DECLARATION PAGE

I declare that this report is my original work and all references have been citied adequately as required by the University

Date : __/__/____

Signature : Full Name : Mustaqem Bin Abdul Aziz ID No : 50206210474

ii

APPROVAL PAGE

We have Supervised and examined this report and verify that it meets the programmed and University requirement for the Bachelor of Engineering Technology (Hons) in Air Conditioning & Industrial Refrigeration.

Date : __/__/____

Signature : Supervisors Name : Mr. Ng Wen Bin Official Stamp :

iii

ACKNOWLEDGEMENT

I consider myself fortunate to have done my Final Year Project at the Bachelor of ACIR in University Kuala Lumpur Malaysia France Institute ( UniKL MFI ). At this point special thanks to UniKL MFI for introduce this type of subject included in my studies. By doing this kind of learning subject, the student can do more research about his/her field will be involved after graduated from the college and also increase their understanding about the courses.. Special thanks go to my advisors Mr.Ng Wen Bin, who always kept me motivated during slow times of the project. He were always very helpful and had many great ideas for this project. This work could not have been accomplished without him. I am really thankful to the lecterur of the ACIR department for letting me further pursue my education at the workshop. Not only did I further improve my engineering skills, but when preparing the report, I can do it more quality. Also, I have greatly enjoyed the friendly environment in the ACIR department, having met many students from the state around the Malaysia, like from Kelantan, Sabah, Johor, Perak and too many to mention them all. I will definitely take many good memories of that time with me. In times of hard working, one need a place to relax. Fortunately, and for sure it is our own village. I want to thank my roommates and friends for having a great time in Bangi, Selangor and lots of fun. Especially, I want to thank Fitri Afham and Azmi for beta-reading my report and giving me helpful advice concerning my writing style. Last but not at least, I want to thank my parents who always supported me in my education and by having done this they pay a great contribution to my stay here at the University of Kuala Lumpur Malaysia France Institute .

iv

ABSTRACT

The good operation of the system is determined by the system design, energy requirements and the power consumptions of its heating, ventilation and air conditioning system (HVAC-system). So, all the factor must be calculate properly to achieve the good operation of system. This project is about to design one (1) completed air-cooled air conditioning which correct of the compressor, condenser, evaporator and capillary tube. The project will start by design and select the compressor capacity, model and type of the compressor. Then need to find the value of density and specific heat for the air. After that, the surface coefficient and capacity of the condenser and evaporator need to be calculate. At this section, the entering and temperature of exit air at the coil of condenser and evaporator also can be determined. After design these three (3) component, the last component must be design is the capillary tube. By the calculation, then the length of the capillary tube can be known. After design the system, the next step is to cover the main objective. That is by using varies evaporating temperature, then what is the effect on the cooling capacity. Then make the comparison of the compression ratio and coefficient of performance (C.O.P) to determine the evaporating temperature for Malaysia conditions. The other research involve is to know the effect of the evaporating and condensing temperature on the system design. The last is to study the effect of evaporating and condensing temperature on the capillary tube design. From the result and conclusion, then the value of evaporating temperature for Malaysia condition can be determined and also can know the effect of the evaporating temperature on the cooling capacity.

TABLE OF CONTENTS Page No. Title Page Declaration Approval Acknowledgement Abstract Table of Contents List of Tables List of Figure List of Graph List of Chart CHAPTER 1 1.1 1.2 1.3 1.4 1.5 1.6 INTRODUCTION 1 1 2 3 3 4 LITERATURE REVIEW 6 6 6 7 8 i ii iii iv v vi x xii xiii xiv

Project Introduction About the System Objective Project overview Scope of work Gantt Chart

CHAPTER 2 2.1 2.2 2.3

Basic Concepts The Goal of Air Conditioning System Design Split-System Air Conditioners design standard 2.3.1 2.3.2 Materials Quality Control

vi

2.4

Design Criteria for Scroll compressor 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 Scroll Compression Process Compressor Handling Lubrication and Oil Removal Accumulators Screens Crankcase Heaters Pumpdown Minimum Run Time Discharge Temperature Protection 8 9 10 11 12 13 14 15 15 16 17 17 17

2.5

Design Criteria Condensing Temperature 2.5.1 2.5.2 2.5.3 2.5.4 Sizing Condenser Total Heat Rejection Wet Bulb How Does a Larger Condenser Affect Energy Consumption

17 19 19 21 26

2.6

Design Criteria Evaporators 2.6.1 Materials of Construction

2.7 2.8 2.9

Effect of Evaporator Temperature R407C Characteristics Malaysia Standard ( MS1525 ) 2.9.1 ACMV System Equipment, Electrically Operated, Cooling Mode 2.9.2 ACMV System Equipment/Component Heat-Operated (absorption), Cooling Mode

29

30

CHAPTER 3 3.1 3.2

METHODOLOGY 31

Select and Design The Compressor System Cycle and Air Properties 3.2.1 3.2.2 Air Properties System Cycle

33 33

3.3

Surface Coefficient (KS) and Capacity of Condenser and Evaporator 33

vii

3.4

Design the Condenser and Evaporator 3.4.1 3.4.2 Data The Calculation 34 35

3.5

Design Capillary Tube 3.5.1 3.5.2 Data The calculation SYSTEM DESIGN 35 36

CHAPTER 4 4.1

The Compressor Design 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 Data Determine the Capacity Determine the Power Input Compressor cycle Compressor Select 37 37 38 40 41

4.2

System Cycle and Air Properties 4.2.1 4.2.2 Determine the Density and Specific Heat of Air System Cycle 42 44

4.3

Condenser and Evaporator Capacity 4.3.1 4.3.2 4.3.3 Data The Condenser The Evaporator 46 47 48

4.4

Sizing the Condenser 4.4.1 4.4.2 4.4.3 Data Calculation and Design Drawing of Condenser 49 49 59

4.5

Sizing the Evaporator 4.5.1 4.5.2 4.5.3 Data Calculation and Design Drawing of Evaporator 61 61 71

4.6

Sizing the Capillary Tube 4.6.1 4.6.2 Data Calculation 73 74

viii

CHAPTER 5 5.1

RESULT AND ANALYSIS

Effect of Evaporating Temperature On Cooling Capacity 5.1.1 5.1.2 Evaporating Temperature vs Cooling Capacity Compression Ratio and Coefficient of Perfomance vs Cooling Capacity 5.1.3 Power Consumption vs Cooling Capacity 79 80 78

5.2

Effect of Condensing Temperature On Condenser Sizing 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 Temperature Vs Depth Temperature Vs Height Temperature Vs Width Temperature Vs Rows of Tube Temperature Vs Tube per Rows 81 81 82 82 83

5.3

Effect of Evaporating Temperature On Evaporator Sizing 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 Temperature Vs Depth Temperature Vs Height Temperature Vs Width Temperature Vs Rows of Tube Temperature Vs Tube per Rows 83 84 84 85 85

5.4

Effect of Condensing and Evaporating Temperature On Capillary Tube Length 5.4.1 5.4.2 Condensing Temperature Vs Length Evaporating Temperature Vs Length CONCLUSION AND RECOMMENDATIONS 89 89 92 86 87

CHAPTER 6 6.1 6.2 Conclusion

Recommendations

REFERENCES APPENDIX

ix

LIST OF TABLES Page No. Table 2.1 : Design condensing temperature typically used Table 2.2 : Typical materials of construction Table 2.3 : Standard rating temperatures cooling Table 2.4 : Standard rating conditions cooling, heat-operated Table 3.1 : Data for capillary tube Table 4.1 : Data of the capacity Table 4.2 : Data for temperature vs capacity Table 4.3 : Data for the power input Table 4.4 : Data for evaporating temperature vs power input Table 4.5 : Data of the compressor cycle Table 4.6 :Perfomance at specified operating point ZR22K3E-TFD Data at 50 Hz Table 4.7 : Compressor mechanical and physical data Table 4.8 : Compressor electrical data (380/420V - 3~ - 50Hz) Table 4.9 : Common properties for air Table 4.10 : Data for the system cycle Table 4.11 : Table for the system cycle Table 4.12 : Data for calculate condenser and evaporator capacity Table 4.13 : Table for the condenser capacity Table 4.14 : Data for the evaporator capacity Table 5.1 : Data for evaporating temperature vs cooling capacity Table 5.2 : Data for evaporating temperature Vs cooling capacity Vs compression ratio Vs C.O.P Table 5.3 : Data for cooling capacity vs rate Table 5.4 : Data for condensing temperature vs depth Table 5.5 : Data for condensing temperature vs height 79 80 81 81 41 41 41 42 45 45 46 47 48 78 16 20 29 30 35 37 38 38 39 40

Table 5.5 : Data for condensing temperature vs width Table 5.6 : Data for condensing temperature vs rows of tube Table 5.7 : Data for condensing temperature vs tube per rows Table 5.8 : Data for evaporating temperature vs depth Table 5.9 : Data for evaporating temperature vs height Table 5.10 : Data for evaporating temperature vs width Table 5.11 : Data for evaporating temperature vs rows of tube Table 5.12 : Data for evaporating temperature vs tube per rows Table 5.13 : Data for condensing temperature vs length Table 5.14 : Data for evaporating temperature vs Length

82 82 83 83 84 84 85 85 86 87

xi

LIST OF FIGURES Page No. Figure 2.1 : The process of the scroll compressor Figure 2.2 : Suction tube brazing Figure 2.3 : Absorption of moisture in ester oil in comparison to mineral oil in [ppm] by weight at 25C and 50% relative humidity. h = hours. Figure 2.4 : Bottom shell temperature Figure 2.5 : Suction accumulator Figure 2.6 : Crankcase heater location Figure 2.7 : Internal discharge temperature protection Figure 2.8 : Effect of evaporator temperature on clearance volumetric efficiency and refrigerant mass flow rate Figure 2.9 : Effect of evaporator temperature on COP and volume flow rate per unit capacity (V) Figure 2.10 : Temperature Glide Figure 3.1 : Fill the data in the software Figure 3.2 : Select type of compressor Figure 3.3 : Export the data to Microsoft Excel Figure 4.1 : Air conditioning system component Figure 4.2 : Isometric view of condenser Figure 4.3 :Plant view of condenser Figure 4.4 :Side view of condenser Figure 4.5 : Front view of condenser Figure 4.6 : Isometric view of evaporator Figure 4.7 : Plant view of evaporator Figure 4.8 : Side view of evaporator Figure 4.9 : Front view of evaporator 26 27 31 32 32 44 59 59 60 60 71 71 72 72 22 10 12 14 14 15 9 9

xii

LIST OF GRAPHS Page No. Graph 2.1 : RXF-101 Perfomance at various condensing pressures Graph 2.2 : Compressor energy consumption vs condensing pressure Graph 2.3 : P-V diagram for different evaporator pressures and a fixed condenser pressure Graph 4.1 : Temperature vs capacity Graph 4.2 : Evaporating temperature vs capacity Graph 4.3 : Temperature vs capacity Graph 4.4 : Evaporating temperature vs capacity Graph 4.5 : Temperature vs density Graph 4.6 : Temperature vs specific heat Graph 5.1 : Evaporating temperature Vs cooling capacity Graph 5.2 : Cooling capacity Vs rate Graph 5.3 : Condensing temperature Vs depth Graph 5.4 : Condensing temperature Vs height Graph 5.5 : Condensing temperature Vs width Graph 5.6 : Condensing temperature Vs rows of tube Graph 5.7 : Condensing temperature Vs tube per rows Graph 5.8 : Evaporating temperature Vs depth Graph 5.9 : Evaporating temperature Vs height Graph 5.10 : Evaporating temperature Vs width Graph 5.11 : Evaporating temperature Vs rows of tube Graph 5.12 : Evaporating temperature Vs tube per rows Graph 5.13 : Condensing temperature Vs length Graph 5.14 : Evaporating temperature Vs Length 21 37 38 39 39 43 43 78 80 81 81 82 82 83 83 84 84 85 85 86 87 18 18

xiii

LIST OF CHARTS Page No. Chart 2.1 : How condensing temperature affects The size of the condenser Chart 2.2 : Effect of evaporator temperature on refrigeration effect on P-h diagram Chart 2.3 : Effect of evaporator temperature on refrigeration effect and refrigeration capacity Chart 2.4 : Effect of evaporator temperature on work of compression (hc) and power input to compressor (Wc) Chart 4.1 : Compressor cycle Chart 4.2 : System cycle Chart 4.3 : Condenser system cycle Chart 4.4 : Evaporator system cycle Chart 4.5 : Heat-transfer correlation for smooth plate-fin-tube coils Chart 4.6 : Effectiveness for counter-flow exchanger Chart 4.7 : Correlation of friction data for smooth plate-fin-coils Chart 4.8 : Friction factors for pipe flow Chart 4.9 : Heat-transfer correlation for smooth plate-fin-tube coils Chart 4.10 : Effectiveness for counter-flow exchanger Chart 4.11 : Correlation of friction data for smooth plate-fin-coils Chart 4.12 : Friction factors for pipe flow Chart 5.1 : Cooling capacity Vs compression ratio & C.O.P 24 40 44 47 48 51 54 56 58 63 66 68 70 79 23 23 16

xiv

xvi