Professional Documents
Culture Documents
PLANT
Performance and Efficiency Test
ARCHINUE | DEL CASTILLO | GAÑOLO | LLAMERA | LLORENTE | MADRIDEO | NUYLES | OROZCO | PEÑAFLOR | SERRADO
01 Introduction to Refrigeration Plant
Definition | Components | Diagrams | Mass & Energy Balance
02 Performance Test
Definition | Methodology | Parameters | Indicator | Instruments
03 Sensitivity Analysis
Analysis Proper
04 Sample Problems
Applications | Equations | Variables | Solution
05 Cooling Tower
Definition | Function | Performance Test
06 Conclusion
How to improve the cycle efficiency?
INTRODUCTION
Refrigeration Plant
INTRODUCTION
𝑊 = 𝑚 ℎ2 − ℎ1 𝑉1 = 𝑚𝑣1
W = theoretical compressor power, kJ/s or kW V1 = volume flow rate, m3/s or L/s
h1 = enthalpy entering the compressor, kJ/kg v1 = specific volume of vapor, m3/kg or L/kg
h2 = enthalpy leaving the compressor, kJ/kg m = mass flow rate, kg/s
m = mass flow rate, kg/s
COMPONENTS
CONDENSER
The purpose of the condenser is to extract heat from the
refrigerant to the outside air. The condenser is usually
installed on the reinforced roof of the building, which
enables the transfer of heat. Fans mounted above the
condenser unit are used to draw air through the
condenser coils.
COMPONENTS
CONDENSER
The temperature of the high-pressure vapour determines the
temperature at which the condensation begins. As heat has
to flow from the condenser to the air, the condensation
temperature must be higher than that of the air; usually
between - 12°C and -1°C. The high-pressure vapour within
the condenser is then cooled to the point where it becomes a
liquid refrigerant once more, whilst retaining some heat. The
liquid refrigerant then flows from the condenser in to the
liquid line.
Shell-and-tube water-cooled condenser
Air-cooled condenser
CONDENSER
Mass and Energy Balance
Qr = m(h2 – h3)
Qc = total heat rejected, kJ/s
h2 = enthalpy entering the condenser, kJ/kg
h3 = enthalpy leaving the condenser, kJ/kg
COMPONENTS
EVAPORATOR
The purpose of the evaporator is to remove unwanted heat
from the product, via the liquid refrigerant. The liquid
refrigerant contained within the evaporator is boiling at a
low-pressure. The level of this pressure is determined by
two factors:
- The rate at which the heat is absorbed from the product
to the liquid refrigerant in the evaporator
- The rate at which the low-pressure vapour is removed
from the evaporator by the compressor
COMPONENTS
EVAPORATOR
To enable the transfer of heat, the temperature of
the liquid refrigerant must be lower than the
temperature of the product being cooled. Once
transferred, the liquid refrigerant is drawn from the
evaporator by the compressor via the suction line.
When leaving the evaporator coil the liquid
refrigerant is in vapor form.
Liquid chilling evaporator
EVAPORATOR
Mass and Energy Balance
Qe = (h1 – h4)
Qe = refrigerating capacity, kJ/s or Kw
h1 = enthalpy leaving the evaporator, kJ/kg
h4 = enthalpy entering the evaporator, kJ/kg
COMPONENTS
EXPANSION VALVES
It is located at the end of the liquid line, before the evaporator.
The high-pressure liquid reaches the expansion valve, having
come from the condenser. The valve then reduces the pressur
e of the refrigerant as it passes through the orifice, which is
located inside the valve. On reducing the pressure, the
temperature of the refrigerant also decreases to a level below
the surrounding air. This low-pressure, low-temperature liquid
is then pumped in to the evaporator.
Thermostatic
expansion valve
Schematic diagram
of basic
superheat-controlled
expansion valve
EXPANSION VALVE
Mass and Energy Balance
h3 = h4
REFRIGERANT
A refrigerant is a substance or mixture, usually a fluid, us
ed in a heat pump and refrigeration cycle. In most cycles
it undergoes phase transitions from a liquid to a gas and
back again. Many working fluids have been used for
such purposes.
How is the Operation of a Refrigeration Plant Controlled?
-10 108.6 1.943 0.1489 4.19 14.30 50.32 0.839 261.3 4.355
Saturated 110.8 1.904 0.1237 4.88 16.66 43.22 0.720 254.2 4.24
With
useful 123.5 1.709 0.1213 4.94 16.86 42.73 0.712 253.8 4.23
Cooling
Superheated
Without
Useful 110.8 1.904 0.1352 4.43 15.12 47.60 0.793 282.7 4.71
cooling
EFFECTS OF OPERATION CONDITIONS
Effects of superheating the suction vapor when
superheating produces useful cooling:
1. The refrigerating effect per unit mass increases.
2. The mass flow rate per ton decreases.
3. The volume flow rate per ton decreases.
4. The COP increases.
5. The EER increases.
6. The work per ton decreases.
7. The heat rejected at the condenser per ton increases.
EFFECTS OF OPERATION CONDITIONS
Effects of superheating the suction vapor when superheating
occurs without useful cooling:
1. The refrigerating effect per unit mass remains the same.
2. The mass flow rate per ton remains the same.
3. The volume flow rate per ton increases.
4. The COP decreases.
5. The EER decreases.
6. The work per ton increases.
7. The heat rejected at the condenser per ton increases.
SENSITIVITY ANALYSIS
Effects of subcooling the liquid
Mass
Compressor Condenser Condenser
Refrigerating flow Work per ton Work per ton
Volume Performance Performance
Liquid Effect rate per COP EER of refrigeration of refrigeration
Capacity (heat rejected) (heat rejected)
kJ/kg Ton kJ/min·ton kW/ton
m3/min·ton kJ/min·ton kW/ton
kg/min·ton
Saturated 110.8 1.918 0.1246 4.88 16.66 43.53 0.726 256.1 4.268
Subcooled 120.8 1.747 0.1135 5.32 18.16 39.66 0.661 250.7 4.178
EFFECTS OF OPERATION CONDITIONS
Effects of sub-cooling the liquid:
1. The refrigerating effect per unit mass increases.
2. The mass flow rate per ton decreases.
3. The volume flow rate per ton decreases.
4. The COP increases.
5. The EER increases.
6. The work per ton decreases.
7. The heat rejected at the condenser per ton decreases.
SOLVED PROBLEMS
Refrigeration Plant
A San Miguel Corporation processing plant that requires
cooling of 120 gpm of water from 15.6˚C to 10˚C, assume
that the cooler heat transfer surface area will enable a 5.5˚C
differential between the chilled water leaving the cooler and the
R-12 evaporating temperature. Also assume that the condenser
heat transfer surface area will enable a 5.5˚C differential
between the condenser water out and R-12 condensing
temperature. Water be available for the condensing medium at
29.4˚C inlet and 35˚C outlet. Assume no liquid subcooling or
suction gas superheating. Find the tons of refrigeration.
Given:
𝑔𝑎𝑙
V = 120
𝑚𝑖𝑛
𝑡1 = 15.6˚C
𝑡2 = 10˚C
𝑘𝐽
𝐶𝑝 = 4.187
𝑘𝑔 · 𝐾
Solution:
Refrigerating Load = m𝐶𝑝 ∆𝑡
𝑔𝑎𝑙 3.785 𝑙𝑖 1 𝑚𝑖𝑛
V = (120 )( )( )
𝑚𝑖𝑛 1 𝑔𝑎𝑙 60 𝑠
V = 7.57 L/s
7.57𝐿Τ𝑠
m=
1𝐿ൗ𝑘𝑔
m = 7.57 kg/s
∆t = 15.6˚C - 10˚C = 5.6˚C
Thus,
𝑘𝐽
Refrigerating Load = (7.57 kg/s)(4.187 )(5.6˚C)
𝑘𝑔·𝐾
= 177.51 kW
1 𝑡𝑜𝑛 𝑜𝑓 𝑟𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛
= (177.51 kW)
3.516 𝑘𝑊
Refrigerating Load = 50.49 tons of refrigeration
A refrigerant 22 vapor compression system includes a liquid-to-suction heat
exchanger in the system. The heat exchanger warms saturated vapor coming
from the evaporator from -10° to 5°C with liquid which comes from the condenser
at 30 ⁰C. The compressions are isentropic in both cases listed below:
a. Calculate the coefficient of performance of the system without the heat exchange
r but with the condensing temperature at 30 ⁰C and an evaporating temperature of
-10 ⁰C.
b. Calculate the coefficient of performance of the system with the heat exchanger?
c. If the compressor is capable of pumping 12.0 L/s measured at the compressor su
ction, what is the refrigeration capacity of the system without the heat exchanger?
d. With the same compressor capacity as in (c), what is the refrigerating capacity of
the system with the heat exchanger?
Given:
Refrigerant 22
Liquid-to-suction heat exchanger
Evaporator from -10 to 5 C
Condenser at 30 C
Required:
• Coefficient of performance of the system without the heat exchanger but with the
condensing temperature at 30 C and an evaporating temperature of -10 C.
• Coefficient of performance of the system with the heat exchanger?
• Refrigeration capacity of the system without the heat exchanger?
• Refrigerating capacity of the system with the heat exchanger?
Solution:
A. Without heat exchanger
At 1,6, -10 C, Table A-6. (Stoecker and Jones)
h1 = h6 = 401.555 kJ/kg
s1 = s6 = 1.76713 kJ/kg∙K
At 3, 30 C, table A-6
h3 = 236.664 kJ/kg
h3 – h4 = h1 – h6
h4 = h3 + h6 – h 1
h4 = 236.664 kJ/kg + 401.555 kJ/kg – 411.845 kJ/kg = 226.374 kJ/kg
h5 = h4 = 226.374 kJ/kg
𝑘𝐽 𝑘𝐽
ℎ6 − ℎ5 401.555 − 226.374
𝑘𝑔 𝑘𝑔
𝐶𝑂𝑃 = = = 5.38
ℎ2 − ℎ1 𝑘𝐽 𝑘𝐽
444.407 − 411.845
𝑘𝑔 𝑘𝑔
C. Refrigerating capacity without heat exchanger
At 1, v = 65.3399 L/kg
𝐿
12.0 𝑠
Refrigerating Capacity = 𝐿 ℎ6 − ℎ5
65.3399 𝑘𝑔
𝐿
12.0 𝑠
= 𝐿 (401.555 kJ/kg – 236.664 kJ/kg) = 30.3 kW
65.3399 𝑘𝑔
Performance Testing
© Company: GTPL or Gactel Turnkey Projects Limited
PERFORMANCE TEST
A.Condition of equipment
1. At the time of test, the tower shall be in good
operating condition. Tower may be inspected and
repaired, (if necessary) by the contractor, before the
test to ensure following.
GENERAL CONDITIONS
B. Operating Conditions
1. The test shall be conducted within the following li
mitations.
GENERAL CONDITIONS
2. Every effort shall be made to run the test under
design conditions or as close to design conditions as
possible.
GENERAL CONDITIONS
C. Duration of Test
After reaching steady state conditions the duration of
test run shall not be less than one hour.
For mechanical –draft towers, duration of the test
run shall be not less than one hour, if thermal leg
time is greater than five minutes, the time test period
shall be at least one hour plus thermal lag.
GENERAL CONDITIONS
D. Frequency of Test
Test readings shall be taken as per following schedule.
GENERAL CONDITIONS
E. Constancy of Test condition
For a valid test verifications in the test condition shall be
within the following limits.
a. Circulating water flow not varies by more than 2%.
b. Heat load shall not vary by more than 5%.
c. Range shall not vary by more than 5%.
d. WBT 1 ⁰C per Hour.
e. DBT 3 ⁰C per Hour.
GENERAL CONDITIONS
F. Test Instruments and their locations
1. Water flow measurements:
Water flow measurements can be made any of the following means.
- Pitot tube.
- Orifice plate.
- Venturi meter/ UFM’s.
- Weit
- Measurement of flow through single nozzle.
By measuring pump parameters or by pump manufacturer curves.
GENERAL CONDITIONS
2. Wet bulb temperature measurements:
The measurement of inlet WBT is required for the testing of all t
ypes of cooling towers covered by this code.
WBT measurements shall be made by mechanically aspirated
Psychrometer or by sling psychrometer.
At each time four successive readings shall be made at four diff
erent stations located within 1.5 m of the air intake(s). Average
of these four readings will give a final reading for that time.
GENERAL CONDITIONS
3. Water temperature measurements:
Water temperature measurements shall be made by
resistance. Thermometer or mercury in glass thermometers th
e indicator of which shall not be guaranteed in increments of n
ot more than 0.1 ⁰C.
a. Hot circulating water temperature measurements shall be m
ade tower riser or at outlet of tower riser on top of the tower.
b. Cold Circulating water temperature measurement shall be
made in cold water basin.
GENERAL CONDITIONS
G. Report of Result.
Recorded data during test will be co-related with perf
ormance with performance Curves of cooling tower a
nd report will be submitted in a month
CONCLUSION
Refrigeration Plant
Significant amounts of energy are consumed by refrigeration/air-conditioning
systems. An energy-saving approach that can be applied to new or existing
refrigeration/air-conditioning installations is discussed to increase system
performance and reduce energy consumption. It consists of adding a
mechanical sub-cooling loop to a conventional vapor-compression cycle.
The performance of a modified system is demonstrated for three different
applications. It was found that the system performance peaks at a
sub-cooler saturation temperature midway between the condensing and
evaporating temperatures. Simulations show that performance improvement
for air-conditioning systems can be as high as 20% during peak periods of
high condensing temperatures whereas high-temperature and
low-temperature refrigeration systems under these same conditions will
provide energy-savings of 20 and 40%, respectively.
fin