Advance Refrigeration and Airconditioning

Advance
Refrigeration & Air

Conditioning
1
Training Agenda: Refrigeration &
Air Conditioning
Introduction
Type of refrigeration
Applied Psychrometric
Air Duct Design
Pressurization System
Chilled/Condenser Water Piping Design
Compressors
Condensers & Evaporators
Expansion Devices
Cooling Tower
Assessment of refrigeration and AC
Energy efficiency opportunities
2
Introduction
How does High Temperature Reservoir

it work?
Heat Rejected
R Work Input
Heat Absorbed
Low Temperature Reservoir
3
Introduction
How does it work?

Thermal energy moves from left to right through five
loops of heat transfer:
1) 2) 3) 4) 5)
Indoor air Chilled Refrigerant Condenser Cooling
loop water loop loop water loop water loop
(Bureau of Energy Efficiency, 2004) 4

Introduction
AC Systems
AC options / combinations:
• Air Conditioning (for comfort / machine)
• Split air conditioners
• VRV System in Group Housing etc.
• Fan coil units in a larger system
• Air handling units in a larger system
• Evaporating Cooling in a larger system
5
Introduction
Refrigeration systems for industrial

processes
• Small capacity modular units of direct
expansion type (50 Tons of Refrigeration)
• Centralized chilled water plants with
chilled water as a secondary coolant (50
– 250 TR)
• Brine plants with brines as lower

temperature, secondary coolant (>250 TR)
6
Introduction
Refrigeration at large companies

• Bank of units off-site with common
• Chilled water pumps
• Condenser water pumps
• Cooling towers
• More levels of refrigeration/AC, e.g.

• Comfort air conditioning (20-25 oC)
• Chilled water system (8 – 10 oC)
7
• Brine system (< 0 oC)
Types of Refrigeration
Introduction
Types of refrigeration
Air Duct Design
Compressors
Expansion Devices
Cooling Tower
8
Refrigeration systems
• Vapour Compression
Refrigeration (VCR): uses
mechanical energy
• Vapour Absorption Refrigeration
(VAR): uses thermal energy
9
Vapour Compression Refrigeration

• Highly compressed fluids tend to get
colder when allowed to expand
• If pressure high enough
• Compressed air hotter than source
of cooling
• Expanded gas cooler than desired
cold temperature
10

Two advantages
• Lot of heat can be removed (lot of
thermal energy to change liquid to
vapour)
• Heat transfer rate remains high
(temperature of working fluid much
lower than what is being cooled)
11

Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
12
Low pressure liquid
refrigerant Vapour
in evaporator
Compression Refrigeration
absorbs heat and changes
to a gas Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
13
The superheated vapour
enters the compressor
where its pressure is
raised Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
14
The high pressure
superheated gas is cooled
Vapour
in several stages Compression
in the Refrigeration
condenser
Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
15
Liquid passes through expansion
device, which reduces its pressure
Vapour and
Compression Refrigeration
controls the flow into the
evaporator
Refrigeration cycle
3
Condenser
High
4 Pressure
Side
Expansion
Device Compressor
1 2 Low
Pressure
Evaporator Side
16

Type of refrigerant
• Refrigerant determined by the
required cooling temperature
• Chlorinated fluorocarbons (CFCs) or
freons: R-11, R-12, R-21, R-22 and R-
502
17

Choice of compressor, design of
condenser, evaporator determined by
• Refrigerant
• Required cooling
• Load
• Ease of maintenance
• Physical space requirements
• Availability of utilities (water, power) 18
Vapour Absorption Refrigeration
Condenser Generator
Hot
Side
Evaporator
Cold Absorber
Side
19
20
21
22
23
Refrigerant-absorbent combinations for VARS
The desirable properties of refrigerant-absorbent mixtures for

VARS are:
i The refrigerant should exhibit high solubility with
solution in the absorber. This is to say that it should
exhibit negative deviation from Raoult’s law at absorber.
ii. There should be large difference in the boiling points of

refrigerant and absorbent (greater than 200oC), so that
only refrigerant is boiled-off in the generator. This
ensures that only pure refrigerant circulates through
refrigerant circuit (condenser-expansion valve-
evaporator) leading to isothermal heat transfer in
evaporator and condenser.
24
iii. It should exhibit small heat of mixing so that a high

COP can be achieved. However, this requirement
contradicts the first requirement. Hence, in practice a
trade-off is required between solubility and heat of
mixing.
iv. The refrigerant-absorbent mixture should have high

thermal conductivity and low viscosity for high
performance.
v. It should not undergo crystallization or solidification

inside the system.
vi. The mixture should be safe, chemically stable, non-

corrosive, inexpensive and should be available easily.
25
The most commonly used refrigerant-absorbent pairs in commercial

systems are:
1. Water-Lithium Bromide (H2O-LiBr) system for above 0oC
applications such as air conditioning. Here water is the refrigerant
and lithium bromide is the absorbent.
2. Ammonia-Water (NH3-H2O) system for refrigeration applications
with ammonia as refrigerant and water as absorbent.
Of late efforts are being made to develop other refrigerant-absorbent
systems using both natural and synthetic refrigerants to overcome
some of the limitations of (H2O-LiBr) and (NH3-H2 O) systems.
Currently, large water-lithium bromide (H2O-LiBr) systems are
extensively used in air conditioning applications, where as large
ammonia-water (NH3-H2O) systems are used in refrigeration
applications, while small ammonia-water systems with a third inert
gas are used in a pumpless form in small domestic refrigerators
(triple fluid vapour absorption systems). 26
Evaporative Cooling
• Air in contact with water to cool it close to ‘wet
bulb temperature’
• Advantage: efficient cooling at low cost
• Disadvantage: air is rich in moisture
Sprinkling
Water
Hot Air Cold

(Adapted from
Air
Munters, 2001)
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47
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50
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60
Air Duct Design
61
Air Duct Design
62
Air Duct Design
63
Air Duct Design
64
Air Duct Design
65
Air Duct Design
TABLE 7 – RECOMMENDED MAXIMUM DUCT

VELOCITIES FOR LOW VELOCITY SYSTEMS (FPM)
66
Air Duct Design
67
Air Duct Design
68
Air Duct Design
69
Air Duct Design
70
Air Duct Design
71
Air Duct Design
72
Air Duct Design
Methods of Duct Design

1- Equal friction Method
2- Static Regain Method
1-Equal Friction Method
This method of sizing is used for supply, exhaust and

return air duct systems and employs the same friction loll
per foot of length for the entire system. The equal friction
method is superior to velocity reduction since it requires
less balancing for symmetrical layouts. If a design has a
73
Air Duct Design
mixture of short and long runs, the shortest run

requires considerable dampering. Such a system is
difficult to balance since the equal friction method
makes no provision for equalizing pressure drops in
branches of for providing the same static pressure
behind each air terminal.
74
Air Duct Design
Example 4 – Equal Friction Method of Designing

Ducts
Given:
Duct systems for general office (Fig.47).
Total air quantity – 5400 cfm
18 air terminals – 300 cfm each
Operating pressure forall terminals – 0.15 in. wg
Radius elbows, R/D = 1.25
Find:
1. Initial duct velocity, area, size and friction rate in the
duct section from the fan to the first branch.
2. Size of remaining duct runs.
3. Total equivalent length of duct run with highest
resistance.
4. Total static pressure required at fan discharge
75
Air Duct Design
2-Static Regain Method
The basic principle of the static regain method is to

size a duct run so that the increase in static pressure
(regain due to reduction in velocity) at each branch or air
terminal just offsets the friction loss in the succeeding
section of duct. The static pressure is then the same
before each terminal and at each branch.
The following procedure is used to design a duct
system by this method: select a starting velocity at the fan
discharge from Table 7 and size the initial duct section
from Table 6.
76
Air Duct Design
The remaining sections of duct are sized from Chart

10 (L!Q Ratio) and Chart 11 (Low Velocity Static Regain).
Chart 10 is used to determine the L/Q ratio knowing the
air quantity (Q) and length (L) between outlets or
branches in the duct section to be sized by static regain.
This length (L) is the equivalent length between the
outlets or branches, including elbows, except
transformations. The effect of the transformation section is
accounted for in “Chart 11 3 Static Regain.” This
assumes that the transformation section is laid out
according to the recommendation presented in this
chapter.
77
Air Duct Design
78
STAIRCASE PRESSURIZATION CALCULATION FOR BASEMENT PART - A

BASEMENT TO GROUND FLOOR)
Q1 = Kf A √ Δ P
Q1 = Air Leakage in Cu. M./ Sec.
A = Area of Leakage in Sq.M.
ΔP = Pressure Difference in Pascal ( 50 Pa)
Kf = Coefficient 0.839
No. of Floors = Basement to Ground Floor = 2
No. of Doors = 2
Door Size = 1.2 M x 2.1 M
Gap Between door and Frame/Floor = 6 mm at Top and on side
= 15 mm at Bottom
Area of Leakage Between Door & Frame

= 2 x H x gap (side) + 1 x W x gap (Top) + 1 x W x gap (Bottom )
= 2 x 2.1 x 6/1000 + 1 x 1.2 x 6/1000 + 1 x 1.2 x 15/1000
= 0.0252 + 0.0072 + 0.018
= 0.0504 Sq. M.
79
Area of Leakage in Closed Condition/Door = 0.0504 Sq. M.
Total Leakage Area for 2 No. Doors = 0.0504 x 2
= 0.10 Sq.M.
Q1 = 0.839 x 0.10 x √ 50
= 0.60 Cu. M/Sec.
= 1270 CFM
Leakage of Air Thru 2 No. Open Door ( 1 No. at affected floor + 1 No. at Exit to Building )
Q2 = Area of Doors x Velocity
= 2.1 x 1.2 x2 No. x 1.0 M/sec.
= 5.04 Cu. M./Sec
= 10671 CFM
Total Required Air Quantity = Q1 + Q2
= 1270 + 10671
= 11941 CFM
80
LIFT WELL PRESSURIZATION CALCULATION
TOWER T1 (G+13)- 5 Nos.
Q = Kf A √ Δ P
Q = Air Leakage in Cu. M./ Sec.
A = Area of Leakage in Sq.M.
ΔP = Pressure Difference in Pascal ( 50 Pa)
Kf = Coefficient 0.839
No. of Floors = Lower Basement (Part-A) to 13th Floor = 16
No. of Doors = 16
Door Size = 2.1 M x 1.2 M
Area of Leakage Between Lift Door & Wall/ Door = 0.065 Sq. M.
Total Leakage Area for 16 No. Doors = 0.065 x 16
= 1.04 Sq.M.
Q = 0.839 x 1.04 x √ 50
= 6.17 Cu. M/Sec.
= 13063 CFM
Fan Capacity for Two Lift Well = 13063x2
= 26126 CFM
Say = 26500 CFM
1 No. 26500 CFM DIDW Centrifugal Fan Section For Fresh Air Supply
81
Chilled/Condenser Water Piping
Design
82
Design
83
Design
84
Design
85
Design
86
Design
87
Design
88
Design
89
Design
90
Design
91
Design
92
Design
93
Design
94
Compressors
95
Compressors
96
Compressors
97
Compressors
98
Compressors
99
Compressors
100
Compressors
101
Compressors
102
Compressors
103
Compressors
104
Compressors
105
Compressors
106
Introduction
Reference Handbooks/Standards
Heat Load Calculation
Air Duct Design
Compressors
Expansion Devices
Cooling Tower
107
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111
112
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115
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119
120
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123
124
125
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127
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129
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Expansion Devices
133
Expansion Devices
134
Expansion Devices
135
Expansion Devices
136
Expansion Devices
137
Cooling Tower
Introduction
Air Duct Design
Compressors
Expansion Devices
Cooling Tower
Assessment of Refrigeration and AC
138
Cooling Tower
139
Cooling Tower
140
Cooling Tower
141
Cooling Tower
142
Cooling Tower
143
Cooling Tower
144
Cooling Tower
145
Cooling Tower
146
Cooling Tower
147
Cooling Tower
148
Cooling Tower
149
Cooling Tower
150
Cooling Tower
151
Cooling Tower
152
Cooling Tower
153
Cooling Tower
154
Cooling Tower
155
Cooling Tower
156
Cooling Tower
157
Cooling Tower
158
Cooling Tower
159
Cooling Tower
160
Cooling Tower
161
Cooling Tower
162
Cooling Tower
163
Cooling Tower
164
Cooling Tower
165
Cooling Tower
166
Cooling Tower
167
Cooling Tower
168
Cooling Tower
169
Cooling Tower
170
Cooling Tower
171
Introduction
Reference Handbooks/Standards
Air Duct Design
Compressors
Expansion Devices
Cooling Tower
172
Assessment of Refrigeration
• Cooling effect: Tons of Refrigeration
1 TR = 3024 kCal/hr heat rejected
• TR is assessed as:
TR = Q xCp x (Ti – To) / 3024

Q= mass flow rate of coolant in kg/hr
Cp = is coolant specific heat in kCal /kg deg C
Ti = inlet, temperature of coolant to evaporator (chiller) in 0C
To = outlet temperature of coolant from evaporator (chiller) in 0C
173
Specific Power Consumption (kW/TR)
• Indicator of refrigeration system’s
performance
• kW/TR of centralized chilled water
system is sum of
• Compressor kW/TR
• Chilled water pump kW/TR
• Condenser water pump kW/TR
174
• Cooling tower fan kW/TR
Coefficient of Performance (COPCarnot)
• Standard measure of refrigeration efficiency
• Depends on evaporator temperature Te and
condensing temperature Tc:
COPCarnot = Te / (Tc - Te)
• COP in industry calculated for type of

compressor:
Cooling effect (kW)

COP =
Power input to compressor (kW) 175
COP increases with rising COP increases with

evaporator temperature decreasing condensing
(Te) temperature (Tc) 176
Assessment of Air Conditioning

Measure
• Airflow Q (m3/s) at Fan Coil Units (FCU) or Air
Handling Units (AHU): anemometer
• Air density  (kg/m3)
• Dry bulb and wet bulb temperature: psychrometer
• Enthalpy (kCal/kg) of inlet air (hin) and outlet air
(Hout): psychrometric charts
Calculate TR Q  ρ  h in  h out 
TR 
3024
177
Assessment of Air Conditioning

Indicative TR load profile
• Small office cabins: 0.1 TR/m2
• Medium size office (10 – 30 people
occupancy) with central A/C: 0.06
TR/m2
• Large multistoried office complexes
with central A/C: 0.04 TR/m2
178
Considerations for Assessment

• Accuracy of measurements
• Inlet/outlet temp of chilled and condenser
water
• Flow of chilled and condenser water
• Integrated Part Load Value (IPLV)

• kW/TR for 100% load but most equipment
operate between 50-75% of full load
• IPLV calculates kW/TR with partial loads
• Four points in cycle: 100%, 75%, 50%, 25% 179
180

Advance Refrigeration and Airconditioning

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Advance

Refrigeration & Air

How does High Temperature Reservoir

Low Temperature Reservoir

How does it work?

(Bureau of Energy Efficiency, 2004) 4

Refrigeration systems for industrial

• Brine plants with brines as lower

Refrigeration at large companies

• More levels of refrigeration/AC, e.g.

Vapour Compression Refrigeration

Vapour Compression Refrigeration

Vapour Compression Refrigeration

Vapour Compression Refrigeration

Vapour Compression Refrigeration

Vapour Absorption Refrigeration

Vapour Absorption Refrigeration

Vapour Absorption Refrigeration

Vapour Absorption Refrigeration

Refrigerant-absorbent combinations for VARS

The desirable properties of refrigerant-absorbent mixtures for

ii. There should be large difference in the boiling points of

iii. It should exhibit small heat of mixing so that a high

iv. The refrigerant-absorbent mixture should have high

v. It should not undergo crystallization or solidification

vi. The mixture should be safe, chemically stable, non-

The most commonly used refrigerant-absorbent pairs in commercial

Hot Air Cold

TABLE 7 – RECOMMENDED MAXIMUM DUCT

Methods of Duct Design

1-Equal Friction Method

This method of sizing is used for supply, exhaust and

mixture of short and long runs, the shortest run

Example 4 – Equal Friction Method of Designing

2-Static Regain Method

The basic principle of the static regain method is to

The remaining sections of duct are sized from Chart

STAIRCASE PRESSURIZATION CALCULATION FOR BASEMENT PART - A

Q1 = Air Leakage in Cu. M./ Sec.

A = Area of Leakage in Sq.M.

ΔP = Pressure Difference in Pascal ( 50 Pa)

No. of Floors = Basement to Ground Floor = 2

Door Size = 1.2 M x 2.1 M

Gap Between door and Frame/Floor = 6 mm at Top and on side

Area of Leakage Between Door & Frame

= 2 x 2.1 x 6/1000 + 1 x 1.2 x 6/1000 + 1 x 1.2 x 15/1000

= 0.0252 + 0.0072 + 0.018

Area of Leakage in Closed Condition/Door = 0.0504 Sq. M.

Total Leakage Area for 2 No. Doors = 0.0504 x 2

= 0.60 Cu. M/Sec.

Q2 = Area of Doors x Velocity

= 2.1 x 1.2 x2 No. x 1.0 M/sec.

= 5.04 Cu. M./Sec

Total Required Air Quantity = Q1 + Q2

LIFT WELL PRESSURIZATION CALCULATION

TOWER T1 (G+13)- 5 Nos.

Q = Air Leakage in Cu. M./ Sec.

A = Area of Leakage in Sq.M.

ΔP = Pressure Difference in Pascal ( 50 Pa)

No. of Floors = Lower Basement (Part-A) to 13th Floor = 16

Door Size = 2.1 M x 1.2 M

Total Leakage Area for 16 No. Doors = 0.065 x 16

= 6.17 Cu. M/Sec.