MAB 4533 REFRIGERATION & HVAC SYSTEM

LABORATORY MANUAL
REFRIGERATION – COOLING TOWER

- FOR INTERNAL USE ONLY -

INSTRUCTION TO STUDENTS

1. Read the Laboratory Manual before the lab session begins.

2. There are 2 experiments. Attempt ALL experiments.
3. Answer ALL questions in the workbook.
4. The total maximum duration of the laboratory session is 4 hours.
5. Each group should submit a report before leaving the laboratory.
6. Plagiarism is strictly prohibited. Any report found improperly referenced and copied
from others will not be accepted for assessment.

Mechanical Engineering Department

Universiti Teknologi PETRONAS
2010

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COTETS

SECTIO A: REFRIGERATIO

1. Introduction ……………………………………………………………………… 1
2. Experiment Objectives …………………………………………………………....2
3. Apparatus ……………... ………………………………………………………… 3
4. Experimental Procedure ………………………………………………………… 8
5. Report …………………………………………………………………………….. 9

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SECTIO A: REFRIGERATIO

1. Introduction

The refrigeration cycle in various forms finds applications in industrial and domestic
situations. For example, the storage and transport of perishable foodstuffs and drugs would
be extremely difficult if not impossible without refrigeration. Similarly the efficient
operation of offices and factories in many parts of the world would be impossible without
the use of refrigeration plants in air conditioning systems. It is for these reasons that
engineers of many disciplines must have a good working knowledge of the refrigeration
cycle.
A refrigerator is defined as a machine whose prime function is to remove heat from a low
temperature region. Since the energy extracted cannot be destroyed, it follows that this
energy, plus the energy required to operate the machine, must be rejected to the
surroundings at a higher temperature. If the temperature of rejection is high enough to be
useful (e.g. for space or water heating) and this is the prime object of the machine, then the
machine is called a Heat Pump. The most common type of refrigerator or heat pump
operates on the Vapor Compression Cycle and requires a work input.

Figure 1 Refrigeration Cycle

2. Experiments Objectives
At the end of the lab demonstration and experiment, participants should be able to:
a. Identify the components in a refrigeration system
b. Learn characteristics of refrigeration cycle
c. Plot refrigeration cycle in P-h diagram from experimental data

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3. Experiment Equipment
The apparatus is a Hilton Refrigeration Laboratory Unit. This unit used R134a refrigerant.

Figure 2 Hilton R713 Refrigeration Laboratory Unit

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4. Experimental Procedure
Complete task I and II as follow:
4.1 Task I
DEMOSTRATIO OF THE VAPOR COMPRESSIO REFRIGERATIO
CYCLE AD PRODUCTIO OF THE CYCLE DIAGRAM
Follow instruction below:
1. Make sure main power switch is on and water supply for condenser is open.
2. Turn on main switch.
3. Set evaporator load from 0 to 100, 200, 300, and 400W.
4. Set the cooling water flow to give a condenser pressure of approximately 800-
1200 kN/m2
5. Wait until the unit stable (approx. 5-10 minutes) and collect data for every load
setting.
6. Observe the four main components (i.e. evaporator, compressor, condenser and
expansion valve), the connecting pipe work and instrumentation.
7. Collect system data and complete observation table in page 10 (in constant
condenser pressure condition) and 11 (constant evaporator pressure condition)
Conduct the task below:
1. Determine 4 component of refrigeration cycle!
2. After observing the component and collect the data, analyze the data of each
component, which one component with low temperature and high temperature and
where is heat transfer occurs? Where are pressure drop occurred?
3. Plot cycle diagram in P-h diagram of R134a refrigerant. The cycle diagram can be
plotted on the p-h diagram by noting the following Pc, Pe, t1, t2, t3. (Pc and Pe are
converted to absolute values. i.e. — gauge reading + atmospheric pressure.)
4. What is the effect of increasing load to evaporator? Explain the effect to each
component of the system!

Note that pressure drops in both the evaporator and condenser arc assumed to be
negligible and P and are horizontal lines of constant pressure.
Note that due to motor inefficiencies the increase in measured current may be small the
main parameter affected by an increase in the load on the motor will be the power
factor
Note that under certain low load conditions the compression process may “appear” to
have reducing entropy between state 1 and 2. The cause of this is assumed to be an
internal heat transfer within the compressor between the suction line, which enters via
the entire crankcase, and the compressor discharge at the top of the cylinder head. Gas
entering the compressor at very low temperatures and the thermal mass of the
compressor cylinder and block can result in a net cooling of the compressed gas
leaving at the top of the compressor. If left running at the low load condition for a

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 prolonged period the expected increase in entropy during compression will eventually
be seen.
At higher loads the expected increase in entropy during compression will be seen
sooner due to the larger energy transfer rates involved.

USEFUL DATA (See also Specification)

Compressor (Two cylinder, single acting.)
Bore = 38mm; Stroke = 19mm.
Swept volume 43 cm3 per revolution.
= (nominally) 0.025

Belt Pulley Ratio, = = 1.98

Hence, if Compressor RPM nc = 719
Motor RPM = 718x 1.98
nm = 1423 RPM
Typical Compressor Friction Force (at spring balance) = 5N
Dynamometer Torque arm radius O.165m
Condenser Mean heat transfer area, 0.075m2
Specific heat of water = 4.18 kJ kg-1

4.2 Task II
PRODUCTIO OF A EERGY BALACE FOR THE REFRIGERATOR
The unit should be run for a few minutes at a moderate load of approximately 800-
1000W and then set to the desired conditions for the test. The evaporating temperature,
t4, is set by adjustment of the evaporator heat input. The condensing temperature is set
by adjusting the condenser cooling water flow until (he condenser pressure is the
saturation pressure at the desired condensing temperature.
Take the data from observation table : t1, t2, t3, Pc, Pe.
Take data from p-h chart: h1, h2, h3/4

ENERGY BALANCES
Evaporator
Evaporator Heat Input
R134 Enthalpy Change Rate =

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 Condenser
Heat transfer to Cooling Water
R134a Enthalpy Change Rate =

Compressor
Shaft power =

Friction power =

Where is a motor dynamometer reading with the compressor suction valve closed,
i.e. the compressor doing no nett work on the gas (typically this load is 5 N)
Compressor indicated power
R134a Enthalpy Change Rate =
Heat losses from the compressor in the form of radiated and convection heat represent

Electric Motor
Electrical Power Input
For the complete plant
Calculate
(1st Law)

4.3 Report
Complete the report and submit before leaving the lab. The report must contain:
a. Introduction (write about the experiment and data collection you have done in two
or three paragraph).
b. Task I (include refrigeration cycle drawing on p-h diagram) and Analysis
c. Task II (calculation) and Analysis
d. Conclusion.

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 HILTO REFRIGERATIO LABORATORY UIT
TEST OBSERVATIO

CONDITION:
DATE:
ATMOSPHERIC PRESSURE:

SERIES TEST o. 1 2 3 4 5 6

Condenser pressure
pc/kN m-2
(abs.)
Evaporator Pressure pe/kN m-2

Compressor suction t1/oC

Compressor delivery t2/oC

Liquid leaving
t3/oC
condenser
Evaporator inlet t4/oC

Water inlet t5/oC

Water outlet t6/oC

1
Water flow rate w/gs

1
R134a flow rate r/gs

Evaporator Load eel/W

Motor Input mel/W

Spring balance F/N

Compressor speed nc/rpm

Motor speed
nn/rpm
(nm=nc x pulley ratio)
Note that the above pressures are absolute and have been converted from gauge pgauge =
pabsolute + patmosphere

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SECTIO B: COOLIG TOWER

1. Introduction ……………………………………………………………………… 1
2. Experiment Objectives …………………………………………………………....2
3. Apparatus ……………... ………………………………………………………… 3
4. Experimental Procedure ………………………………………………………… 8
5. Report …………………………………………………………………………….. 9

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SECTIO B: COOLIG TOWER

1. Introduction

Cooling towers are heat removal devices used to transfer process waste heat to
the atmosphere. Cooling towers may either use the evaporation of water to remove process
heat and cool the working fluid to near the wet-bulb air temperature or rely solely on air to
cool the working fluid to near the dry-bulb air temperature. Common applications include
cooling the circulating water used in oil refineries, chemical plants, power stations and
building cooling
An HVAC cooling tower is a subcategory rejecting heat from a chiller. Water-cooled
chillers are normally more energy efficient than air-cooled chillers due to heat rejection to
tower water at or near wet-bulb temperatures. Air-cooled chillers must reject heat at the dry-
bulb temperature, and thus have lower average reverse-Carnot cycle effectiveness. Large
office buildings, hospitals, and schools typically use one or more cooling towers as part of
their air conditioning systems. Generally, industrial cooling towers are much larger than
HVAC towers.
The Hilton Bench Top Cooling Tower H891 has been specifically designed to give
students an appreciation of the construction, design and operational characteristics of a modem
evaporative cooling system. The unit is also an excellent example of an “open system”
through which two streams of fluid flow (water and air) and in which there is a mass transfer
from one stream to the other.
Cooling Tower Terms
Cooling Range: The difference between the water temperature at entry to and exit
from the tower.
Cooling Load: Is the rate at which heat is removed from the water. This may be
expressed in kW1 Btu/h or k Cal/h.
Make-Up: The quantity of fresh water which must be supplied to the water
circuit to make good the losses due to evaporation and other causes.
Drift or Carry Over: Droplets of water which are entrained by the air stream leaving the
tower.
Packing or Fill: The material over which the water flows as it falls through the
tower, so that a large surface area is presented to the air stream.
Approach to Wet Bulb: Is the difference between the temperatures of the water leaving the
Lower and the wet bulb temperature of the air entering.
Drain Down: Water deliberately removed from the water system to prevent the
excessive concentration of dissolved solids due to evaporation and
sludge due to impurities from the atmosphere.

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Basic principles

Figure 1. Cooling tower basic principles

Assuming that the water is hotter than the air, it will be cooled:
i. By radiation
This effect is likely to be very small at normal conditions and may be neglected.
ii. By conduction and convection
This will depend on the temperature difference, the surface area, air velocity, etc.
iii. By evaporation
This is by far the most important effect. Cooling takes place as molecules of 1420
diffuse from the surface into the surrounding air. These molecules are then replaced by
others from the liquid (evaporation) and the energy required for this is taken from the
remaining liquid.

2. Experiments Objectives
At the end of the lab demonstration and experiment, participants should be able to:
a. Identify the components in a cooling tower
b. Investigate the effects of air flow ratewater temperature, cooling load and packing
density on the performance of a cooling tower
c. Review how to perform energy balances and calculate humidity ratios

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 3. Experiment Apparatus

Figure 2. Hilton Cooling tower unit

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4. Experimental Procedure
The Bench Top Cooling Tower behaves in a similar manner and has similar components to
a full size cooling tower and may be used to introduce students to their characteristics and
construction
Collect data and write down in Observation Sheet, conduct task I and II, submit the report
before leaving laboratory.
4.1 Task I
OBSERVATIO OF THE PROCESSES WITHI A FORCED DRAUGHT
COOLIG TOWER
Follow instruction below:
1. Make sure main power switch is on and water supply in make-up tank is enough.
2. Turn on main switch.
3. Set water flow rate to 40 g/s.
4. Set heating load to 1 kW and repeat for 1.5 kW
5. For each heating load repeat data collection for full air supply open and half air
supply open
6. Collect system data and complete observation table

Conduct the task below:

1. Determine component of cooling tower system!
2. Draw system sketch and explain cooling tower principles!
3. Explain water system flows in cooling tower!
4. Explain air system flows in cooling tower
5. Plot point A and B in Psychrometric chart for each experimental data!
6. Explain Psychrometric chart plotting results!
7. What is the effect of changing load and air supply flow rate in cooling tower?

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4.2 Task II
DETERMIATIO OF ALL “ED STATE” PROPERTIES OF THE AIR AD
H20 FROM CHARTS AD TABLES, AD THE APPLICATIO OF THE
STEADY FLOW EQUATIO TO SELECTED SYSTEMS TO DRAW UP
EERGY AD MASS BALACES.
The Bench Top Cooling Tower should be prepared, started and allowed to stabilize
under the following suggested conditions:
Orifice differential 16 mm H20
Water flow rate 40 gm s-1
Cooling load 1.0 kW
(Note: Stability is reached when there is no further appreciable change in temperature,
or flow rate).
At regular intervals over a measured period of say 10 minutes, all temperatures and
flow rates should be noted and the mean values entered on the observation sheet.
At the commencement of this period, fill the make-up tank to the gauge mark with
distilled water. As the end of this period, refill the tank from a known quantity of
distilled water in a measuring cylinder. By difference, determine the quantity of make-
up which has been supplied in the time interval.
The observation may be repeated at other water or air flow rates and with another load.
Typical observations and specimen calculations are given on Pages 28 to 32.

Typical calculation:
Using the wet and dry bulb temperatures, points A and B may be plotted on the
psychrometrics chart, (See Page 29) and the following values read off: , ,
, ,
From the orifice calibration (page 21):

Make up rate

Specific enthalpy of make-up ( = at 20.8 oC

Applying the Steady Row Equation to the system indicated by the chain line (System F):

The small discrepancy may be attributed to errors and heat transfer to or from the
surroundings and to manufacturing tolerances in the rating of heating elements.

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 Mass balance

The discrepancy may be attributed to carry over and errors.

Applying the Steady Row Equation to the system indicated by the chain line (System G):

Figure 3. System F and G

4.4 Report
Complete the report and submit before leaving the lab. The report must contain:
a. Introduction (write about the experiment and data collection you have done in two
or three paragraph).
b. Task I
c. Task II (include psychrometrics chart drawing)
d. Conclusion.

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 HILTO BECH TOP COOLIG TOWER
OBSERVATIO SHEET

Date: Investigation: Atmospheric Pressure:

Test no. 1 2 3 4 5 6

Packing Installed

Packing Density m-1

Air Inlet
t1/oC
Dry Bulb
Air Inlet
t2/oC
Dry Bulb
Air Oulet
t3/oC
Dry Bulb
Air Oulet
t4/oC
Dry Bulb
Water Inlet
t5/oC
Temperature
Water Outlet
t6/oC
Temperature
Water Make-up
Temperature
(Assumed same as t7/oC
ambient dry bulb
temperature t2)
Orifice Differential

Water Flow Rate

Cooling Load /kW

Make-up Quantity m/kg

Time Interval y/s

Pressure Drop
Across packing

Thermodynamics properties of Water

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 Absolute Dynamic Kinematic Specific
Temperature Expansion
pressure viscosity viscosity enthalpy
-t- coefficient
-p- -µ- -ν-
o
( C) (k/m ) (Centipoise) 10 (m /s) 10-3 (l/K) (kJ/kg)
2 -6 2

0.01 0.6 1.78 1.792 -0.07 0

5 0.9 1.52 0.160 21.0
10 1.2 1.31 1.304 0.088 41.9
15 1.7 1.14 0.151 62.9
20 2.3 1.00 1.004 0.207 83.8
25 3.2 0.890 0.257 104.8
30 4.3 0.798 0.801 0.303 125.7
35 5.6 0.719 0.345 146.7
40 7.7 0.653 0.658 0.385 167.6
45 9.6 0.596 0,420 188.6
50 12.5 0.547 0.553 0.457 209.6
55 15.7 0.504 0.486 230.5
60 20.0 0.467 0.474 0.523 251.5
65 25.0 0.434 0.544 272.4
70 31.3 0.404 0.413 0.585 293.4
75 38.6 0.378 0.596 314.3
80 47.5 0.355 0.365 0.643 335.3
85 57.8 0.334 0.644 356.2
90 70.0 0.314 0.326 0.665 377.2
95 84.5 0.297 0.687 398.1
100 101.33 0.281 0.295 0.752 419.1
105 121 0.267 440.2
110 143 0.253 461.3
115 169 0.241 482.5
120 199 0.230 0.249 0.860 503.7

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