IIT, Bhilai

VIT,Vellore

Industrial Training Report

at
CARRIER MIDEA INDIA Pvt. LTD. (AN AIR CONDITIONING SYSTEM)(BAWAL)
Plot no.10, Sector-5, Bawal, Rewari-123501, and Haryana
 ACKNOWLEDGEMENT

I would like to thank Mr. P(Sr. Mgr LC AC) for their unflinching desire to know what
was going on in my projects and for those millions of opportunities he gave to share his
ideas and knowledge in a variety of settings. I am highly thankful to him that in spite of
his demanding professional preoccupation he always made himself available for
guidance and assistance to me in my project works. Working under his able guidance
was not only a learning experience for me but also provided me an insight into the work
culture of such a colossal organization.
I would also like to thank R&D (AC) department specially Mr. Sandeep Thakur, Mr.
Manikandan M. for always making me feel as a team with them & helped me in
increasing my knowledge & understanding of working in an organization. I am grateful
to these for their unending support and for all those good times we shared.
The acknowledgement will not be complete without a vote of thanks to all other
employees of CMI who helped me in one way or the other in completion of my training
and the project.
I extended my heartful thanks to Dr. Sivakumar, DEAN VIT Chennai,
Dr.Sreekanth Dondapati, Program Chair(Mechanical Engineering) and
Dr. Jeyanthi S. (Proctor) for providing this opportunity to carry out two
months industrial training.
 CONTENTS

1. CMI INTRODUCTION
2. CMI HISTORY
3. BRAND IDENTITY
4. CMI PRODUCTS
5. MANUFACTURING PROCESS OF INDOOR UNIT OFSPLIT A.C.
6. MANUFACTURING PROCESS OF OUTDOOR UNIT OF SPLIT
A.C.
7. THEORY OF R&D RAC AT CMI INDIA
8. BASIC OF AIR CONDITIONING
9. PHYCHOMETERIC CALORIMETER
10. CALORIMETER TESTS
11. NOMENCLATURE OF BEE MODEL
12. PROJECTS & OTHER ACTIVITIES.
ABOUT CMI

With a view to combine the strengths of two stalwarts of the global air-conditioning industry,
Carrier and Midea Group have partnered which led to the formation of Carrier Midea India
Private Limited (CMI).
Aiming to be a leading participant in the home appliance segment in India, CMI is a 40:60
Joint Venture between Carrier and Midea. The venture brings together Midea’s world class
design and manufacturing expertise in residential air conditioning coupled with Carrier India’s
strong pan-India distribution network.
CMI, commenced operations in 2012 at its new manufacturing facility situated at Bawal,
Haryana about 60kms from Gurgaon. Spanning approximately 150,000 sq. ft., the plant is one
of India’s largest manufacturing facilities for air conditioners with an initial annual flat volume
production capacity of 7,00,000, which will be expanded to 1,000,000 units. With an
investment of Rs. 500 crore over a five to six year period, Carrier Midea India will further
strengthen its position in the residential air conditioning and white goods market in India.

ABOUT CARRIER

When Willis Carrier invented the first system for “manufactured weather” in 1902, he sparked
an industry that revolutionized the way in which we live, work and play. From that defining
moment – and through to the present day – Carrier has been a company built on a legacy of
innovation. For more than a century, our research, expertise and forethought have resulted in
market-leading innovations and “firsts” that have shaped and defined the heating, air
conditioning and refrigeration industry. Through our history of product excellence and
committed customer service, we have evolved into a global company serving millions of people
and businesses in 172 countries on six continents around the world.
ABOUT MIDEA
Established in 1968, Midea Group is a comprehensive and modern business conglomeration
engaged mainly in the industry of household appliances, as well as the domains of real estate
and logistics. The group is also one of the largest manufacturing and exportation bases of
electric appliances in China. In 1980, Midea entered into the household appliance industry. In
1981, the brand "Midea" was created and used. In 2001, Midea transformed into a private
business. And in 2004, Midea procured the Hefei joint venture of Royalstar-Maytag
(ROYALSTAR) and the Guangzhou Hualing group (HUALING), continuing on the way to
become an electric appliance giant. Midea Group currently has 70,000 employees, with a
dozen brands including Midea and Welling. Apart from our headquarters in Shunde
(Guangdong Province), we have also ten major production bases in Guangzhou (Guangdong),
Zhongshan (Guangdong), Wuhu (Anhui), Wuhan (Hubei), Huai'an (Jiangsu), Kunming
(Yunnan), Changsha (Hunan), Hefei (Anhui), Chongqing (Chongqing),Suzhou (Jiangsu), and
Binh Duong Province (Vietnam) covering a total area of seven million square meters. Our
marketing network covers all over the world, and we have a dozen branches in the United
States, Germany, Japan, Hong Kong, South Korea, Canada and Russia.

CMI OPERATIONS
Employee Strength: The current employee strength is over 300 professionals. Many have
moved from Carrier India and Midea’s existing employee base to form the core operatives of
CMI. The initial employee base was further strengthened by induction of experienced
professionals hired from diverse business backgrounds.

FACTORY
Currently CMI has one manufacturing facility in Haryana. The new factory is spread across
approx.1,50,000sqft. of area. The facility has an initial annual flat volume production capacity
of 7,00,000, which will be expanded to 1,000,000 units.

QUALITY
Quality & Assurance are the key pillars for the organization. High standards for quality and
processes are ensured for all the products offered by us which undergo mandatory 100% quality
check at the production stage.
ENVIRONMENTALLY RESPONSIBLE
The factory is an environmentally responsible facility with 100 percent recycled water, rain
water harvesting, evaporative air-cooling in production areas and maximum use of natural
lighting on the shop floor to save energy.

SALES AND DISTRIBUTION

The existing network of channel partners is over CMI has an extensive network of more than
600 sales and service dealers coupled with over 1000 distributors and retailers throughout the
country.
CMI has 21 sales offices across India.

PRODUCT RANGE

The air conditioners would be available across all BEE star labels
The range would include window and split AC in the residential segment
Light commercial segment includes Inverter AC, cassette, VRF, floor standing, ceiling and
floor and ducted air conditioners
Microwave ovens
Water Dispensers

HEADQUARTERS
1st Floor, Pearl Tower, Plot No.51, Institutional Area, sector 32, Gurgaon – 122001, Haryana
AIR CONDITIONER

It is a device having series of operations in which the refrigerant absorbs the Heat from inside
the room ,absorbed heat is rejected from the refrigerant in to Atmosphere and there by the
refrigerant is back to the original state to again remove the heat from inside the room. this cyclic
operation continues to Maintain the low temperature in the room though air purity has no effect
on the comfort or warmth or cold to the human body, however, it is controlled for health
reasons. Air conditioning includes both the cooling and heating of air. It also cleans the
air and controls the moisture level.

An air conditioner is able to cool a building because

it removes heat from the indoor air and transfers it
outdoors. A chemical refrigerant in the system
absorbs the unwanted heat and pumps it through a
system of piping to the outside coil. The fan,
located in the outside unit blows outside air over
the hot coil, transferring heat from the refrigerant
to the outdoor coil
 BASICS OF AIR – CONDITIONING

AIR CONDITIONING:
Air conditioning is defined as the simultaneous and effective control of temperature,
humidity, air motion and air purity. OR Keeping the room air in an optimum condition,
depending on the use or purpose (cooling, heating, humidity regulating, air cleaning, etc).

AIR CONDITIONER:
• It is a device having series of operations in which the refrigerant absorbs the heat from
inside the room, the absorbed heat is rejected from the refrigerant into the atmosphere and
thereby the refrigerant is back to the original state to again remove the heat from inside the
room. This cyclic operation continues to maintain the low temperature in the room

• Through air purity has no effect on the comfort or warmth or cold to the human body,
however, it is controlled for health reasons.

TYPES OF AIR CONDITIONER

ACCORDING TO FUNCTION:
1. Cooling
2. Cooling+Heating(Electric Heater)
3. Cooling+Heating(Heat Pump)
 ACCORDING TO INSTALLATION

FOUR ELEMENTS OF AIR-CONDITIONING:-

1. TEMPERATURE:The dry bulb temperature by cooling or heating room air.

2. HUMIDITY:A comfortable humidity condition of room air is generally kept by the

relative humidity of air and the room air is controlled into a given relative humidity condition.

3. DEGREE OF PURITY:Remove dust in the air ,and keep smoke from the exceeding
the allowable degree of concentration.

4. AIR MOTION:To disperse properly the air regulated in temperature, humidity and the
degree of purity into indoor ,make an appropriate air flow and keep uniformly the temperature/
humidity condition of room unit.
 OPERATING PRINCIPLE OF AIR –CONDITIONER

A - Hot air to Outside

B - Fan to help improve heat transfer from coils to outside.
C - Fan for more efficient transfer of cool air to inside.
D - Expansion Valve
E - Compressor
F - Cool Air to Inside

A refrigerant such as R-22 mixed with a small amount of a lightweight oil (to lubricate the
compressor) is compressed by the compressor causing it to become a hot, high pressure gas,
this hot gas runs through a series of coils (the red coils in diagram) and with the help of the
fan dissipates this heat to the outside. In this process the Freon cools and condenses into a
liquid which then runs through an expansion valve, at which point the liquid evaporates to
become cold low pressure gas (blue coils in diagram). Going through another series of coils
and with assistance of a second fan, absorbs the heat and thereby cools the inside of the
building.

The cooling coils (blue) causes moisture in the warmer inside air to condense into water
which drips and runs to the outside of the building, this condensation process lowers the
humidity on the inside. This condensation principle is also how de-humidifiers work.

Refrigerators work on the same principle, the red portion of the coils run up the outside rear
of the refrigerator and the blue portion of the coils run inside the insulated walls of the fridge.
To cool down the freezer portion of the fridge cooler than the rest of the fridge, more coils are
run in that area than thru other parts of the refrigerator
This is all a basic description of how air conditioners work, in real life , thermostats are added
to set desired temperature, protection devices to protect the compressor from overheating.

If inadequate or obstructed air vents on the air conditioner can cause the unit to severely ice
up to the point where air flow is blocked. If this happens shut down the unit and let the unit
defrost completely, sometimes you can select to have the fan to run (without running the
compressor) to speed the defrost process. Once defrosted, ensure that no blockage of air flow
exists. Things like drapes or curtains that cover the inside front of the air conditioner is enough
to impede air flow and cause it to ice up. A very close dresser in some circumstance can also
have an effect on air flow.

For a central air conditioner, the compressor and the red coils ( as illustrated in the diagram)
sit in an outside unit , the blue coils (as illustrated in the diagram) is installed in the forced air
plenum of the furnace, the fan inside the furnace is used help in transfer of heat to the coils
and allowing the cooler air to be forced into the interior of the house.
 REFRIGERATION CYCLE

It explains how an air conditioner works in a closed loop. Refrigeration is accomplished by

continuously circulating, evaporating and condensing a fixed supply of refrigerant in a closed
system.
 BASIC COMPONENTS

COMPRESSORS

The compressor, which is controlled by the thermostat, is the heart of the system.
The compressor acts as the pump causing the refrigerant to flow through the system.
Its job is to draw low pressure, low temperature refrigerant in a gaseous state and by
compressing this gas, raise the pressure and temperature of the refrigerant. The high
pressure, high temperature then flows to the condenser coil.

Types Of Compressors

1. Centrifugal compressors
2. Reciprocating compressors
3. Rotary compressors
4. Scroll compressors
 CONDENSER:
The condenser coil is a series of piping with a
fan that draws outside air across the coil. As the
refrigerant passes through the condenser coil
and the cooler outside air passes across the coil,
the air absorbs heat from the refrigerant, which
causes the refrigerant to condense from a gas to
a liquid state. The high pressure, high
temperature liquid then reaches the expansion
valve.
The condenser is generally of Fin and Tube type.
Fins are used to increase the
effective heat transfer area. Two type of coatings is
done on condensers in Air
Conditioners, one is Hydrophilic coating and another is Anti- Corrosive coating.

In some Air conditioner sub cooling is also provided to get maximum heat transfer.
An advantage resulting from using a liquid line is that additional sub cooling occurs
prior to entering the capillary tube. As the calorie emitted from the condenser is the
sum of refrigerating effect(Re) and the heat equivalent of work. (Al)
Calorie of condensation = Re + Al
= (Enthalpy at COND IN) - (Enthalpy at COND OUT)

EXPANSION VALVE:
Capillary Tube: The expansion valve is the brain of the system, by sensing the
temperature of the evaporator or cooling coil, it allows liquid to pass through a very
small orifice, which causes the refrigerant to expand to a low pressure, low
temperature gas. This cold refrigerant flows to the evaporator.

The capillary tube is a simple, cost effective and most commonly used throttling
device used in Air conditioners. It is a small diameter tubing of considerable length
which offers restrictions and meters the refrigerant flow. The length and bore of
capillary are the major controlling factors in balancing the refrigeration cycle.
Resistance to flow = resistivity * length / Cross-sectional area
Resistance to flow µ Length of capillary
µ 1 / Cross sectional Area

CAPILLARY FLOW RATE CHART

 EVAPORATOR COIL:
It is the cooling coil of the Air
conditioner. The work done by the
evaporator is called Refrigeration Effect.
Here the refrigerant material heats up and
boils which creates vapors. The cooling of
Eva coil is done by Forced Convection.
The evaporator is of fins and tube type,
where the louvered fins are used to get the
maximum heat transfer from the coil.

The evaporator coil is a series of piping connected to a furnace or air handler that blows indoor
air across it, causing the coil to absorb heat from the air. The cooled air is then delivered to the
house through the ductwork. The refrigerant flows back to the compressor and the cycle start
all over again.

CMIL itself manufactures the Evaporator and Condenser coils.

 ACCESSORIES

ACCUMULATOR:
A kind of liquid refrigerant separator which prevents the liquid
refrigerant from sucking into compressor and is installed in the
suction inlet of compressor.

DRIER:
Any moisture in refrigeration cycle may cause the compressor
motor to be damaged or the refrigerant to be in ice state in the
middle of cycle, which blocks the flow of refrigerant. Drier is
installed in a cycle for the purpose of removing such moisture.
There are two types of driers: liquid line drier which is connected
serially to the condenser outlet and a suction line dryer which is
connected serially to the suction line, with a desiccate in drier.
The drier is designed for uni-directional flow of refrigerant.

STRAINER:
Strainer serves to remove foreign substances from refrigerant by a
metal net pelt of fine grid or a glass wool being inserted into metal
vessel and refrigerant being passed through between the interval. The
strainer is mounted between condenser and the expansion valve.

FAN:
Serves to blow air through condenser and blow put the heat generated
with refrigerant liquefied in condenser, its structure is similar with a
motor fan.
 BLOWER (Cross flow fan :CFF)

Suck room air, blow into evaporator, make evaporator absorb the heat
and disperse the cooled air into room. Blower is placed indoor unit,
so a small size, high wind flow and low noise type is used.

MOTOR:

Drive a rotating force by electric power and supply the the driving force
to fan and blower in both indoor and outdoor air conditioner

CAPACITOR:

Supply a driving torque to the compressor motor or fan motor for

aircon and make the operating efficiency better during operation.
 Air Conditioning
Manufacturing Process
(Indoor unit)
The Air-conditioning Manufacturing Process and use the part name
and work.

1. Base Pan Loading:-

The main part in air-conditioning is the base pan loading. The
base pan loading is support all part in use air-conditioning
system. e.g.-
 Evaporator coil.
 Blower.
 Blower motor
 Control box

Base Pan Loading

2. Blower:-
Suck room air, blow into evaporator, make evaporator absorb the heat and disperse the
cooled air into room. Blower is placed indoor unit, so a small size, high wind flow and low
noise type is used.
Blower

Blower

3. Blower motor:-
Drive a rotating force by electric power and supply the driving force to fan and blower in
both indoor and outdoor air conditioner.

Blower
motor

Blower motor
4. Evaporator Coil:-
An evaporator coil works in tandem with an air conditioner. As heat
is exchanged, there is also aprocess of dehumidification taking
place. As a result, moisture in your airstream condenses on thecoil
and drips into the drain pan. Modern design provides long-term use
and durability. Materials areused to limit the corrosive effects of
indoor pollutants on the metals used in the coils. Yourevaporator
coil is an essential part of your forced air cooling system.

Evaporator Coil

5. Stepper motor:-
A stepper motor is a brushless, synchronous electric motor that
converts digital pulses into mechanical shaft rotation. Every
revolution of the stepper motor is divided into a discrete number of
steps, in many cases 200 steps, and the motor must be sent a
separate pulse for each step. The stepper motor can only take one
step at a time and each step is the same size. Since each pulse causes
the motor to rotate a precise angle, typically 1.8°, the motor's
position can be controlled without any feedback mechanism. As the
digital pulses increase in frequency, the step movement changes into
continuous rotation, with the speed of rotation directly proportional
to the frequency of the pulses. Stepper motors are used every day in
both industrial and commercial applications
because of their low cost, high reliability, hightorque at low speeds
and a simple, rugged construction that operates in almost any
environment.

Steeple
motor

6. Air out-let:-
The air out-let drives is used in air-conditioning system to change
the direction of air with the help of rotation of stepper motor and it
is also used for spreading the in whole room. This part is made up
of fibers. There are two air out-let used in the system.

Air out-let
7. Control box:-
The control box is main part in air-conditioning system. The control
box is also control compressor, fan, and motor etc.

Control box

8. E.S.T (Electric safety test):-

The electric safety test is most importent process in air-conditioning
system. The E.S.T checks point.
1. Earth check
2. Insulation resistance
3. High voltage
4. Leakage current

9. Run testing:-
After assemble of stepper motor, blower, evaporator
coil and control box. We check the flow current. The current is
flowing each and every part is not and we keep any dangerous
regarding to current.
10. Middleframe:- The middle frame is most
part in the air-conditioning system. The middle frame is use to the
cover evaporator coil, blower & control box.

11. Fillter:-
A particulate air fillter is a device composed of fibrous materials
whichremoves solid particulates such as dust, pollen, mold, and
bacteria fromthe air. A chemical air filter consists of an absorbent or
catalyst for theremoval of airborne molecular contaminants such as
volatile organiccompounds or ozone. Air filters are used in
applications where air qualityis important, air-conditioning system.
Air filters
12. Panel fitting (top panel):-The top panel is
the last component in the assembly part in the air-conditioning
system. the top panel are cover the filter.

Top panel

13. Sound test:-

Indoor Noise Level Measurement. All the effort in designing the indoor
HVAC system with care andthought might be wasted if installation
and commissioning of theequipment is not proper. The following
check points shall be followedto determine if the total noise level in
occupied areas within thebuilding exceed the limits as specified in the
General Specification orthe Particular Specification.
 Air Conditioning Manufacturing Process
(Outdoor unit)
The Air-conditioning Manufacturing Process and use the part name
and work.

1.Base Pan Loading:-

The mean part in air-conditioning is the bass pan loading. The
bass pan loading is support all part in use air-conditioning. Ex-

1. Compressor
2. Condenser coil
3. Brackets-(Motor holder)
4. Casing (All panel set in the body)

BASE PAN LOADING

 2. Compressor:-
The compressor, which is controlled by the thermostat, is the heart
of the system.The compressor acts as the pump causing the
refrigerant to flow through the system.
Its job is to draw low pressure, low temperature refrigerant in a
gaseous state and by compressing this gas, raise the pressure and
temperature of the refrigerant. The high pressure, high temperature
then flows to the condenser coil.

Port
Accumulato
r

COMPRESSOR

3. Condensor coil:-
The condensorcoil is a series of piping with afan that draws outside
air across the coil. As therefrigerant passes through the condensor
coiland the cooler outside air passes across the coil,the air absorbs
heat from the refrigerant, whichcauses the refrigerant to condense
from a gas toa liquid state. The high pressure, hightemperature
liquid then reaches the expansionvalve.
The condensor is generally of Fin and Tube type.
Fins are used to increase theeffective heat transfer area. Two type
of coatings is done on condensers in AirConditioners, one is
Hydrophilic coating and another is Anti- Corrosive coating.

In some Air conditioner sub cooling is also provided to get maximum

heat transfer.An advantage resulting from using a liquid line is that
additional sub cooling occursprior to entering the capillary tube. As
the calorie emitted from the condenser is thesum of refrigerating
effect (Re) and the heat equivalent of work.

Condensor coil

Condensor coil
Fin: -A fin is a thin component or appendage attached to a
largerbody or structure. Fins typically function as foils thatproduce
lift or thrust, or provide the ability to steer orstabilize motion while
traveling in water, air, or other fluidmedia. Fins are also used to
increase surface areas for heattransfer purposes, or simply as
ornamentation.
4. Valve (Suction & Discharge line):-
The suction and discharge
line is connecting the compressor and condenser. With capillary
tube and accumulator.
Valve Suction
Gromme Plate Valve
Discharge
t Valve
Discharge
Discharge

Discharg
e Valve

Suctio
n
5. Capillary tube:-
Capillary tube is one of the most commonly used throttling devices
in the refrigeration and the air condition-ning systems. The capillary
tube is a copper tube of verysmall internal diameter. It is of very
long length and it is coiled to several turns so
that it would occupy less space. The internal diameter of the
capillary tube used forthe refrigeration and air conditioning
applications varies from 0.5 to 2.28 mm (0.020 to 0.09 inches).
Capillary tube used as the throttling device in the
domesticrefrigerators, deep freezers, water coolers and air
conditioners.

Capillary tube

6. Brazing:-
Brazing is a process intended to permanently join two or more
metals/materials together to form a single assembly by heating
them in the presence of a filler metal that begins to melt above
450° C (840° F). The liquid filler metal is then drawn into the gap
between the closely fitted facing surfacesOf the joint by capillary
action.

Brazing is a thermal, material binding, joining process for metallic

materials. For generations, soldering and brazing have made it
possible for every fitter to achieve a secure and guaranteed joint.

Brazing permanently joint two or more work pieces together with

brazing alloy and flux using heat. The parent metals are moistened
by the brazing alloy that has been liquefied by heat using the
correct working method. The brazing alloy
spreads out and joints the two pieces together.

7. Nitrogen flushing:-
The nitrogen flushing process is the leak check
in all brazing point.

8. Grommet:-
A grommet is a ring inserted into a hole through thin material, such
as fabric. Grommets are generally flared or collared on each side to
keep them in place, and are often made of metal, plastic, or rubber.
They maybe used to prevent tearing or abrasion of the pierced
material, to coversharp edges of the piercing, or both. A small
grommet may also be called an eyelet.

Grommet
Coupler:-
The coupler are used the vacuuming, gas charging, and C P T
(computer performance).

Coupler
9. Brackets:-
The brackets are motor holder.

Brackets Hold motor

10. Motor:-
Drive a rotating force by electric power and
supply the driving force to fan and blower
in both indoor and outdoor air conditioner.

11. Vacuuming:-
A refrigeration vacuum pump is a device
used to purge air conditioning and
refrigeration (AC/R)systems of
contaminants such as moisture and air. This purging action is
achieved by inducing a deep vacuum in the system by continuously
drawing small amounts of gas out over a protracted period. During
this process, any water in the system is boiled off and the resultant
vapor and any air is drawn out. Refrigeration vacuum pumps are
typically rotary variants, many of which feature two stage
operations. The vacuum values in question are expressed in microns
with the average two stage vacuum pump capable of producing
values of 50 microns or less.

Vacuuming station
12. Fan:-
Serves to blow air through condenser and blow put the heat
generated with refrigerant liquefied in condenser; its structure is
similar with a motor fan.

13. Gas:-
Two types gas use in air- conditioning System.
 R22 (monochloro-difloro-methane)
 R410(hydro-fluorocarbon)

The R-22 gas and R-410 gas are not toxic and not affect the human
health. The R-22 is a man-made refrigerant developed
forrefrigeration installation that need low evaporating temp., as in
fast cooling unit which maintain a temperature of -29 ͦc to -40 ͦ c. It
has also been successfully used in air-conditioning unit and
household refrigerators. It is use with reciprocating and rotary
comp.

Difference between R-22 and R-410A:-

R-22:-
 Often referred to by a brand name like Freon.

 As of 2010, R-22 was discontinued for use in new air

conditioning systems.
  R-22 is a hydro-chlorofluorocarbon (HCFC)
which contributes to ozone depletion

R-410A:-
 Often referred to by a brand name like Peron

 Has been approved for use in new residential air conditioners

 It is a hydro-fluorocarbon (HFC) which does not contribute to

ozone depletion.

 Will become the new standard for U.S. residential air

conditioning systems in 2015

14. Brazing:-
Gas charging line is most important point in the
brazing. When joint the two component.

15. HLT process (Helium leak testing):-

The H LT process (Helium leak testing)use to the leak testing in air-
conditioning system.All part joint in air-conditioning system e.g.-
compressor, condenser, suction line, discharge line, capillary tube
etc.

H L T system
16. Wiring box (control box):-
The control box is main part in air-
conditioning system. The control box control is compressor, fan, and
motor etc.
Wiring box (control
box)

The mean component in control box:-

Capacitor:-
Supply a driving torque to the compressor motor or fan motor for
air on and make the operating efficiency better during operation.

Capacitor
17. Casing:-
Casing is the process of all panel set in air-conditioning
system.eg.
1. Bass pan loading
2. Front side panel
3. Rear side panel
 4. Colum
5. Front panel (Grill)
6. Top cover

18. E S T (Electric safety test):-

The electric safety test is most impotent process in air-conditioning
system. the E S T check point.
5. Earth check
6. Insulation resistance
7. High voltage
8. Leakage current

Specification

S.n Parameter voltage current resistant Time

1 Earth check NA 25A 0~100m 2 sec

2 Insulation 500V NA 50~∞ 2sec

resistance
3 High voltage 1600V 0.10MA NA 1sec

4 Leakage 254V 0.15AM NA 3sec

current
 AIR- CONDITIONER SIZING

Air conditioner sizing is a very important step before anyone buy or rent a unit.
Wrong sizing can cause problems such as insufficient cooling, insufficient moisture
removal, and unnecessarily high electricity bills .
Heat transfer occurs whenever there is a temperature difference between two solids,
fluid (liquid or gas) sections, and through vacuum. It may happen through

Conduction, Convention or Radiation, or any combination between these three.

Hence, heat transfer between outside and inside of your dwelling space is inevitable.
It either transfers out of your house (during cold season), or transfers in (during hot
season).

Air conditioning units are designed to control heat gain or loss within conditioned air,
these are:

A)SENSIBLE HEAT:

It is defined as the heat of dry air. It is the “dry heat” from anything that has the
temperature above 0 Kelvin, be it from electrical appliances, lighting and sun’s
radiation.

B) LATENT HEAT:

It is the heat contained in the water vapor, carried by the air. The higher the water
vapor content, the higher the latent heat. Examples are, your perspiration, cooking
by steam, or hot water vapor from the bathroom.
 FACTORS THAT INFLUENCE THE
SENSIBLE COOLING LOAD

1) Glass windows or doors

2) Sunlight striking windows, skylights, or glass doors and heating the room
3) Exterior walls
4) Partitions (that separate spaces of different temperatures)
5) Ceilings under an attic
6) Roofs
7) Floors over an open crawl space
8) Air infiltration through cracks in the building, doors, and windows
9) People in the building
10) Equipment and appliances operated in the summer
11) Lights
12) Other sensible heat gains are taken care of by the HVAC equipment before the air
13) reaches the rooms (system gains). Two items that require additional sensible cooling
14) capacity from the HVAC equipment are:
15) Ductwork located in an unconditioned space
16) Ventilation air (air that is mechanically introduced into the building)

Other sensible heat gains are taken care of by the HVAC equipment before the air
reaches the rooms (system gains). Two items that require additional sensible cooling
capacity from the HVAC equipment are:

a) Ductwork located in an unconditioned space

b) Ventilation air (air that is mechanically introduced into the building)

FACTORS THAT INFLUENCE TO THE LATENT COOLING

LOAD

Moisture is introduced into a structure through:

a) People
b) Equipment and appliances
c) Air infiltration through cracks in the building, doors, and windows
 UNITS OF REFRIGERATION / AIRCONDITIONING

TON OF REFRIGERATION (TR):

1 TR is the amount of cooling effect produced when 1 ton (1000 kg) of ice melts
at 0°C continuously for 24 Hrs.

BRITISH THERMAL UNIT PER HOUR (BTU/ HR):

A BTU is defined as the amount of heat required to raise the temperature of 1

pound of liquid water from 60°F to 61°F at a constant pressure of 1 atmosphere.
1 TR = 12,000 BTU/ Hr
= 12,660 kJ/ Hr
= 3.517 kW
1 kW = 0.7457 horsepower (HP),
1 kWhr = 3,413 BTU/hr (British Thermal Units)
 NEED AIR- CONDITIONER
TESTING

It is necessary to check the reliability of the products because the conditions

are not same everywhere, some places have higher temperature relative to
another places, likewise the voltage, frequency, air conditions, air motion, humidity
etc are not same everywhere. So it is necessary to check the reliability of the
product at the worse conditions, i.e. at the maximum and minimum values of
temperature, voltage, humidity, air flow etc.
In India, ambient temperatures during summer in most part of the country
can be as high as 45°C to 48°C with a very high relative humidity (95% to 98%),
in coastal areas. Grid power supply voltage can fluctuate from 150 to 280 volts
(230 volts being the standard) In country, summer period is longer than the winter
(7-8months/year). So to check reliability in the worse conditions the different types
of test are done on an Air conditioner

The Bureau of Indian Standards recommends the testing standards for Air
conditioners by ISO(for ac up to 2 ton) and IS (for Commercial air conditioners).
Tests for the performance testing of Air conditioner include:
1. Cooling capacity test
2. Maximum Operating Condition test
3. Minimum Operating Condition test
4. Sweat/Dew test
5. Freeze up test
6. Vibration test etc.
 PSYCHOMETRIC TYPE
CALORIMETER

The Room Air Conditioner performance test room (Psychometric Calorimeter) at Carrier
Midea India Pvt. Ltd. has been designed as per IS-1391(part 1): 1992. It is also
provided with a control panel and a data logger/data acquisition system with a
computer interface. The test facility is described briefly below.
These calorimeters are based on the air enthalpy method, and are used to measure
the performance of room, package and automobile Air- conditioners. The Air
conditioner under test is installed in the normal way, and the heating and cooling
capacity is calculated using the inlet and outlet air temperature and humidity, air flow
values of the indoor unit of the Air conditioner.

Use of a direct expansion refrigeration method and an accurate high quality code
tester (air flow measuring apparatus) allows easy adaptation of changes in test
conditions. These calorimeters allows efficient testing of air conditioners under all
conditions specified by ISO, and are indispensable in the new product
development.
 BALANCED ROOM TYPE
CALORIMETER

The performance of indoor test units is measured directly. The cooling and
dehumidifying capacity for the Air conditioner’s indoor unit in cooling mode, and the
heating capacity for the Air- conditioner’s indoor unit in heating mode, are balanced
with thermal capacity of the measuring device, and the thermal input is measured.
The thermal input for heating and cooling is measured in the same way for outdoor
units. The calculated value based on the outdoor unit’s measurement must be within
4% of the indoor unit’s measurement.

Capacity can be measured more accurately when the heat leakage from the test
chamber approaches zero. this measurement method is most suitable when
accurate capacity measurement is of prime importance with standard test conditions.
This type has a dual construction in which an additional temperature control chamber
is provided outside the indoor and outdoor chambers. Equilibrium between the
temperatures at the indoor and outdoor unit test chambers and that of external
chambers is maintained to eliminate temperature difference, and allow accurate
Capacity measurement
 COOLING CAPACITY TEST

TEST PURPOSE:-
To determine
The cooling capacity.
Power Input.
EER (Energy Efficiency Ratio).
Drawing Current.

TESTING CONDITIONS TEMPERATURE(°C)

UNIT Dry Bulb Wet Bulb

Temperature Temperature
Indoor Side 27 19
Outdoor Side 35 24

Voltage: Rated Voltage

Frequency: Rated Frequency
Fan speed: Maximum
Thermostat position: Max. cool

PROCEDURE:
When the set conditions are maintained and stabilized for at least 1 hour, put the
Machine into 70 minute integration.
The data for every 10 minutes is noted down by this method.

JUDGMENT:
1. Cooling Capacity Should be More than Rated Capacity.
2. Power Consumption should be less than 110% of Rated Value.
3. Running Ampere Should be Less than 110% of Rated Value.
4. E.E.R should be More than Rated Value.
5. Fan Motor RPM as per Product Standard.
MAX COOLING CAPACITY TEST

TEST PURPOSE:-
To ensure that our Air Conditioner can satisfactory work under maximum operating
condition.

TEST CONDITION:-

Temperature(°C)
UNIT Dry Bulb Wet Bulb
Temperature Temperature
Indoor Side 35 24
Outdoor Side 46 27

TEST VOLTAGE:-
1. Low Voltage:- 187 V, High Voltage:- 253 (For Rotary Compressor), 265 V for
Reciprocating Compressor.
2. Rated Frequency.
3. Damper Fully Closed.
4. Thermostat :- Max Cooling.
5. Fan Speed;- High.
6. Vertical Louvers set as less resistance to Air Flow

TEST PROCEDURE:-
Stabilize the condition and run the test unit at low voltage, after 2 hours switch off
the compressor for 3 minutes and restart compressor after 3 minutes. Allow
test unit to run for an hour. Then follow the same procedure for high test
voltage.

JUDGEMENT CRITERIA:-.
Test unit should not trip in stabilizing time and also after starting the compressor
after 3 minutes at mentioned condition. No abnormal noise should be
audible at the time of running.
 SWEAT ENCLOUSER TEST

TEST PURPOSE:
a) Resistance to sweating of air conditioner when
operating under conditions of high humidity.
b) To determine the capability of air conditioner to
disposeoff condensate
.
TEST CONDITION:-

UNIT Dry Bulb Wet Bulb

Temperature Temperature
Indoor Side 27 24
Outdoor Side 27 24

TEST PROCEDURE:
1 .Stabilize the Conditions in the Chamber for Not less than1hour.
2. Run the Test Unit for 4Hrs maintaining the Test Condition.
3. After Running the Unit for 4 Hrs Check the Following :
a) Dew Formation in Control Box
b) Water dripping or blow off the outlet/mouth of indoor unit.

TEST PROCEDURE:
1. No Sweating or Dew Formation in Control Box.
2. No Water Dripping from duct outlet.
3. No water blow - off
4. Check whether the condensate is disposed off without water being splashed out
such that the installation surroundings may become wet
Development of
New Split AC’s
DEVELOPMENT
PROCESS

PROTO of NEW AC

PERFORMANCE TESTING

LINE TRIAL(MCS) & IMPROVEMENTS

RELIABILITY TESTING

PILOT TRIAL & IMPROVEMENTS

MASS PRODUCTION
 Development Process
of
Model

18K(1.5 Tr) MULTIMA

MIDEA

1. PROTO of SPLIT AC:-

Proto of AC is made in following Steps-

a) Initially, Designing/Drawing of parts and unit(AC) is

prepared.
b) As per design, the material of unit are Check/verify.
c) As per Design, PROTO of Indoor and Outdoor Unit AC
is prepared in R&D LAB.
 Proto of Indoor Unit

Proto of Outdoor Unit

2. Performance Testing:-
In Performance Testing of Proto AC, the Cooling Capacity
Test of Proto Ac is performed in R&D Lab.
Procedure of Cooling Capacity Test:-
a) Initially, Proto AC is installin R&D Lab.
b) Connection Setup is done and check in Indoor and
Outdoor Testing Room.
c) Cooling Capacity Test is performed.
d) Test Report is compare with Standard Report of Unit.

• Cooling Capacity Test Conditions are:-

Indoor Dry Bulb Temp.- 270C
Indoor Wet Bulb Temp.-190C
Outdoor Dry Bulb Temp.-350C
Voltage- 230V
Fan Speed- Turbo
TEST PURPOSE:-
To determine-
Cooling capacity.
Power Input.
EER (Energy Efficiency Ratio).

Cooling Capacity Test

• Test Report of 1.5 TrMultima:-

Power- 1433 W
Capacity- 5195.9 W
EER-3.63
3. Manufacturing Check Sample
(Line Trial):-

In Line Trial(MCS), 3-Units of AC are manufactured on the production line.

MCS(Line Trial) is done in following steps:-

1) Initially, Material of Units are issue and verify as per design of unit.
2) Then,the manufacturing of units on production line is done.
3) Correction points(if any) Observe are noted and Corrective measure are
done by R&D Deptt.

Line Trial(MCS)
Improvements on Observe Points:-
Points Observe(if any) in line trial are noted and Corrective
measure are done as per Design/manufacturing requirements.

Points Corrected in 18K(1.5Tr)Multima Line Trial:-

The issue arise during line trial of 1.5 TrMultima is Issue of
Capillary touching with Tubing, and it was noted&corrected it by
R&D Deptt. through Re-design capillary of theModel(AC) as per
requirement in Line Trial.

18K(1.5Tr) Multima(Re-Design Capillary)

 4. Reliability Testing:-
In Reliability Testing of AC, there are many tests are performed
by AC units to test their Reliability in different Conditions.
Mostlty, test performed through AC in Reliability Testing are
as follows:-

 Maximum Operating Condition Test.

 Minimum Operating Condition Test.
 Sweat Test.

Maximum/Minimum Operating Condition Test:-

In Maximum/Minimum Operating Condition Test, the
Reliability of AC in maximum/Minimum condition is check.

TEST PURPOSE:-
To ensure that our Air Conditioner can satisfactory work under
maximum/Minimum operating condition.

• Test Conditions of Max. Operating Test are:-

Indoor Dry Bulb Temp.- 350C

Indoor Wet Bulb Temp.-240C
Outdoor Dry Bulb Temp.-460C
Voltage- 253V
Fan Speed- Turbo
 Maximum Operaing Condition Test

• Test Conditions Minimum Operating Test are:-

Indoor Dry Bulb Temp.- 350C

Indoor Wet Bulb Temp.-240C
Outdoor Dry Bulb Temp.460C
Voltage- 195V
Fan Speed- Turbo
 Minimum Operating Condition Test

TEST PROCEDURE:-
Stabilize the condition and run the test unit at low voltage, after 2 hours switch off
the compressor for 3 minutes and restart compressor after 3 minutes. Allow
test unit to run for an hour. Then follow the same procedure for high test
voltage.

JUDGEMENT CRITERIA:-.
Test unit should not trip in stabilizing time and also after starting the compressor
after 3 minutes at mentioned condition. No abnormal noise should be
audible at the time of running.
 Sweat Test:-
In Sweat Test of AC, the Resistance to sweating of air conditioner when operating
under conditions of high humidity is Check.

TEST PURPOSE:

a) Resistance to sweating of air conditioner when

operating under conditions of high humidity.
b) To determine the capability of air conditioner to
disposeoff condensate.

• Test Conditions of Sweat Test are:-

Indoor Dry Bulb Temp.- 270C

Indoor Wet Bulb Temp.-240C
Outdoor Dry Bulb Temp.-270C
Voltage- 230V
Fan Speed- Low

Unit Fail
 Unit Pass

TEST PROCEDURE:
1 .Stabilize the Conditions in the Chamber for Not less than1hour.
2. Run the Test Unit for 4Hrs maintaining the Test Condition.
3. After Running the Unit for 4 Hrs Check the Following :
a) Dew Formation in Control Box
b) Water dripping or blow off the outlet/mouth of indoor unit.

TEST PROCEDURE:
1. No Sweating or Dew Formation in Control Box.
2. No Water Dripping from duct outlet.
3. No water blow - off
4. Check whether the condensate is disposed off without water being splashed out
such that the installation surroundings may become wet .

5.Pilot Trial:-
In Pilot Trial, 20 Units of AC are manufactured on the production line.

Pilot Trial is done in following steps:-

1) Initially, Material of Units are issue and verify as per design of unit.
2) Then,the manufacturing of units on production line is done.
 3) Correction points(if any) Observe are noted and
Corrective measure are done by R&D Deptt.

Pilot Trial

Improvements on Observe Points:-

Points Observe(if any) in line trial are noted and Corrective
measure are done as per Design/manufacturing requirements.
 Improvements in Pilot Trial

6.Mass Production:-
In the Final Step i.e.Mass Production, the Production of
Units(AC) in Finite number of units is done on Production Line.

Mass Production of Units is Done as follows:-

 Materialof Units are issue and verify as per design of unit.

 Then,the manufacturing of units on production line is done.

 Correction points(if any) Observe are noted and Corrective measure

are done by R&D Deptt.
 Then, the Manufacture New Units(AC) are Dispatch to
Storage/Finish Goods area.
Mass Production
 DEVELOPMENT STAGE-1
R&D TRIAL

 This is very first stage in new model development.

 Cycle is balanced in this stage.
 Onlyperformance (cooling capacity, power input, EER, various temperatures)
ofthe machine is tested in this stage.

 Two tests are performed in this stageàcooling capacity test & max. operating
conditions test. Heating capacity is also tested in case of heat pump machine.

TESTS PERFORMED IN STAGE 1:

1. Cooling Capacity Test

2. Max. Cooling Capacity Test
3. Dew Test
4. Low temp Test.

DEVELOPMENT STAGE-2
DESIGNVERIFICATION
  Stage 1-- R&D Trail, is complete by now.
 In stage 2 ---Design Verification (DV), machine design is verified for its
Performance and quality aspects as well.
 Two machines are made after releasing drawings of parts, for testing purposes in
thisstage . These machines are called Engineering Samples, which are
scrappedafter completion of this stage.
 All quality tests, other than cooling test and max. operating conditions test, are
Performed in this stage.
 All the tests are performed by QA (Quality Assurance) department. Any issue
found is resolved by coordination of both departments, R&D and QA.

PRODUCT QUALIFICATION

 Stage 1-- R&D Trail, is completed by now.

 Stage 2--Design Verification (DV), is completed by now
 Twenty five or fifty machines are made after releasing drawings of
 parts, for testing purposes in this stage . These machines are called
 PQ Samples, which are sold after completion of this stage.
 All quality tests are performed in this stage.
 Feasibility of product manufacturing on line is checked at this stage
 so that maximum nos of products can be produced at the time of
 mass production with best quality as per spec.
 All the tests are performed by QA (Quality Assurance) department.
 Any issue found is resolved by coordination of both departments, R&D
 and QA.
 Analysis of Heat and Mass transfer
for Heat exchanger (Condenser Coil 3 Row 5MM)

A PROJECT REPORT

OBJECTIVE OF THE PROJECT

As rapid increase in global warming leads to higher temperatures throughout with

respect to different geographical locations of places, we can observe a non-fluctuating
increasing trend in demand and supply of Air Conditioners of various types for different
site based applications. This can be directly linked with increment in electricity
consumption and thus huge amount of money has to be spent to deal with high
temperature variations. A relief to the consumer of Air Conditioners by the
manufacturing side can be mentioned as reduced energy consumption of that product.
By reducing energy consumption without compromising with the efficiency of the air
conditioners is the most challenging part for any ACs manufacturing companies.

Air Conditioners and their prices are classified on the basis of “Tonnage” of that
particular product. More the tonnage, more will be its cost but more efficiency as well.
Daily competition among the companies to modify and manufacture more efficient
units without compromising with efficiency and keeping costing in mind as well.

Our objective for this project is to test currently used 11TR ( TR - Tonnage of
Refrigeration ) Outdoor Unit of an air conditioner and modify the outdoor unit
accordingly without much of change in costing but a reasonable amount of change in
its efficiency and energy consumption.

Currently used 11TR outdoor unit gives the change in temperature of refrigerant of 35˚C
but our objective from this project is to get the temperature difference of 40˚C so as to
increase its efficiency.
 Appendix

COP Coefficient of performance

HRR Heat Rejection Ratio

Cp Specific heat capacity

k Thermal Conductivity

h Convective heat transfer coefficient

hf Enthalpy of refrigerant liquid phase

hg Enthalpy of refrigerant gas phase

hfg Latent heat of condensation

Q Total Heat transfer

Qe Heat transfer from evaporator

qc Heat transfer in the circuit

ṁa Mass flow rate of air

ṁr Mass flow rate of refrigerant

ṁrc Mass flow rate of refrigerant in a circuit

ṁac Mass flow rate of air in a circuit

Ui Overall heat transfer coefficient of inner portion

Uo Overall heat transfer coefficient of outer portion

hoa Convective heat transfer coefficient of outside air (single phase change)

hir Convective heat transfer coefficient of inside refrigerant (single phase change)

htp Convective heat transfer coefficient for two phase change inside the coil

LMTD Log Mean Temperature Difference

Tr Temperature of refrigerant

Ta Temperature of air

Vf Face Velocity

P Pressure of Refrigerant

µ Coefficient of viscosity

𝝆f Density of refrigerant in liquid phase

𝝆g Density of refrigerant in vapour phase

Ab Base area

Af Fin area

Ac Cross-sectional area (Face area)

B Distance between two pipes in a column

C Distance between two pipes in a row

D Distance between two fins

t Thickness of fin

di Internal diameter of coil pipe

do External diameter of coil pipe

Dh Hydraulic diameter

Pr Prandlt number

Nu Nusselt number

Ref Reynold’s number for liquid phase

 Reg Reynold’s number for vapour phase

Reeq Equivalent Reynold’s number

A]. Analysis of Current Circuit-

First, we have to analyse the current circuit that has been used in the condenser and find where
the improvements and modifications can be made.

• Given :
• Capacity of condenser = 11TR
• COP = 3
• Height of condenser ( H ) = 1560 mm
• B = 19.5 mm
• C = 11.6 mm
• D = 1.33 mm
• t = 0.105 mm
• Number of circuits = 40
• Face Velocity ( Vf ) = 2.4 m/s.
• Temperature :
- Tro = 45˚C
- Tri = 85˚C
- Tai = 35˚C
- Tao = 52˚C
• Pressure of Refrigerant = 3.2 MPa
• di = 4.56 mm
• do = 5mm
• Number of Rows ( N ) = 3
• Length of Condenser = 1000 mm

We know,

- Q = HRR⨯Qe
- HRR = 1 + (1/COP)
- HRR = 1.334
- Q = 1.334 ⨯11⨯3517 = 51582.667 W
- qc = Q/40 = 1289.5667 W

• Properties of Air :

- ρ = 1.367 kg/m^3
- µ = 1.9067⨯10e-5 kg/m-sec.
- Pr = 0.7057
- k = 27.67 ⨯10e-3 W/m-K
- Cp = 1.00965 kJ/kg-K

• Areas :

Ao = Ab + Af
The below table can be used to determine the values for the

mentioned variables according to the conditions.

- Nu = ho Dh / k
- Ab = 4.73844 m2
- Af= 74.16 m2
- Ao = 78.898 m2
- Dh = 0.62862 mm

- Heat transfer coefficient of air(ho)

- Re = (ρVf Dh)/µ
- Re = 109
- ho = 237 W/m^2-K

• Properties of Refrigerant :

- hg = 477.8 kJ/kg
- hfg = 131 kJ/kg
- hf = 142 kJ/kg
- kf = 82.42 mW/m-K
- kg = 25.70 mW/m-K
- µf = 79.9 μkg/m-sec
- µg = 15.96 μkg/m-sec
- Cpf = 2.348 kJ/kg-K
- Cpg = 2.575 kJ/kg-K
- Prf = 2.276
- Prg = 1.545
- ρf = 900 kg/m^3
- ρg = 104 kg/m^3

• Mass flow rate of refrigerant

- ṁr(hg - hf) = Qc
- ṁr = 0.1536 kg/S
- ṁrc = ṁr /40 = 3.84 mKg/S

• Mass flow rate of air through circuit

- Qc = ṁac Cp ∆Ta
- ṁac = 0.07512 kg/sec

• Reynold’s number of refrigerant

Re = 4ṁr/(µ.di.π)
Reg = 71493.34
Ref = 13402.52

Reeq = Ref (1-x) + x.Reg(µg / µf ) (𝝆f / 𝝆g)^0.5

Reeq = 9924.6875 + 14277.44.x

Reeq = 17063.41

• Pressure drop across various sections of the coil

We know the pressure drop is created by frictional effect experienced by fluid (refrigerant)
inside the coil and thus more pressure drop more will be the heat transfer rate.As we have seen,
the old 11TR condenser was providing the change in inlet and outlet temperature as 35˚C.
Now, are main aim is to increase the temperature difference so as to ensure much more heat
transfer with respect to keeping the power consumption same or changes not with much of the
value.
1. Condensation heat transfer coefficient

When refrigerant comes into the contact with the surface whose temperature is lower tan the
saturation temperature of the refrigerant at condenser pressure , the refrigerant condenses.
Depending upon the type of the surface, condensation can be film-wise or drop-wise. Even
though drop-wise condensation yields higher heat transfer coefficient as compared to film-
wise condensation, normally design calculations are based on film-wise condensation. This is
due to reason that it is difficult to maintain the drop-wise condensation continuously as the
surface characteristics may undergoing with time. In film-wise condensation, the condensed
refrigerant liquid forms a film over the condensing surface. The liquid film resists heat transfer,
hence, for high condensation heat transfer rate the thickness of the condensing film should be
as small as possible.

2. Correlation between heat transfer coefficient and various

factors of condensation.

Some of the features of this correlation are mentioned below

• As the thermal conductivity kf increases, the heat transfer coefficient increases since the
thermal resistance of the condensate film decreases.
• Similarly a decrease in viscosity or increase in density will offer less frictional resistance
and cause rapid draining of the condensate, thereby causing an increase in heat transfer
coefficient.
• High value of latent heat hfg means that for each kW of heat transfer there will be smaller
condensate thickness and higher heat transfer coefficient.
• A large value of temperature difference can lead to more condensation and larger condensate
thickness and will lead to smaller coefficient of heat transfer.
• An increase number of tubes will lead to larger condensate thickness in the lower tubes
leading to smaller heat transfer coefficient.

Heat transfer coefficient of refrigerant

Here, we are considering three different phases with respect to different temperatures :

Phase 1 (g) - 85˚C to 51.81˚C (vapour to vapour) - h1

Phase 2 (fg) - 51.81˚C to 51.81˚C (vapour to liquid) - h2
Phase 3 (f) - 51.81˚C to 45˚C (liquid to liquid) - h3

We know,
Nu = (h.di) / k

h1 = 1119.98 W/m^2 K
h3 = 1137.2 W/m^2 K

h2 =

Therefore,
h2 = 2881.1 W/m^2 K

Overall heat transfer coefficient - Evaluation of overall heat transfer coefficient, U is an

important step in the design of condenser. The overall heat transfer coefficient can be based
on either internal area or external are of coil or say condenser.

For overall heat transfer coefficient we have to consider 3 phases as well.

In above equation, we are considering overall heat transfer coefficient for inner portion of coil
tube.Hence, denoted Ui .

Here, the term : ri.ln(do/di) / k is of order of 10^-7 therefore neglecting this in real time
calculations.
Ai / Ao.ho = 0.000383

U1 = 783.65 W/m^2 K
U2 = 1396.67 W/m^2 K
U3 = 792.31 W/m^2 K

Change in temperature of air for different phases.

Phase 1 - ṁac Cp ∆T1 = ṁrc ( 477.8 - 420.63 )*1000

∆T1 = 2.89˚C

Phase 2 - ṁac Cp ∆T2 = ṁrc (131000)

∆T2 = 6.6325˚C

Phase 3 - ṁac Cp ∆T3 = ṁrc (289.62 - 142)*1000

∆T3 = 7.47˚C

In a typical design problem the main focus is to find the are of the condenser that can be used
to provide the required output power. For eg. if we consider 11TR condenser then the number
of coils, their size ( area, length, gap between two coil pipes and pitch ).
The heat transfer rate in the condenser depends on the refrigeration capacity of the system and
system COP. The overall heat transfer coefficient depends on the size and design of the
condenser.

LMTD - the mean temperature difference depends upon the operating temperature of
refrigerant system, the type of the condenser, and the external fluid.

This factor is also considered with respect to three different phases.

Ambient temperature of air at : phase 1 - 50.55˚C

phase 2 - 41.20625˚C
phase 3 - 38.74˚C

(LMTD)1 = 9.77˚C
(LMTD)2 = 10.60375˚C
(LMTD)3 = 9.25˚C

Heat transfer in different phases -

Phase 1 -
Q1 = 3.84 (477.8 - 420.62)
Q1 = 219.57W
Phase 2 -
Q2 = 131*3.84
Q2 = 503.04W

Phase 3 -
Q3 = 147.62*3.84
Q3 = 566.86W

Q1 = U1*A1* (LMTD)1
A1 = πdiL1
L1 = 2 m

Q2 = U2*A2* (LMTD)2
L2 = 2.4 m

Q3 = U3*A3* (LMTD)3
L3 = 5.4 m

Total length required = L1 + L2 + L3 = 10 m

But practically we have only 6 m of length of pipe so it is difficult to achieve the required
temperature.

Analysis of modified circuit-

Now by doubling the length of the circuit :

1. Number of circuits decreases by half.
2. Mass flow rate gets twice the previous value so as the heat transfer in every phase.
3. Reynold’s number also gets doubled.
4. The properties of air remain the same.
5. LMTD remains the same for every phase.
Therefore ,

Modified Reynold’s number -

Reg = 142986.68

Ref = 26805.04

Reeq = 34126.82

Modified Enthalpy -

h1 = 1948.46 W/m^2 K

h2 = 4637.56 W/m^2 K

h3 = 1979.98 W/m^2 K

Modified Overall heat transfer coefficient -

U1 = 1115.63 W/m^2 K

U2 = 1670.4 W/m^2 K

U3 = 1126.055 W/m^2 K
Modified Heat rejection values -

Q1 = 439.14 W

Q2 = 1006.08 W

Q3 = 1133.7216 W

Therefore, updated lengths are -

Q1 = U1*A1* (LMTD)1
A1 = πdiL1
L1 = 3.04 m

Q2 = U2*A2* (LMTD)2
L2 = 3.96 m

Q3 = U3*A3* (LMTD)3
L3 = 7 m

Total length required = L1 + L2 + L3 =~ 14 m

Here the length of the circuit is 12m and the required is 14m.If we consider the fins inside the
tube the inside area of the tube increases. So the required length is going to decrease. It will
be less than 14m.

Pressure drop-

We know,

where,
f - coefficient of friction
N - number of rows
V - velocity

note: We have considered the coil pipe without inside grooves therefore pressure drop for this
is very less.