The University of Calgary Faculty of Engineering ENME 485 Mechanical Engineering Thermodynamics Laboratory Experiment 1: Refrigeration and Mechanical

Heat Pump Experiment Objectives: i) To demonstrate the principles of a refrigeration cycle (Chapter 10 of Cengel and Boles). ii) To demonstrate the principles of a heat pump (Chapter 10 of Cengel and Boles). Introduction: It has been estimated that at least 85% of the refrigeration processes in use today are powered by vapor compression systems. The applications embrace many varied disciplines including catering, public health, architecture, food storage, transport and food processing. An improved understanding of refrigerating techniques is demanded of engineers, particularly in the fields of building services and environmental control. The purpose of the experiment is to demonstrate the basic principles of refrigeration, i.e. how heat can be transferred from a cooler object to a hotter object. The mechanical heat pump unit, shown in Fig. 1 (a), consists of a standard compressor-condenser unit, a watt meter, and controls and instrumentation including flow meters, thermocouples and pressure gauges.

Figure 1 (a): Picture of Mechanical Heat Pump The Mechanical Heat Pump was designed solely for educational purposes and yields data in a quantitative and qualitative form in a manner easily understood by the student regardless of their level of interest in the subject. The equipment is compact, bench mounted and instrumented

1 ENME 485 Experiment #1: Heat Pump Experiment

sufficiently for students to make measurements and perform calculations. All instruments are located at the actual point of measurement (Fig. 1(b)) and connecting pipes are open to view to allow the lab instructor to conveniently describe the sequence of events occurring in the refrigeration cycle.

P2, T3

P1, T2

P2, T4

P1,T1

P2, T4

Red Tank

Blue Tank

Figure 1 (b): Schematic of the Mechanical Heat Pump Cycle of Operation: The method of operation of the Heat Pump can be explained by reference to the schematic diagram in Fig. 1 (b). The working fluid or heat transfer medium is the refrigerant Dichlorodifluoromethane (Freon 12 or R-12) and the heat source and heat sink is cold running water. The sealed compressor, rated at 0.5 h.p. and operating on either 220V-50Hz or 110V-60 Hz acts as an external energy source. The super-heated refrigerant is compressed and pumped through insulated copper pipes to the nickel plated; copper condensing coil at pressure P2 and temperature T3. The coil is immersed in cold flowing water in the stainless steel condensing tank. The refrigerant pressure remains substantially constant at P2 while passing through the coil, but falls in temperature from T3 to T4, losing its super-heat and all of its latent heat or heat of change of phase to the water. It reaches the refrigerant flowmeter as a sub-cooled liquid still at pressure P2 and temperature T4. The function of the silica gel drier is to eliminate water, not liquid refrigerant. The pipe work here is nickel plated copper with brass fittings. The refrigerant now expands through the manually variable nickel-plated brass expansion valve where it expands to a lower pressure P1 and commences to boil. The boiling temperature or wet

2 ENME 485 Experiment #1: Heat Pump Experiment

vapor temperature T1 is measured before the refrigerant passes through the nickel-plated copper evaporator coil. This coil is also immersed in cold flowing water in the stainless steel evaporating tank. During its passage through the coil the refrigerant absorbs from the water the latent heat of evaporation or heat of change of phase, and in addition may receive some further heat to superheat the refrigerant to temperature T2. The boiling or evaporation process occurs at constant pressure P1. The super-heated vapor refrigerant leaves the evaporator to return to the compressor through insulated copper pipes to begin the cycle again. The heat source and sink water is taken from the cold mains supply and passed through a small pressure reducing valve to ensure a standard flow rate by reducing mains pressure fluctuations. Separate control valves are used to adjust the low of water to the condensing and evaporating tanks. The water flow rates through the stainless steel tanks are determined by flowmeters. An annular tank design is employed to reduce thermal inertia. Both water and refrigerant temperatures are measured by standard thermocouples with each refrigerant thermocouple resting in sealed pockets in the refrigerant circuit. Pressures are measured by refrigeration quality pressure gauges. Electrical power input to the Heat Pump compressor is measured by an integrating watt hour meter where power consumed is a direct function of the speed of the rotating disc and by timing a revolution of the disc a very accurate power figure can be obtained. The relationships between compressor shaft speed and torque versus power are given later in this handout. Potential Experiments: Some of the thermodynamic and refrigeration experiments of which the equipment is capable of performing are listed below. We will perform the experiments that are in bold font. 1. Construction of elementary energy balances. 2. Determination of compressor efficiencies. 3. Calculation of performance coefficients. 4. Calculation of refrigerating efficiency 5. Comprehensive use of refrigerant tables. 6. Analysis of refrigerating cycles using the temperature-entropy diagram. 7. Analysis of refrigerating cycles using the pressure-enthalpy diagram. 8. Comparing the practical reversible cycle with the reversible ideal Carnot cycle. 9. Comparing theoretical results with actual practical results and understanding the limitations of a practical refrigerator. 10. Investigating the performance of a vapor compression refrigerator acting as a Heat Pump. 11. Investigating the improvement in performance as a result of superheating the refrigerant during evaporation. 12. Investigating the improvement in performance as a result of supercooling the refrigerant during condensation.

Safety Features: Refrigerant 12 used in the heat pump is incombustible and non-toxic so that leakages of refrigerant arising from an accident or from student abuse will not cause any harm (except perhaps to the ozone layer). To eliminate the possibility of an excessive refrigerant pressure from occurring in the condensing coil a differential pressure switch is fitted in the refrigerant circuit. The switch will isolate the

3 ENME 485 Experiment #1: Heat Pump Experiment

compressor drive motor. The maximum condenser pressure is marked on the dial of the pressure gauge. The compressor motor is protected by thermal overload relays and a thermal switch. Should the compressor be switched on under conditions of high load e.g. a high compression ratio across the compressor, the motor starting current will also be high and there is a risk of the compressor and motor being stalled. Under these conditions the relay will go open circuit and isolate the motor. Whenever the compressor is in continuous use for several hours under high load it will generate heavy thermal losses due to mechanical friction and motor winding losses. These must be dissipated through the casing of the compressor to the surroundings. This is the function of the air cooling fan. To protect the resin insulation of the motor windings the internal temperature of the compressor casing must not exceed the fusion temperature of the resin. The purpose of the thermal switch attached to the inside of the casing is to isolate the motor under conditions of excessive casing temperature. In both situations described above, allow the compressor to cool before attempting to re-start. As an added precaution a fuse link is located in a housing on the front of the instrument panel. Set Up and Operating Instructions: The apparatus is delivered complete, charged with refrigerant, ready to operate with the minimum of preparatory work. A single phase electricity supply, a water supply and water drain are the only external facilities required. The following order of instructions should be followed: 1. Stand the unit on a firm even surface higher than the water drain which is to be used. 2. Provide two 15mm (1/2) bore plastic or rubber pipes to lead from the drain to main drainage. These pipes are a push-fit and do not need further securing. 3. Remove the red blanking cap from the water inlet to the pressure reducing valve. 4. Provide 8mm (5/16) bore copper pipe to lead from tie water supply to the pressure reducing valve. Fit pipe and secure to both the valve inlet and the supply tap by wire or clips. Do not turn the water on at this stage. 5. Position thermocouples in the pockets provided in accordance with the range. 6. Plug the lead from the unit into the laboratory socket. Do not switch on at this stage. 7. Turn on the mains water supply and by a process of trial and error set the pressure reducing valve and the two adjustable tank supply valves to give a suitable steady flow of water. 8 Set to refrigerant expansion valve to approximately the middle of its range. 9. Switch on the mains electricity supply and switch on the compressor. 10. As the unit reaches equilibrium, there wilt be some ice formation evident in the right- hand evaporating tank. This is normal but the water flow should be adjusted so that this ice formation does not become excessive. The unit will take about 30 minutes to obtain equilibrium from its initial start-up. The water tank supply valves (not the pressure reducing valve), and the refrigerant expansion valve can now be adjusted to obtain the required conditions. Once the apparatus has been running for some time a substantial change of conditions will require approximately 15-20 minutes to obtain equilibrium. When the experiments have been completed, the electricity should be first switched off and then the water supply, not the reverse order.

4 ENME 485 Experiment #1: Heat Pump Experiment

Performance Analysis of the Mechanical Heat Pump: Assumptions Practical limitations are imposed on the analysis of all vapor compression refrigeration systems such that care must be taken to ensure that all assumptions are relevant to the particular system under analysis. For example, a refrigerant condenser having numerous sharp bends and where the bore of the pipe is small enough to cause high velocity flow will lead to excessive refrigerant pressure drop from viscous friction. Significant errors could arise in calculations if the condensing process is assumed to occur at constant pressure. Such limitations must be carefully considered in the design of educational equipment to produce meaningful results. A practical refrigerant cycle for the Hilton Mechanical Heat Pump is outlined in Fig. 2 on a Pressure-Enthalpy diagram. The changes in properties between state points are exaggerated for clarity.

Figure 2: Realistic P-h Cycle Diagram Process 1-2 is vaporization of the refrigerant in the evaporator followed by some useful superheating, 2-3, of the refrigerant while still in the evaporator. The pressure drop shown between states 1-3 will be negligible and has been measured to be less than 7 kN/m2 (1 psi). The average operating increase in pressure across the compressor is approximately 800 kN/m2 and the pressure drop through the evaporator is less than 1% of this. It may be safely assumed, with little error that vaporization occurs at constant pressure. Process 3-4 takes place in the compressor suction line, i.e. between the outlet from the evaporator and inlet to the compressor casing. There are two sources of error here: 1. The refrigerant leaving the evaporator will, in most operating conditions, be below ambient temperature resulting in a heat gain from the surroundings to increase superheat. The suction line is adequately insulated to allow the assumption that this does not occur. 2. Viscous friction in the suction line producing a pressure drop. Apart from the fact that the refrigerant is in the vapor state giving low frictional losses, the suction line is very short in length and a pressure drop will be quite small. It is reasonable to assume, therefore, that no ambient super-heating occurs and the pressure drop may be ignored. Process 4-5. The compressor is of the fully hermetic type where both the compressor and its drive motor are immersed in the refrigerant suction vapor. A pressure drop may occur as the refrigerant expands into the compressor casing from the suction line, but the refrigerant also simultaneously absorbs the drive motor winding losses (Process 5-6) and mechanical friction

5 ENME 485 Experiment #1: Heat Pump Experiment

losses from the compressor. It is therefore assumed unlikely that a drop in pressure on entry into the casing will be significant. Process 6-7 results from frictional losses in the refrigerant in flowing around the compressor suction flap valve and passages into the cylinder. Some super-heating occurs by mechanical friction heat transfer from the cylinder wall. These errors are difficult to quantify but it can be assumed frictional losses are small in comparison with the actual work done on the refrigerant during compression. Pressure energy losses arising from viscous friction when the refrigerant is in the vapor state are quite small in comparison to the overall changes in energy being measured. Process 7-8. Compression. Process 8-9. Fall in pressure caused by the opening of the compressor discharge flap valve pressure and by flow losses around the valve and passages. The design of the Mechanical Heat Pump does not attempt to extract and isolate the errors described between state points 4 and 9 for reasons already mentioned. The purpose of the exercise is to make the student aware of the effect practical limitations can have upon a theoretical study. Process 9-10 occurs in the compressor discharge line, i.e. between the outlet from the compressor and inlet to the condenser. Similar comments used in describing process 3-4 may be applied here. Process 10-11 is condensation of the refrigerant followed by some liquid sub-cooling (process 1112). Generally, similar assumptions may be made for condensing as for vaporization with the exception that liquid viscous friction causes a greater pressure drop. Process 12-1, throttling, is usually assumed to take place at constant enthalpy. Throttling is discussed in detail in most text books dealing with Applied Thermodynamics. See the list of references given in the end of this handout. Fig. 3 shows the cycle diagram in its simplified form. Compression is shown as a dotted line indicating an estimated process. The state points representing the start and finish of compression are those given by the temperature and pressure measured at the outlet from the evaporator and inlet to the condenser.

Figure 3: Idealized P-h Cycle Diagram

6 ENME 485 Experiment #1: Heat Pump Experiment

Procedure: DAY ONE: Experiment #1: Refrigeration Performance Analysis 1. Turn on the main water supply and by a process of trial and error set the evaporator flow rate to 70 kg/hr, the condenser flow rate to 30 kg/hr, and the water supply temperature to 12C. 2. Set the refrigerant expansion valve to approximately half the middle of its range. 3. Switch on the compressor. 4. Set the refrigerant flow rate to 10 kg/hr. 6. Allow the system to stabilize by monitoring the temperatures in the LabVIEW program. This will probably take around 30 minutes. 7. Collect data as shown in Table 1 (should be similar to Column 1 data). NOTE: As the unit reaches equilibrium, there will be some ice formation evident in the right-hand (blue) evaporating tank. This is normal but the water flow should be adjusted so that this ice formation does not become excessive. Also be careful not to overflow either of the two tanks. Experiment #2: Operation of the Equipment as a Heat Pump 1. Turn on the main water supply and by a process of trial and error set the evaporator flow rate to 120 kg/hr, the condenser flow rate to 120 kg/hr, and the water supply temperature to 15C. Be careful not to overflow either tank. 2. Set the refrigerant expansion valve to fully open. 3. Switch on the compressor. 4. Allow the system to stabilize by monitoring the temperatures in the LabVIEW program. This will probably take around 30 minutes. 7. Collect data as shown in Table 1 (should be similar to Column 2 data). 8. Reduce the condenser (red tank) water flow rate in small increments (5 kg/hr), allow the equipment to stabilize (by watching the temperatures), and collect data. 9. Repeat step 8 until the condenser water flow rate gets to 5 kg/hr. DAY TWO: Experiment #3: Refrigeration Performance by Supercooling during Condensation 1. Turn on the main water supply and by a process of trial and error set the evaporator (blue tank) flow rate to 120 kg/hr, the condenser (red tank) flow rate to 20 kg/hr, and the water supply temperature to 15C. Be careful not to overflow either tank. 2. Set the refrigerant expansion valve to approximately half the middle of its range. 3. Switch on the compressor. 4. Allow the system to stabilize by monitoring the temperatures in the LabVIEW program. This will probably take around 30 minutes. 7. Collect data as shown in Table 1 (should be similar to Column 2 data). 8. Reduce the condenser (red tank) water flow rate in small increments (5 kg/hr), allow the equipment to stabilize (by watching the temperatures), and collect data. 9. Repeat step 8 until the condenser water flow rate has been turned off.

7 ENME 485 Experiment #1: Heat Pump Experiment

Calculations: Experiment #1: Refrigeration Performance Analysis Students are often introduced to the topic of vapor compression refrigeration via a discussion of the Carnot Cycle and the Temperature-Entropy properties diagram. A T-s diagram has been supplied and analysis is conducted using the T-s diagram. This exercise will demonstrate the use of thermodynamic charts and their respective advantages and disadvantages. Temperature-Entropy Diagram

Figure 4: T-s Cycle Diagram, Idealized Straight-Line Compression In the cycle diagram shown in Fig. 4 it is assumed that the compression process approximates to a straight line. Using the T-s diagram for R-12, the Refrigerating Effect can be computed using: Refrigerating Effect = Area dbhj = cbhk + dckj = R.E. = T1 (sk sh ) + (hd hc ) The work done by the compressor can be computed using:

& W comp = he hd
The work done by the compressor can also be computed graphically using:

& W comp = Area adef

This can be estimated by integrating the area within the curve, and noting that for the linear scales on the T-s diagram 2.7X2.7 cm2 corresponds to 2.5 kJ/kg. Compute the theoretical Coefficient of Performance using:

COPR ,theoretical =
Comparison to Ideal Reversible Carnot Cycle:

R.E. & W

comp

8 ENME 485 Experiment #1: Heat Pump Experiment

By superimposing the ideal reversible Carnot cycle on the practical T-s cycle, as shown in Fig. 5, one can examine deviations from the ideal and calculate the refrigeration efficiency. Refrigeration efficiency expresses the approach of the practical cycle to the ideal Carnot cycle.

Figure 5: T-s Cycle Diagram, Practical Cycle versus Carnot Cycle

Refrigerating Efficiency =

COPR COPR ,Carnot

Ideal refrigerating effect:

= T1 (s1 s2 )
Ideal compressor work:

= (T5 T1 )(s1 s2 )
Ideal Carnot Coefficient of Performance:

COPR ,Carnot =

R.E. COPR

With this and COPR ,theoretical , the theoretical refrigerating efficiency can be computed.

From Fig. 5 it is seen that the practical refrigerating effect is made larger than the ideal by subcooling the liquid refrigerant in the condenser before expansion through the throttle and also superheating the refrigerant during evaporation. These gains appear to give a very efficient cycle but this is only true on a theoretical basis. No account is taken of the compressor losses and other thermal losses in the system. Consider the actual energy consumed by the compressor as measured by the Watt-hour meter. In this particular test the instrument measuring disc is calibrated at 333.33 revs/h = 1 kW. The elapsed time for one revolution of the disc is measured using a stopwatch. Say this time is t seconds, then the power going to the compressor can be computed as:

9 ENME 485 Experiment #1: Heat Pump Experiment

1000 * 3600 & W comp = 333.33 * t

The total refrigerating effect can be computed knowing the mass flow rate of refrigerant and the refrigerating effect:

&r QL = Area(dbhj ) * m
The overall practical Coefficient of Performance can be computed using:

COPR , practical =

& Q L & W comp

With this, the practical refrigerating efficiency can be computed. Experiment #2: Operation of the Equipment as a Heat Pump While operating as a Heat Pump, heat is removed from a cold source at or below ambient temperature (the blue water cooled evaporator) and transferred to a sink (the red water cooled condenser) above ambient temperature. As shown in Fig. 6, this heat could be used for space heating.

Figure 6: Operation of System as a Heat Pump Space Heating Example The performance of the Heat Pump can be quantified by the Coefficient of Performance and is found to vary as the temperature difference ( T ) between the condenser water outlet temperature ( Th ) and the ambient air temperature ( Ta ). The temperature gradient is computed from:

T = Th Ta
From this the heat in the condenser water that is transferred to the ambient air can be computed as:

& =m & h C p (Th Ta ) Q H

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In the context of this experiment the Coefficient of Performance can be computed by the energy output from the condenser water divided by the energy input to the compressor.

COPHP =

& Q H & W

comp

The power into the heat pump can be estimated using the Watt-hour meter reading. Using the

& and W & as a function of the temperature above equations, compute and plot both Q H comp
difference ( T ) between the condenser water and the ambient air temperature. Also compute and plot the Coefficient of Performance of the heat pump as a function of the same temperature difference. Comment on the temperature difference over which the heat pump operates most efficiently (most heat produced for the given amount of compressor work input). Experiment #3: Refrigeration Performance by Supercooling during Condensation Supercooling is often described in textbooks as occurring at constant condenser pressure and constant refrigerant mass flow. In practice, it is not possible to supercool the refrigerant without changing either or both the mass flow and condenser pressure. Clearly, changes in condenser pressure are accompanied by a change in compression ratio and compressor work. Similarly a change in mass flow will affect an energy balance and overall coefficient of performance. Supercooling in a practical cycle may not therefore result in an automatic increase in performance. In this experiment the effect of supercooling is examined while maintaining the electrical power input to the compressor constant. The analysis should be based upon changes in the overall coefficient of performance with refrigerating effect, refrigerant mass flow rate, compression ratio, and liquid refrigerant temperature.

Figure 7: P-h and T-s Diagrams Illustrating Superheating and Supercooling Compute the Coefficient of Performance of the refrigeration cycle as a function of increased supercooled refrigerant. Plot the Coefficient of Performance as a function of the Refrigerating Effect, the Refrigerant Mass Flow Rate, the Compression Ratio, and the Liquid Refrigerant Temperature. Is supercooling useful and why?

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TABLE 1 Examples of Data to be Collected Observed Experimental Data Water supply temperature Evaporator water outlet temperature Condenser water outlet temperature Evaporator water flow rate Condenser water flow rate Refrigerant flow rate Watt-hour meter. Time per revolution. Ambient temperature Symbol Units C C C kg/h kg/h kg/h s/rev C Test 1 11.0 5.3 27.5 70.0 33.0 9.4 61.4 18.5 Test 2 15.0 9.0 36.0 120.0 40.0 19.0 45.0 18.5

Ts Tc Th
&c m &h m
&r m
s

Ta

EVAPORATOR Refrigerant absolute pressure Refrigerant inlet (wet vapor) temperature Refrigerant outet (superheat) temperature

Pe
T1 T2

kN/m2 C C

135 -22.0 -4.0

240 -6.0 +8.5

CONDENSER Refrigerant absolute pressure Refrigerant inlet (superheat) temperature Refrigerant outlet (liquid) temperature

Pc T3
T4

kN/m2 C C

870 59.0 13.0

1050 73.5 20.0

References: 1. Hewett, G. A., Mechanical Heat Pump (Vapor Compression Refrigerator) Operating Instructions and Performance Notes, P.A. Hilton Ltd., England, 1978. 2. Haywood, R.W., Thermodynamic Tables in SI (metric) Units, 2nd Edition, Cambridge University Press, 1968. 3. Cengel, Y.A., and Boles, M., Thermodynamics: An Engineering Approach, 4th Edition, McGraw Hill, 2002.

12 ENME 485 Experiment #1: Heat Pump Experiment