 30 32 34 24 26 28 30 32 34
Figure (5-50): DS and EEV opening verses (Tcon,wi) at the three sets of (Tev,wi).
The EEV controller depends on the speed of the compressor and

Tev,wi as a feed forward signals to regulate the EEV opening by EEVeq,
thus the DS decreases with increasing Tcon,wi due to increasing the speed
of the compressor. The increase in Tev,wi could directly lead to increasing
the valve opening that decreases the DS.
3600 4.00
(Tev,wo ,Tev,wi)
3.75 (8-15)
3400 (10-17)
compressor speed (rpm)
3.50 (12-19)
3200
3.25
3000
COP
3.00
2.75
2800
2.50
2600
(Tev,wo ,Tev,wi) (8-15) 2.25
(10-17) (12-19)
2400 2.00
24 26 28 30 32 34 24 25 26 27 28 29 30 31 32 33 34
Figure (5-51): Speed and COP versus (Tcon,wi) at the three sets of (Tev,wi).
Increasing Tcon,wi reflected on increasing the pressure ratio and

compressor speed to maintain the refrigeration capacity at a constant
level by increasing the refrigerant flow. Increasing compressor speed
decreases the COP value due to increases the power required at constant
141
`
cooling load as shown in Figure (5-51), and also increasing Tev,wi results
in decreasing the pressure ratio and compressor speed. The desired
indicator here could increase Tev,wi for 2°C that results in increasing the
COP about 3.8%.
5.4.2 Transient performance

The experimental refrigeration system was examined at three
external effects to test the response stability and the ability of the system
to cope with different operating conditions. The first test was achieved
by increasing the cooling load of the system and the second test was
done by decreasing the evaporator water flow rate. The last test was done
by increasing the inlet water temperature of the condenser. At all three
tests, the system was only at one controlling loop for the speed of the
compressor with a PD-fuzzy controller and at a direct EEVeq to control
the valve opening.
The increasing of heating load was conducted by using a 700 W

electrical heater to heat the inlet water of the evaporator as a thermal
load. The heater was turned on for 900s after 500s of stable operation
and then turned off; the experimental results are appeared in Figure (5-
52). The speed of the compressor was increased to reach the maximum
value of 3600 rpm at the second 1100 and then decreased to 2500 rpm
after the second 1450 due to the heating load. The response of the cold
water temperature was almost constant at 10°C with low fluctuations
±0.2°C during the exciting period. The degree of superheating decreased
from 8°C to 6.3°C during this period due to increasing the speed of the
compressor without any fluctuations in the DS response which was a
good indication for the stability of the system with the new controlling
method.
142
`
heater on
heater on
4.0 heater on
3.5
COP
3.0
2.5
2.0
3000
Qe (W)
2750
2500
6
subcooling (°C)
5
4
3
2
8.5
8.0
7.5
DS(°C)
7.0
6.5
6.0
160
EEV (step)
140
120
100
10.4
Tw (°C)
10.2
10.0
9.8
9.6
speed (rpm)
3500
3000
2500
2000
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
time (s)
Figure (5-52): Effect of increasing the thermal load
on the system performance.
143
`
The second effect was performed by decreasing the inlet water flow
rate of the evaporator at constant steps 86, 66, 56 to 46 mL/s by
changing the voltage of the water pump. The experimental results could
indicate good stability with low fluctuation in the temperature of the cold
water Tev,wo and also in the degree of superheat response as shown in
Figure (5-53). The good response was due to the new controlling method
with only one controlling loop which estimates directly the EEV opening
value. The speed of the compressor decreased gradually from 2500 rpm
to 1900 rpm at steps depending on the cooling load which was related to
the water flow rate.
The last effect was by gradually changing the inlet water temperature
of the condenser from 24°C to 40°C by using an electrical heater. The
outlet cold water temperature of the evaporator and the degree of
superheat (DS) were slightly affected by the change in the inlet water
temperature of the condenser as shown in Figure (5-54). The working
pressure of the condenser increased from 22 to 34 bar due to the
increasing Tcon,wi and therefore the speed of the compressor was
increased from 2000 to 2500 rpm. The process of heat rejection at the
high temperature of the condenser required high compressor power [70].
The COP decreased during this test from 4.5 to 2.7 due to increasing the
power consumed by the compressor at a constant amount of the
refrigeration effect.
These tests showed the system response to external effects was at

high accuracy to maintain the outlet temperature of the cold water from
the evaporator at the desired value. The PD-fuzzy controller was used to
control the speed of the compressor which was very suitable to the
variable speed refrigeration systems. The new controlling method had
144
`
the greatest impact on the stability of the system as appeared with the DS
response in all privies tests.
0 500 1000 1500 2000 2500 3000 3500
4
COP
2 76
90
Mw ev (mL/s)
80
70 66
60 56
50 46
40
6
sub cool (C°)
0
8.5
DS (C°)
8.0
7.5
7.0
open n (step)
120
110
100
90
10.4
Tw4 (C°)
10.2
10.0
9.8
9.6
speed (rpm)
2500
2000
1500
0 500 1000 1500 2000 2500 3000 3500
time (s)
Figure (5-53) The effect of decreasing the evaporator inlet water flow rate
(from 86 to 46) ml/s on the system performance
145
`
0 500 1000 1500 2000 2500 3000 3500 4000
5
COP
4
3
2
45 40
Tcon (°C)
40
35
30 24
25
8
sub cool (C°)
0
7.5
DS (C°)
7.0
6.5
120
open n (step)
110
100
90
80
10.5
Tw4 (C°)
10.2
9.9
9.6
speed (rpm)
2500
2000
1500
0 500 1000 1500 2000 2500 3000 3500 4000
time (s)
Figure (5-54) The effect of increasing the condenser inlet water

temperature (from 25 to 40)°C on the system
146
Chapter Six
Conclusions and
Recommendations
Chapter Six
Conclusions and recommendations
6.1 Conclusions
In this study, the performance of a water chilling system has been
investigated with a variable speed compressor and electronic expansion
valve. Different control strategies have been applied to obtain high
performance and stable operation. The experimental results were
summarized in the following conclusions:
 EEV opening plays the main role in regulating the DS and

refrigerant subcooling depending on the speed of the compressor
and the temperature of the evaporator.
 Optimum operation conditions were related to the degree of

refrigerant superheating which should be considered as a variable
value for variable speed refrigeration systems. Superheating is a
function of the compressor speed and inlet water temperature of the
evaporator.
 Coupling between the speed of the compressor and EEV opening

control loops affects the stability of the system. This can be solved
using the direct empirical equation (feed forward inputs) to control
the EEV opening which is a function to compressor speed and
evaporator inlet water temperature.
 Comparison results between PI, PID, P-fuzzy, P+D fuzzy, and PD-
fuzzy controllers were used to control the compressor speed while
the direct feed forward method used to control the EEV opening
147
showed that intelligent controllers (PD-fuzzy) were more efficient

than the (PID) controller.
 The derivative term in the PID controller increased the oscillation

response 4% that decreased efficiency 5% compared to the PI
controller.
 PD-fuzzy controller with a single control loop for compressor and

feed forward control for the EEV resulted in the maximum
percentage power reduction which was 30.6% and the DS
controlling index enhancement 91% compared On/Off method.
 The derivative term in the PID controller decreases the percentage

of reduction in power by 21.8% and also the DS controlling index
enhanced by 81% compared to the On/Off method.
 Energy efficiency ratio increases with decreasing the cooling load

due to the decrease in the compressor speed and pressure ratio.
 Increasing the temperature of the condenser decreases the COP of

the system at constant cooling load due to the increase in the
pressure of the condenser that increases the power and speed of the
compressor.
 At constant cooling load and temperature of the condenser,

increasing the temperature of the evaporator increases the COP of
the system due to the decrease in the compression ratio.
148
6.2 Recommendations
For future work, it is suggested to:
 Compare the experimental results with the other refrigerant for

example R32.
 Test the two improved controlling methods (variable DS and

direct EEV opening) with a direct expansion air condition system.
 Investigate the performance of the refrigeration in an experimental

system with an Artificial Neural Network (ANN) controller and
compare results with the suggested controllers of the current
study.
149
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Appendixes
Appendix (A-1)
Heat exchangers calculations
To found the refrigerant copper tube length of the evaporator and condenser
helical coils, the conservation of energy low was applied by assuming the amount of
the heat transferred between the water and refrigerant by convection which will
affect the changing water temperature and refrigerant enthalpy.
̇ ( ) ……………….. heat causes refrigerant enthalpy change
̇ ( ) …….. heat caused a change in water temperature
( ) … heat convicted between refrigerant and water
( ) ( )
( )
( )
water
Tw,i Tw,o
Tr,o Q Tr,i
Twall
Q
Tm
The amount of the heat convicted depended on the value of the heat transfer
coefficient for the water side and the refrigerant side for each region of the coil.
1- Calculating the refrigerant flow rate:
From the compressor manufacture data sheet: (N 3600 rpm; ξ 0.85; VD 15

cm3/rev) and from the pressure enthalpy diagram of the refrigerant R410a and at
(T=10° and P=8 bar) the specific volume of R410a is 0.0325 m3/kg. By subtitling
these values in above equation, the refrigerant flow rate is equal to 0.023 kg/s.
158
2- Calculate the water side heat transfer coefficient:
* +
For above equation, at evaporation temperature 10°C and from water properties
tables, the =8 and =0.59 W/m.C . Water Reynolds number ( ) is
calculated from the equation :
The dynamic viscosity of the water (μw) is equal (43438 10-3) (kg/m.s) from the
water tables at 10°C and the mass flux of water is calculated from the equation:
Where the evaporator water flow rate ( ̇ ) is (0.075 kg/s) and the ( ) is cross-
sectional area of water flow is calculated from the equation:
[( ) (( ) ( ) )]
( ) is represented the area between the inner and outer shells minus the area of
the refrigerant tube with the diameters = 0.0095m and =0.13m =0.11m.
The center diameter of the water shell cylinder is calculated from the equation:
The results of the above equations were:
Dc=0.012m ; Acw= 0.0001885 m2 and Gw= 291.8 kg/s.m2
The hydraulic diameter of the water flow is calculated from the equation:
159
Where ( ) is the net volume of the water flow through one turn:
( )
And the value of ( ) is (2 dto) which is equal (0.019m). and thus (Va is equal
(71.63*10-6 m3).
‫؞‬ ( ) 71.63 10-6 m3
( )
(( ) )
‫؞‬ (( ) ) = 0.3775 m
‫؞‬ ( ) = 26.76 10-6 m3
‫؞‬ = 71.63*10-6 - 26.76 *10-6 = 44.87 10-6 m3
‫؞‬ = 0.01593 m
* + = 1743 W/m2.°C
For the condenser calculation, the thermodynamic properties of the water were taken
at condenser temperature 80°C; (Muw,c=0.78*10-3, Pr,c=5.1, and Kw,c=0.62) and
the condenser heat transfer coefficient will be 1850 W/m2.°C.
3- Condenser tube length calculations:
The condenser was consists of three regions and for each one there is a tube length
which is calculated as flow. For single-phase refrigerant fluid state (liquid or vapor),
the heat transfer coefficient can be calculated using the following correlation:
160
(1+3.455( )) ( )
Where: di = 0.0095m , Dc = 0.012m , mr = 0.023 kg/s , and Gf = 457.6 kg/s.m2.
The amount of heat transfer from the refrigerant to the water (Q) is constant for
each region. The refrigerant and water thermodynamics properties are calculated at
condenser pressure 33bar and the mean temperature of the input and output for each
region. For a mixture of the refrigerant vapor and liquid inside circular tubes with
R410a as a refrigerant the refrigerant heat transfer coefficient is calculated from the
following equation:
∫ *( ) ( ) +
All thermodynamic properties of the refrigerant are calculated at saturation

conditions of the condenser pressure. The results of all calculations can be
summarized with the flowing table.
properties Liquid region Mixed region Superheated region

Tw,i (°C) 35 37 46
Tw,o (°C) 37 46 52
Tr,i (°C) 50 50 80
Tr,o (°C) 40 50 50
Tw,m (°C) 36 50 49
Twall (°C) 42 48.4 60
Cw (kJ/kg.C) 4.19 4.19 4.19
Q (w) 460 3230 1408
(kg/m.s) 0.0000841 0.0000841 0.0000157
(W/m.C) 84.14 84.14 23.89
(J/kg.C) 2211 1984 2333
43526 43526 98546
2.21 0.62 1.521
hr (W/m.C) 4475 9273 4581
Tube length
1.4 5.8 1.8
(m)
161
4- evaporator tube length calculations:
The evaporator was consists of two regions and for each one there is a tube length
which is calculated with the same procedure of the condenser. All thermodynamics
properties of the refrigerant were calculated at the evaporator pressure 8.5bar and
the results for each region can be summarized with the flowing table:
properties Mixed region Superheated region

Tw,i (°C) 16.4 17
Tw,o (°C) 2. 6 16.4
Tr,i (°C) -8 -8
Tr,o (°C) -8 0
Tw,m (°C) 9.5 16.7
Twall (°C) -6.5 12.4
Cw (kJ/kg.C) 4.19 4.19
Q (w) 4650 190
(kg/m.s) 0.0001941 0.0000117
(W/m.C) 84.14 0.01184
(J/kg.C) 1214 1064
24946 31153
2.332 1.089
hr (W/m.C) 23078 1281
Tube length (m) 5.5 0.5
162
START
INPUT
Do, Di, do, di
Prw, μw, Kw, mw ,
mr
Calculate the hydraulic diameter

Calculate Dc from equation (8)
Calculate Lcoil from equation (14)
Calculate Vc from equation (13)
Calculate Vf from equation (10)
Calculate DH from equation (9)
Calculate the convection heat

transfer coefficient of the water
Calculate Gw from equation (6)
Calculate Acw from equation (7)
Calculate Re from equation (5)
Calculate hw from equation (4)
hw
Mixed-region
Single-region INPUT
INPUT (μl ,μv ,ρl ,ρv , Ps, Pc,
Kv , μr,v , Cpv ,Tri , Tro
Cpw, Cpl, Kl, Trs, Twi)
Calculation of the heat transfer coefficient Calculation of the heat transfer coefficient
Calculate Gr,v from equation (18) Calculate Gr,l from equation (27)
Calculate Re,v from equation (16) Calculate Re,l from equation (26)
Calculate Pr,v from equation (17) Calculate Pr,l from equation (28)
Calculate hr,v from equation (15) Calculate hr,x from equation (24)
Two
Calculation of the copper tube length 2 Calculation of the copper tube length 1
By solve the equations By solve the equations
19 , 20 , 21 , 22 , 23 29 , 30 , 31 , 32
To fined Lc2 To fined Lc1 and Two
Tube length= Lc1+Lc2
Print the
tube length
END
Figure (1): Evaporator tube length calculations flowchart.
163
Appendix (A-2)
EES program of evaporator tube length calculations
Evaporator total copper tube length “Lcoil Lc1+Lc2”
“ EVAPURATOR CALCULATION WATER SIDE"
dto=0.0095 ;Do=0.13 ;Di=0.110
MWe=0.07: Muwe=1.138E-3; Prwe=8; Kwe=0.59
"CALCULATION OF HYDROLIC DIAMETER OF HELICAL COIL"
Dc=Di+(Do-Di)/2 ; PICH=2*dto
Lcoill=SQRT((PI*Dc)^2+PICH^2)
Vc=PI/4*dto^2*Lcoill
Va=PI/4*(Do^2-Di^2)*PICH
Vf=Va-Vc
De=4*Vf/(PI*dto*Lcoill)
"CALCULATION OF CONVECTION HEAT TRANSFER COFFICIENT OF WATER"
Gwe=Mwe/Ace
Ace=pi/4*(((Do^2)-(Di^2))-((Dc+dto)^2-(Dc-dto)^2))
REe=Gwe*De/Muwe
Nuwe=0.8*(REe^.4)*(Prwe^.36")Incropera and Dewitt"
HWe=Nuwe*Kwe/De
“ Evaporation two phase SHAHA development equation 2015"
Hre=(0.023 *INTEGRAL( (Rel^0.8) * (Prl^0.4) * (kl/dti) *
(((1-x)^0.8)+3.8/(PR^0.52)*(x/(1-x))^0.201),x,0.326,.99))/(.99-.326)
Rel=G*dti/mul
G=Mr/(pi/4*dti^2)
Prl=mul*cpl/kl
PR=ps/pc
mul=191.4E-6; muv=11.48E-6; rol=1203.9; rov=1/0.04352; dto=0.0095; dti=0.008;
ps =600000 ; pc=4926100
Hw=1748; cpw=4180; cpl=1479; kl=0.1214; Trs=-8;Twi=25 ;Mr=0.023; tr= -8; Mw=0.07
Qev2=Mr*(420-265)*1000
Qev2=Hre*(pi*dti*Lc1)*)Twall-Trs)
Qev2=Mw*Cpw*(Twi-Two)
Qev2= Hw*(pi*dto*Lc1)*(Twm-twal)
Twm=(Twi+Two)/2
"HEAT TRANSFER COFICIENT XIN and EBADIAN"
Hve=.00619 * (Rev^.92) * (Prv^0.4) * (1+3.455*(dti/dc)) *(kv/dti)
Rev=G*dti/muv
G=mr/(pi/4*dti^2)
Prv=muv*CPv/Kv
Uv=1/Hw+dto/(dti*Hve)
lmtd=((twi-tro)-(two-tri))/LN((twi-tro)/(two-tri))
Qv=Mw*CPw*(twi-two)
Qv=Mr*(hro-hri)*1000
Qv=Uv*Av*lmtd
Av=Lc2*pi*dto
dti=.008; dto=.0095; dc=.12; Kv=.01148; Mr=.023; Mw=0.07;
Muv=11.75E-6; Cpv=1.064E3
twi=4.775; tri= -8; tro=0; Hw=1743; cpw=4180
hri=Enthalpy(R410A,T=tri,P=600)
hro=Enthalpy(R410A,T=0,P=600)
164
START
INPUT
Do, Di, do, di
Prw, μw, Kw, mw ,
mr
Calculate the hydraulic diameter

Calculate Dc from equation (8)
Calculate Lcoil from equation (14)
Calculate Vc from equation (13)
Calculate Vf from equation (10)
Calculate DH from equation (9)
Calculate the convection heat

transfer coefficient of the water
Calculate Gw from equation (6)
Calculate Acw from equation (7)
Calculate Re from equation (5)
Calculate hw from equation (4)
hw hw
Single-region Single-region
(superheat) Mixed-region (subcool)
INPUT
INPUT (μl ,μv ,ρl ,ρv , Ps, Pc, INPUT
Kv , μr,v , Cpv ,Tri , Tro Kl , μr,l , Cpl ,Tri , Tro
Cpw, Cpl, Kl, Trs)
Two1
Calculation of the heat transfer coefficient Calculation of the heat transfer coefficient Two2 Calculation of the heat transfer coefficient
Calculate Gr,v from equation (18) Calculate Gr,l from equation (27) Calculate Gr,l from equation (18)
Calculate Re,v from equation (16) Calculate Re,l from equation (26) Calculate Re,l from equation (16)
Calculate Pr,v from equation (17) Calculate Pr,l from equation (28) Calculate Pr,l from equation (17)
Calculate hr,v from equation (15) Calculate hr,x from equation (24) Calculate hr,l from equation (15)
Calculation of the copper tube length 2 Calculation of the copper tube length 1 Calculation of the copper tube length 2
By solve the equations By solve the equations By solve the equations
19 , 20 , 21 , 22 , 23 29 , 30 , 31 , 32 19 , 20 , 21 , 22 , 23
To fined Lc1 and Two1 To fined Lc2 and Two2 To fined Lc3 and Two3
Lc2
Lc1 Tube length= Lc1+Lc2Lc3 Lc3
Print the
tube length
END
Figure (2): Condenser tube length calculation flowchart.
165
Appendix (A-3)
EES program of condenser tube length calculations
Condenser total copper tube length “Lcoil Lc1+Lc2 +Lc3”
"CONNDENEOR CALCULATION WATER SIDE "
dto=0.0095; Do=0.13; Di=0.11;MWc=0.07; Muwc=0.78E-3;Prwc=5.1;Kwc=0.62
Dc=Di+(Do-Di)/2
PICH=2*dto
Lcoill=SQRT((PI*Dc)^2+PICH^2)
Vc=PI/4*dto^2*Lcoill
Va=PI/4*(Do^2-Di^2)*PICH; Vf=Va-Vc
De=4*Vf/(PI*dto*Lcoill)
Gwc=Mwc/Acc
Acc=pi*((((Do^2)-(Di^2))-((Dc+dto)^2-(Dc-dto)^2)))/4
REc=Gwc*De/Muwc
Nuwc=0.8*(REc^.4)*(Prwc^.36" )Incropera and Dewitt"
HWc=Nuwc*Kwc/De
"part 1 condensation heat transfer coefficient for vapor by Xin and Ebadian"
Hr=0.00619*(Re^0.92)*(prl^1.4)*(1+3.455*(di/dc))*(kr/di)
Re=Gr*di/mul; Gr=Mr/(pi/4*di^2); prl=mul*Cpr/kr
Cpr=233; Cpw=4190; Mr=0.03; Mw=0.07; Hw=1850; di=0.008; do=0.0095; dc=0.12
mul=15.57E-6; kr=0.02389; Tri=80; Tro=50; Pc=3000; Twi=44
Dh=(Enthalpy(R410A,T=Tri,P=Pc) - Enthalpy(R410A,T=Tro,P=Pc))*1000
Qev1=Mr*Dh
Qev1=Hr*(pi*di*Lc1)*)Trm-Twall)
Trm=(Tri+Tro)/2
Qev1=Mw*Cpw*(Two-Twi)
Qev1= Hw*(pi*do*Lc)*(twall-Twm)
Twm=(Twi+Two)/2
"PRT 2 condensation two phase shah development equation 2015"
Hct=0.023 *INTEGRAL( (Rel^0.8) * (Prl^0.4) * (kl/di) * (((1-x)^0.8)+3.8/(PR^0.52)*

(x/(1-x))^0.201),x,0,.99)
Rel=G*di/mul ; G=Mr/(pi/4*di^2) ; Prl=mul*cpl/kl ; PR=ps/pc
mul=84.1E-6; muv=15.57E-6; rol=914.5; rov=137.17;
do=0.0095; di=0.008; ps=3000000; pc=4926100
Hw=1850; cpw=4190; cpl=2211; kl=0.08414;Trs=50 ; Twi=27.5 ; Mr=0.023 ;tr= 50;Mw=0.07
Qev2=Mr*Enthalpy_vaporization(R410A,T=trs)*1000
Qev2=Hct*(pi*di*Lc)*(Trs-Twall)
Qev2= Hw*(pi*do*Lc2)*)twall-Twm)
Twm=(Twi+Two)/2
"PART 3 condensation heat transfer coefficient for liquid by Xin and Ebadian"
Hr=0.00619*(Re^0.92)*(prl^1.4)*(1+3.455*(di/dc))*(kr/di)
Re=Gr*di/mul ; Gr=Mr/(pi/4*di^2); prl=mul*Cpr/kr
Cpr=2211; Cpw=4190; Mr=0.023; Mw=0.07; Hw=1850; di=.008; do=.0095 : dc=.124
mul=84.1E-6; kr=.08414 ; Tri=50; Tro=40 ; Pc=3000; Twi=38
Qev1=Mr*20*1000
Qev1=Hr*(pi*di*Lc)*(Trm-Twall)
Trm=(Tri+Tro)/2
Qev1= Hw*(pi*do*Lc3)*)twall-Twm); Twm=(Twi+Two)/2
166
Appendix (A-4)
Block diagram of LabVIEW experimental rig program.
167
Appendix (B-1)
Optimum results of the manual 45 experiments at different evaporator and condenser inlet water temperature with compressor speed.
inlet water Comp. EEV Sub
Mr Mw,cond Mw,ev P1 Tr1 Tw1 P2 Tr2 Tw2 P3 Tr3 Tw3 P4 Tr4 Tw4 Power Q,con Q,ev COP DS
Test No. temperature to Speed opening Cool
g/s mL/s mL/s bar °C °C bar °C °C bar °C °C bar °C °C w w w °C
Cond , Eva °C rpm step °C
1 25,14 1200 60 9.855 75.79 80.99 7.036 3.68 13.86 19.920 45.69 31.25 19.820 33.09 26.04 7.118 3.49 8.93 291 5511 1669 5.73 8.53 -0.24
2 25,17 1200 65 9.920 76.32 82.56 8.006 7.11 17.16 19.404 43.07 30.99 19.304 33.33 24.66 8.089 7.03 12.35 284 4412 1660 5.84 8.01 -0.46
3 25,20 1200 75 10.592 74.92 80.55 8.669 9.52 20.03 20.331 46.53 31.99 20.231 33.61 25.57 8.764 9.27 14.96 287 3745 1747 5.95 7.51 -0.96
4 29,14 1200 60 8.955 74.67 81.93 7.083 3.91 14.05 21.178 44.79 34.64 21.078 36.62 29.10 7.158 3.85 9.28 317 6426 1635 5.16 8.55 -0.30
5 29,17 1200 68 9.220 75.66 87.16 7.993 7.23 17.10 22.176 54.21 35.65 22.076 36.11 29.46 8.068 6.75 12.46 331 5868 1692 5.11 8.03 0.04
6 29,20 1200 70 10.092 79.46 84.84 8.894 10.04 20.04 22.163 53.30 35.45 22.063 36.04 29.00 8.979 9.47 15.20 327 5117 1715 5.24 7.53 0.09
7 33,14 1200 60 8.703 78.26 80.82 7.127 4.31 14.10 22.781 50.21 36.94 23.100 37.37 31.68 7.209 4.05 9.57 344 7473 1530 4.57 8.59 0.63
8 33,17 1200 70 9.374 75.96 83.74 7.867 6.81 16.73 19.116 56.36 39.06 24.300 40.00 33.32 7.940 6.56 12.38 359 7090 1521 4.51 8.07 0.07
9 33,20 1200 80 10.109 76.68 85.75 9.156 10.79 20.35 20.843 59.03 39.45 25.100 40.22 32.87 9.231 10.19 15.64 370 6121 1689 4.57 7.57 1.20
10 25,14 1800 70 9.607 73.35 80.33 5.511 -1.57 14.00 19.592 43.79 31.01 19.492 30.53 23.72 5.600 -1.28 8.31 435 5216 1909 4.39 8.32 0.71
11 25,17 1800 85 11.843 76.31 81.69 7.193 4.19 17.22 21.579 50.98 33.56 21.479 34.93 25.29 7.273 4.48 10.85 472 5212 2175 4.60 7.81 0.12
12 25,20 1800 115 13.001 74.96 82.37 7.885 6.50 20.01 22.065 53.74 34.20 21.965 35.56 25.12 7.952 6.74 13.52 487 4446 2235 4.49 7.32 0.41
13 29,14 1800 70 10.579 74.22 80.51 6.132 0.48 14.05 22.773 49.88 36.17 22.673 36.75 28.72 6.204 0.84 8.31 502 6862 1933 3.85 8.34 0.53
14 29,17 1800 90 12.139 76.97 87.59 7.302 4.49 17.16 22.799 61.26 37.62 23.700 38.37 29.26 7.398 4.57 11.18 530 6585 2190 4.14 7.83 0.67
15 29,20 1800 110 13.009 81.83 81.67 7.978 6.47 19.81 22.586 60.85 37.28 24.100 37.16 28.86 8.070 6.35 13.28 527 5974 2229 4.23 7.34 2.57
16 33,14 1800 70 10.757 78.77 79.98 5.960 0.03 14.13 22.792 54.96 38.84 24.300 39.90 32.35 6.030 0.20 8.71 538 8134 1812 3.56 8.38 0.17
17 33,17 1800 90 12.577 76.35 83.13 7.383 4.45 17.07 18.619 63.53 40.75 26.100 41.95 32.73 7.466 4.63 11.59 575 7557 1904 3.60 7.78 1.09
18 33,20 1800 110 13.419 76.83 86.42 8.297 7.43 20.16 22.746 66.53 41.69 26.300 41.81 32.87 8.381 7.55 14.23 587 6914 2142 3.70 7.38 1.56
19 25,14 2400 90 11.774 73.25 78.55 5.065 -3.97 14.13 21.044 49.12 33.11 20.944 32.98 24.28 5.144 -3.11 7.27 621 5813 2254 3.25 8.15 1.09
20 25,17 2400 105 14.541 76.34 81.68 6.586 1.50 16.91 22.798 54.60 35.02 22.700 36.37 25.09 6.664 2.33 9.58 675 5778 2501 3.71 7.65 0.92
21 25,20 2400 125 15.742 75.91 85.89 7.337 4.06 20.07 22.798 60.06 35.71 23.100 35.82 24.56 7.423 4.94 12.51 696 4962 2715 3.90 7.10 2.18
22 29,14 2400 90 10.520 74.39 78.57 4.458 -6.89 14.38 22.795 62.70 36.73 23.300 37.11 29.01 4.547 -6.19 7.55 655 6951 2243 2.82 8.17 1.24
23 29,17 2400 108 14.490 76.42 87.26 6.597 1.81 16.91 22.783 67.61 39.34 25.100 39.90 29.09 6.669 2.42 10.08 734 7164 2493 3.40 7.67 1.52
24 29,20 2400 125 15.740 79.06 81.33 7.269 3.97 19.71 19.821 67.58 39.72 25.300 39.69 29.32 7.357 4.36 11.79 757 6612 2694 3.42 7.12 2.06
25 33,14 2400 90 10.779 78.92 78.99 4.466 -6.44 13.90 22.793 62.64 39.05 25.100 39.57 31.93 4.553 -5.78 7.43 688 8295 2137 2.67 8.11 1.84
26 33,17 2400 110 14.931 76.87 83.68 6.772 1.89 16.85 22.776 69.82 42.71 27.900 43.06 32.88 6.852 2.64 10.19 795 8308 2329 3.06 7.57 2.80
27 33,20 2400 123 16.413 76.27 86.05 7.704 5.15 20.03 22.653 71.81 43.06 28.700 43.75 32.31 7.766 5.78 12.96 822 7342 2544 3.14 7.16 3.33
28 25,14 3000 105 1.042 73.98 76.29 4.062 -9.01 14.82 21.342 52.17 33.73 21.242 34.95 25.05 4.138 -7.55 6.97 770 5846 2502 2.51 7.76 0.33
29 25,17 3000 135 16.862 76.22 83.84 6.253 -0.46 16.89 22.780 59.73 36.92 23.500 37.99 25.46 6.350 1.15 9.33 889 6383 2651 3.14 7.41 0.71
30 25,20 3000 165 17.829 74.35 85.56 7.056 2.62 20.32 22.771 64.49 38.51 24.700 39.44 25.44 7.127 4.11 11.88 933 5653 3020 3.21 6.82 1.31
31 29,14 3000 105 11.156 74.25 74.49 3.709 -10.86 13.94 22.788 62.57 37.23 23.300 38.03 29.33 3.762 -9.60 5.93 807 7230 2494 2.20 7.77 0.32
32 29,17 3000 138 15.563 76.59 86.18 5.710 -1.83 16.80 22.787 71.34 40.49 25.300 41.36 29.39 5.797 -0.40 9.45 915 7583 2646 2.75 7.43 0.38
33 29,20 3000 160 18.903 78.84 81.22 7.079 2.30 20.06 14.018 72.42 41.49 27.300 42.57 29.07 7.156 3.78 11.29 988 7064 2979 2.85 6.84 2.37
34 33,14 3000 105 11.531 78.95 74.60 3.912 -9.36 13.95 16.449 65.95 40.67 25.300 41.60 33.23 4.008 -8.14 6.49 858 8817 2327 2.01 7.80 0.14
35 33,17 3000 140 16.764 77.82 83.06 6.279 -0.66 16.97 22.783 72.80 43.71 29.100 44.50 32.89 6.349 0.79 9.65 1017 8698 2541 2.56 7.47 3.17
36 33,20 3000 160 18.737 75.67 85.96 7.216 2.84 19.61 20.461 77.47 45.23 29.700 46.09 32.76 7.292 4.27 11.78 1069 8103 2814 2.65 6.88 2.46
37 25,14 3600 120 12.549 73.72 76.90 3.965 -10.17 14.54 22.692 52.36 35.57 22.592 37.18 25.87 4.037 -7.77 6.05 975 6482 2730 1.98 7.52 0.08
38 25,17 3600 155 16.217 74.68 79.70 4.966 -5.96 16.95 22.789 56.86 36.09 24.100 37.41 24.54 5.060 -3.51 8.49 1044 5973 2818 2.32 7.02 2.33
39 25,20 3600 185 20.237 74.17 85.38 6.680 0.44 19.85 22.739 67.45 39.74 25.700 41.00 25.22 6.755 2.91 11.07 1159 6167 3133 2.70 6.55 1.40
40 29,14 3600 120 12.259 74.94 74.66 3.534 -11.99 14.40 22.748 66.75 38.08 24.300 38.75 29.02 3.615 -10.06 5.76 995 7418 2690 1.90 7.54 1.33
41 29,17 3600 158 16.560 81.87 84.50 5.160 -4.88 17.08 22.247 71.81 40.07 26.100 40.58 29.00 5.236 -2.69 9.14 1119 7869 2805 2.33 7.04 2.47
42 29,20 3600 180 20.657 79.09 81.94 6.748 0.46 20.16 22.799 76.38 43.15 28.100 43.32 29.23 6.830 2.64 11.11 1237 7601 3098 2.41 6.57 2.85
43 33,14 3600 120 13.751 78.78 78.66 4.086 -9.52 13.97 22.784 65.59 41.94 27.300 42.32 33.07 4.161 -7.34 6.32 1090 9211 2515 1.76 7.58 2.62
44 33,17 3600 160 17.835 77.73 82.45 5.729 -3.46 16.89 22.705 71.99 44.31 29.100 44.61 32.81 5.803 -1.09 9.10 1228 8909 2686 2.15 7.08 3.06
45 33,20 3600 180 20.484 75.77 83.23 6.834 1.02 19.81 22.762 80.99 46.43 30.500 46.76 32.56 6.929 3.26 11.34 1312 8432 2945 2.30 6.51 2.94
168
Appendix (B-2)
Performance results at manual operation by changing EEV opening for each
compressor speed at constant evaporator and condenser inlet water temperatures
17,29 °C respectively.
Speed EEV Tev,wo Mr DS Power Pcon Pev Qe

COP
Rpm step °C g/s °C w bar bar w
1200 90 13 11.6 7.6 355 23 8.1 1775 5
1200 80 12.6 11.3 7.8 360 23.7 8.06 1818 5.05
1200 70 12.1 11.1 8.1 365 24.3 8.02 1858 5.09
1200 60 11.9 11 8.5 368 25 7.98 1934 5.12
1200 55 11.8 10.8 8.9 372 25.8 7.94 1939 5.2
1200 50 11.85 10.7 9.4 375 26.9 7.9 2024 5.17
1800 120 11.5 12.8 6.8 460 24.3 7.98 2102 4.4
1800 110 11.3 12.6 7.2 467 25 7.95 2148 4.5
1800 100 11.1 12.45 7.5 472 25.7 7.9 2194 4.55
1800 90 11 12.3 7.9 477 26.5 7.87 2265 4.6
1800 80 10.9 12.1 8.2 482 27.4 7.84 2265 4.7
1800 70 11 12.05 8.6 485 28.5 7.82 2482 4.67
2400 140 10.8 14.3 6.5 730 25.4 7.8 2573 3.4
2400 120 10.3 14.1 7 735 26.3 7.73 2660 3.5
2400 110 10.2 14 7.3 743 27.2 7.69 2775 3.58
2400 100 10.1 13.9 7.6 750 28.1 7.63 2880 3.7
2400 90 10 13.8 8 758 28.9 7.59 2892 3.8
2400 80 10.1 13.75 8.4 765 29.8 7.54 2470 3.78
3000 160 10.2 15.5 6.2 950 26 7.35 2506 2.6
3000 140 9.9 15.2 6.6 960 26.9 7.3 2551 2.61
3000 130 9.7 14.95 6.8 970 27.7 7.22 2551 2.63
3000 120 9.6 14.7 7.1 985 28.5 7.15 2600 2.64
3000 110 9.4 14.6 7.4 999 29.4 7.1 2647 2.65
3000 100 9.45 14.4 7.8 1015 30.5 7 2669 2.63
3600 180 9.8 17.5 5.8 1200 27.2 6.8 2760 2.3
3600 160 9.6 17.1 6.3 1210 27.8 6.75 2795 2.31
3600 150 9.5 16.7 6.6 1220 28.5 6.7 2830 2.32
3600 140 9.3 16.3 6.8 1235 29.8 6.6 2890 2.34
3600 130 9.2 15.9 7 1250 30.8 6.5 2938 2.35
3600 120 9.2 15.5 7.5 1260 32 6.3 2942 2.335
169
Appendix (B-3)
Optimum EEV opening of the manual 45 experiments at different evaporator and
condenser inlet water temperature with compressor speed.
200 200
Tcon,wi=25 Tev,wi=14
opening / step
150 150
opening / step
100 100
50 50
13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 34
200 200
150
opening / step
150
opening / step
100 100
50 50
13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 34
200 200
150 150
opening / step
opening / step
100 100
50 50
13 14 15 16 17 18 19 20 21 24 25 26 27 28 29 30 31 32 33 34
Compressor speed: ♦1200 □1800 ▲2400 ●3000 Δ3600 (rpm)
170
Appendix (B-4)
Performance results at automatic control operation with constant cooling load for each evaporator and condenser inlet water temperature
sets (14,17,19), (25,27,29,31,33) °C respectively.
test Tcon,wi Tev,wi Tev,wo Speed Open Mr Pev Pcon Power Q ev sub cool Ds eq. DS
COP
NO. °C °C °C rpm step g/s bar bar w w °C °C °C
1 25 14.797 7.97 2929 94 10.996 6.799 24.394 704 2299 3.195 7.47 6.89 6.83
2 25 17.026 9.92 2621 108 10.196 7.699 25.292 679 2350 3.315 7.28 6.55 6.53
3 25 19.008 11.89 2511 124 9.694 8.199 26.190 650 2265 3.464 7.08 6.22 6.24
4 27 14.797 7.97 3114 98 11.797 6.950 26.294 749 2302 3.006 5.97 6.82 6.78
5 27 17.016 10.06 2784 112 10.945 7.819 26.991 728 2277 3.094 5.68 6.49 6.50
6 27 19.007 11.89 2704 128 10.393 8.249 27.588 699 2281 3.222 5.17 6.16 6.19
7 29 14.799 7.97 3364 102 12.597 7.099 28.896 805 2304 2.785 5.37 6.74 6.71
8 29 17.023 9.89 3018 116 11.693 7.968 29.686 765 2263 2.942 4.28 6.41 6.40
9 29 19.006 11.89 2909 132 10.977 8.328 30.185 740 2269 3.041 3.98 6.07 6.12
10 30 14.793 7.91 3604 105 14.292 7.238 29.978 842 2317 2.668 4.79 6.66 6.63
11 30 17.021 9.89 3236 120 12.997 8.199 30.396 814 2267 2.767 3.87 6.33 6.34
12 30 19.007 11.89 3053 136 12.194 8.529 31.189 795 2252 2.873 3.28 5.99 6.05
13 31 15.025 7.89 3514 107 15.593 7.319 32.387 861 2277 2.612 4.18 6.62 6.59
14 31 17.008 9.89 3311 122 14.795 8.299 32.691 835 2242 2.694 2.28 6.28 6.32
15 31 19.009 11.89 3106 140 13.397 8.779 33.094 808 2304 2.786 1.78 5.95 5.99
171
Appendix (C)
Tuning Tables
Table (C-1): PI controller tuning results.
compressor controller gains EEV controller gains

Test No.
kp ki kp ki
test 1 0.03 0.0003
At first controlled by equation
test 2 0.03 0.002
for EEV opening
test 3 0.02 0.002
test 4 0.02 0.002 1.5 0.001
test 5 0.02 0.002 1 0.01
test 6 0.02 0.002 0.8 0.01
Table (C-2): PID controller tuning results.
Test NO. Controller kp ki kd

Compressor 0.03 0.00002 0.000002
test 1
EEV By equation of EEV opening
Compressor 0.025 0.00001 0.000005
test 2
Compressor 0.025 0.00002 0.00001
test 3
Compressor 0.025 0.00002 0.00001
test 4
EEV 1.2 0.1 0.2
Compressor 0.025 0.00002 0.00001
test 5
EEV 1 0.001 0.01
Compressor 0.025 0.00002 0.00001
test 6
EEV 0.6 0.02 0.01
172
input (ΔTw)
-5V -4V -3V -2V -1V0 +1V+2V +3V +4V +5V

output (Δv)
Figure (C-1): P-fuzzy compressor membership.
input (ΔDS)
-5ST -4ST -3ST -2ST-1ST 0 +1ST+2ST +3ST +4ST

+5ST
output (Δstep)
Figure (C-2): P-fuzzy EEV membership.
173
Table (C-3): P-fuzzy controller tuning weights.
Test 1 Compressor membership weights Test 1 EEV membership weights

input +1Tw +2Tw +3Tw +4Tw +5Tw input +1DS +2DS +3DS +4DS +5DS
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
output +1V +2V +3V +4V +5V output +1ST +2ST +3ST +4ST +5ST
Δv 0.018 0.036 0.054 0.072 0.09 Δ step 0.6 1.2 1.8 2.4 3

ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
Δv 0.0048 0.012 0.036 0.072 0.12 Δ step 0.17 0.4 0.9 1.7 3

ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
Δv 0.007 0.025 0.06 0.115 0.2 Δ step 0.3 0.8 1.6 3 5

ΔTw 0.2 0.4 0.6 0.8 1 ΔDS 0.6 1.2 1.8 2.4 3
Δv 0.003 0.01 0.03 0.08 0.2 Δ step 0.17 0.4 0.9 1.7 3

ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
Δv 0.003 0.01 0.03 0.08 0.2 Δ step 0.17 0.4 0.9 1.7 3

ΔTw 0.2 0.4 0.6 0.8 1 ΔDS 0.6 1.2 1.8 2.4 3
Δv 0.003 0.01 0.03 0.08 0.2 Δ step 0.15 0.4 1 2 4
Note: the values of the negative linguistic variables (-Tw,-V,-DS,-ST) are the same values
of the positive linguistic variables (+Tw,+V,+DS,+ST) multiplying by (-1).
174
first input (ΔTw)
-5V -4V -3V -2V-1V 0 +1V+2V +3V +4V +5V

first output (Δv 1)
Figure (C-3): P-fuzzy compressor membership.
-5dTw -4dTw -3dTw -2dTw -1dTw 0 +1dTw +2dTw +3dTw +4dTw +5dTw
second input d(Tw)/dt
-5V -4V -3V -2V -1V 0 +1V+2V +3V +4V +5V

second output (Δv 2)
Figure (C-4): D-fuzzy compressor membership.
175
first input (ΔDS)
-5ST -4ST -3ST -2ST -1ST0 +1ST+2ST +3ST +4ST +5ST

first output (Δstep 1)
Figure (C-5): P-fuzzy EEV membership.
-5dDS -4dDS -3dDS -2dDS -1dDS 0 +1dDS +2dDS +3dDS +4dDS +5dDS
second input d(DS)/dt
-5ST -4ST -3ST -2ST-1ST 0 +1ST+2ST +3ST +4ST +5ST

second output (Δstep 2)
Figure (C-6): D-fuzzy EEV membership.
176
Table (C-4): the P+D fuzzy controller tuning weights.
Input 1 +1Tw +2Tw +3Tw +4Tw +5Tw Input 1 +1DS +2DS +3DS +4DS +5DS
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
output 1 +1V +2V +3V +4V +5V Output 1 +1ST +2ST +3ST +4ST +5ST
Δv 1 0.007 0.025 0.06 0.115 0.2 Δ step1 0.3 0.8 1.6 3 5
Input 2 +1dTw +2dTw +3dTw +4dTw +5dT Input 2 +1dDS +2dDS +3dDS +4dDS +5dDS
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 1 2 3 4 5
Output 2 +1V +2V +3V +4V +5V Output 2 +1ST +2ST +3ST +4ST +5ST
Δv 2 0.002 0.01 0.03 0.06 0.1 Δ step2 0.125 0.25 0.5 1 2
Input 1 +1Tw +2Tw +3Tw +4Tw 5Tw Input 1 +1DS +2DS +3DS +4DS +5DS
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
Δv 1 0.015 0.06 0.15 0.3 0.5 Δ step1 0.6 1.6 3.2 6 10
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 1 2 3 4 5
Δv 2 0.002 0.01 0.03 0.06 0.1 Δ step2 0.125 0.25 0.5 1 2
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
Δv 1 0.015 0.06 0.15 0.3 0.5 Δ step1 0.6 1.6 3.2 6 10
177
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 1 2 3 4 5
Δv 2 0.008 0.02 0.05 0.11 0.2 Δ step2 0.1 0.4 1.2 2.5 5
ΔTw 0.2 0.4 0.6 0.8 1 ΔDS 0.6 1.2 1.8 2.4 3
Δv 1 0.003 0.01 0.03 0.08 0.2 Δ step1 0.15 0.4 1 2 4
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 1 2 3 4 5
Δv 2 0.008 0.02 0.05 0.11 0.2 Δ step2 0.1 0.4 1.2 2.5 5
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
Δv 1 0.003 0.01 0.03 0.08 0.2 Δ step1 0.3 0.8 1.6 3 5
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 1 2 3 4 5
Δv 2 0.002 0.01 0.03 0.06 0.1 Δ step2 0.125 0.25 0.5 1 2
Note: Values of the negative linguistic variables (-Tw,-V,-DS,….) are the same values of
the positive linguistic variables (+Tw,+V,+DS,….) multiplying by (-1).
178
first input (ΔTw)
-5dTw -4dTw -3dTw -2dTw -1dTw 0 +1dTw +2dTw +3dTw +4dTw +5dTw
second input d(Tw)/dt
-5V -4V -3V -2V -1V 0 +1V+2V +3V +4V +5V

output (Δv)
Figure (C-7): PD-fuzzy compressor membership.
179
first input (ΔDS )
-5dDS -4dDS -3dDS -2dDS -1dDS 0 +1dDS +2dDS +3dDS +4dDS +5dDS
second input d(DS)/dt
-5ST -4ST -3ST -2ST-1ST0 +1ST+2ST +3ST +4ST +5ST

output (Δ step)
Figure (C-8): PD-fuzzy EEV membership.
180
Table (C-5): the PD-fuzzy controller tuning weights.
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 1 2 3 4 5
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 2 4 6 8 10
Output +1V +2V +3V +4V +5V Output +1ST +2ST +3ST +4ST +5ST
Δv 0.003 0.01 0.03 0.08 0.2 Δ step 0.125 0.25 0.5 1 2
ΔTw 0.4 0.8 1.2 1.6 2 ΔDS 0.6 1.2 1.8 2.4 3
d(Tw)/dt 0.6 1.2 1.8 2.4 3 d(DS)/dt 1 2 3 4 5
Δv 0.003 0.01 0.03 0.08 0.2 Δ step 0.2125 0.425 .75 1.5 3
ΔTw 0.2 0.4 0.6 0.8 1 ΔDS 0.6 1.2 1.8 2.4 3
d(Tw)/dt 0.4 0.8 1.2 1.6 2 d(DS)/dt 1 2 3 4 5
Δv 0.003 0.01 0.03 0.08 0.2 Δ step 0.125 0.25 0.5 1 2
Note: Values of the negative linguistic variables (-Tw,-V,-DS,….) are the same values of
the positive linguistic variables (+Tw, +V, +DS,….) multiplying by (-1).
181
‫اىرْاسث‪ ٜ‬اىرفاضي‪ٍ )PD-fuzzy) ٜ‬ع حيقح ذحنٌ ٗاحذج ماُ ٕ٘ االفضو ٍِ ح‪ٞ‬ث االسرقزار‪ٝ‬ح ٗاالداء‬
‫تاىَقارّح ٍع طز‪ٝ‬قح اىرحنٌ اىرقي‪ٞ‬ذ‪ٝ‬ح تاإلطفاء ٗاىرشغ‪ٞ‬و )‪ 3)On-Off‬ف‪ ٜ‬اىَزحيح اىثاّ‪ٞ‬ح ذٌ اخرثار أداء‬
‫ّظاً اىرجَ‪ٞ‬ذ اىَرحنٌ عْذ حاىح االسرقزار عِ طز‪ٝ‬ق ذغ‪ٞٞ‬ز درجح حزارج اىَاء اىذاخو ىيَثخز ٗاىَنثف ٍع‬
‫ثثاخ حَو اىرثز‪ٝ‬ذ‪ 3‬أظٖزخ اىْرائج اُ س‪ٝ‬ادج درجح حزارج اىَاء اىذاخو ىيَنثف قييد مفاءج اىْظاً تسثة‬
‫س‪ٝ‬ادج ّسثح االّضغاط ٗمذىل سزعح اىضاغظ ‪ 3‬مَا اُ مفاءج اىْظاً ماّد ذشداد ٍع س‪ٝ‬ادج درجح حزارج‬
‫اىَاء اىذاخو ىيَثخز عْذ ثثاخ درجح حزارج اىَنثف ٗمذىل حَو اىرثز‪ٝ‬ذ‪3‬‬
‫ذٌ اخرثار اداء اىْظاً ذحد اىرحنٌ عْذ حاىح اىرشغ‪ٞ‬و اىَسرقز عِ طز‪ٝ‬ق ذغ‪ٞٞ‬ز درجح حزارج اىَاء اىذاخو‬
‫ىيَثخز ٗاىَنثف عْذ ثثاخ اىحَو اىرثز‪ٝ‬ذ‪ 3ٛ‬س‪ٝ‬ادج درجح حزارج اىَاء اىذاخو ىيَنثف ٍِ ‪ °25‬اى‪°33 ٚ‬‬
‫اد‪ ٙ‬اى‪ ٚ‬ذقي‪ٞ‬و ٍعاٍو االداء تح٘اى‪ %42 ٜ‬تسة س‪ٝ‬ادج ّسثح االّضغاط ٗمذىل سزعح اىضاغظ‪ 3‬مَا اُ‬
‫ٍعاٍو االداء قذ ذحسِ تْسثح ‪ٍ %635‬ع س‪ٝ‬ادج درجح حزارج اىَاء اىذاخو ىيَثخز ٍِ ‪ °45‬اى‪ °49 ٚ‬عْذ‬
‫ثثاخ درجح حزارج اىَنثف‪ 3‬االخرثار االخ‪ٞ‬ز ماُ عِ طز‪ٝ‬ق ذغ‪ٞٞ‬ز اىحَو اىرثز‪ٝ‬ذ‪ٍ ٗ ٛ‬عذه ذذفق اىَاء‬
‫اىذاخو ىيَنثف ٗمذىل س‪ٝ‬ادج درجح حزارج اىَاء اىذاخو ىيَنثف ىغزض اخرثار اٍناّ‪ٞ‬ح اىرحنٌ ىيْظاً ف‪ٜ‬‬
‫ٍزحيح االسرجاتح اىعاتزج‪ 3‬ح‪ٞ‬ث اظٖزخ اىْرائج اسرقزار‪ٝ‬ح ج‪ٞ‬ذج ٍع اداء عاى‪ ٜ‬تاسرخذاً طز‪ٝ‬قح اىرحنٌ‬
‫تاىفرحح ٍثاشزج ٍع ٍرحنٌ ‪ PD-fuzzy‬ىيرحنٌ تسزعح اىضاغظ‪3‬‬
‫الخالصت‬
‫اُ اىض٘اغظ ٍرغ‪ٞ‬زج اىسزعح ٍع طز‪ٝ‬قح ذحنٌ ٍْاسثح ذسرخذً ىرحس‪ ِٞ‬اداء اّظَح ذن‪ٞٞ‬ف اىٖ٘اء‬
‫ٗاىرجَ‪ٞ‬ذ ٍِ خاله ذقي‪ٞ‬و اسرٖالك اىطاقح‪ 3‬ف‪ٕ ٜ‬ذٓ اىذراسح ذٌ اخرثار أداء ٍْظٍ٘ح ذثز‪ٝ‬ذ اىَاء )ج‪ٞ‬يز) ٍع‬
‫ضاغظ ٍرغ‪ٞ‬ز اىسزعح ٗصَاً ذَذد إى‪ٞ‬نرزّٗ‪ ٜ‬ح‪ٞ‬ث ذٌ دراسح ذأث‪ٞ‬ز ذغ‪ٞ‬زاخ سزعح اىضاغظ ٗفرحح‬
‫اىصَاً عي‪ ٚ‬مفاءج اىْظاً ٗاسرقزار‪ٝ‬رٔ‪ٝ 3‬رٌ اىرحنٌ تسزعح اىضاغظ تاالعرَاد عي‪ ٚ‬درجح حزارج اىَاء‬
‫اىثارد اىَْرج ٍِ اىَثخز عِ طز‪ٝ‬ق حيقح ذحنٌ اٗى‪ 3ٚ‬اٍا اىحيقح اىثاّ‪ٞ‬ح ماّد ذسرخذً ىرْظ‪ ٌٞ‬فرحح صَاً‬
‫اىرَذد ىغزض اىحفاظ عي‪ ٚ‬درجح ذحَ‪ٞ‬ص ٍائع اىرثي‪ٞ‬ج عْذ ق‪َٖٞ‬ا اىَحذدج‪ 3‬ذٌ اقرزاح طز‪ٝ‬قر‪ ِٞ‬جذ‪ٝ‬ذذ‪ِٞ‬‬
‫ىيرحنٌ تفرحح صَاً اىرَذد االى‪ٞ‬نرزّٗ‪ٗ ٜ‬اىر‪ ٜ‬ماّد ذحقق االداء االفضو عْذ ٍخريف ظزٗف اىرشغ‪ٞ‬و‪3‬‬
‫اىطز‪ٝ‬قح االٗى‪ ٚ‬افرزضد اُ ق‪َٞ‬ح درجح اىرحَ‪ٞ‬ص ى‪ٞ‬سد ثاترٔ تو ٕ‪ٍ ٜ‬رغ‪ٞ‬زج ت‪ 835 ٗ 635 ِٞ‬ذٌ ذقذ‪ٝ‬زٕا‬
‫تاسرخذاً ٍعادىح ذجز‪ٝ‬ث‪ٞ‬ح تاالعرَاد عي‪ ٚ‬سزعح اىضاغظ ٗدرجح حزارج اىَاء اىذاخو ىيَثخز ٍع اسرخذاً‬
‫حيقر‪ ِٞ‬ىيرحنٌ )حيقح سزعح اىضاغظ ٗحيقح فرحح اىصَاً)‪ٗ 3‬ىنِ ٍع ٗج٘د اىرزاتظ ت‪ ِٞ‬اىحيقر‪ ِٞ‬اىذ‪ ٛ‬أد‪ٙ‬‬
‫اى‪ ٚ‬ذقي‪ٞ‬و اسرقزار‪ ٔٝ‬اىْظاً‪ 3‬ذٌ ذقي‪ٞ‬و ٕذا اىرزاتظ تاقرزاح اىطز‪ٝ‬قح اىثاّ‪ٞ‬ح تاسرخذاً حيقح ذحنٌ ٗاحذج‬
‫ىيرحنٌ تسزعح اىضاغظ فقظ ت‪َْٞ‬ا فرحح اىصَاً ماّد ذع‪ٍ ِٞ‬ثاشزج تاسرخذاً ٍعادىح ذجز‪ٝ‬ث‪ٞ‬ح تاالعرَاد‬
‫عي‪ ٚ‬اىحَو اىرثز‪ٝ‬ذ‪ 3ٛ‬ىنيرا اىطز‪ٝ‬قر‪ ِٞ‬ذٌ اخرثار عذج ٍرحنَاخ ‪ :‬اىرْاسث‪ ٜ‬اىرناٍي‪ ٗ )PI) ٜ‬اىرْاسث‪ٜ‬‬
‫اىرناٍي‪ ٜ‬اىرفاضي‪ ٗ )PID) ٜ‬اىرْاسث‪ ٜ‬اىضثات‪ ٗ )P-fuzzy) ٜ‬اىرْاسث‪ٍ ٜ‬ع اىرفاضي‪ ٜ‬اىضثات‪P+D ) ٜ‬‬
‫‪ ٗ )fuzzy‬اىرْاسث‪ ٜ‬اىرفاضي‪ ٜ‬اىضثات‪ 3)PD-fuzzy) ٜ‬ح‪ٞ‬ث أظٖزخ ّرائج اخرثاراخ اىرحنٌ اسرقزار‪ٝ‬ح‬
‫عاى‪ٞ‬ح ىق‪َٞ‬ح درجح اىرحَ‪ٞ‬ص ٍع ذقي‪ٞ‬و ذذتذب االسرجاتح تح٘اى‪ٍ %45 ٜ‬ع طز‪ٝ‬قح اىرحَ‪ٞ‬ص اىَرغ‪ٞ‬ز ٗ‬
‫‪ٍ % 35‬ع طز‪ٝ‬قح اىفرحح اىَثاشزج ىيصَاً ٍقارّح ٍع اىطز‪ٝ‬قح اىرقي‪ٞ‬ذ‪ٝ‬ح تثثاخ درجح اىرحَ‪ٞ‬ص عْذ ‪ 7‬درجح‬
‫ٍؤ‪ 3ٛ‬ذيل االسرقزار‪ٝ‬ح ف‪ ٜ‬درجح اىرحَ‪ٞ‬ص ماُ ىٖا االثز اىَثاشز عي‪ ٚ‬اسرجاتح درجح حزارج اىَاء اىثارد‬
‫اىَْرج ٗمذىل عي‪ٍ ٚ‬عاٍو اداء اىْظاً )‪ (COP‬اىذ‪ ٛ‬اسداد تح٘اى‪ٍ %7 ٜ‬ع طز‪ٝ‬قح اىرحَ‪ٞ‬ص اىَرغ‪ٞ‬ز ٗ‬
‫‪ٍ %48‬ع طز‪ٝ‬قح اىفرحح اىَثاشزج ىيصَاً تاىَقارّح ٍع اىطز‪ٝ‬قح اىرقي‪ٞ‬ذ‪ٝ‬ح‪ 3‬مذىل ماُ ٍقذار اىرقي‪ٞ‬و ف‪ٍ ٜ‬قذار‬
‫اىطاقح اىَصزٗفح تح٘اى‪ٍ %35 ٜ‬ع اسرخذاً اىَرحنٌ‬
‫جوهىرٌت العراق‬
‫وزارة التعلٍن العالً والبحث العلوً‬
‫جاهعت واضط ‪ /‬كلٍت الهنذضت‬
‫قطن الهنذضت الوٍكانٍكٍت‬
‫دراضت االداء الحراري لنظام تجوٍذ هسود بضاغط هتغٍر الطرعت و‬

‫وحذاث تحكن هختلفت‬
‫رضالت‬
‫هقذهت الى هجلص كلٍت الهنذضت فً جاهعت واضط‬
‫كجسء هن هتطلباث نٍل شهادة الواجطتٍر فً علىم الهنذضت الوٍكانٍكٍت‬
‫تكٍٍف الهىاء والتجوٍذ‬
‫هن قبل‬
‫أحوذ حاهذ حطانً‬
‫بكالىرٌىش فً الهنذضت الوٍكانٍكٍت ‪1995‬‬
‫بأشراف‬
‫أ‪.‬م‪ .‬د‪ .‬عالء رحوت كاظن‬
‫‪1441‬هـ‬ ‫‪ 2020‬م‬
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Study The Thermal Performance of A Refrigeration System Equipped with

Thesis · August 2020

Variable speed compressor chiller refrigeration system performance View project

The user has requested enhancement of the downloaded file.

Study The Thermal Performance of

‫سا ۡن ۡما لۡم يۡع َّۡل (‪)٥‬‬ ‫عۡ ه َّۡل ٱ ِۡلن ۡ‬

‫ۡصدق هللا ال ۡع ُيل ال ۡعظي‬

We are the members of the examining committee certify that after

Prof. Dr. Asst. Prof. Dr.

Lect. Dr. Asst. Prof. Dr.

I certify that the thesis entitled ″ Study the thermal performance of

Asst. Prof. Dr. Alaa R. Al-Badri

Asst. Dr. Radwan M. Aljuhashy

To ALLAH “Greatest Creator”

To the Prophet of ALLAH “Mohammed” and his pure immediate family

To All Believers in the World

To all who helped and taught me in completing this research

I dedicate this modest endeavor …

Ahmed Hamed Hassani

patience to prepare this research carefully

Also, I extend my sincere thanks, gratitude, all respect, and appreciation,

I would like to extend my thanks and appreciation to my family for their

patience and unlimited support

Ahmed Hamed Hassani

A variable speed compressor with different controlling methods is

water temperature response and system coefficient of performance

The performance of the controlled system was examined at steady-

5.2 Manual operation performance 98

5.2.1 Compressor speed and EEV opening effects 455

5.2.2 Refrigerant superheat 106

5.2.3 Two loops with variable superheat controlling method 140

5.2.4 Coupling effect 142

5.2.5 Single loop Controlling method 144

5.2.6 Controllers Tuning 118

5.3 Automatic control operation 122

5.3.1 Controlling methods comparison 123

5.3.2 Controllers comparisons 129

5.3.3 Comparison with conventional controllers 134

5.3.4 Performance comparisons 133

5.4 Controlled system performance 137

5.4.1 Steady state performance 137

5.4.2 Transient performance 142

6.2 Recommendations 149

(B) Experimental results 163

(C) Tuning tables and figures 167

Symbol Definition Unit

1.2 Motivations for the current study

The International Energy Agency provided statistics about the growth

Million A/C solid units

Air-conditioning systems consumed about 40-50% of electrical energy

1.3 Refrigeration cycle

The working principle of variable speed refrigeration and heat pump

 Compressor: A mechanical equipment that is working to

variable speed refrigeration systems can be regulated by using a control

Figure (1-2): Refrigeration cycle.

 Condenser: A heat exchanger condenses refrigerant vapor into a

Variable speed refrigeration systems are equipped with a control

1.4 Controlling capacity methods

Designers of the refrigeration system depend on the maximum load to

the set conditions, refrigeration capacity must be regulated depending on

 Start and stop: A conventional controlling method that is used for

1.5 System improvement work