Technological University of the Philippines

Ayala Boulevard, Ermita, Manila

College of Engineering
Mechanical Engineering

ACTIVITY 3: REFRIGERATION SYSTEM

PREPARED BY: MARIUS ERVIE APALIT

EARL LESTER JOHN CONCEPCION
JAMES VINCENT BARRAMEDA
SECTION: BSME 4D
SUBMITTED TO: ENGR. MANUEL EUROPEO
Objectives:

1. Understand the fundamental principles of refrigeration systems, including the

refrigeration cycle, heat transfer, and the role of refrigerants.

2. Identify and describe the key components of a refrigeration system, including the
compressor, condenser, expansion valve, evaporator, piping, controls, heat
exchangers, and intercooler.

3. Explain the operation of each component within the refrigeration cycle, including
compression, condensation, expansion, and evaporation.

4. Recognize the significance of proper maintenance practices in ensuring the

efficient operation and longevity of refrigeration systems.

5. Identify common issues and troubleshooting techniques related to refrigeration

systems, such as insufficient cooling capacity, compressor problems, refrigerant
leaks, ice formation, thermostat issues, condenser blockages, electrical problems,
oil contamination, and environmental factors.

6. Understand the concept of vapor locking in refrigeration systems, including its

causes, effects, and potential solutions.

7. Explore the diverse applications of refrigeration systems in various settings,

including domestic, commercial, and industrial environments, as well as their role
in food preservation, air conditioning, medical and pharmaceutical storage,
industrial processes, transportation refrigeration, and HVAC systems.

8. Gain insight into the importance of refrigeration systems in preserving perishable

goods, maintaining optimal conditions for sensitive products, supporting industrial
processes, and providing comfort cooling in buildings.

9. Recognize the environmental impact of refrigeration systems and the importance

of adopting eco-friendly refrigerants and sustainable practices in refrigeration
technology.
Intended Learning Outcome

Upon completion of this report, students will be able to:

1. Describe the fundamental principles underlying refrigeration systems, including

the refrigeration cycle and heat transfer mechanisms.

2. Identify and explain the functions of key components within a refrigeration

system, such as the compressor, condenser, expansion valve, evaporator, and
controls.

3. Analyze the sequential operation of components within the refrigeration cycle,

including compression, condensation, expansion, and evaporation.

4. Apply knowledge of refrigeration system components and processes to diagnose

common issues and propose appropriate troubleshooting techniques.

5. Recognize the significance of proper maintenance practices in ensuring the

efficiency and longevity of refrigeration systems.

6. Discuss the concept of vapor locking in refrigeration systems, including its

causes, effects, and potential solutions.

7. Explore diverse applications of refrigeration systems in various contexts, such as

domestic, commercial, industrial, and transportation settings.

8. Evaluate the role of refrigeration systems in preserving perishable goods,

supporting industrial processes, and providing comfort cooling in buildings.

9. Reflect on the environmental impact of refrigeration systems and consider the

importance of sustainable practices and eco-friendly refrigerants in refrigeration
technology.
Refrigeration System

A refrigeration system is a mechanical system designed to transfer heat from a

low-temperature area (typically the interior of a refrigerator or freezer) to a higher-
temperature area (usually the surrounding environment). It operates on the principles of
thermodynamics, specifically the refrigeration cycle, which involves the transfer of heat
using a refrigerant substance.

1. Compressor: The compressor is the heart of the refrigeration system. It is

responsible for compressing the low-pressure refrigerant vapor from the
evaporator to a high-pressure, high-temperature vapor. This compression
increases the refrigerant's temperature and pressure, making it easier to transfer
heat.

2. Condenser: The high-pressure, high-temperature refrigerant vapor leaving the

compressor then flows into the condenser. In the condenser, the refrigerant vapor
releases heat to the surrounding air or water, causing it to condense into a high-
pressure liquid. The condenser is typically a coil or series of coils with fins to
facilitate heat transfer.

3. Expansion Valve: After exiting the condenser, the high-pressure liquid refrigerant
passes through an expansion valve or throttling device. The expansion valve
reduces the pressure and temperature of the refrigerant, causing it to partially
vaporize and cool down as it enters the next component, the evaporator.

4. Evaporator: The low-pressure, low-temperature refrigerant mixture enters the

evaporator. Inside the evaporator, the refrigerant absorbs heat from the space
being cooled (e.g., the interior of a refrigerator). As heat is absorbed, the refrigerant
evaporates into a low-pressure vapor. This process cools the space while allowing
the refrigerant to return to the compressor to start the cycle anew.

5. Refrigerant: The refrigerant is the substance that circulates through the entire
refrigeration system, undergoing phase changes (vaporization and condensation)
as it absorbs and releases heat. Common refrigerants include chlorofluorocarbons
(CFCs), hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), and
more environmentally friendly options like hydrocarbons (e.g., propane, isobutane)
and natural refrigerants (e.g., ammonia, carbon dioxide).

6. Piping and Tubing: Refrigerant flows through a system of pipes and tubing that
connect the various components of the refrigeration system. These pipes must be
 appropriately sized and insulated to minimize heat gain or loss and prevent
refrigerant leaks.

7. Controls and Sensors: Modern refrigeration systems incorporate various controls

and sensors to monitor and regulate temperature, pressure, and other parameters.
Thermostats, pressure switches, and electronic controllers ensure the system
operates efficiently and maintains the desired conditions within the refrigerated
space.

8. Heat Exchangers: Heat exchangers are devices used to transfer heat between
two fluids without allowing them to mix. In a refrigeration system, the condenser
and evaporator act as heat exchangers, facilitating the transfer of heat between
the refrigerant and the surrounding air or water.

9. Intercooler: is a mechanical device used to cool air or gas between stages of

compression in a system. It is commonly used in applications such as internal
combustion engines, turbochargers, and refrigeration systems to improve
performance and efficiency. It serves a similar purpose but with refrigerant vapor
instead of air or gas. It cools the refrigerant vapor between stages of compression
to prevent overheating and improve the efficiency of the refrigeration cycle.

A refrigeration system works by continuously circulating refrigerant through a

closed loop, transferring heat from a cold space to a warmer space, thereby cooling the
desired area. This process enables the preservation of perishable goods, comfort cooling
in buildings, and various industrial applications.

The refrigeration cycle is the fundamental process that underlies the operation of
any refrigeration or air conditioning system. It describes the continuous circulation of a
refrigerant through four main stages or processes, during which the refrigerant
undergoes changes in temperature and pressure to transfer heat from one area to
another. The four primary components of the refrigeration cycle are the compressor,
condenser, expansion valve, and evaporator.

1. Compression: The cycle begins with the compressor, which draws low-pressure
refrigerant vapor from the evaporator and compresses it into a high-pressure, high-
temperature vapor. The compression increases the energy and temperature of the
refrigerant, making it easier to release heat in the subsequent stages.
 2. Condensation: The high-pressure, high-temperature refrigerant vapor exits the
compressor and enters the condenser. In the condenser, the refrigerant releases
heat to the surrounding environment (usually air or water). As the heat is removed,
the refrigerant condenses into a high-pressure liquid. The condenser typically
consists of coils or tubes with fins to facilitate heat transfer.

3. Expansion: After leaving the condenser, the high-pressure liquid refrigerant passes
through an expansion valve or throttling device. The expansion valve reduces the
pressure of the refrigerant, causing it to expand rapidly. This sudden expansion
results in a decrease in temperature and pressure, leading to a mixture of liquid
and vapor refrigerant at a lower temperature.

4. Evaporation: The low-pressure, low-temperature refrigerant mixture enters the

evaporator. Inside the evaporator, the refrigerant absorbs heat from the space
being cooled (such as the interior of a refrigerator or the air in an air conditioning
system). As heat is absorbed, the refrigerant evaporates into a low-pressure vapor.
This process cools the space while allowing the refrigerant to return to the
compressor to start the cycle anew.

The refrigeration cycle is continuous, with the refrigerant continuously circulating

through the system. Each stage of the cycle plays a crucial role in transferring heat from
a low-temperature area (the evaporator) to a higher-temperature area (the condenser),
allowing the refrigeration system to maintain the desired temperature within the
refrigerated space. By repeating this cycle, refrigeration systems can efficiently cool
spaces, preserve perishable goods, and provide comfort cooling in various applications.

Vapor Compression Cycle

The phase change in refrigeration involves the transition of a refrigerant between

different states of matter, such as from liquid to vapor or vice versa, within a
refrigeration system. One of the most employed refrigeration cycles is the vapor
compression cycle, extensively utilized in both household and commercial refrigeration
setups. Here, I'll elucidate the phase change within the vapor compression cycle,
accompanied by an illustrative diagram.
Compression (State 1 to State 2): The refrigerant initiates the process by entering the
compressor as a vapor at low pressure (State 1). Through compression, the vapor's
pressure and temperature escalate, a transformation often depicted as a vertical line on
a pressure-enthalpy diagram.

Condensation (State 2 to State 3): The ensuing high-pressure, high-temperature vapor

proceeds to the condenser. Within this component, heat is extracted from the
refrigerant, prompting its transition into a high-pressure liquid state (State 3). This
phase change liberates latent heat into the surrounding environment.

Expansion (State 3 to State 4): Subsequently, the high-pressure liquid refrigerant

traverses the expansion valve or throttle valve. Here, the valve precipitously reduces the
refrigerant's pressure, inducing a substantial decline in both temperature and pressure.
Consequently, the refrigerant undergoes partial evaporation, manifesting as a mixture of
liquid and vapor (State 4).

Evaporation (State 4 to State 1): Finally, the low-pressure, low-temperature refrigerant

enters the evaporator coil situated within the refrigerated space. Within this
environment, the refrigerant absorbs heat from its surroundings, transitioning entirely
into a low-pressure vapor (State 1). This phase transition, characterized by heat
absorption from the refrigerated area, facilitates cooling. The cycle then repeats itself.
Troubles in refrigeration processes
Troubles can arise due to various factors, including equipment malfunction,
improper maintenance, and environmental conditions. Here are some common troubles
encountered in refrigeration processes:

• Insufficient Cooling Capacity: If the refrigeration system is unable to provide

adequate cooling, it may fail to maintain the desired temperature in the
refrigerated space. This can be caused by factors such as low refrigerant levels,
compressor inefficiency, or inadequate insulation.

• Compressor Issues: Compressor problems, such as overheating, mechanical

failure, or refrigerant leakage, can significantly impact the performance of the
refrigeration system. Compressor issues may result from poor maintenance,
wear and tear, or electrical problems.

• Refrigerant Leaks: Leaks in the refrigeration system can lead to a loss of

refrigerant, which can impair cooling efficiency and increase energy
consumption. Refrigerant leaks may occur due to damaged components,
corrosion, or poor installation practices.

• Ice Formation: Excessive ice buildup on evaporator coils or other components

can restrict airflow and reduce cooling efficiency. Ice formation may be caused
by factors such as low refrigerant levels, inadequate defrosting, or poor airflow.

• Thermostat Problems: Malfunctioning thermostats can lead to temperature

fluctuations or inaccurate temperature control in the refrigerated space.
Thermostat issues may result from calibration errors, electrical faults, or sensor
damage.

• Condenser Blockages: Blockages in the condenser coils can impede heat

transfer and reduce the efficiency of the refrigeration system. Condenser
blockages may occur due to dirt, debris, or vegetation accumulation on the coils.

• Electrical Problems: Electrical faults, such as faulty wiring, blown fuses, or

tripped breakers, can disrupt the operation of refrigeration equipment. Electrical
problems may arise from wiring defects, power surges, or component failures.

• Oil Contamination: Contamination of the refrigeration system with oil or debris

can degrade system performance and damage components. Oil contamination
 may occur due to compressor wear, refrigerant leaks, or poor maintenance
practices.

• Environmental Factors: External factors such as high ambient temperatures,

humidity levels, or airborne contaminants can affect the performance of
refrigeration systems. Extreme environmental conditions may strain the system
and reduce its efficiency.

• Poor Maintenance Practices: Inadequate maintenance, such as infrequent

cleaning, lack of lubrication, or neglecting to replace worn components, can lead
to system failures and performance issues over time.

• Wet compression: liquid refrigerant enters the compressor along with the vapor
refrigerant. As the compressor operates, it compresses both the liquid and vapor
phases of the refrigerant mixture. This can occur in certain operating conditions
or system designs where liquid refrigerant is not properly evaporated before
entering the compressor.

• Vapor locking: in refrigeration systems occurs when the refrigerant vaporizes

prematurely, obstructing the normal flow of refrigerant through the system. This
phenomenon can lead to several operational issues and inefficiencies. Here's an
explanation of vapor locking:

Vapor lock

In refrigeration systems arises when refrigerant prematurely vaporizes,

impeding the regular flow of refrigerant throughout the system. This phenomenon
manifests in several operational effects: Throughout the evaporation process
within a refrigeration system, occurring within the evaporator component, the
refrigerant undergoes a transformation from liquid to vapor by absorbing heat
from the surrounding environment, which could be the air, or a substance intended
for cooling. At the onset of the evaporation process, prior to any liquid refrigerant
transitioning into vapor, the parameter "x" signifies 100% liquid, indicating the
absence of vapor, while "y" denotes 0%, denoting the lack of vapor presence.

As the evaporation proceeds and more liquid refrigerant converts into

vapor, the values represented by "x" and "y" adjust correspondingly. By the
conclusion of the evaporation phase, wherein all liquid refrigerant has transitioned
into vapor, "x" reflects 0%, signifying the absence of liquid, while "y" denotes 100%,
indicating the presence of vapor in its entirety.

This transition occurs due to the refrigerant absorbing heat from its
surroundings during the evaporation process, prompting the phase change from
liquid to vapor. This progression continues until all the liquid refrigerant has
transitioned entirely into vapor. Consequently, at the conclusion of evaporation,
the refrigerant solely exists in the vapor phase, leading to "x" being represented as
0%, and "y" as 100%.

Diminished Cooling Capacity: The disruption of refrigerant circulation by vapor

lock can result in reduced cooling efficiency, leading to insufficient temperature
regulation within the refrigerated environment.

Compressor Overheating: Vapor lock imposes added strain on the

compressor, causing it to overheat. Compressors are engineered to compress
liquid refrigerant, not vapor, and the energy-intensive compression of vapor can
elevate temperatures within the compressor.

Pressure Fluctuations: Vapor lock induces fluctuations in system pressure,

affecting overall stability and performance. These fluctuations may lead to
operational challenges and potential long-term damage to system components.

Inefficiency: Vapor lock compromises system efficiency, resulting in higher

energy consumption and increased operational costs. Moreover, this inefficiency
may necessitate more frequent maintenance and shorten the lifespan of
equipment.

Vapor lock tends to occur under specific conditions:

• Insufficient Refrigerant Levels: Low refrigerant charge heightens the risk

of vapor lock, as inadequate liquid refrigerant may fail to adequately cool
the compressor, impairing system function.

• Elevated Ambient Temperatures: High ambient temperatures prompt

refrigerant vaporization, particularly under heavy cooling demands or high
system loads.
 • Restricted Refrigerant Flow: Obstructions or constriction in refrigerant
lines, such as blockages or improperly sized components, obstruct
refrigerant flow and contribute to vapor lock.

• Defective Components: Malfunctioning or improperly calibrated system

elements, such as expansion valves or pressure regulators, can disrupt
refrigerant flow and distribution, exacerbating vapor lock.

The process of vapor locking in a refrigeration system occurs due to several

factors and involves the premature vaporization of the refrigerant, hindering its
normal flow within the system. Below are the key processes involved in vapor
locking:

1. Premature Vaporization: Under the influence of the conditions, the refrigerant

within the system may start to vaporize prematurely. This premature
vaporization occurs before the refrigerant reaches the intended point in the
refrigeration cycle where it should undergo controlled evaporation.

2. Obstruction of Refrigerant Flow: As the refrigerant vaporizes prematurely, it

can obstruct the normal flow of refrigerant within the system. The formation of
vapor bubbles or pockets can create blockages in the refrigerant lines,
impeding the circulation of refrigerant to critical components such as the
compressor, condenser, expansion valve, and evaporator.

3. Disruption of System Operation: The obstruction caused by vapor locking

disrupts the normal operation of the refrigeration system. The flow of
refrigerant is impeded, leading to inefficiencies in heat transfer and
temperature regulation within the system. This disruption can result in reduced
cooling capacity, compressor overheating, pressure fluctuations, and overall
system inefficiency.

4. Potential Damage and Performance Issues: Continued vapor locking can lead
to damage to system components and reduced system performance over time.
The compressor may experience increased stress and overheating due to the
compression of vapor instead of liquid refrigerant. Pressure fluctuations and
inefficient operation may also contribute to system wear and tear, increasing
the risk of component failure and costly repairs.
Application of Refrigeration system in various settings

• Domestic Refrigeration System - these systems are small and capacity, with a
simple design that is easy to install and operate making them suitable for
household settings. Domestic refrigerators are designed to maintain temperatures
between 0 to 4 degrees Celsius for storing perishable items such as fruits,
vegetables, dairy products, and meats. They usually have a single compressor and
refrigeration cycle, and are commonly equipped with features like adjustable
shelves, door storage, and temperature controls for user convenience. Domestic
refrigerators are usually compact in size and have a capacity ranging from 5 to 25
cubic feet, providing enough space for the storage needs of a typical household.
These systems often feature a single cooling zone, making them suitable for
residential use where precise temperature control is not critical.

• Commercial Refrigeration System - these systems are larger and have a higher
cooling capacity compared to domestic systems. They are designed to handle a
larger quantity of perishable goods like food and beverages and are used in a
higher usage environment such as malls, supermarkets, and restaurants. These
systems are available in various types such as reach-in coolers, walk-in coolers,
display cases, and blast freezers, depending on the specific requirements of the
business. Commercial refrigeration systems typically have multiple compressors,
evaporators, and temperature zones to cater to different storage needs. They also
come with advanced features like automatic defrosting, energy-saving modes, and
remote monitoring capabilities for better efficiency and control. Commercial
refrigerators typically have capacities ranging from 25 to 100 cubic feet or more,
with some larger units exceeding 200 cubic feet. These systems are equipped with
features such as glass doors, adjustable shelves, and high-capacity compressors
to meet the demands of commercial operations.

• Industrial Refrigeration System - these systems are the largest and have the
highest cooling capacity among the three categories with capacities ranging from
several hundred tons to several megatons exceeding domestic and commercial
refrigeration systems. They are complexly designed to handle large quantities of
food and other products and are used in high-demand environments. Industrial
refrigeration systems also often have advanced features such as remote
monitoring and control capabilities. Industrial refrigeration systems consist of
multiple compressors, condensers, evaporators, and cooling towers connected to
a network of pipes and ducts for efficient cooling and distribution. They are
designed to operate continuously at low temperatures (-30 to -40 degrees Celsius)
 to meet the stringent storage requirements of industrial processes and
applications. Typically used in industries such as food processing,
pharmaceuticals, chemicals, and cold storage warehouses, where the
preservation of large quantities of products is critical.

Refrigeration systems play a critical role in various aspects of our world,

ranging from preserving food and medicine to industrial processes and climate
control. Here are some common applications and components of refrigeration
systems:

• Food Preservation: Refrigeration systems are widely used in the food industry to
preserve perishable food items such as fruits, vegetables, dairy products, meats,
and seafood. Refrigerators and freezers in homes, supermarkets, restaurants, and
food processing facilities utilize refrigeration technology to maintain low
temperatures and extend the shelf life of food products.

• Air Conditioning: Refrigeration systems are essential for air conditioning in

residential, commercial, and industrial buildings. Air conditioning units use
refrigeration technology to cool and dehumidify indoor air, providing comfort and
maintaining optimal indoor air quality.

• Medical and Pharmaceutical Storage: Refrigeration systems are critical for

storing vaccines, medications, blood samples, and other temperature-sensitive
medical and pharmaceutical products. Proper temperature control is essential to
ensure the effectiveness and safety of these products, particularly vaccines that
require specific temperature ranges for storage and transportation.

• Industrial Processes: Refrigeration systems are utilized in various industrial

processes such as chemical manufacturing, petrochemical refining, food
processing, and cold storage warehouses. These systems help maintain specific
temperature conditions required for production, storage, and transportation of
goods and raw materials.

• Transportation Refrigeration: Refrigeration systems are integrated into

refrigerated trucks, vans, ships, and containers for transporting perishable goods
over long distances. These systems ensure that temperature-sensitive products
remain fresh and intact during transit.
 • HVAC Systems: Heating, ventilation, and air conditioning (HVAC) systems often
incorporate refrigeration technology for cooling purposes. Chillers, cooling towers,
and heat pumps are common components of HVAC systems used in large
buildings, industrial facilities, and data centers.

Conclusion

In conclusion, refrigeration systems play a vital role in our everyday lives by

preserving perishable items and maintaining optimal temperatures for various
applications, using basic processes involved in refrigeration systems: compression,
condensation, expansion, and evaporation. All of which work together to remove heat
from the air or substance being cooled. Troubles like vapor locking can occur in
refrigeration systems when air or non-condensable gasses become trapped in the
system, disrupting the process and reducing efficiency.

Refrigeration systems are categorized as domestic, commercial, and industrial.

Domestic refrigeration systems typically have smaller capacities and are designed for
personal use in homes with capacity ranging at five to 25 cubic feet. Commercial systems
are larger and cater to the needs of restaurants, supermarkets, and other businesses with
capacity ranging from 25 to 100 cubic feet and some reaching to 200 cubic feet. Industrial
refrigeration systems, on the other hand, are the largest and most powerful, used in
industries such as food processing, pharmaceuticals, and chemical manufacturing that
exceed the capacities of the previous refrigeration systems reaching more than 200 tons.