Principles of Mechanical Refrig 1

2012 Rocky Mountain ASHRAE Technical
Conference
Energy Use in
Refrigeration Systems
PRESENTED BY:
Scott Martin, PE, LEED AP

BD+C
Objectives
Understand mechanical refrigeration terms
Describe how heat is transferred and what methods
are primarily used in the refrigeration cycle
Describe the 4 principles of the refrigeration process
Explain the function of the 4 system components
Explain refrigerant properties
Section 1 Introduction
Definition of Refrigeration
refrigeration (n.)
Mechanical refrigeration is the process
of using a volatile fluid to absorb heat
from a lower temperature place, raising
the fluids pressure and temperature so
it can be rejected to a higher
temperature place
Section 1 Introduction
Basic Principals
Heat is a form of energy
First law of thermodynamics: Energy
can neither be created or destroyed
Heat flows from a higher temperature to
a lower temperature
Heat energy can move by one of three
methods of heat transfer
Three Types of Heat Transfer

Conduction Transfer by contact
Convection May be natural or forced

transfer by density currents and fluid motion
Radiation Transfer by electromagnetic waves
Mechanical refrigeration uses the first two.

Section 2 Basic Principles
Two Forms of Heat Energy

Sensible Heat
Associated with molecular movement
Measured with a thermometer
Latent Heat
Change of state
Latent heat of fusion (solid to liquid)
Latent heat of vaporization (liquid to gas)
Latent heat of sublimation (solid to gas)
Sensible Heat of Water

212
Temperature F
132
100
42
32
0 10
100
Enthalpy (Btu/lb)
180
Latent Heat
Total Heat (Enthalpy) = Sensible Heat + Latent Heat
212F
liquid
212F gas
Latent heat
cannot be
measured on
a thermometer
Change of State
Change of State
Latent Heat of Fusion
Latent Heat of Vaporization
1 lb ice
32 F
970 Btu/lb
32 F
144 Btu/lb
Temperature-Enthalpy Plot
Example:
R-718 (water)
1 pound at standard barometric pressure
Latent Heat of
Vaporization
L iq
u id
Latent heat
of fusion
970 Btu
32
Ic
e
Temperature F
212
-176
Subcooled Solid
-144
180
Enthalpy (Btu/lb)
(Sensible + Latent Heat)
1150
Superheat
Saturated Vapor
@ 212 F
Pressure is constant
@14.7 psia
Superheated
Vapor
@ 242 F
212 F
Water
Superheat
t2 t1 = 30 F
Temperature-Enthalpy Plot
Va
po
Superheated
Vapor
Saturated
Liquid
242
Latent Heat of
Vaporization
L iq
u id
Temperature F
212
Subcooled
Liquid
Saturated
Vapor
Condensation
Evaporation
32
Ic
e
1 Btu/lb
-176
-144
970 Btu/lb
180
0.45
Btu/lb
1150
Enthalpy (Btu/lb)
NOTE: THERE IS NO TIME ON THIS SCALE

1160
Rate of heat transfer

Btu is a measure of quantity
Btuh is a measure of quantity per unit of time (hour)
1 Ton of Ice
288,000 Btu
1 Day
1 Ton
= Btu
12,000
12,000 Btuh
1 hour
200 Btu
Latent heat of
fusion
144 Btu 2000 lb = 288,000 Btu

1 Min
Four Laws of System Operation

No Flow
70
70
212
70
70
So
me
Mo
re
Heat only moves from

higher temperature to
a lower temperature
Flo
w
32
Flo
w
70
The greater the difference

the greater the flow

1. Heat only moves from a
higher temperature to a
lower temperature
Sensible Heat
71 F
70 F
1 Btu / lb

lower temperature
2. A large amount of energy
is required to change the
state of matter
Latent Heat
Saturated
Vapor
212 F
212 F
970 Btu/lb
Change of
state occurs at
a constant
temperature

lower temperature
state of matter
3. The temperature and
energy required to change
state are a function of
pressure
Pressure Affects the Boiling Point

0 psig
5 psig
50 psig
212 F
227 F
298 F
970 Btu/lb
960 Btu/lb
912 Btu/lb
If we control the pressure, we control the boiling point

Measuring Pressure
Absolute Pressure Scales Compared
0 psia
in. Hg Abs
PRESSURE
14.696 psia
12.23 psia
PRESSURE
psia
29.921 in. Hg (sea level)

24.9 in. Hg
(5000 ft above sea level)
0 in. Hg
(no atmosphere)
0 psig = 14.696 psia

MERCURY
Refrigerant Boiling Points
-40 F
Water
212 F
HFC-134a
-15 F
HCFC-22
-41 F
HFC-410A
-62 F

lower temperature
state of matter
3. The temperature and
energy required to change
state are a function of
pressure
4. Fluid flow only occurs if a
pressure difference exists
Pressure Difference Creates Flow

Flow may be caused by:
Static pressure difference
Pressure difference
Mechanical work
Static
Pressure
Vapor
Suction

1. Heat only moves from a higher temperature
to a lower temperature
2. A large amount of energy is required to
change the state of matter
3. The temperature and energy required to
change state are a function of pressure
4. Fluid flow only occurs if a pressure
difference exists
The Mechanical Refrigeration Cycle
Four Components Are Required
3. Heat rejecting section

4. Pressure/
flow control
valve
1. Heat absorbing section

Section 3 The Mechanical Refrigeration Cycle
2. Vapor
pump
An Open Cycle
14.7
psia
AIR
Refrigerant
Under
Pressure
R410a
-60.8F
The Closed Cycle

Metering Device
Evaporator
Condenser
Compressor
2-Pressure Zone
Typical conditions
at peak load for:
120 F / 431.6 psia

120 F / 274.7 psia
HCFC-22
HFC-410A
Condenser
(Rejects Heat)
Hot Gas Line
Metering
Device
Evaporator
(Absorbs Heat)
45 F / 90.8 psia
45 F / 144.5 psia
Suction Line
Compressor
High Side
Low Side
Pressure-Enthalpy Diagram
Refrigeration Cycle
Saturated Condensing
SA
VAP T.
OR
LIFT
SA
LIQ T.
UID
PRESSURE
Pc
Ps
Saturated Suction
RE
ENTHALPY
Section 2 Basic Refrigeration Cycle
The Evaporator Absorbs Heat

60 F
All Vapor
AIR
Liquid and Vapor
80 F
Basic System Components

Every system has four
basic components
Evaporator
Absorbs the heat from
the space or the load
Mostly liquid refrigerant boils
(evaporators) in the tubes
as the heat load is absorbed,
changing to vapor often
with some superheat
Air out: 59.7 F db / 57.3 F wb
Cold
Mixture
45 F
90.8 psia
SET
55 F
90.8 psia
Evaporator
Air in: 80 F db / 67 F wb
Cold
Vapor
Refrigeration Cycle
SA
VAP T.
OR
LIFT
SA
LIQ T.
UID
PRESSURE
Pc
Ps
Saturated Suction
RE
ENTHALPY

Hot Vapor
120 F
274.7 psia
SDT
Compressor
SET
Evaporator
Compressor
SST
45 F
90.8 psia

basic components
Raises the pressure from the evaporator

pressure to the condensing temperature
and creates a pressure differential to
cause refrigerant flow
55 F
90.8 psia
Evaporator
Cold
Vapor
SA
VAP T.
OR
Pc
Tc
HEAD
LIFT
SA
LIQ T.
UID
TEMP
PRESSURE
Refrigeration Cycle
Ps
Ts
Saturated Suction
RE
ENTHALPY
COMP
Compressor Suction
Suction Line
HCFC-22
Causes flow by
creating a low
pressure area
90.8 psia & 45 F SST

90.8 psia & 55 F actual
HFC-410A
144.5 psia & 45 F SST
Actual
Actual is
is the
the
temperature
temperature with
with
superheat
superheat
Compressor Discharge
Hot Gas Line
Suction Line
HCFC-22
HCFC-22
274.7 psia & 120 F SDT

90.8 psia & 45 F SST

HFC-410A
HFC-410A
431.6 psia & 120 F SDT

144.5 psia & 45 F SST

High Side
Low Side
Compresses
Compresses the
the vapor
vapor
to
to raise
raise the
the pressure
pressure and
and
temperature
temperature above
above the
the
condensing
condensing temperature
temperature

Condenser
Air out: 115 F db
108 F
274.7 psia
120 F
274.7 psia
SCT
SDT
Air in: 95 F
SST
Evaporator
55 F
90.8 psia
SET
Evaporator
Compressor
Compressor
45 F
90.8 psia

basic components
Condenser
Rejects the heat from the load
and system losses
Highly superheated refrigerant
condenses in the tubes as heat load is
rejected and changes back to a
liquid and is subcooled
Refrigeration Cycle
Condenser
SA
VAP T.
OR
LIFT
SA
LIQ T.
UID
PRESSURE
Pc
Ps
Saturated Suction
RE
ENTHALPY
COMP
Example Air-Cooled
(HCFC-22) (HFC-410A)
95 F Air
R-22
R-410A
SCT 120 F
274 p
s
ia
Actual
Condensing
180 F
432 psia
Actual Liquid
108 F
Subcooling = ? F
Example Water-Cooled Condenser

LEAVING
DIFFERENCE
Hot Gas Line
To Tower 95 F
105 F SCT
Liquid Line
100 F Actual
From Tower 85 F
The Metering Device

TXV: Thermostatic Expansion Valve
HCFC-22
HCFC-22
274.7 psia & 120 F SCT

90.8 psia & 45 F SET

Low Side
High Side
HFC-410A
431.6 psia & 120 F SCT
TXV:
HFC-410A
144.5 psia & 45 F SET
- Controls the refrigerant flow rate

- Reduces the pressure of the refrigerant gas
- Refrigerant gas temperature is reduced
Refrigeration Cycle with Subcooling

SUBCOOLING
tc
SA
VAP T.
OR
SA
LIQ T.
UID
TXV
PRESSURE
Pc
Vgs
Ps
ts
RE
hfc
ENTHALPY
hgs
Refrigeration Cycle with Subcooling

SUBCOOLING
tc
SA
VAP T.
OR
SA
LIQ T.
UID
PRESSURE
Pc
Vgs
Ps
ts
Superheat
RE
hfc
ENTHALPY
hgs
Compressor Energy
SCT
SAT. LIQUID
Heat Rejection
si
pr
es
Reduced Lift
42
SST
on
82
Co
m
Pressure
97
Refrigerant Effect
(Capacity)
Enthalpy
SAT.
VAPOR

Condenser
Air out: 115 F db
108 F
274.7 psia
120 F
274.7 psia
SCT
SDT
Air in: 95 F
Evaporator
Compressor
Compressor
SST
Metering Device

basic components
Condenser
Metering Device
45 F
90.8 psia
Evaporator
55 F
90.8 psia
SET
Regulates the flow and decreases

the pressure from
condensing pressure to
evaporator pressure
Refrigeration Lines
Liquid Line
Evaporator Coil
Condenser Coil
Hot Gas
Line
Suction
Line
Other System Components

In addition to the four basic components, refrigeration systems
may have other components that enhance system safety,
performance, or reliability:
System protectors
Storage devices
Performance devices
System pressure regulators
Valves and solenoids
Temperature and pressure controls
Oil controls
Refrigeration Cycle Accessories

System Protectors
Filter-Driers
Normally in the liquid line
and sometimes in the suction line
Removes particles,water, acids, solids and sludge
Sight Glasses
Located in the liquid line
Indicates moisture and is sometimes used to determine charge
Mufflers
Located in the hot gas line
Reduces gas pulsations

Storage Devices
Accumulators
In the suction before the compressor
Used on heat pumps and long line
applications
Protects against liquid
returning to the compressor
Receivers
In the liquid line after the condenser
Not often used in comfort air conditioning
Stores refrigerant

Performance Devices
Desuperheaters
In the hot gas line after the condenser
Used in some heat pump systems
Heats water for domestic use
Subcoolers
In the liquid line after the condenser
Uses water to cool the
liquid refrigerant
Reduces flash gas
and increases efficiency
Economizers
Reduces flash gas
and increases efficiency

System Pressure Regulators
Outlet Crankcase Pressure
In the suction line after the condenser
Controls maximum outlet pressure
Used primarily in lowtemperature refrigeration
Prevents compressor overload
Inlet Evaporator Pressure

In the suction line
Controls minimum pressure
Used primarily in refrigeration
with multiple evaporators
Maintains consistent
suction pressure

System Pressure Regulators
Hot Gas Bypass
Located between the hot gas discharge line
and the TXV outlet
Admits a small amount of gas back to the
evaporator without going to the condenser
Provides stable low load operation
Head Pressure Control

at the condenser outlet
Regulates the condenser capacity
by allowing refrigerant to flood
the condenser tubes
Provides stable low ambient operation

Refrigerant Valves
Many locations
Controls flow
Holds refrigerant for capacity
control, off-cycle charge
control, and service
Hand
Solenoid Valves
Check Valves
Relief Valves
Special (defrost/heat reclaim)

Temperature and Pressure Controls
Many locations in the system
For system control and safety
Oil Controls
Located in the hot gas line
Assures oil return to the compressors
Not often used in comfort AC
Heat Pump System

A heat pump system has the same four basic components
but adds a Reversing Valve and Accumulator
Evaporator
Compressor
Condenser
Metering Device (2)
Reversing Valve
Accumulator
Heat Pump System

Ball Valve
TXV
4-Way
Valve
INDOOR COIL
OUTDOOR COIL
Check Valve
Compressor
Filter
Drier
Accumulator
Accurator
Cooling Mode
TXV
Heat Pump System

Ball Valve
TXV
4-Way
Valve
INDOOR COIL
OUTDOOR COIL
Check Valve
Compressor
Filter
Drier
Accumulator
Accurator
Heating Mode
TXV
Refrigeration Lines
Liquid Line
Evaporator Coil
Condenser Coil
Hot Gas
Line
Suction
Line
Indoor Coil Loading - Tons Per Circuit

Refrigerant velocity must be high
enough to keep compressor oil
entrained with refrigerant vapor.
EVA
TOR
A
R
PO
AI
RF
LO
W
TXV
Refrigerant paths
Minimum tons/circuit:
3/8 tubes = 0.4 tons/circuit
5/8 tubes = 0.6 tons/circuit
Section 3 System Components
Indoor Unit Refrigerant Circuits

Single Circuit
Distributor
Dual Circuit
Solenoid
LIQUID
LINE
TXV
LIQUID
LINE
TXV
Filter Drier
Distributor
Section 2 System Basics
Tons Per Circuit Example

Model
007
008
012
014
016
024
028
034
# of coil splits # of circuits/splits # of circuits total

12
12
1
15
15
1
18
9
2
18
9
2
24
12
2
26
13
2
30
15
2
36
18
2
Standard Unloaded capacity, 7 tons

ACCEPTABLE 7 tons/18 circuits = 0.4 tons/circuit
With additional unloading Unloaded capacity, 3.3 tons
TOO LOW! 3.3 tons / 18 circuits = 0.2 tons/circuit
Add capacity control solenoid valve
ACCEPTABLE Now 3.3 tons / 9 circuits = 0.4 tons/circuit
Section 3 System Components
Elevation
LIQUID LINE 1-2 ton UNITS
LIQUID LINE
UNIT
MAX
ALLOW.
LIFT
(ft)
012
014
016
024
65
67
82
87
Max Allow.
Pressure
Drop
(psi)
Max Allow.
Temp
Loss
(F)
NOTE: Data above is for units at 45 F saturated

suction and 95 F entering air.
LIQUID LIFT
Section 6 Installation
Suction Riser
Refrigerant velocity in
suction riser must be
high enough to entrain
compressor oil with the
refrigerant
Double suction riser or
reduced diameter riser
may be required
Consult manufacturers
recommendations
Refrigerant Piping (6-10 Ton, R-22)

UNIT
SIZE
Refer to manufacturers recommendations

DO NOT bury refrigerant piping underground!
Maximum Length of Refrigerant Piping
Piping length depends on the application

Heat pumps 100 linear feet
Consult manufacturers recommendations
Long Line Applications

LONG LINE = 75 LINEAR FEET OR LONGER
Lift vs. Run

LIFT
RUN
Long Lines Require:

1. Liquid line solenoid valve(s)
2. Suction line accumulator(s)
Refrigerants
What is a Refrigerant
A refrigerant is a fluid that absorbs heat and changes from vapor to liquid phase at
reasonable pressures and temperatures as encountered in mechanical refrigeration.
PRESSURE psia
F
Water
HCFC-22
HFC-410A
-40
0.00186
15.26
26
0.0185
38.73
40
0.122
100
CO2
Propane
7.43
145.77
16.1
64
21.62
305.80
38.4
82.28
132
49.70
567.50
78.6
0.950
210.70
340
138.80
188.6
130
2.225
311.60
500
213.40
273.3
212
14.696
*CP
*CP
587.20
*Critical Point, pressure psia
HFC-134a
What Makes a Good Refrigerant

Safe Efficient Stable Cost Effective Compatible
1.
Non-toxic and non-flammable
2.
Reasonable operating pressures
3.
Leakage resistance
4.
Large heat of vaporization
5.
Relatively low specific volume
6.
Low liquid specific heat (reduced flash gas)
7.
Easy to detect leaks
8.
Compatible with oils (vapor side)
9.
High coefficient of heat transfer
10. Easy to handle and cost effective

11. Non-corrosive and chemically stable
12. No Ozone Depletion Potential (ODP)
or Global Warming Potential (GWP)
Section 4 Refrigerants
Summary
Discussed mechanical refrigeration terms
Described how heat is transferred and
which methods are primarily used in the
refrigeration cycle
Described the four principles of the
refrigeration process
Explained the function of the four system
components
Listed characteristics of a good refrigerant
Section 5 Summary
2012 RM ASHRAE
Technical Conference
This completes the presentation.

Principles of Mechanical Refrig 1

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Principles of Mechanical Refrig 1

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2012 Rocky Mountain ASHRAE Technical

Scott Martin, PE, LEED AP

Three Types of Heat Transfer

Convection May be natural or forced

Radiation Transfer by electromagnetic waves

Mechanical refrigeration uses the first two.

Two Forms of Heat Energy

Sensible Heat of Water

Section 2 Basic Principles

Section 2 Basic Principles

Latent Heat of Vaporization

Section 2 Basic Principles

NOTE: THERE IS NO TIME ON THIS SCALE

Rate of heat transfer

144 Btu 2000 lb = 288,000 Btu

Four Laws of System Operation

Heat only moves from

The greater the difference

Four Laws of System Operation

Four Laws of System Operation

Four Laws of System Operation

Section 2 Basic Principles

Pressure Affects the Boiling Point

If we control the pressure, we control the boiling point

29.921 in. Hg (sea level)

0 psig = 14.696 psia

Refrigerant Boiling Points

Section 2 Basic Principles

Four Laws of System Operation

Pressure Difference Creates Flow

Four Laws of System Operation

The Mechanical Refrigeration Cycle

Four Components Are Required

3. Heat rejecting section

1. Heat absorbing section

Section 3 The Mechanical Refrigeration Cycle

The Closed Cycle

Section 3 The Mechanical Refrigeration Cycle

120 F / 431.6 psia

The Evaporator Absorbs Heat

Liquid and Vapor

Basic System Components

Air out: 59.7 F db / 57.3 F wb

Basic System Components

Air out: 59.7 F db / 57.3 F wb

Every system has four

Raises the pressure from the evaporator

90.8 psia & 45 F SST

Section 3 The Mechanical Refrigeration Cycle

274.7 psia & 120 F SDT

90.8 psia & 45 F SST

431.6 psia & 120 F SDT

144.5 psia & 45 F SST

Basic System Components

Air out: 115 F db

Section 3 The Mechanical Refrigeration Cycle

Every system has four

Example Water-Cooled Condenser

Hot Gas Line

Section 3 The Mechanical Refrigeration Cycle

The Metering Device

274.7 psia & 120 F SCT

90.8 psia & 45 F SET

- Controls the refrigerant flow rate