Refrigeration and Air Conditioning

Training Session on Refrigeration & Air Conditioning
Refrigeration & Air Conditioning

Presentation by
Mohammad Salim M/s Unitech Ltd., Gurgaon.

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Training Agenda: Refrigeration & Air Conditioning

Introduction Reference Handbooks/Standards Type of refrigeration Applied Psychrometric Heat Load Calculation 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
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Introduction How does it work?

High Temperature Reservoir Heat Rejected R Work Input
Heat Absorbed Low Temperature Reservoir

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Introduction How does it work?

Thermal energy moves from left to right through five loops of heat transfer:
1) Indoor air loop 2) Chilled water loop 3) Refrigerant loop 4) Condenser water loop 5) Cooling water loop
(Bureau of Energy Efficiency, 2004)
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
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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
250 TR) (50
Brine plants with brines as lower temperature, secondary coolant (>250 TR)
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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) Brine system (< 0 oC)
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Reference Handbooks/Standards
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Reference Handbooks/Standards
ASHRAE Handbook of Fundamentals ASHRAE Handbook of Refrigeration ASHRAE Handbook of Application ASHRAE Handbook of System & Equipments ASHRAE Standards 62.1 ASHRAE Standards 90.1 ISHRAE Weather Data Carrier Handbook NBC-2005 LEED-2009 NFPA-92A ECBC-2007 Heat and Mass Transfer SMACNA Standard Indian Standards
Types of Refrigeration
Introduction Reference Handbooks/Standards Types of refrigeration Applied Psychrometric Heat Load Calculation 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
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Types of Refrigeration Refrigeration systems

Vapour Compression Refrigeration (VCR): uses mechanical energy Vapour Absorption Refrigeration (VAR): uses thermal energy
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Types of Refrigeration 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
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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)
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Refrigeration cycle
Condenser 4 Expansion Device Compressor 3 High Pressure Side
1 Evaporator
Low Pressure Side
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Low pressure liquid refrigerant in evaporator Vapour Compression absorbs heat and changes to a gas Refrigeration cycle
Condenser 4 Expansion Device Compressor
Refrigeration
3 High Pressure Side
1 Evaporator
Low Pressure Side
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The superheated vapour enters the compressor Vapour Compression where its pressure is raised Refrigeration cycle
Refrigeration
1 Evaporator
Low Pressure Side
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The high pressure superheated gas is cooled in several stages Vapour Compression in the condenser
Refrigeration
Refrigeration cycle
1 Evaporator
Low Pressure Side
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Types of Refrigeration Vapour

Liquid passes through expansion device, which reduces its Compression Refrigeration pressure and controls the flow into the evaporator
Condenser 4 Expansion Device Compressor 3 High Pressure Side
Refrigeration cycle
1 Evaporator
Low Pressure Side
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Type of refrigerant Refrigerant determined by the required cooling temperature Chlorinated fluorocarbons (CFCs) or freons: R-11, R-12, R-21, R-22 and R502
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Choice of compressor, design of condenser, evaporator determined by
Refrigerant Required cooling Load Ease of maintenance Physical space requirements Availability of utilities (water, power)
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Types of Refrigeration Vapour Absorption Refrigeration

Condenser Generator Hot Side Evaporator Cold Side Absorber
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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 Raoults law at absorber. ii. There should be large difference in the boiling points of refrigerant and absorbent (greater than 200 oC), 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.
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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. The refrigerant-absorbent mixture should have high thermal conductivity and low viscosity for high performance. It should not undergo crystallization or solidification inside the system.
iv.
v.
vi. The mixture should be safe, chemically stable, noncorrosive, inexpensive and should be available easily.
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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 refrigerantabsorbent systems using both natural and synthetic refrigerants to overcome some of the limitations of (H 2O-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).
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Types of Refrigeration 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 Air
(Adapted from Munters, 2001)

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Applied Psychrometric
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Heat Load Calculation

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Air Duct Design

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Air Duct Design
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Air Duct Design
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Air Duct Design
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Air Duct Design
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Air Duct Design
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Air Duct Design

TABLE 7 RECOMMENDED MAXIMUM DUCT VELOCITIES FOR LOW VELOCITY SYSTEMS (FPM)
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Air Duct Design
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Air Duct Design
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Air Duct Design
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Air Duct Design
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Air Duct Design
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Air Duct Design
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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
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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.
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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
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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.
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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.
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Air Duct Design
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Pressurization System
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STAIRCASE PRESSURIZATION CALCULATION FOR BASEMENT PART - A BASEMENT TO GROUND FLOOR)
Q1 Q1 A P Kf No. of Floors No. of Doors Door Size Gap Between door and Frame/Floor = = = = = = = = = = 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. Kf A P Air Leakage in Cu. M./ Sec. Area of Leakage in Sq.M. Pressure Difference in Pascal ( 50 Pa) Coefficient 0.839 Basement to Ground Floor = 2 2 1.2 M x 2.1 M 6 mm at Top and on side 15 mm at Bottom
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Area of Leakage in Closed Condition/Door Total Leakage Area for 2 No. Doors
= = =
0.0504 Sq. M. 0.0504 x 2 0.10 Sq.M. 0.839 x 0.10 x 50 0.60 Cu. M/Sec. 1270 CFM
Q1
= = =
Leakage of Air Thru 2 No. Open Door ( 1 No. at affected floor + 1 No. at Exit to Building ) Q2 = = = = Total Required Air Quantity = = = Area of Doors x Velocity 2.1 x 1.2 x2 No. x 1.0 M/sec. 5.04 Cu. M./Sec 10671 CFM Q1 + Q2 1270 + 10671 11941 CFM
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LIFT WELL PRESSURIZATION CALCULATION TOWER T1 (G+13)- 5 Nos.
Q Q A P Kf No. of Floors No. of Doors Door Size Area of Leakage Between Lift Door & Wall/ Door = = = = = = = = = = = Q = = = Fan Capacity for Two Lift Well = = Say 1 No. 26500 CFM DIDW Centrifugal Fan Section For Fresh Air Supply = Kf A P Air Leakage in Cu. M./ Sec. Area of Leakage in Sq.M. Pressure Difference in Pascal ( 50 Pa) Coefficient 0.839 Lower Basement (Part-A) to 13th Floor = 16 16 2.1 M x 1.2 M 0.065 Sq. M. 0.065 x 16 1.04 Sq.M. 0.839 x 1.04 x 50 6.17 Cu. M/Sec. 13063 CFM 13063x2 26126 CFM 26500 CFM
Total Leakage Area for 16 No. Doors
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Chilled/Condenser Water Piping Design

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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Compressors
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Condensers & Evaporators

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Expansion Devices
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Expansion Devices
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Expansion Devices
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Expansion Devices
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Expansion Devices
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Expansion Devices
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Cooling Tower
Introduction Reference Handbooks/Standards Type of refrigeration Applied Psychrometric Heat Load Calculation 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
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Cooling Tower
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Assessment of Refrigeration and AC

Introduction Reference Handbooks/Standards Type of refrigeration Applied Psychrometric Heat Load Calculation 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
203
Assessment of Refrigeration and AC 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= Cp = Ti = To = mass flow rate of coolant in kg/hr is coolant specific heat in kCal /kg deg C inlet, temperature of coolant to evaporator (chiller) in 0C outlet temperature of coolant from evaporator (chiller) in 0C
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Specific Power Consumption (kW/TR) Indicator of refrigeration systems performance kW/TR of centralized chilled water system is sum of
Compressor kW/TR Chilled water pump kW/TR Condenser water pump kW/TR Cooling tower fan kW/TR
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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:

COP = Cooling effect (kW) Power input to compressor (kW)
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COP increases with rising evaporator temperature (Te)
COP increases with decreasing condensing temperature (Tc)
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Assessment of Refrigeration and AC 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
TR = Q ( h in h out ) 3024
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Calculate TR
Assessment of Refrigeration and AC 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
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Assessment of Refrigeration and AC 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%
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Energy Efficiency Opportunities

Introduction Reference Handbooks/Standards Type of refrigeration Applied Psychrometric Heat Load Calculation 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
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Energy Efficiency Opportunities

1. Optimize process heat exchange 2. Maintain heat exchanger surfaces 3. Multi-staging systems 4. Matching capacity to system load 5. Capacity control of compressors 6. Multi-level refrigeration for plant needs 7. Chilled water storage 8. System design features
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Energy Efficiency Opportunities 1. Optimize Process Heat Exchange

High compressor safety margins: energy loss 1. Proper sizing heat transfer areas of
heat exchangers and evaporators Heat transfer coefficient on refrigerant side: 1400 2800 Watt/m2K Heat transfer area refrigerant side: >0.5 m2/TR
2. Optimum driving force (difference Te and

Tc): 1oC raise in Te = 3% power savings
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Evaporator Temperature (0C)
5.0 0.0 -5.0 -10.0 -20.0
Condenser temperature 40C
Refrigeration Capacity*(tons)
67.58 56.07 45.98 37.20 23.12
Specific Power Consumption (kW/TR)

0.81 0.94 1.08 1.25 1.67
Increase kW/TR (%)

16.0 33.0 54.0 106.0
(National Productivity Council)

Specific Power Consumption (kW /TR) 1.17 1.27 1.41 Increase kW/TR (%) 8.5 20.5
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Condensing Temperature (0C) 26.7 35.0 40.0
Refrigeration Capacity (tons) 31.5 21.4 20.0
*Reciprocating compressor using R-22 refrigerant. Evaporator temperature.-10 C

3. Selection of condensers Options:
Air cooled condensers Air-cooled with water spray condensers Shell & tube condensers with water-cooling
Water-cooled shell & tube condenser

Lower discharge pressure Higher TR Lower power consumption
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Energy Efficiency Opportunities 2. Maintain Heat Exchanger Surfaces

Poor maintenance = increased power consumption Maintain condensers and evaporators
Separation of lubricating oil and refrigerant Timely defrosting of coils Increased velocity of secondary coolant
Maintain cooling towers

0.55C reduction in returning water from cooling tower = 3.0 % reduced power
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Energy Efficiency Opportunities 2. Maintain Heat Exchanger Surfaces

Effect of poor maintenance on compressor power consumption
Condition Normal Dirty condenser Dirty evaporator Dirty condenser and evaporator Te (0C) 7.2 7.2 1.7 1.7 Tc (0C) 40.5 46.1 40.5 46.1 Refrigeration Capacity* (TR) 17.0 15.6 13.8 12.7 Specific Power Consumption (kW/TR) 0.69 0.84 0.82 0.96 Increase kW/TR (%) 20.4 18.3 38.7
(National Productivity Council)
Energy Efficiency Opportunities 3. Multi-Staging Systems

Suited for Low temp applications with high compression Wide temperature range Two types for all compressor types Compound Cascade
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Energy Efficiency Opportunities 3. Multi-Stage Systems

a. Compound
Two low compression ratios = 1 high First stage compressor meets cooling load Second stage compressor meets load evaporator and flash gas Single refrigerant
b. Cascade
Preferred for -46 oC to -101oC Two systems with different refrigerants
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Energy Efficiency Opportunities 4. Matching Capacity to Load System

Most applications have varying loads Consequence of part-load operation
COP increases but lower efficiency
Match refrigeration capacity to load requires knowledge of

Compressor performance Variations in ambient conditions Cooling load
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Energy Efficiency Opportunities 5. Capacity Control of Compressors

Cylinder unloading, vanes, valves
Reciprocating compressors: step-by-step
through cylinder unloading:
Centrifugal compressors: continuous

modulation through vane control Screw compressors: sliding valves
Speed control
Reciprocating compressors: ensure lubrication system is not affected Centrifugal compressors: >50% of capacity
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Energy Efficiency Opportunities 5. Capacity Control of Compressors

Temperature monitoring
Reciprocating compressors: return water (if varying loads), water leaving chiller (constant loads) Centrifugal compressors: outgoing water temperature Screw compressors: outgoing water temperature
Part load applications: screw compressors more efficient
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Energy Efficiency Opportunities 6. Multi-Level Refrigeration

Bank of compressors at central plant
Monitor cooling and chiller load: 1 chiller full load more efficient than 2 chillers at part-load Distribution system: individual chillers feed all branch lines; Isolation valves; Valves to isolate sections Load individual compressors to full capacity before operating second compressor Provide smaller capacity chiller to meet peak demands
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Energy Efficiency Opportunities 6. Multi-Level Refrigeration

Packaged units (instead of central plant)
Diverse applications with wide temp range and long distance Benefits: economical, flexible and reliable Disadvantage: central plants use less power
Flow control
Reduced flow Operation at normal flow with shut-off periods
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Energy Efficiency Opportunities 7. Chilled Water Storage

Chilled water storage facility with insulation Suited only if temp variations are acceptable Economical because
Chillers operate during low peak demand hours: reduced peak demand charges Chillers operate at nighttime: reduced tariffs 225 and improved COP
Energy Efficiency Opportunities 8. System Design Features

FRP impellers, film fills, PVC drift eliminators Softened water for condensers Economic insulation thickness Roof coatings and false ceilings Energy efficient heat recovery devices Variable air volume systems Sun film application for heat reflection Optimizing lighting loads
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Training Session on Energy Equipment
Refrigeration & Air Conditioning Systems

THANK YOU FOR YOUR ATTENTION
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Refrigeration and Air Conditioning

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Training Session on Refrigeration & Air Conditioning

Refrigeration & Air Conditioning

Mohammad Salim M/s Unitech Ltd., Gurgaon.

Training Agenda: Refrigeration & Air Conditioning

Introduction How does it work?

Heat Absorbed Low Temperature Reservoir

Introduction How does it work?

(Bureau of Energy Efficiency, 2004)

Introduction Refrigeration systems for industrial processes

Introduction Refrigeration at large companies

More levels of refrigeration/AC, e.g. Comfort air conditioning (20-25 oC)

Types of Refrigeration Refrigeration systems

Types of Refrigeration Vapour Compression Refrigeration

Types of Refrigeration Vapour Compression Refrigeration

Types of Refrigeration Vapour Compression Refrigeration

Low Pressure Side

Low Pressure Side

Low Pressure Side

Condenser 4 Expansion Device Compressor

Low Pressure Side

Types of Refrigeration Vapour

Low Pressure Side

Types of Refrigeration Vapour Compression Refrigeration

Types of Refrigeration Vapour Compression Refrigeration

Types of Refrigeration Vapour Absorption Refrigeration

Types of Refrigeration Vapour Absorption Refrigeration

Types of Refrigeration Vapour Absorption Refrigeration

Types of Refrigeration Vapour Absorption Refrigeration

Types of Refrigeration Evaporative Cooling

(Adapted from Munters, 2001)

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Heat Load Calculation

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design

Air Duct Design