1-Fundamentals of

Reffregeration
1-1Application
Preservation of foods/slightly above Freezing
temp
Air conditioning
Beverage cooling & Humidity control
Industrial process-Nitrogen plant, BT200
Research
1-2First Law of thermodynamic
heat and mechanical energy are mutually

1-3Sensible Heat
Heat which causes a change in temperature
If heat is added and temperature rises as heat is
added
1-4Latent heat
Heat added to or removed from a substance during
a change of state, but no change in temperature
Latent heat of fusion
Latent heat of condensation
Latent heat of vaporization
Latent heat of sublimation

1-5Application of Latent heat

As ice melts, its temperature remains constant.
Nevertheless, it absorbs a considerable amount of heat in
changing from ice to water.
When a substance passes from a liquid to a vapour, its
ability to absorb heat is very high.
The temperature at which a substance changes its state
depends on pressure. The higher the pressure, the higher
the temperature needed to bring about the change.
Conversely, if pressure lowered, the temperature is
lowered.
A liquid under low pressure will boil at a lower temp. If the
vapour resulting from this boiling is then compressed, it
will condense back in to a liquid at a higher Temp. Each
substance has a different latent heat value.

In the evaporator, the pressure is greatly

reduced. The refrigerant boils, absorbing heat

from the evaporator. This produce low
temperature and cools the evaporator. The
compressor pumps this vaporized refrigerant
out of the evaporator and compresses it in to
the condenser. Here the heat that was
absorbed is released to the surrounding.
Having lost this heat of vaporization, the
refrigerant becomes a liquid again. The cycle
is then repeated.

2-Refrigeration
systems and
classification
2-1Principles
As a liquid changes to a vapour, it absorbs large
quantity of heat the converse is true changing
from vapour to liquid.
The boiling point of a liquid can be changed by
changing the pressure exerted on the liquid. In
other words, the boiling point of a liquid can be
raised by increasing its pressure and it can be
lowered by reducing its pressure.

2-2Classification
Evaporation (Mechanical)
Absorption (gas)
Thermo-electric /peltier effect
2-3According to use
High-temperature system(25-45C) Air
conditioning
Medium-temperature system(25-0C) Food
storage
Low-temperature system(0 and below)

3-Components of
refrigeration system

3-1Compressor
Heart of vapour-compression system
Reduce evaporator pressure
Increase condenser pressure(causing rise in
temp)
Refrigerant circulation

Compressor types
Positive displacement
Reciprocating/ piston type
Rotary
Scroll
Screw
dynamic
Turbo/centrifugal field
Further classification
Open/shaft seal to protect Ref. leakage
Hermetic/welded
Semi- hermetic

3-2The electric winding

Direct/Indirect contact with refrigerant vapour
and oil
Cooled by the Refrigerant, oil or external
means
If the electric motor burns occurred(corrosive
products), all the system should be cleaned
before new motor installed.
Oil in the refrigeration system is not desirable.
Different designs are available for oil free
compression for different refrigerants.
According to solubility of oil in the refrigerant
and density

3-3Evaporators
Bare tube evaporator/simplest
Plate- surface evaporator/easy to
manufacture
Finned evaporator/increased surface area
efficiently

3-4Condensers
Mounted at the back of cabinet/should not be
obstructed
Air cooled/natural or forced
Water cooled
Evaporative
3-5Accumulators
Safety device to prevent liquid refrigerant
from flowing in to the suction line and the
compressor.
If it flows in to the compressor it will cause
knocking and damage the compressor

3-6Liquid receives
Storage tank to reserve liquid Refrigerant.
Insures enough liquid refrigerant in liquid line
free of gas.
Mostly used in systems with the low side float
type or the expansion valve type.

3-7Electric motors for refrigeration

systems
For most fractional horse power appliance,
split phase induction motor is used.
Two stator winding is used, one for starting
and one for running.
The starting windings are disconnected when
approximately 75% of its running speed.
No rotor winding/sqirrel cage winding

Capacitor start induction motor

Capacitor in starting winding/in series
High starting torque

3-8Motor starting device and protection

3-8-1 Starting
Limit current & produce torque
Starting relays(outside of the hermetic
compressor)
1-Magnetic
-current(amperage) relays
-potential(voltage) relays
2-PTC positive temperature coefficient
3-Thermal Relay
4-solid state(electronic) Relay

PTC
Start winding gets current through PTC
When the device is cold it has low resistance
and current can flow.
The PTC heats up very quickly and its resistance
gets very high. The starting winding now
disconnected.

3-8-2Protection
Bimetal switch(Located at important place
in the Unit)
Excessive current draw
Excessive over-heating(compressor)
-poor air circulation
-poor refrigerant circulation
-low level refrigerant
-friction

3-9Refrigeration control
-operation control-temperature &
humidity
-Refrigerant control- rate of flow in
evaporator

3-9-1Operation control
1-pressure control
2-Temperature control(thermostat)
3-Thermostat
-sensing bulb(remote
bulb)
-Bimetals
-solid state(PTC or NTC)

1-Remote bulb control

The bulb filled with a liquid that is easily
evaporated connected by capillary tub with
the bellow.
The screw adjustment-spring pressure.
-cut-in and cut-out
temp.
-differential temp
service tec.

2-Pressure control
As the temperature at the evaporator (low side)
warms, the pressure increase and hence the
below pressure. (Switch is closed)
As the temperature at the evaporator (low
side) low, the pressure decrease and hence
the below pressure. (Switch is open)

3-9-2Refrigerant control(throttling)
Rapid expansion of refrigerant
The Function is to control rate of flow from liquid
line to evaporator and to maintain pressure
difference.
Types of throttling valve
- hand expansion valve
-capillary tube
-Thermostatic expansion valve(TEV)
-Low pressure side float
-High pressure side float
-Thermal-electric expansion valve
-Automatic expansion valve

1-Capillary tubes
Small diameter tube connected directly b/n
condenser and evaporator.
Principle
restriction in fluid flow line
pressure goes down as the refrigerant moves
through
the tube until the liquid starts to evaporate.
sudden pressure and temperature drop at last
quarter.
Advantage
No moving part-no wear or stick/ simple design
Pressure balance when the unit stops
Minimum starting torque

2-The hand expansion valve

Screw to control size of orifice
Used only for large refrigeration system
The operator should look after the plant the
whole time.

3-Thermostatic expansion valve (TEV)

Principle
Constant super heat temperature at the suction
line end of evaporator.
Pressure balance b/n bulb
pressure(Diaphragm)
-Evaporator pressure
-spring pressure

4-Refrigerant and Dryers

4-1Introduction
Primary refrigerant-phase change
Secondary refrigerant-No phase change
Qualities
- Boils at low temperature-except water
- Non flammable
-Non explosive
-Not be poisonous
-Flow easily
-Able to conduct well

Requirement
Non Toxic, Non poisonous
Non Explosive
Non corrosive
Non Flammable
Leaks easily detected, located
Operate under low pressure/low boiling point
stable gas
moving part in the fluid be easily lubricated

Pressure-Temperature curve
Refrigerant in state of equilibrium
Reading the pressure at any particular
Temperature
Example
R12 at 100F(38C) is 117psi(909kpa)
The temperature and pressure value for the
condensing are always higher than the equilibrium.

Grouping and classification of refrigerant

national refrigertion safety code(NRSC)
Group one/ safest
Group two/ Toxic and somewhat flammable
Group three/ Flammable

Group one Refrigerants

Allowable quantities
up to 20lb hospital and residntial AC systems
up to 50lb public assembly(indirect)/residential in
precaution
R-11
R-12
R-22
R-500/73.8% R12 and 26.2% R-152a
R502/48.8% R-22 and 51.2% R-115
R503/40.1% R-23 and 59.9% R-13
R744/CO

R-22
colourless, odourless liquid at-29C(bp) &
atmospheric pressure
non toxic, non irritating, non corosive, non
flammable
inert, thermally stable to above 427C
R-22
synthetic, stable, non toxic, noncorrosive, non
irritating, non flammable(-41C bp)
application is in fast freezing unit(-20 to -40C)
R-11
synthetic, stable, non flammable, non toxic
used as flushing agent for cleaning when
overhauling system

Group two
toxic, irritating to breath, somewhat flammable
R-717 Ammonia
R-40 Methyl chloride
R-764 Sulphur Dioxide
Ammonia
commonly used in industrial systems
colourless gas(bp=-33C) at atmospheric pressure
low bp makes it possible to have refrigeration without using
pressure in evaporator.
caution in operating amonia valve/couse instant loss of consciousness
and damage the eye(wwear mask)
R-717 attacks copper and bronze, does not corrode steel or iron
lighter than oil/ separation is easy
excess oil easily removed from evaporator by opening the valve bottom

Group three
may form combustible mixture when mixed with
air
R-600 Butane
R-170 Ethane
R-290 propane
Water as a refrigerant
the latent heat of water at 100C is
2260kj/kg(effective)
b/p=100C

Refrigerant applications
Low temperature -126C R-14
-99 C R-503
-82 C R-13
Medium Temperature-46 C R-502
-30 C R-12
High Temperature 4 C R-114
48 C R-113
28 C R-123
24 C R-11
Type of compressor centrifugal
Rotary
Reciprocating

Refrigeration oil
- circulate with the refrigerant/mixed
-Lubricate and cool compressor moving parts
-Direct contact with motor winding
-must withstand extreme temperatures/ high, low
-harmless to refrigerant and equipment
-fluidity of oil-refrigerant mixture determined by
Refrigerant used
temperature
properties of the oil
solubility of refrigerant
solubility of oil

properties of Good refrigerant oil

Low wax content
Good thermal stability/hard carbon deposit
Good chemical stability
Low pour point/ability to remain fluid at lowest
temperature.
low viscosity
In addition manufacturers add chemicals to inhibit the
formation of sludge or foaming/ oil removed from
system
Should be clear/no discolouration/ if this happens, place
new dryer.
Dirty oil may be acidic and will burn the hands
Containers must be kept tightly sealed

4-2Halocarbon compounds
(chlorine, fluorine,bromine)
R-11 Trichluoro monofluro methane CClF
R-12 Dichloro difluoro methane
CClF
R-13 Monochloro trifluoro methane
CClF
R-22 Monochloro difluoro methane
CHClF
R-40 Methyl chloride
CHCl
R-113 Trichloro trifluro ethane
CClFCClF
R-114 Dichloro tetra fluro ethane
CClFCClF

4-3Inorganic refrigerants
R-717
R-718
R-729
R-740
R-764

Ammonia
Water
Air
Carbon dioxide
Sulphur dioxide

NH
HO

Hydro chloro fluorocarbons

Hydro fluoro carbons

CO
SO
HClFC
HFC

4-4Environmental Impact

-Ozone depletion potential(ODP)

-Global warming potential(GWP)
-Cancer

4-5Moiler diagram and thermodynamic

properties
Pressure- enthalpy
Temperature- enthalpy

Sub-cooled liquid
saturated liquid line
Mixture
saturated vapour line
Superheated vapour

Cooling load
Refrigerating rate
4-6Coefficient of performance(COP)
The measure of efficiency of refrigeration
cycle
Heat absorbed from space
Heat supplied to compressor
C.O.P.=

Refrigerating effect
Heat of compression

4-7Refrigerant and moisture

Moisture Acid corrosion sludge
Blockage
Driers
Liquid line Driers
Suction line Driers

Liquid line driers

parts
- course filter
- Felt pad
-De hydrating
material(desiccant)

Types of desiccants
Absorption/chemically react/for short
time use
Adsorption/chemically stick-silicon jell
-activated alumina

5-Refrigeration Materials and hand

tools
1-Piping an tubing
2-welded and brazed tubing
seamless copper tubing/except ammonia/good
for Freon
- aluminum tubing/Evaporator in domestic refrig.
- stainless tubing/ Condenser
3-Tubing cutters- Hand Held tubing cutter
- Hack saw and sawing fixture
4-Tubing Reamers
5-Pinch-off tools
6-Tubing benders

7-Pressure Gauge
8-Valve Manifolds
9-Charging Hose
10-Pocket thermometer
11-Welding Unit
12-Charging Cylinders
13-Fitting Brush
14- Flaring

6-Servicing of
Refrigeration