REFRIGERATION

PLANT
Performance and Efficiency Test

ARCHINUE | DEL CASTILLO | GAÑOLO | LLAMERA | LLORENTE | MADRIDEO | NUYLES | OROZCO | PEÑAFLOR | SERRADO
01 Introduction to Refrigeration Plant
Definition | Components | Diagrams | Mass & Energy Balance

02 Performance Test
Definition | Methodology | Parameters | Indicator | Instruments

03 Sensitivity Analysis
Analysis Proper

04 Sample Problems
Applications | Equations | Variables | Solution

05 Cooling Tower
Definition | Function | Performance Test

06 Conclusion
How to improve the cycle efficiency?
INTRODUCTION
Refrigeration Plant
 INTRODUCTION

Refrigerant plants come in all different shapes and sizes.

Refrigeration Plant is often used in ships or industrial
refrigeration sectors for maintaining the temperature of
different provision rooms carrying food for crew members
or maintaining sensitive cargo such as chemicals, liquefied
gas, etc.
 INTRODUCTION
Refrigeration is defined as the process of extracting h
eat from a lower-temperature heat source, substance,
or cooling medium and transferring it to a higher-temp
erature heat sink. Refrigeration maintains the tempera
ture of the heat source below that of its surroundings
while transferring the extracted heat, and any required
energy input, to a heat sink, atmospheric air, or
surface water.
PURPOSE OF REFRIGERATION PLANT

The job of a refrigeration plant is to cool articles or

substances down, and to maintain them at a
temperature lower than the ambient temperature.
Refrigeration can be defined as a process that
removes heat.
 INTRODUCTION
Applications of Refrigeration
• Food storage and distribution
• Food processing (dairy products, beverages, etc.)
• Chemical and process industries
• Dehumidifiers
• Ice makers, ice-skating rinks
• Construction
• Desalting of seawater
AIR CONDITIONING REFRIGERATION
Cooling and Industrial refrigeration,
Heating,
humidifying, dehumidifying including food preservat
and control of air operations in air ion, chemical, and proc
ess industries
quality conditioning
 INTRODUCTION
In vapor compression systems, compressors activate the
refrigerant by compressing it to a higher pressure and higher
temperature level after it has produced its refrigeration effect.
The compressed refrigerant transfers its heat to the sink and is
condensed to liquid form. This liquid refrigerant is then throttled
to a low-pressure, low temperature vapor to produce
refrigerating effect during evaporation. Vapor compression
systems are the most widely adopted refrigeration systems in
both comfort and process air conditioning.
 INTRODUCTION
Major components of a Refrigeration Plant:
• Compressor
• Condenser
• Evaporator
• Expansion valve
• Cooling tower
• Refrigerant
 COMPONENTS
COMPRESSOR
- The heart of the vapor-compression system
- a mechanical device that increases the pressure of a
gas by reducing its volume.
In the process, receiving vapor at low temperature and
pressure, the refrigerant is compressed resulting in an
increase in vapor pressure and higher temperature,
Leaving the compressors a superheated vapor at a
much higher temperature.
 COMPRESSOR

Common types of refrigeration compressors:

– Reciprocating Compressor
– Rotary Screw Compressor
– Vane Compressor
– Centrifugal Compressor
16-cylinder reciprocating compressor for ammonia
Compressor and condenser combined into a condensing unit
Water-chilling package that uses a screw compressor
Roller-type vane compressor
Centrifugal compressor system
 COMPRESSOR
Mass and Energy Balance

𝑊 = 𝑚 ℎ2 − ℎ1
W = theoretical compressor power, kJ/s or kW
h1 = enthalpy entering the compressor, kJ/kg
h2 = enthalpy leaving the compressor, kJ/kg
m = mass flow rate, kg/s
𝑉1 = 𝑚𝑣1
V1 = volume flow rate, m3/s or L/s
v1 = specific volume of vapor, m3/kg or L/kg
m = mass flow rate, kg/s
 COMPONENTS

CONDENSER
The purpose of the condenser is to extract heat from the
refrigerant to the outside air. The condenser is usually
installed on the reinforced roof of the building, which
enables the transfer of heat. Fans mounted above the
condenser unit are used to draw air through the
condenser coils.
 COMPONENTS
CONDENSER
The temperature of the high-pressure vapour determines the
temperature at which the condensation begins. As heat has
to flow from the condenser to the air, the condensation
temperature must be higher than that of the air; usually
between - 12°C and -1°C. The high-pressure vapour within
the condenser is then cooled to the point where it becomes a
liquid refrigerant once more, whilst retaining some heat. The
liquid refrigerant then flows from the condenser in to the
liquid line.
Shell-and-tube water-cooled condenser
Air-cooled condenser
 CONDENSER
Mass and Energy Balance

Qr = m(h2 – h3)
Qc = total heat rejected, kJ/s
h2 = enthalpy entering the condenser, kJ/kg
h3 = enthalpy leaving the condenser, kJ/kg
 COMPONENTS
EVAPORATOR
The purpose of the evaporator is to remove unwanted heat
from the product, via the liquid refrigerant. The liquid
refrigerant contained within the evaporator is boiling at a
low-pressure. The level of this pressure is determined by
two factors:
- The rate at which the heat is absorbed from the product
to the liquid refrigerant in the evaporator
- The rate at which the low-pressure vapour is removed
from the evaporator by the compressor
 COMPONENTS
EVAPORATOR
To enable the transfer of heat, the temperature of
the liquid refrigerant must be lower than the
temperature of the product being cooled. Once
transferred, the liquid refrigerant is drawn from the
evaporator by the compressor via the suction line.
When leaving the evaporator coil the liquid
refrigerant is in vapor form.
Liquid chilling evaporator
 EVAPORATOR
Mass and Energy Balance

Qe = (h1 – h4)
Qe = refrigerating capacity, kJ/s or Kw
h1 = enthalpy leaving the evaporator, kJ/kg
h4 = enthalpy entering the evaporator, kJ/kg
 COMPONENTS
EXPANSION VALVES
It is located at the end of the liquid line, before the evaporator.
The high-pressure liquid reaches the expansion valve, having
come from the condenser. The valve then reduces the pressur
e of the refrigerant as it passes through the orifice, which is
located inside the valve. On reducing the pressure, the
temperature of the refrigerant also decreases to a level below
the surrounding air. This low-pressure, low-temperature liquid
is then pumped in to the evaporator.
Thermostatic
expansion valve
Schematic diagram
of basic
superheat-controlled
expansion valve
 EXPANSION VALVE
Mass and Energy Balance

h3 = h4

h3 = enthalpy entering the expansion valve, kJ/kg

h4 = enthalpy leaving the expansion valve, kJ/kg
 COMPONENTS

REFRIGERANT
A refrigerant is a substance or mixture, usually a fluid, us
ed in a heat pump and refrigeration cycle. In most cycles
it undergoes phase transitions from a liquid to a gas and
back again. Many working fluids have been used for
such purposes.
How is the Operation of a Refrigeration Plant Controlled?

Refrigeration Plants are controlled by multiple

equipment that optimize and manage temperatures
and pressures in a refrigeration system, and
automatically adjust the refrigeration system's
operation to minimize its energy consumption, while
maintaining within predefined temperature that limits
the spaces, processes or equipment's being
refrigerated, and reflecting changes in load, weather
conditions and operating requirements.
PERFORMANCE TEST
Refrigeration Plant
 What is Performance Test?

A performance Test is the process of evaluating of

the quality or capability of a Refrigeration plant. It is
one of the final tests to prove accurately that the
plant will deliver the guaranteed figures as specified,
tendered, contracted, and supervised during
execution and finally tested and certified by
professional.
 Why is Performance Test conducted?

Performance Test will show you how to:

• understand the quality and cost of the refrigeration;
• reduce the cost of the refrigeration;
• improve the reliability of the system;
• reduce the environmental impact of the plant.
 TERMS AND DEFINITIONS
Tons of refrigeration (TR): One ton of refrigeration is the amount of cooling obtained
by one ton of ice melting in one day: 3024 kCal/h, 12,000 Btu/h or 3.516 thermal kW.
Net Refrigerating Capacity. A quantity defined as the mass flow rate of the evaporator
water multiplied by the difference in enthalpy of water entering and leaving the cooler,
expressed in kCal/h, tons of Refrigeration.
kW/ton rating: Commonly referred to as efficiency, but actually power input to
compressor motor divided by tons of cooling produced, or kilowatts per ton (kW/ton).
Lower kW/ton indicates higher efficiency.
Coefficient of Performance (COP): Chiller efficiency measured in Btu output (cooling)
divided by Btu input (electric power).
Energy Efficiency Ratio (EER): Performance of smaller chillers and rooftop units is
frequently measured in EER rather than kW/ton. EER is calculated by dividing a
chiller's cooling capacity (in Btu/h) by its power input (in watts) at full-load conditions.
The higher the EER, the more efficient the unit.
The Performance Test will verify the following guaranteed
parameters:
• Refrigerating effects
• Mass flow rate
• Volume flow rate
• Coefficient of Performance
• Energy efficiency ratio
• Work per ton
• Condenser performance
 PERFORMANCE TEST

After commissioning, the contractor should conduct one or

more performance tests to ensure that the plant is meeting its
design specifications. The designer should indicate which
test is appropriate. These are the four main tests.
 PERFORMANCE TEST

Demonstration Run Test. Operating the plant under supervi

sion for a reasonable period and noting the performance data
from the normal instrumentation. The results can then be co
mpared with the specification and the contractor’s tender. Cle
arly, this is best carried out at times when the plant is operati
ng close to design capacity.
 PERFORMANCE TEST

Formal full-load test. Not common due to the cost, but it is o

ften possible to make special arrangements to ensure that th
e plant operates at its design conditions. This may involve si
mulating cooling loads with electric heaters, and additional ca
librated instrumentation.
 PERFORMANCE TEST

A factory test. This is suitable for many types of factory-built,

packaged units, but not applicable to site-installed systems.
 PERFORMANCE TEST
Monitoring over an extended period. The plant is
monitored over a period and its performance checked against
predicted running costs. However small a plant is, it is always
worth monitoring. As a minimum, suction/discharge gauge
pressures should be logged. If they change when they should
n’t it indicates that something is wrong. And the contract can
be alerted.
 PERFORMANCE TEST CODE BASICS

1. Reach an agreement on the test parameters during contract discussion.

2. Determine the boundaries of the refrigeration plant.
3. Design of the plant to accommodate accurate instrumentation to match
the boundaries of the plant.
4. Develop performance test procedures on how to collect the plant data
and correct to the reference conditions.
5. Conduct the test and collect the data and perform the calculation to
determine the guarantees of the reference conditions.
6. Demonstrate compliance or determine penalties or bonuses.
To determine the net refrigeration capacity:
The test shall include a measurement of the net heat removed from the water as it
passes through the evaporator by determination of the following:
a. Water flow rate
b. Temperature difference between entering and leaving water
The heat removed from the chilled water is equal to the product of the chilled water
flow rate, the water temperature difference, and the specific heat of the water is
defined as follows The net refrigeration capacity in tons shall be obtained by the
following equation:
Performance calculations
The energy efficiency of a chiller is commonly expressed in
one of the three following ratios:
First calculate the kW/ton rating from the measured parameters.
 EQUIPMENT
THERMOMETER
A thermometer is a device that measures temperatur
e or a temperature gradient. A thermometer has two
important elements:
(1) a temperature sensor (e.g. the bulb of a mercury –
in - glass thermometer or the digital sensor in an infrar
ed thermometer) in which some change occurs with a
change in temperature, and
(2) some means of converting this change into a num
erical value (e.g. the visible scale that is marked on a
mercury-in-glass thermometer or the digital readout o
n an infrared model). Thermometers are widely used i
n industries to monitor processes.
 EQUIPMENT
THERMOCOUPLE
A thermocouple is an electrical device consisting of two dis
similar electrical conductors forming electrical junctions at
differing temperatures. A thermocouple produces a tempe
rature-dependent voltage as a result of the thermoelectric
effect, and this voltage can be interpreted to measure tem
perature. Thermocouples are a widely used type of temper
ature sensor.
 EQUIPMENT
DIFFERENTIAL PRESSURE GAUGE
Differential pressure is the difference in pressure betwe
en two points.
Differential pressures are commonly used in industrial p
rocess systems. Differential pressure gauges have two in
let ports, each connected to one of the volumes whose
pressure is to be monitored. In effect, such a gauge perf
orms the mathematical operation of subtraction throug
h mechanical means, obviating the need for an operator
or control system to watch two separate gauges and det
ermine the difference in readings.
 EQUIPMENT
ULTRASONIC FLOW METER
An ultrasonic flow meter is a type of flow meter that me
asures the velocity of a fluid with ultrasound to calculat
e volume flow. Using ultrasonic transducers, the flow m
eter can measure the average velocity along the path of
an emitted beam of ultrasound, by averaging the differe
nce in measured transit time between the pulses of ultr
asound propagating into and against the direction of the
flow or by measuring the frequency shift from the Doppl
er effect. Ultrasonic flow meters are affected by the aco
ustic properties of the fluid and can be impacted by tem
perature, density, viscosity and suspended particulates d
epending on the exact flow meter.
 EQUIPMENT
AIR FLOW METER
An air flow meter is a device that measures air flow, i.e.
how much air is flowing through a tube. It does not
measure the volume of the air passing through the t
ube, it measures the mass of air flowing through the
device per unit time. Thus air flow meters are simpl
y an application of mass flow meters for a special m
edium. Typically, mass air flow measurements are e
xpressed in the units of kilograms per second (kg/s)
.
 EQUIPMENT
PSYCHROMETER
A psychrometer, or wet-and-dry-bulb thermometer, con
sists of two thermometers, one that is dry and one that i
s kept moist with distilled water on a sock or wick. At te
mperatures above the freezing point of water, evaporati
on of water from the wick lowers the temperature, so th
at the wet-bulb thermometer usually shows a lower tem
perature than that of the dry-bulb thermometer. When t
he air temperature is below freezing, however, the wet-
bulb is covered with a thin coating of ice and may be wa
rmer than the dry bulb.
 EQUIPMENT
ELECTRICITY METER
An electricity meter, electric meter, electrical meter, or e
nergy meter is a device that measures the amount of ele
ctric energy consumed by a residence, a business, or an
electrically powered device
 EQUIPMENT
TACHOMETER
A tachometer (revolution-counter, tach, rev-counter, RP
M gauge) is an instrument measuring the rotation speed
of a shaft or disk, as in a motor or other machine. The d
evice usually displays the revolutions per minute (RPM)
on a calibrated analogue dial, but digital displays are inc
reasingly common. Essentially the words tachometer an
d speedometer have identical meaning: a device that m
easures speed. It is by arbitrary convention that in the a
utomotive world one is used for engine and the other fo
r vehicle speed. In formal engineering nomenclature, m
ore precise terms are used to distinguish the two
 EQUIPMENT
AMMETER
An ammeter (from Ampere Meter) is a measuring instru
ment used to measure the current in a circuit. Electric c
urrents are measured in amperes (A), hence the name. I
nstruments used to measure smaller currents, in the mil
liampere or microampere range, are designated as millia
mmeters or microammeters. Early ammeters were labor
atory instruments which relied on the Earth's magnetic f
ield for operation.
 EQUIPMENT
VOLTMETER
A voltmeter is an instrument used for measuring el
ectrical potential difference between two points in
an electric circuit. Analog voltmeters move a point
er across a scale in proportion to the voltage of th
e circuit; digital voltmeters give a numerical displa
y of voltage by use of an analog to digital converte
r.
 EQUIPMENT
COMPRESSOR:
PARAMETER DEVICE
Temperature Thermometer
Thermocouple
Pressure Differential Pressure Gauge
Flow Rate Ultrasonic Flow Meter
Electric Demand Electricity Meter
Speed Tachometer
Current and Voltage Ammeter and Voltmeter
 EQUIPMENT
CONDENSER:
PARAMETER DEVICE
Temperature Thermometer
Thermocouple
Pressure Differential Pressure Gauge
Flow Rate Ultrasonic Flow Meter
Electric Demand Electricity Meter
Speed Tachometer
Current and Voltage Ammeter and Voltmeter
 EQUIPMENT
EVAPORATOR:
PARAMETER DEVICE
Temperature Thermometer
Thermocouple
Pressure Differential Pressure Gauge
Flow Rate Ultrasonic Flow Meter
 EQUIPMENT
EXPANSION VALVE:
PARAMETER DEVICE
Temperature Thermometer
Thermocouple
Pressure Differential Pressure Gauge
Flow Rate Ultrasonic Flow Meter
 EQUIPMENT
COOLING TOWER:
PARAMETER DEVICE
Temperature Thermometer
Thermocouple
Flow Rate Ultrasonic Flow Meter
Electric Demand Electricity Meter
Speed Tachometer
Current and Voltage Ammeter and Voltmeter
 EQUIPMENT
REFRIGERANT:
PARAMETER DEVICE
Temperature Thermometer
Thermocouple
Pressure Differential Pressure Gauge
Flow Rate Ultrasonic Flow Meter
SENSITIVITY ANALYSIS
Refrigeration Plant
𝑅𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑒𝑓𝑓𝑒𝑐𝑡 = ℎ1 − ℎ4
211
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 =
ℎ1 − ℎ4
𝑣𝑜𝑙𝑢𝑚𝑒 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 𝑚 ∙ 𝑣1
ℎ1 − ℎ4
𝐶𝑂𝑃 =
ℎ2 − ℎ1
𝐸𝐸𝑅 = 3.413 ∙ 𝐶𝑂𝑃
𝑤𝑜𝑟𝑘 𝑝𝑒𝑟 𝑡𝑜𝑛 = 𝑚 ℎ2 − ℎ1
ℎ𝑒𝑎𝑡 𝑟𝑒𝑗𝑒𝑐𝑡𝑒𝑑 = 𝑚 ℎ2 − ℎ3
Independent Variables: Dependent variables:
• Vaporizing temperature • Refrigerating effects
• Condenser temperature • Mass flow rate
• Suction vapor • Volume flow rate
• Sub-cooling the liquid • Coefficient of Performance
• Energy efficiency ratio
• Work per ton
• Condenser performance
 SENSITIVITY ANALYSIS
Effects of increasing the vaporizing temperature

Compressor Condenser Condenser

Vaporizing Mass flow Work per ton Work per ton
Refrigerating Volume Performance Performance
temperature rate per ton k COP EER of refrigeration of refrigeration
Effect kJ/kg Capacity (heat rejected) (heat rejected)
⁰C g/min·ton kJ/min·ton kW/ton
m3/min·ton kJ/min·ton kW/ton

-10 108.6 1.943 0.1489 4.19 14.30 50.32 0.839 261.3 4.355

5 115.1 1.833 0.087 6.61 22.56 31.89 0.532 242.9 4.05

EFFECTS OF OPERATION CONDITIONS
Effects of increasing the vaporizing temperature:
1. The refrigerating effect per unit mass increases.
2. The mass flow rate per ton decreases.
3. The volume flow rate per ton decreases.
4. The COP increases.
5. The EER increases.
6. The work per ton decreases.
7. The heat rejected at the condenser per ton decreases.
 SENSITIVITY ANALYSIS
Effects of increasing the condenser temperature

Compressor Condenser Condenser

Condensing Refrigerating Mass flow Work per ton Work per ton
Volume Performance Performance
temperature Effect rate per ton COP EER of refrigeration of refrigeration
Capacity (heat rejected) (heat rejected)
⁰C kJ/kg kg/min·ton kJ/min·ton kW/ton
m3/min·ton kJ/min·ton kW/ton

40 108.6 1.943 0.1489 4.19 14.30 50.32 0.839 261.3 4.355

50 98.2 2.149 0.1647 3.18 10.85 66.40 1.107 277.4 4.623

EFFECTS OF OPERATION CONDITIONS
Effects of increasing the condenser temperature:
1. The refrigerating effect per unit mass decreases.
2. The mass flow rate per ton increases.
3. The volume flow rate per ton increases.
4. The COP decreases.
5. The EER decreases.
6. The work per ton increases.
7. The heat rejected at the condenser per ton increases.
 SENSITIVITY ANALYSIS
Effects of increasing the suction vapor

Mass Compressor Condenser Condenser

Refrigerating Work per ton Work per ton
Type of flow rate Volume Performance Performance
Effect COP EER of refrigeration of refrigeration
Vapor per ton Capacity (heat rejected) (heat rejected)
kJ/kg kJ/min·ton kW/ton
kg/min·ton m3/min·ton kJ/min·ton kW/ton

Saturated 110.8 1.904 0.1237 4.88 16.66 43.22 0.720 254.2 4.24

With
useful 123.5 1.709 0.1213 4.94 16.86 42.73 0.712 253.8 4.23
Cooling
Superheated
Without
Useful 110.8 1.904 0.1352 4.43 15.12 47.60 0.793 282.7 4.71
cooling
EFFECTS OF OPERATION CONDITIONS
Effects of superheating the suction vapor when
superheating produces useful cooling:
1. The refrigerating effect per unit mass increases.
2. The mass flow rate per ton decreases.
3. The volume flow rate per ton decreases.
4. The COP increases.
5. The EER increases.
6. The work per ton decreases.
7. The heat rejected at the condenser per ton increases.
EFFECTS OF OPERATION CONDITIONS
Effects of superheating the suction vapor when superheating
occurs without useful cooling:
1. The refrigerating effect per unit mass remains the same.
2. The mass flow rate per ton remains the same.
3. The volume flow rate per ton increases.
4. The COP decreases.
5. The EER decreases.
6. The work per ton increases.
7. The heat rejected at the condenser per ton increases.
 SENSITIVITY ANALYSIS
Effects of subcooling the liquid

Mass
Compressor Condenser Condenser
Refrigerating flow Work per ton Work per ton
Volume Performance Performance
Liquid Effect rate per COP EER of refrigeration of refrigeration
Capacity (heat rejected) (heat rejected)
kJ/kg Ton kJ/min·ton kW/ton
m3/min·ton kJ/min·ton kW/ton
kg/min·ton

Saturated 110.8 1.918 0.1246 4.88 16.66 43.53 0.726 256.1 4.268

Subcooled 120.8 1.747 0.1135 5.32 18.16 39.66 0.661 250.7 4.178
EFFECTS OF OPERATION CONDITIONS
Effects of sub-cooling the liquid:
1. The refrigerating effect per unit mass increases.
2. The mass flow rate per ton decreases.
3. The volume flow rate per ton decreases.
4. The COP increases.
5. The EER increases.
6. The work per ton decreases.
7. The heat rejected at the condenser per ton decreases.
SOLVED PROBLEMS
Refrigeration Plant
 A San Miguel Corporation processing plant that requires
cooling of 120 gpm of water from 15.6˚C to 10˚C, assume
that the cooler heat transfer surface area will enable a 5.5˚C
differential between the chilled water leaving the cooler and the
R-12 evaporating temperature. Also assume that the condenser
heat transfer surface area will enable a 5.5˚C differential
between the condenser water out and R-12 condensing
temperature. Water be available for the condensing medium at
29.4˚C inlet and 35˚C outlet. Assume no liquid subcooling or
suction gas superheating. Find the tons of refrigeration.
Given:
𝑔𝑎𝑙
V = 120
𝑚𝑖𝑛
𝑡1 = 15.6˚C
𝑡2 = 10˚C
𝑘𝐽
𝐶𝑝 = 4.187
𝑘𝑔 · 𝐾
Solution:
Refrigerating Load = m𝐶𝑝 ∆𝑡
𝑔𝑎𝑙 3.785 𝑙𝑖 1 𝑚𝑖𝑛
V = (120 )( )( )
𝑚𝑖𝑛 1 𝑔𝑎𝑙 60 𝑠
V = 7.57 L/s
7.57𝐿Τ𝑠
m=
1𝐿ൗ𝑘𝑔
m = 7.57 kg/s
∆t = 15.6˚C - 10˚C = 5.6˚C
Thus,
𝑘𝐽
Refrigerating Load = (7.57 kg/s)(4.187 )(5.6˚C)
𝑘𝑔·𝐾
= 177.51 kW
1 𝑡𝑜𝑛 𝑜𝑓 𝑟𝑒𝑓𝑟𝑖𝑔𝑒𝑟𝑎𝑡𝑖𝑜𝑛
= (177.51 kW)
3.516 𝑘𝑊
Refrigerating Load = 50.49 tons of refrigeration
A refrigerant 22 vapor compression system includes a liquid-to-suction heat
exchanger in the system. The heat exchanger warms saturated vapor coming
from the evaporator from -10° to 5°C with liquid which comes from the condenser
at 30 ⁰C. The compressions are isentropic in both cases listed below:

a. Calculate the coefficient of performance of the system without the heat exchange
r but with the condensing temperature at 30 ⁰C and an evaporating temperature of
-10 ⁰C.
b. Calculate the coefficient of performance of the system with the heat exchanger?
c. If the compressor is capable of pumping 12.0 L/s measured at the compressor su
ction, what is the refrigeration capacity of the system without the heat exchanger?
d. With the same compressor capacity as in (c), what is the refrigerating capacity of
the system with the heat exchanger?
Given:
Refrigerant 22
Liquid-to-suction heat exchanger
Evaporator from -10 to 5 C
Condenser at 30 C

Required:
• Coefficient of performance of the system without the heat exchanger but with the
condensing temperature at 30 C and an evaporating temperature of -10 C.
• Coefficient of performance of the system with the heat exchanger?
• Refrigeration capacity of the system without the heat exchanger?
• Refrigerating capacity of the system with the heat exchanger?
Solution:
A. Without heat exchanger
At 1,6, -10 C, Table A-6. (Stoecker and Jones)
h1 = h6 = 401.555 kJ/kg
s1 = s6 = 1.76713 kJ/kg∙K

At 2, 30 C, constant entropy, Table A-7

h2 = 431.787 kJ/kg

At 3,4 , 30 C, Table A-6

h3 = h4 = 236.664 kJ/kg
At 5, h5 = h4 = 236.664 kJ/kg
𝑘𝐽 𝑘𝐽
ℎ6 −ℎ5 401.555𝑘𝑔−236.664𝑘𝑔
𝐶𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑜𝑓 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 = = 𝑘𝐽 𝑘𝐽 = 5.46
ℎ2 −ℎ1 431.787𝑘𝑔 −401.555𝑘𝑔
B. With heat exchanger
At 6, -10 C, Table A-6 (Stoecker and Jones)
h6 = 401.555 kJ/kg

At 1, -10 C evaporator temperature, 5 C, Table A-7

h1 = 411.845 kJ/kg

At 2, 30 C, constant entropy, Table A-7

h2 = 444.407 kJ/kg

At 3, 30 C, table A-6
h3 = 236.664 kJ/kg
h3 – h4 = h1 – h6
h4 = h3 + h6 – h 1
h4 = 236.664 kJ/kg + 401.555 kJ/kg – 411.845 kJ/kg = 226.374 kJ/kg
h5 = h4 = 226.374 kJ/kg

𝑘𝐽 𝑘𝐽
ℎ6 − ℎ5 401.555 − 226.374
𝑘𝑔 𝑘𝑔
𝐶𝑂𝑃 = = = 5.38
ℎ2 − ℎ1 𝑘𝐽 𝑘𝐽
444.407 − 411.845
𝑘𝑔 𝑘𝑔
C. Refrigerating capacity without heat exchanger
At 1, v = 65.3399 L/kg
𝐿
12.0 𝑠
Refrigerating Capacity = 𝐿 ℎ6 − ℎ5
65.3399 𝑘𝑔
𝐿
12.0 𝑠
= 𝐿 (401.555 kJ/kg – 236.664 kJ/kg) = 30.3 kW
65.3399 𝑘𝑔

D. Refrigerating capacity with heat exchanger

At 1, v = 70.2751 L/kg
𝐿
12.0 𝑠
Refrigerating Capacity = 𝐿 (ℎ1 − ℎ5 )
70.2751 𝑘𝑔
𝐿
12.0 𝑠
= 𝐿 (401.555 kJ/kg – 226.374 kJ/kg) = 29.9 kW
70.2751 𝑘𝑔
COOLING TOWER
Refrigeration Plant
 COOLING TOWER

A cooling tower is a heat rejection device that rejects

waste heat to the atmosphere through the cooling of
a water stream to a lower temperature.
 COOLING TOWER

Heat is rejected primarily through EVAPORATION of

a small percentage of the circulating water – about
1% of the circulating flow rate for every 10 o F of
temperature drop (a.k.a Cooling range)
 Purpose of a Cooling tower
• The main purpose of a cooling tower is t
o cool water or other working medium to
near-ambient temperature.
• It also improves the over-all efficiency of
Refrigeration plant.
 Types of Cooling Tower
Direct System (Open Circuit) Indirect System (Closed Circuit)
 Direct System(Open Circuit)
• It is a heat exchanger that
cools the water through direct
contact with the air. The heat
transfer happens partially
through the heat exchange
between air and water, but
mainly through the evaporatio
n of part of the water that
needs to be cooled.
 Indirect System (Closed Circuit)
• An Indirect system is designed
so that there is no direct contac
t between the air and water that i
s being cooled. This kind of a sy
stem is also called a Closed Loo
p or Closed Circuit system, since
they do not allow the water to co
me into contact with any outside
contaminates. This keeps the
water much pure due to the lack
of foreign substances being allo
wed to enter the system.
 COOLING TOWER
How The Cooling Tower Impacts the Efficiency of Refriger
ation Cycle
It follows that the lower the condenser water temperature (that
which is circulating to the cooling towers) is, the less work the
compressor has to do. This helps keep the operational cost of
our chiller down. Specifically, for every pound of water, it
enables to evaporate in the cooling tower, we absorb another
1000 BTU from a building. That’s why the efficiency of the
cooling tower is so vital to the efficiency of the overall chilled w
ater system.
 COOLING TOWER
How does cooling tower work?
Cooling tower systems work by using water to extract waste heat from a
system and ejecting it into the atmosphere primarily through evaporation.
The three key components of a cooling system are the cooling tower,
recirculating pump, and heat exchanger. Water first passes through a heat
exchanger where it absorbs heat. The water is then distributed over the top
of the cooling tower where air travels past the warm water causing a
portion of the water to evaporate. The heat is transferred from the water
stream to the air stream, raising the air's temperature and its relative
humidity to 100%. This warm air is then discharged to the atmosphere,
resulting
in a cool water stream. The cooled water from the basin is then pumped
back through a heat exchanger and the cycle repeats.
 COOLING TOWER

Performance Testing
© Company: GTPL or Gactel Turnkey Projects Limited
 PERFORMANCE TEST

The purpose of this test procedure is to describe

instrumentation and procedures for testing and
performance evaluation of cooling towers.
 PERFORMANCE TEST

The cooling tower test is conducted in

reference with CTI Code ATC 105(00),
Schedule II Performance curve method &
mutually agreed conditions between client and
cooling tower supplier.
 CONDITION OF TEST
1. Test shall be conducted by accredited
representative of contractor and owner. The contract
or shall be given permission to inspect the tower in a
dvance and ready it for test. The readings recorded
at site shall be made in duplicate and shall be
signed by the representatives of contractor and own
er.
 CONDITION OF TEST
2. The guaranteed performance of the equipment shall
be demonstrated by the Contactor after evaluating the
P.G. Test. Should the results of the test deviates from the
guaranteed values the contractor shall be given
opportunity to modify the equipment as required to
enable it to meet the guarantees. In such cases the cost
of modification, including labor, materials and cost
of additional testing shall be born by contractor.
 CONDITION OF TEST

3. A maximum tolerance of 0.5 ⁰C in the cold

water temperature shall however be allowed to
take care of design and instrument
inaccuracies.
 GENERAL CONDITIONS

A.Condition of equipment
1. At the time of test, the tower shall be in good
operating condition. Tower may be inspected and
repaired, (if necessary) by the contractor, before the
test to ensure following.
 GENERAL CONDITIONS

2. Water distribution system shall be essentially

clear and free from foreign Materials, which may
impede the normal water flow.
 GENERAL CONDITIONS

3. Mechanical equipment shall be in good working

condition, with fans adjusted for proper rotation
and specified horse power loading.
 GENERAL CONDITIONS

4.Fills shall be essentially free from foreign materials

such as oil, tar, scale or Algae.

5. Drift eliminator shall be essentially clear and free

of algae and other deposits, which may impede
normal air flow.
 GENERAL CONDITIONS

6. Water level in the cold water basin shall be at

normal operating level and shall be maintained
substantially constant during the test.

7. The water quality shall be as close as possible to

its specifications. The Maximum TDS (Total Dissolve
d Solid) shall be +/- 10%.
 GENERAL CONDITIONS

B. Operating Conditions
1. The test shall be conducted within the following li
mitations.
 GENERAL CONDITIONS
2. Every effort shall be made to run the test under
design conditions or as close to design conditions as
possible.
 GENERAL CONDITIONS

C. Duration of Test
After reaching steady state conditions the duration of
test run shall not be less than one hour.
For mechanical –draft towers, duration of the test
run shall be not less than one hour, if thermal leg
time is greater than five minutes, the time test period
shall be at least one hour plus thermal lag.
 GENERAL CONDITIONS
D. Frequency of Test
Test readings shall be taken as per following schedule.
 GENERAL CONDITIONS
E. Constancy of Test condition
For a valid test verifications in the test condition shall be
within the following limits.
a. Circulating water flow not varies by more than 2%.
b. Heat load shall not vary by more than 5%.
c. Range shall not vary by more than 5%.
d. WBT 1 ⁰C per Hour.
e. DBT 3 ⁰C per Hour.
 GENERAL CONDITIONS
F. Test Instruments and their locations
1. Water flow measurements:
Water flow measurements can be made any of the following means.
- Pitot tube.
- Orifice plate.
- Venturi meter/ UFM’s.
- Weit
- Measurement of flow through single nozzle.
By measuring pump parameters or by pump manufacturer curves.
 GENERAL CONDITIONS
2. Wet bulb temperature measurements:
The measurement of inlet WBT is required for the testing of all t
ypes of cooling towers covered by this code.
WBT measurements shall be made by mechanically aspirated
Psychrometer or by sling psychrometer.
At each time four successive readings shall be made at four diff
erent stations located within 1.5 m of the air intake(s). Average
of these four readings will give a final reading for that time.
 GENERAL CONDITIONS
3. Water temperature measurements:
Water temperature measurements shall be made by
resistance. Thermometer or mercury in glass thermometers th
e indicator of which shall not be guaranteed in increments of n
ot more than 0.1 ⁰C.
a. Hot circulating water temperature measurements shall be m
ade tower riser or at outlet of tower riser on top of the tower.
b. Cold Circulating water temperature measurement shall be
made in cold water basin.
 GENERAL CONDITIONS

4. Power input measurements:

In case of electrical motors power input shall be det
ermined by measurement of voltage, current and po
wer factor. The measurement shall be made at mot
or terminal, proper de-rating for motor efficiency, po
wer factor to be considered in calculation.
 GENERAL CONDITIONS

G. Report of Result.
Recorded data during test will be co-related with perf
ormance with performance Curves of cooling tower a
nd report will be submitted in a month
CONCLUSION
Refrigeration Plant
Significant amounts of energy are consumed by refrigeration/air-conditioning
systems. An energy-saving approach that can be applied to new or existing
refrigeration/air-conditioning installations is discussed to increase system
performance and reduce energy consumption. It consists of adding a
mechanical sub-cooling loop to a conventional vapor-compression cycle.
The performance of a modified system is demonstrated for three different
applications. It was found that the system performance peaks at a
sub-cooler saturation temperature midway between the condensing and
evaporating temperatures. Simulations show that performance improvement
for air-conditioning systems can be as high as 20% during peak periods of
high condensing temperatures whereas high-temperature and
low-temperature refrigeration systems under these same conditions will
provide energy-savings of 20 and 40%, respectively.
fin