SUSTAINABLE ENERGY UTILISATION SEU-LAB3

MEASURING PERFORMANCE OF A COMPRESSOR

REFRIGERATING RIG

Read the lab sheet very carefully before come to the lab lesson. You need to refer
chapter 3 in the textbook Refrigerating Engineering", Granryd, E. et al., 2002.
Comparisons are also made with test results recorded in chapters 2 and 7.
Additional paper with previous experimental results (same as the page number 7,
which is to be filled during the lab lesson) has been provided with this lab sheet
(Table 1: test values with scroll compressor). Select one of a measuring point series
(1, 2 or 3) and do the calculations with the instructions given in the lab sheet. You have
to handover this to the lab instructor before the lab lesson.

Before start the lab lesson you should be able to answer the following questions:

1. How is the refrigerating capacity, Q& 2 , determined in this lab lesson?

2. What do the coefficients of performance, COP2t, COP2C and COP2 d stand for?

3. How do we calculate the total Carnot efficiency, Ct , and the Carnot efficiency of the
refrigerant, Cd ?

4. What kind of compressors are used in this lab lesson?

5. What differences as to efficiencies are here used for hermetic and non-hermetic
compressors?
SUSTAINABLE ENERGY UTILISATION - LAB LESSON NO. 3

MEASURING PERFORMANCE OF A
COMPRESSOR REFRIGERATING RIG
OBJECTIVES:
This laboratory lesson involves measurements when operating a compressor
refrigerating rig at different evaporation temperatures, using R22 as refrigerant. The
main objectives of are to:
Investigate the influence of the evaporation temperature on the systems
capacities and efficiencies
Study the efficiencies of rotary and scroll compressors
The theory below is mainly based on chapter 3 in the textbook Refrigerating
Engineering", Granryd, E.; etal, 2005 [1]. During the lab lesson comparisons will be
made with test results recorded in chapters 2 and 7.

THEORY:
The coefficient of performance, COP2t, for a refrigeration process is defined as
Q& 2
COP2 t = & (1)
Et

where Q& 2 (kW) is the refrigerating capacity and E& t (kW) is the total power used to
operate the compressor motor.

The Carnot cycle is often used as an ideal reference process between the
temperatures t1 and t2 corresponding to the saturated pressures in the evaporator and
condenser. The Carnot coefficient of performance, COP2C, is a function only of the
absolute temperatures T1 and T, (in K), where
T2
COP2 C = (2)
T1 T2
The total coefficient of performance, COP2t, in real process is of course less than the
coefficient of performance for a Carnot process. A total Carnot efficiency, Ct , can
be introduced and COP2t can then be calculated as
COP2 t = Ct COP2 C (3)
The total Carnot efficiency is dependent on the efficiencies of the compressor and of
the properties of the refrigerant used. Figure 2:16 in [1] gives estimated values of
Ct for different compressor sizes as a function of the temperature difference, (t1 -
t2).

When a refrigeration process is used as a heat pump it is the condenser power

output, Q&1 , rather than the refrigerating capacity, Q& 2 , that is of primary interest. The
coefficient of performance for a heat pump, COP1t, is defined as

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 Q& 1
COP1t = & (4)
Et

where Q&1 Q& 2 + E& t gives COP1t COP2 t + 1 (5)

and where equality ( = ) would be valid only if no loss of heat takes place in motor
and compressor.

Refrigeration process calculations

The vapor refrigeration process is represented in the h, log p diagram in Figure 1
as an aid to calculate the refrigerating capacity, the condenser power and the
coefficients of performance in a real refrigerating process.

The refrigerating capacity is fixed by the relation

Q& 2 = m
& R h2 (6)
where m& R is the mass flow in kg/s of the circulated refrigerant and h2 (kJ/kg) is the
enthalpy difference in the evaporator (See Figure 1).

A heat balance for the condenser can be performed to determine the mass flow m& R .
The condenser power output can be expressed with the relation
Q& 1 = m& R h1 (7)
where h1 is the enthalpy difference over the condenser. (See Figure 1).

The condenser power output can for a water cooled condenser be calculated as
Q& 1 = m& w c p ,w t w (8)

where the water flow m& w rate (kg/s) and the temperature difference, t w (C), can be
measured and where specific heat for water c p ,w 4190 J/kgK.

The power demand for an isentropic compressor, E& d (kW), can be obtained from

E& d = E& is = m& R his (9)

where his is the enthalpy increase of the refrigerant at isentropic compression
between the pressures p1k and p2k (See Figure 1).

The real power input to an electric motor, E& t , is of course larger than E& d . With non
hermetic compressors this can be taken into consideration by introducing different
efficiencies for the various losses. We can then write
E& d = E& t k mt elm (10)
where k is the total isentropic compression efficiency of the compressor, mt and
elm are the efficiencies of the transmission and the electric motor.

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The total coefficient of performance of a refrigeration process, COP2t, can be
written:
h2
COP2 t = k mt elm (11)
his
With hermetic compressors (as we have in this lab lesson) it is convenient to
introduce an overall efficiency of the compressor, H , that replaces k mt elm in
eqns 10 and 11 when his is the enthalpy change for an isentropic compression
between the inlet conditions of the compressor envelope to the exit pressure
(Explained further in 7.11 in [1]).

Examples of test results showing the overall efficiency ( H ) of hermetic piston and
scroll compressors are given in Figure 7.44 in [1], in this figure the overall efficiency
is referred to as total isentropic efficiency. We assume here that the overall efficiency
of a rotary compressor is similar to that of a piston compressor.
h2
The enthalpy ratio represent a coefficient of performance for the
his
refrigerant, COP2d , that can be obtained from the h, log p diagram. COP2d can be
related to the COP2C by introducing the Carnot efficiency of the refrigerant, Cd , in
the following relation:
h2
COP2 d = = Cd COP2 C (12)
his
As can be seen in table 3.23-3.25 in [1], for evaporation temperature of -15C and
condensing temperature of +30C values for the Carnot efficiency for the refrigerant,
Cd , are in the region of 0.80 to 0.85.

Volumetric efficiency for the compressor

The refrigerant capacity for a compressor can be calculated from
h
Q& 2 = S V&S 2 (13)
v2 k
where S is the volumetric efficiency of the compressor; v2 k is the specific volume
at the compressor intake and V& is the swept volume flow (expressed in m3/s).
S

The two lab lesson rigs use two different kinds of compressors. One rig uses a scroll
compressor and the other one a rotary. The swept volume flow of the scroll
compressor is V&S = 5.42 m3/h and of the rotary compressor V&S = 4.22 m3/h.

Examples of test results showing volumetric efficiency of hermetic piston and scroll
compressors are given in Figure 7.44 in [1]. We assume here that the volumetric
efficiency of a rotary compressor is rather similar to that of a piston compressor and
depends mainly on the pressure ratio (p1/p2) but also somewhat on the superheat and
on the refrigerant used.

TEST EQUIPMENT:

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The laboratory test equipment consists of two separate test rigs; one runs with scroll
compressor and the other runs with a rotary. A water cooled condenser and a plate
heat exchanger as evaporator are used. Figure 2 shows a schematic of the compressor
refrigeration test rig. The refrigerant used is R22.

The evaporation temperature is controlled by the load of the electric heater. The heat
to the evaporator is supplied with a secondary refrigerant, circulated by a pump in an
indirect circuit. This circuit consists of the evaporator, a pump and an electric heater.

The electric power to the heater is regulated with a transformer. The power to the
heater and compressors is measured with a kWh-meter and a stopwatch.

The refrigerant flow to the evaporator is regulated with a thermostatic expansion

valve with the bulb placed on the suction line after the evaporator.

The evaporator consists of a plate heat exchanger with 12 plates i.e. 5 channels for
the refrigerant and 6 channels for the secondary refrigerant.

An oil separator is placed after the compressor to separate oil drops that follow the
refrigerant out of the compressor. This oil is brought back to the crankcase of the
compressor with a return pipe.

The condenser is of shell and tube type with cooling water from the tap flowing
inside the tubes. A water regulating valve is controlled by the condenser pressure by
means of a capillary connected to the condenser. This valve maintains the condenser
pressure almost constant, independent of the heat load of the condenser.

The lab equipment has high and low pressure controls as security devices. These
controls breaks the electric power input to the test rig if the condenser pressure
exceeds the maximum level of the high pressure control or if the evaporator pressure
gets lower than the minimum level of the low pressure control.

Precision manometers are used for pressure measurements at the inlet and outlet of
the compressor that here are used to represent the pressure in the evaporator and the
condenser. The temperatures are measured with thermocouples connected to a
computer.

TEST PROCEDURE:

Starting the machinery:

Your laboratory assistant has usually already started the computer and the machinery
and set it for the first measuring point in order to save time.

Measurements:
Check on the computer screen that running conditions are reasonably stable before
each measuring set is performed. The following quantities are then measured;
electric power to the motor, E& t , power to the heater, Q& E , cooling water flow to the
condenser, m& w , evaporating and condensing pressures, p2 and p1, pressures at the

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inlet and at the outlet of the compressor, p2k and p1k and a number of temperatures
continuously registered on the screen. Enter the measured values in Tables 1&3!

When all measurements have been made, increase the power to the electric heater for
the next operating point and start the calculations while running conditions stabilize.
The electric power to the heater is reduced in two steps so that three measuring
points will be obtained. This reduction of the load of the evaporator will decrease the
evaporation temperature in steps of approximately 4-5 C.

CALCULATIONS:
Draw first the process in the attached h, log p diagram of R22. (Compare Figure
1). Calculations are then made according to the following order and the obtained
values are entered in Tables 2&4 for the scroll and rotary compressors respectively.

All the equations needed for the calculations below are provided in this handout.

Calculate the condenser power output, Q&1 . The refrigerant mass flow rate, m
& R , and
the refrigerating capacity, Q& .
2

Calculate the total coefficient of performance of the refrigeration cycle, COP2 t , the
coefficient of performance of the Carnot refrigeration cycle, COP2 C , and the total
Carnot efficiency, Ct .

Calculate the coefficient of performance of the refrigerant, COP2d , and the Carnot
efficiency for the refrigerant, Cd .

Calculate the volumetric, S , and the overall efficiencies of the compressor, H , that
replaces k mt elm .

Estimate the coefficient of performance, COP1t, that could be obtained if the

equipment would work as a heat pump.

REPRESENTATION IN PLOTS AND CONCLUSIONS:

- Only for scroll compressor: Plot calculated values for the condenser power
output, Q&1 , the refrigerating capacity, Q& 2 , as well as the values for the total power to
the compressor motor, E& t , in Plot 1. How do they vary with the evaporation
temperature? Explain why!

- Only for scroll compressor: Plot the calculated coefficients of performance,

COP2 t , COP2 C and COP2d in Plot 2. How do they vary with the evaporation
temperature? Explain why!

- For both compressors: Plot the calculated efficiencies; Cd , S as well as H in

Plot 3. How do they vary with the evaporation temperature? Only for Scroll
compressor: Plot Ct and compare it with the curves of Figure 2.16 in [1]? Explain
the results!

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- Compare also the calculated values of the overall efficiency of the compressor, H ,
and the volumetric efficiency, S , with values given in Figure 7.44 in [1]. (Note
again that we here assume that the overall efficiency and the volumetric efficiency of
a rotary compressor are similar to that of a piston compressor).

- How would the Carnot efficiency for the refrigerant, Cd , change if the refrigerant
(liquid) could be subcooled efficiently with the cooling water of the condenser
(Compare eqn 12 and Figure 1)?

- What would the coefficient of performance, COP1t, be if the equipment worked as a

heat pump? Compare results from eqns (4) and (5). Plot COP1t from eqn (4) in Plot
2.

How does the condenser power output, Q&1 , change when the temperature of the heat
source decreases? How does this affect the performance of a heat pump?

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SYMBOLS USED IN TABLES 2&4: CALCULATIONS:

Description Symbol
Condenser power output (heating capacity) Q&1
Enthalpy difference over the condenser h1
Mass flow rate of refrigerant m& R
Enthalpy difference over the evaporator h2
Refrigerating capacity Q& 2
Total coefficient of performance of the refrigeration cycle COP2 t
Coefficient of performance of the Carnot refrigeration cycle COP2 C
Total Carnot efficiency Ct
Enthalpy increase at isentropic compression his
Coefficient of performance of the refrigerant in the refrigeration COP2d

Carnot efficiency of the refrigerant Cd

Specific volume at compressor inlet v2 k
Volumetric efficiency S
Pressure ratio p1/p2
Overall efficiency of hermetic compressor H
Total coefficient of performance of the heat pump cycle COP1t

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 TABLE 1: MEASURED VALUES-SCROLL COMPRESSOR

Measuring point
Symbol Unit 1 2 3

Electrical power
Compressor E& t W

Heater Q& E W

Pressure
Compressor inlet p2k bar
Compressor outlet p1k bar

Flow rate
Condenser water flow m& w kg/s

Temperatures [C] Point

Compressor inlet t1 1
Compressor outlet t2 2
Condenser inlet t3 3
Condenser outlet t4 4
Evaporator inlet t5 5
Evaporator outlet t6 6
Water inlet to condenser t7 7
Water outlet to condenser t8 8
Brine inlet, evaporator t9 9
Brine outlet, evaporator t10 10

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TABLE 2: CALCULATIONS -SCROLL COMPRESSOR

Measuring point
Symbol 1 2 3

Q&1
h1
m& R
h2

Q& 2
COP2 t
COP2 C
Ct
Ct (From Fig 2:16)

his
COP2d
Cd
v2 k
S
p1/p2
S (From Fig 7:44)
H
H (From Fig 7:44)
COP1t
COP1t (From Eq. 4)

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 TABLE 3: MEASURED VALUES-ROTARY COMPRESSOR

Measuring point
Symbol Unit 1 2 3

Electrical power
Compressor E& t W

Heater Q& E W

Pressure
Compressor inlet p2k bar
Compressor outlet p1k bar

Flow rate
Condenser water flow m& w kg/s

Temperatures [C] Point

Compressor inlet t1 1
Compressor outlet t2 2
Condenser inlet t3 3
Condenser outlet t4 4
Evaporator inlet t5 5
Evaporator outlet t6 6
Water inlet to condenser t7 7
Water outlet to condenser t8 8
Brine inlet, evaporator t9 9
Brine outlet, evaporator t10 10

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TABLE 4: CALCULATIONS-ROTARY COMPRESSOR

Measuring point
Symbol 1 2 3

Q&1
h1
m& R
h2

Q& 2
COP2 t
COP2 C
Ct
Ct (From Fig 2:16)

his
COP2d
Cd
v2 k
S
p1/p2
S (From Fig 7:44)
H
H (From Fig 7:44)

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Figure 1: Refrigeration process in h, log p diagram

p
h1

t1
p1

t2 v2 k
p2
t2 k
h2 his

h
Figure 2: Schematic diagram of the test rig
t3
Condenser
t7

t8 Oil
separator
Regulating P
valve p
t4 t2
Compressor
M
Sight glass Electric
motor P
t1

Drying filter

Liquid
Evaporator separator

Thermostatic t5 t6
Expansion
valve t10 t9

Electric Brine
heater pump

Brine loop

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NOTE: These plots are guidelines for analysis. You can use Excel to analyze the
data and generate plots.

Plot 1: Condenser power output, refrigerating capacity and total power to

compressor motor as a function of the evaporation temperature

Q&1 , Q& 2 , E& t (W )

4000

3000

2000

1000

-20 -15 -10 -5 0 -20 t2 ( C )

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Plot 2: Coefficients of performance as a function of the evaporation
temperature:

COP2t , COP2c , COP2d , COP

1t

t2 ( C )

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Plot 3: Various efficiencies as a function of the evaporation temperature

Ct Cd S H

0.75

0.5

0.25

-20 -15 -10 -5 0 -20 t2 ( C )

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Plot 4: R22 h, log p diagram

References:
1. Granryd, E., et al., Refrigerating Engineering. 2005, Stockholm, Sweden:
Department of energy engineering, Division of applied thermodynamics and
refrigeration, Royal Institute of Technology (KTH).

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