Chapter 3

REFRIGERANTS SYSTEM COMPONENTS

3.1 REFRIGERANT COMPRESSOR

Compressor is the heart of a VCR system. It sucks low pressure and temperature vapor
refrigerant from the evaporator and compresses it to high pressure and temperature vapor
refrigerant.

Function: Compressor helps in:

 Circulation of the refrigerant through the system.
 Producing low pressure in the evaporator so that liquid refrigerant evaporate at low
temperature prevailing there and thereby produce refrigerating effect.
 Increasing the temperature of the vapor refrigerant beyond the temperature of the
condensing medium (air or water) in order to reject heat.
Location: Compressor is located between the evaporator and condenser

CLASSIFICATION/TYPES OF REFRIGERANT COMPRESSORS S-18, 17, W-18, 16, 14

Refrigerant Compressors are classified on following basis:
Classification based on WORKING PRINCIPLE/METHOD OF COMPRESSION:
a) Positive Displacement Compressors
Eg. Reciprocating Compressors, Screw Compressors, etc.
b) Non-Positive Displacement Compressors or Dynamic Compressors
Eg. Centrifugal Compressors
Classification based on TYPE OF MOTION OF MOVING ELEMENT:
a) Reciprocating Compressors
b) Rotary Compressors Eg. Screw & Scroll Compressors
Classification based on LOCATION OF PRIMEMOVER:
a) Hermetically Sealed Compressors
b) Semi-Hermetic Compressors
c) Open Compressors
Classification based on ORIENTATION OF COMPRESSOR AXIS:
a) Vertical Compressors
b) Horizontal Compressors
Classification based on NUMBER OF STAGES:
a) Single Stage Compressors
b) Multi Stage Compressors
Classification based on NUMBER OF WORKING STROKES:
c) Single Acting Compressors
d) Double Acting Compressors
RECIPROCATING COMPRESSOR: (Construction & Working) S-17, W-17
Reciprocating compressor is a positive displacement compressor in which the refrigerant
vapour is compressed in two strokes of piston:
i. Suction Stroke: The refrigerant vapor is sucked from the evaporator through the suction
line when the piston moves from TDC to BDC, filling the cylinder.
i. Delivery or Discharge Stroke: The trapped refrigerant vapour is now compressed as the
piston moves from BDC to TDC. The compressed vapour is discharged to condenser.
 SUCTION STROKE DISCHARGE STROKE

HERMETICALLY SEALED COMPRESSOR S-22, 19, 16, W-18

A compressor is called hermetically sealed compressor, when the compressor & motor are
mounted on the same shaft and both are encased (sealed) in a welded steel shell or casing.
There is no need of crank shaft seal as leakage of refrigerant is fully eliminated.
Capacity: Hermetic compressors are available in the range of 0.5 to 10 tons.
Advantages or Merits of Hermetic Compressors: S-22, 16, 15, W-15
a) Leakage of refrigerant is eliminated.
b) It is compact & light – weight unit. So require less space.
c) Portable unit.
d) It has less noise & vibration.
e) Motor is cooled by the low temperature vapor refrigerant.
f) It is moisture and dust free unit.
g) Simple lubrication.
h) Efficient unit.
i) No need of crankshaft seal.
j) It gives service for prolonged period without requiring constant attention.
k) Suitable for small capacity home appliances like window/split a/c, freezer, water cooler.

Disadvantages or Limitations or Demerits: S-16, 15, W-15

a) Maintenance, service & repair is difficult as parts are inaccessible.
b) Separate Vacuum Pump is required for evacuation & charging of refrigerant.
c) Capacity of hermetic units is limited.
d) Presence of moisture may harm the motor windings.
e) Lubricating oil may mix with refrigerant.
f) Compressor must be scrapped in the event of damage.
Applications: S-19, 16
a) Hermetic compressors are preferred for small capacity constant load applications
Eg. In Domestic Refrigerators, Water Coolers, Window/Split A/C, Freezers, etc.
 b) It is preferred for household applications since it doesn’t require constant attention,
eliminates leakage and reduces noise.

SEMI-HERMETIC COMPRESSOR
Semi-hermetic compressors use a cast iron casing. The motor and compressor are still housed
together but located in a two-piece shell. The covers are bolted together, allowing the cover to
be opened for servicing, repair, etc.
Advantages:
o It provides access to key compressor parts so they can be repaired or replaced.
o This enables easy maintenance checks & servicing.
o These have longer life

Note:
Semi-hermetic compressors are generally a little
more expensive than hermetic compressors, due to
the bolts and O-rings needed to join the covers.
Applications:
For larger capacity applications compared to
hermetic units.

OPEN COMPRESSOR S-17, 16, 14

In an open compressor, the motor and the compressor housing are mounted separately. An
open compressor is driven by the motor/prime mover with the help of pulley – belt system.
The compressor & motor are mounted on the same base plate and are kept open for servicing,
maintenance or repair.

Because the open compressor lacks a seal around it, there is risk of refrigerant leakage.
The advantages are that the compressor components are easily accessible for maintenance or
repair and the cost of a shell can be avoided.
Use or Application: In large installations, industrial applications, Central A/C, etc. where
capacity requirement is high and fluctuating in nature. These units require frequent
service/repair.
 Note: In open compressors, Motor is cooled by
atmospheric air

COMPARISON OF OPEN & HERMETICALLY SEALED COMPRESSORS S-17, 16, 14

OPEN
PARAMETERS HERMETIC COMPRESSORS
COMPRESSORS
Compressor & motor are not
1. Compressor & mounted on the same shaft. Pulley
Compressor & motor are
Motor assembly mounted on the same shaft.
– belt system is used for coupling.
Easily accessible for servicing, Not accessible for servicing,
2. Accessibility
for
maintenance or repair as it is kept maintenance or repair as it is
Maintenance &
open. So maintenance & servicing sealed (encased) in a welded
Servicing
is easy. steel shell
Leakage is eliminated due to
3. Leakage More chances of leakage
casing.
Cooled by vapor refrigerant
4. Motor Cooling Cooled by atmospheric air.
from evaporator
5. Noise Noisy in operation. Less noisy.
6. Moisture/dust It is not free from moisture & dust It is moisture & dust free unit.
7. Space More. Less as it is a compact unit.
requirement
8. Construction Simple Difficult
In large capacity applications like In small capacity constant load
9. Applications cold storage, ice plant, central air domestic uses like refrigerators,
conditioning, etc. coolers, etc.

ROTARY COMPRESSORS
SCREW COMPRESSORS S-16, W-15
It is composed of two rotors with complementary profiles referred to as male (Driver) and
female (Driven) rotors. The rotor profiles are designed to decrease the volume between them
continuously from the inlet to the outlet of the compressor.
Vapor refrigerant is thus squeezed between the two meshed rotors, the volume is then
continuously reduced as it moves through the rotors. The reduction in volume results in
compressed vapor.

The refrigerant is drawn from the low-pressure to the high pressure side with a continuously
decreasing volume, i.e. continuously increasing pressure.
Note: Screw compressors have neither suction valves nor delivery valves, only a non-return
valve to ensure that there is no return flow of refrigerant when the compressor is stopped.
A screw compressor is a rotary type of
positive displacement compressor

Advantages: W-15
a) Screw compressors can work at a high compression ratio.
b) High Volumetric Efficiency.
c) High Mechanical Efficiency.
d) Higher part load efficiency.
e) Less moving parts. Hence wear & tear is limited.
f) Continuous & uniform discharge.
g) Less noise & vibrations.
h) High overall efficiency & reliability.
i) Eliminates pressure drops due to absence of suction/discharge valves.

Application: Screw compressors can commonly be found where large volumes of high pressure
refrigerant is required.
SCROLL COMPRESSORS S-19, 16, 14
Scroll compressors capture the vapour in the volume formed between one fixed and one
orbiting scroll. The orbiting scroll is driven by an electric motor, which rotates a shaft. The
scrolls perform an orbiting motion. They do not rotate.

A scroll compressor is a rotary type of positive

displacement compressor. Vapor refrigerant enters
at the outer ends of the spirals and is compressed
on its way through the scrolls due to the orbiting
motion of one of the spirals. The discharge hole,
where high-pressure gas leaves, is located in the
centre of the scrolls.

Applications: S-19
a) Residential & automotive air conditioning.
b) Heat Pumps.
c) Refrigerated Vans.
d) Refrigerated marine containers, etc.

Note: Scroll compressors are available in both open and hermetic design.
Advantages: S-16, 14
a. The absence of suction and discharge valves eliminates pressure drops.
b. Lower maintenance requirements.
c. The scrolls have no dead space, which results in high volumetric efficiencies.
d. Fewer moving components, leading to a lower failure rate.
e. High durability & long life.
f. High efficiency and reliability
g. Low noise & vibrations
Disadvantages: S-16, 14
a. Complicated design
b. Expensive
c. Low capacity (up to 20 tons)
d. These units are not easily repairable. So, they are usually replaced.
CENTRIFUGAL COMPRESSORS
Working:
Centrifugal compressors, also known as turbo or radial compressors, pressurize a refrigerant
by forcing the refrigerant through a rotating impeller. The impeller spins the refrigerant at high
speed. The kinetic energy is then used to pressurize the refrigerant by passing it through a
diffuser and volute casing, which slows the refrigerant vapour’s radial speed, resulting in
conversion of the kinetic energy to pressure energy.

Applications: Centrifugal compressors suited for compressing refrigerants having large volumes
and requiring low condensing pressures (like R-11, R-113). Additionally, centrifugal
compressors can be set up in either single, two-stage, or multi-stage configurations to further
compress the refrigerant to a higher pressure and temperature based on the application
requirements.
 Centrifugal compressor is a dynamic or non-
positive displacement compressor

Advantages of Centrifugal Compressor

a) Suitable for high capacity systems (50 to 5000 Tons).
b) High reliability and long life.
c) Low maintenance cost and easy lubrication.
d) Low floor space requirement.
e) Fewer rubbing parts.
f) High speed and hence can be directly coupled with prime mover.
g) Ability to handle high refrigerant flow rate due to high speed.
h) Energy efficient.
i) Low noise & vibrations.
Disadvantages of Centrifugal Compressor
a) Unsuitable for low capacity applications (less than 50 tons).
b) Unsuitable for very high compression, limited pressure rise per stage.
c) They are sensitive to changes in gas composition.
d) They work at high speed, sophisticated vibration mounting needed.
e) Problem of surging when refrigerant load decreases.
Applications of Centrifugal Compressor S-19
a) Suitable for use with refrigerants having high specific volumes.
b) Suitable for high capacity applications requiring large refrigerant flow rates.
3.2 CONDENSER W-18, 17, S-16
Function: A condenser is a heat exchanger which rejects the heat of compression and the heat
absorbed in the evaporator (RE) by the refrigerant by cooling the refrigerant vapor coming from
the compressor, it is converted back into liquid phase.

 During condensation heat is rejected in the form of latent heat of vaporization.

 Condenser makes available the liquid refrigerant for re – expansion in the evaporator.
 Cooling Medium: Air or Water is used as
the cooling medium in the condensers.
Location: Located after compressor and
before expansion device in the high
pressure side of VCRS.

CLASSIFICATION OR TYPES OF CONDENSERS W-18, S-16, 15

Condensers may be classified on the following basis:
1. On the basis of cooling medium used:
a) Air cooled Condensers
b) Water cooled Condensers
c) Evaporative Condensers
2. On the basis of construction:
a) Shell & Tube Condensers
b) Shell & coil Condensers
c) Double pipe Condensers
d) Finned Condensers

AIR COOLED CONDENSERS

An air cooled condenser is one where refrigerant vapor is condensed inside air-cooled
condenser tubes. The cool ambient air flowing outside the tubes is used as cooling medium to
remove heat.

Advantages:
a) Simple
b) Low maintenance
c) Low initial cost
d) Low operating cost
e) No fouling problem

Applications:
Suitable for low capacity home use
like refrigerator, window & split a/c,
water cooler, etc.
Note: The condenser tubes are usually provided with thin Aluminium fins to increase the
surface area of contact to increase heat transfer rate.
Disadvantages of Air Cooled Condensers:
a) Operates at high condensing temperature.
b) More power required by compressor due to high condensing temperature.
c) Low heat transfer rates.
 d) Large size condenser required.
e) Its use is restricted to 10 tons.

Types:
Natural Convection Type Eg. Finned Condensers & Plate Condensers.
Forced Convection Type Eg. Bare tube & Finned Condensers

Natural Convection Type Air Cooled Condensers:

The heat is transferred from the refrigerant inside condenser coils to the outside atmospheric
air due to natural convection.

Use: They have limited applications as they are large and have low heat transfer
rate.

Forced Convection Type Air Cooled Condensers:

The heat is transferred from the refrigerant inside condenser coils to the outside atmospheric
air due to forced convection using a condenser fan.

Use: They are smaller in size with higher heat

transfer rate and hence suitable for small
capacity domestic use.

WATER COOLED CONDENSERS:

A water cooled condenser is one where refrigerant vapor is condensed in condenser tubes
using water as cooling medium to remove heat.

Advantages of Water Cooled Condensers:

a) High heat transfer rate
b) Low condensing temperature
c) Suitable for high capacity installations.
d) Quiet operation.
e) Higher COP using this type condenser.

Disadvantages of Water Cooled Condensers:

a) Higher maintenance & capital cost.
b) Fouling problem with condenser surface.
c) Requires cooling tower or cooling pond.
So construction is complicated.

Applications of Water Cooled Condensers: It is suitable for high capacity applications like
a) Cold Storage
b) Ice Plant
c) Central Air Conditioning
d) Industrial or Process Refrigeration & air conditioning applications
Types of Water Cooled Condensers:
a) Shell & Tube Condensers
b) Shell & coil Condensers
c) Double Pipe or Tube in Tube Condensers

COMPARISON OF AIR COOLED CONDENSERS & WATER COOLED CONDENSERS.

Parameters Air Cooled Condensers Water Cooled Condensers
1. Cooling Medium Atmospheric Air Water
Complicated.
2. Construction Simple
More no of parts
3. Maintenance Cost Low High
4. Initial Cost Low High
5. Handling Problem No Handling Problem Handling is difficult
6. Condensing
High Low
Temperature
7. Corrosion Little or no corrosion More prone to corrosion
8. Fouling Problem Low High due to corrosion
Low as air has low High as water has higher
9. Heat Transfer Rate
conductivity conductivity
10. Disposal &
Cooling Water is usually recirculated
Recirculation of Not required for cooling air
after cooling in cooling tower/pond
Cooling Medium
11. Noise Noisy due to condenser fan Less noisy
Low when using air cooled High when using water cooled
12. COP
condenser condenser
13. Power/TR Power per TR is more Power per TR is less
Low capacity domestic units
Higher capacity units like Central
like Window/Split A/C, Water
14. Applications A/C, Cold Storage, Ice Plant, etc.
Coolers, Freezers, etc.
requiring more than 15 TR.
requiring less than 15 TR.

EVAPORATIVE CONDENSERS: Construction & Working: W-17, S-19, 17, 16

In evaporative condensers, both air and water are used to extract heat from the condensing
refrigerant.
In these condensers, the water is sprayed from the top on a bank of condenser coils or tubes carrying
the refrigerant vapor to be condensed. Air is pulled over the coil, causing a small portion of the
recirculating water to evaporate. The evaporation removes latent heat from the refrigerant vapor in
the coil, causing it to condense.

The counter current of water spray to the airflow acts as cooling tower. A small quantity of
water is evaporated into the air thereby cooling the remaining water cascading to the basin at
the bottom. Post evaporation the saturated air passes through the drift eliminators and then
forced out using a fan
Note: There is a thin water film around the condenser tubes from which evaporative cooling
takes place. The heat transfer for evaporative cooling is very large. Hence, the refrigeration
system can be operated at low condensing temperatures.

Advantages or Benefits of Evaporative Condenser Limitations of Evaporative Condenser

a) These condensers require less power. a) More refrigerant required.
b) Installation and maintenance are easier. b) Long condenser tube required.
c) Cheaper than water cooled condensers
d) Less cooling water required.
e) Fast & efficient heat transfer.
f) Compact unit and hence less space required.

Applications of Evaporative
Condenser:
It is used in large capacity
applications where cooling
water available is scarce or
space is limited.

SHELL & TUBE WATER COOLED CONDENSERS: I

Construction: It consists of a cylindrical steel shell containing a number of straight
water tubes, placed horizontally. The water tubes can be made of copper or steel
depending on the type of refrigerant. The tube sheets are welded to both ends of the shell.
The shell is closed at both ends by removable cover box which are bolted to it.

Working: In this type of condenser, the hot vapour refrigerant enters from the top of shell
and condenses as it comes in contact with the straight horizontal tubes, containing cold
water. The condensed liquid refrigerant drops to the bottom of the shell, which often
serves as a receiver.
Note: It can be made in single or multiple pass configuration.
Advantages:
a) Relatively simple design.
b) Suitable for higher pressures and temperatures
c) Pressure drop is less than a plate heat exchanger.
d) Easy to find and isolate leaking tubes.
Disadvantages
a) Heat transfer efficiency is less compared to plate type cooler.
b) Cleaning and maintenance is difficult.
c) Capacity cannot be increased.
d) Requires more space in comparison to plate coolers.
DOUBLE PIPE OR TUBE IN TUBE WATER COOLED CONDENSER:
It consists of two tubes arranged in such a manner that, one tube is inside the other. In this
type of condenser, the hot vapour refrigerant enters from the top side of the condenser and is
circulated through outer tubes. The cooling water passing through the inside tube in counter
flow arrangement cools the refrigerant in the outside tubing till it is condensed and collected
at the bottom.

3.3 WHAT IS AN EVAPORATOR? W-17, 15

An evaporator is that part of VCR System in which liquid refrigerant is vaporized at the
prevailing low pressure and temperature conditions to produce refrigerating effect due to the
extraction of latent heat of vaporization from the surrounding space which is cooled or
refrigerated.
Function of Evaporator: S-15
To produce cooling or Refrigeration Effect by absorbing latent heat from the space/substance
cooled
Location of Evaporator:
In the low pressure side after expansion device and before compressor.
Necessity to Maintain Low Pressure in the Evaporator
Maintaining low pressure is necessary in the evaporator so that the refrigerant evaporates in it
at a temperature lower than the temperature required to be maintained in the refrigerated
space. So, heat is transferred from the refrigerated space to the refrigerant in the form of latent
heat of vaporization of vaporizing refrigerant.
CLASSIFICATION OF EVAPORATOR
On the basis of construction: Shell & Coil Evaporator
 Bare Tube Evaporators
 Finned or Extended Surface Evaporators
 Plate Evaporators
 Shell & Tube Evaporators
 Shell & Coil Evaporators
 Tube in Tube Evaporators

On the basis of operating condition: Tube in Tube Evaporator

 Flooded – type Evaporators
 Dry Expansion Evaporators

On the basis of mode of heat transfer:

 Natural Convection Evaporators
 Forced Convection Evaporators

On the basis of operating temperature or frosting:

 Frosting Evaporators: Operates below 0⁰C and the coil frosts continuously.
Eg. Freezer
Non-Frosting Evaporators: Operates above 0⁰C and so does not frost.
Eg. Chiller, Refrigerator for fruits & vegetables.
 Defrosting Evaporators: Frost is formed when unit is running and defrosts when unit is
stopped.

BARE TUBE EVAPORATORS:

Bare tube evaporators are the simplest type of evaporator. These evaporators comprises of
several turns of the evaporator tubing (made of either copper or steel). No fins are provided
on the tubes.
Note: These evaporator tubes
are most commonly flat,
circular and oval shaped.

Applications:
a) In low capacity applications like household refrigerators and freezers.
b) In liquid chilling.
c) In the blast cooling and the freezing operations.
Advantages: Bare tube evaporators are:
a) Simple & cheap
b) Easy to clean
c) Easy to defrost
d) Suitable for household low capacity applications.
Limitations of Bare Tube Evaporators:
a) Low heat transfer rate
b) Unsuitable for large cooling requirements in commercial & industrial uses.

FINNED OR EXTENDED SURFACE EVAPORATORS:

The finned evaporators are bare tube type evaporators covered with fins. The finned tube
evaporator is more complex and more effective.

Note: The fins are the external protrusions in the form of thin plates from the surface of the coil.
They help in removing the heat from the fluid that otherwise would not have come in contact
with the coil. This is what makes the finned tube evaporators the most effective.
Applications:
The finned evaporators are used in air conditioners of almost all types like window, split,
packaged and the central air conditioning systems.

PLATE EVAPORATORS:
In plate evaporators the coils are either welded to one side of a plate or embedded between
two plates, so as so to form a flat looking surface.
Externally the plate type of evaporator looks like a single plate, but inside it there are several
turns of the metal tubing through which the refrigerant flows.
Advantages of the Plate Evaporators:
a) They are more rigid as the external plate provides lot of safety.
b) The external plate also helps increasing the heat transfer rate.
c) They are easy to clean and manufacture.
d) They can be easily formed into various shapes as per requirement.
e) High flexibility

Plate Evaporator Types

Applications: Due to various advantages and flexibility offered by the plate evaporators, they
are used extensively as listed below:
a) In the household refrigerators & deep freezers, where they are used most commonly,
they can be converted into the box shape to form a closed enclosure, where various
food can be kept in the frozen state.
b) Plate types of evaporators provide excellent shelves in the freezers and similar
applications.
c) They can be used as the as partitions in the freezers, frozen food display cases, ice
cream cabinets, soda fountains and others.
FLOODED EVAPORATORS: S-18, 16, W-18, 16, 15
Evaporator is said to be flooded type if liquid refrigerant wets the entire tube surface by filling
the evaporator tubes completely with liquid refrigerant irrespective of the load
applied on the evaporator. As the refrigeration load varies, a refrigerant -level
control acts to maintain the required liquid level in the accumulator shell.
Construction: The flooded evaporator consists of a drum (Accumulator or Flash Chamber) which
is used to store the liquid refrigerant by maintaining the required level of liquid refrigerant in
the evaporator with the help of float control. The flooded evaporator drum is also used to
separate the liquid refrigerant from vapour refrigerant. The vapor refrigerant is sucked by the
compressor after passing through baffle or eliminators which trap and retain the liquid
refrigerant.
Working: When load increases, due to the heat absorbed by the liquid refrigerant from the
substance to be cooled, it converts into vapour refrigerant and moves to the top of the
accumulator drum for suction to compressor. Consequently, the liquid level in the drum gets
decreased. The float senses the fall in liquid level and allows more liquid refrigerant to enter
through the float valve till the liquid refrigerant regains the required level.
When load decreases, the float mechanism will reduce or stop the flow of liquid
refrigerant. Since the evaporator tubes are always filled with refrigerant, only saturated vapour
refrigerant is produced by flooded evaporators.
Advantages of Flooded Evaporators:
a) High heat transfer rates.
b) Better heat transfer efficiency.
c) Fully wetted heat transfer surface increases the efficiency of evaporator.
d) Higher partial load efficiency.
e) Suitable for heavy duty and fluctuating refrigeration loads.

Disadvantages of Flooded Evaporators:

a) Expensive.
b) More refrigerant required.
c) Danger of wet compression.

Applications of Flooded Evaporators: These evaporators are suitable for use in:-
a) Large refrigeration installations like cold storage, ice plant, etc.
b) Fluctuating refrigeration loads like in process refrigeration & A/C.
c) Industrial refrigeration & air conditioning.
d) Multi-evaporator systems.

DRY EXPANSION EVAPORATORS: S-15, W-17

The dry expansion or direct expansion is the type of evaporator in which the mass flow of the
refrigerant to the evaporator is limited to the amount that can be evaporated completely, so
that only slightly superheated refrigerant vapour enters the compressor.

The expansion device normally used is Thermostatic Expansion Valve. The superheat at the
outlet end of the evaporator is usually about 5 to 10 ⁰C. The expansion valve uses the superheat
detected by the temperature sensor to adjust the refrigerant flow required by the evaporator.
Advantages of Dry Expansion Evaporators:
a) Simple and light weight.
b) Cheap.
c) Less refrigerant required.
d) Prevents entry of wet refrigerant into compressor.
e) Suitable for low to medium capacity installations.
Disadvantages of Dry Expansion Evaporators:
a) Less efficiency.
b) Less heat transfer rates & heat transfer efficiency
c) Unsuitable for large fluctuating loads.

Applications: These evaporators are the most commonly used in:-

a) In small & medium capacity domestic and commercial refrigeration systems like room
air conditioners, water coolers, refrigerators, freezers.
b) Water chilling in air conditioning plants.
c) Liquid or brine solutions cooling in refrigeration plants.
d) Water heating in heat pump systems.
e) In medium and low temperature refrigeration.

COMPARISON OF DRY EXPANSION & FLOODED EVAPORATORS: W-18

Parameters Dry Expansion Evaporators Flooded Evaporators

1. Construction Simple & Light weight Complicated & Heavy

2. Initial Cost Low High

3. Refrigerant required Less More
4. Efficiency Less High
5. Heat Transfer Rate Low High
⅓ to ⅕ filled with liquid
6. Evaporator Coils refrigerant
Full of liquid refrigerant

Small & medium capacity Large installations requiring

7. Applications installations fluctuating loads
SHELL AND TUBE EVAPORATOR:
Shell and tube evaporator consists of a copper/steel tube bundle inside a large outer shell.
They are very efficient at cooling large quantities of water/fluid.
Heat will transfer from the water/fluid inside the coils to the refrigerant in outer shell.
Refrigerant gets vaporized and thereby cool the water/fluid. The refrigerant vapour is sucked
by compressor.
Applications:
The shell and tube types of evaporators are
a) Used in the large refrigeration and central air conditioning systems.
b) Used as chillers in industrial or commercial settings where large quantities of cold
water/fluid are needed.

Limitations:
a) It is not suitable for small capacity applications.
b) It cannot be used in freezing applications
c) Expensive
d) Requires costly maintenance.

CLASSIFICATION OR TYPES OF CHILLERS: S-18, 15, W-16

On the basis of operating condition:
 Dry Expansion Chillers
 Flooded Chillers
On the basis of Refrigeration Cycle used:
 Vapor Compression type Chillers
 Vapor Absorption type Chillers
DRY EXPANSION TYPE (DX) CHILLERS: S-18
The refrigerant flows along the tube side and the fluid to be chilled flows along the shell side.
The flow of the refrigerant to these chillers is controlled by the expansion valve. It is ensured
that refrigerant leaves the chiller as superheated vapour by controlling flow rate of refrigerant
as per the cooling load requirements.
Advantages: It is a low cost & light-weight chiller.
Applications: Suitable for low capacity chillers.
Flooded Chillers:
The refrigerant flows along the shell side and fluid to be chilled (water or brine) flows along the
tube. This is opposite of dry expansion chillers. In these chillers the level of the refrigerant is
kept constant by the float valve that acts as the expansion valve. The level of refrigerant in the
shell is maintained such that the tube bundle is fully submerged or flooded.
Advantages: High heat transfer rate and chilling capacity.
Limitations:
a) It is heavy & expensive Chiller.
b) Requires large quantity of refrigerant.
Applications:
a) Suitable for high capacity industrial chillers and air conditioning applications.
b) Suitable for fluctuating load applications.

3.4 Give the location of an expansion device in Vapor Compression Refrigeration (VCR) System?
Explain its function. S-16, W-16
Location of an Expansion Device:
An expansion device is located after condenser and before evaporator in the liquid line.
Functions of an Expansion Device:
a) Throttling Function: It expands the high pressure and temperature liquid refrigerant
entering from condenser into low pressure and temperature mainly liquid refrigerant,
which is fed into the evaporator.
b) Metering Function: It may also regulate the refrigerant flow rate to suit varying load
conditions.

Classify the expansion devices or List the types of expansion devices. W-16
Main types of expansion devices are:
a) Capillary Tubes.
b) Thermostatic Expansion Valves (TEVs) or Constant Superheat Expansion Valves.
c) Automatic Expansion Valves (AEVs) or Constant Pressure Expansion Valves.
d) Electronic Expansion Valves.
e) Manual Expansion Valves.
f) Float Valves.
State the construction & working principle of capillary tube. State its advantages. S-18, W-17
The capillary tube is one of the most commonly used throttling devices in small capacity
refrigeration and air conditioning systems subjected to constant load.

Construction: The capillary tube is usually a copper tube with a very small internal diameter
fitted in the liquid line before evaporator. It is of very long length and is coiled to several turns
so that it would occupy less space.

Working Principle: S-18

The capillary tube throttles the refrigerant from the condenser to the evaporator. When the
refrigerant leaves the condenser and enters the capillary tube, its pressure drops down due to
the frictional resistance encountered in the flow of liquid refrigerant through the capillary tube
having a very small diameter and long length.

Note: The capillary tube is a non-adjustable device that means one cannot control the mass
flow rate of the refrigerant. That is why the capillary tube is designed for constant load/certain
ambient conditions.
Capillary Tube Size: A capillary tube is usually 1–6 m long with an inside diameter generally from
0.5 – 2.28 mm.
Applications of Capillary Tube: It is used in small capacity constant load applications. Capillary
tubes are used as the throttling device in
a) Domestic Refrigerators,
b) Freezers,
c) Water Coolers,
d) Room Air Conditioners, etc.

Advantages of Capillary Tube: W-17

a) It is simple & cheap.
b) It has no moving parts. Therefore it doesn’t need maintenance.
c) Long life.
d) It is compact and light weight.
e) It can be used for hermetic compressor-based systems.
f) Receiver is not required in these systems as the refrigerant flow rate is constant.
g) During off-cycle, pressure equalization occurs between condenser and evaporator. This
reduces the starting torque requirement.
Disadvantages of Capillary Tube:
a) It is unsuitable for fluctuating & large refrigeration loads.
b) It is not capable of metering refrigerant flow for changing load requirements.
c) Clogging may happen due to narrow bore of the tube..
d) During off-cycle liquid refrigerant flows to evaporator. The evaporator may get flooded
and the liquid refrigerant may flow to the compressor and damage it.
e) Accumulator is required after the evaporator to prevent entry of liquid refrigerant to
compressor.

Why is capillary tube usually used as an expansion device for domestic applications like
refrigerators, water coolers and room air – conditioners? S-16
Capillary tube is usually used as an expansion device for domestic refrigerators, water coolers
and room air – conditioners because:
 It is cheap.
 It is simple in construction and operation.
 It is very compact and light weight.
 It is suitable for constant load applications.

Explain the construction & working principle of Automatic Expansion Valve (AEV) or Constant
Pressure Expansion Valve S-16
Construction: It consists-
a) Metallic body containing a metallic diaphragm or bellow & inlet/outlet ports..
b) On the upper side of the diaphragm is a spring which is under pressure (controlled by
the adjusting screw).
c) Below the diaphragm, there is a thin plate or valve seat that has a small opening. The
opening in the seat is controlled by the needle valve connected to the diaphragm.
Working Principle:
AEV works in response to pressure changes in evaporator due to increase or decrease in
refrigeration load. The valve maintains constant evaporator pressure irrespective of the varying
load by controlling the mass of refrigerant flowing into the evaporator. Therefore, AEV is also
called as Constant Pressure Expansion Valve.

Working: The opening and closing of this valve depends on two forces:
i. Spring Pressure (Ps) acts on the top of diaphragm and pushes it down with the needle
valve causing the valve to open.
ii. Evaporator Pressure (Pe) acts beneath the diaphragm and pushes it in an upward
direction. Due to this, the needle valve tends to move in an upward direction to close
the valve.

Normal operation:
The valve maintains equilibrium between the evaporator pressure and the spring pressure and
maintains a certain opening of the valve to allow the flow of refrigerant through it.
Operation under reduced refrigeration load:
Evaporator pressure (Pe) decreases in response to reduction in refrigeration load. Therefore
spring pressure will be more than evaporator pressure causing the valve to open to increase
the mass flow rate of refrigerant to evaporator till desired evaporator pressure is reached.
Operation under increased refrigeration load:
Evaporator pressure (Pe) increases in response to increase in refrigeration load. Therefore
spring pressure will be less than evaporator pressure causing the valve to move in the closing
direction to reduce the mass flow rate of refrigerant to evaporator till desired evaporator
pressure is reached.
Advantages of Automatic Expansion Valve (AEV):
a) It is simple.
b) Relatively cheap compared to other valves.
c) Low maintenance
d) Highly suitable for applications having constant cooling requirement.
e) AEV provides constant pressure. This makes it easier to adjust.
f) The consistent pressure also makes the compressor more efficient.
Disadvantages or Limitations of Automatic Expansion Valve (AEV):
a) Starving of evaporator when the refrigeration load increases:
When the load on the evaporator is increases it won’t allow more flow of the refrigerant
as per the requirement leading to starvation of evaporator and reduced cooling.
b) Flooding/Damage of compressor when the refrigeration load decreases:
When the load is lesser, it won’t allow a reduction of the flow of the refrigerant as per
the requirement. The valve will open and allow more liquid refrigerant to enter
evaporator and leading to flooding of compressor and consequent damage.
c) It does not allow the control of the mass flow of the refrigerant as per load requirements.
So it is unsuitable for fluctuating load applications.

Application of Automatic Expansion Valve:

a) Highly suitable for applications having constant cooling requirement.
Eg. Milk chilling units, water coolers, ice cream storage cabinets, etc.
b) They are also used in home freezers and small commercial refrigeration systems where
hermetic compressors are used.

Explain the construction & working principle of Thermostatic Expansion Valve (TEV)
S S-19, 18, 17, 16, W- 17, 16
Thermostatic expansion valves or TEVs are popular expansion devices due to their simplicity
and their relatively good sensitivity & accuracy in regulation.
The TEV maintains a constant superheat of vapour refrigerant at the exit of the evaporator
under all conditions by adjusting the mass flow of refrigerant in response to the cooling load.
So this valve is also called as CONSTANT SUPERHEAT EXPANSION VALVE.
Construction: It consists of:
i. Valve housing containing a metallic diaphragm.
ii. Spring which is under pressure (controlled by the adjusting screw) on the lower side of
the diaphragm.
iii. Valve seat below the diaphragm.
iv. Needle valve connected to the diaphragm.
v. Feeler or Thermal Bulb containing a volatile fluid mounted on the suction line near the
exit of evaporator. A capillary conveys the feeler bulb pressure on the top of diaphragm.
vi. There are also two openings in the valve for the refrigerant entry & exit.

Working: The opening and closing of this valve depends on the following forces:
i. Spring Pressure (PS) acting vertically upwards on the below the diaphragm.
ii. Evaporator Pressure (PE) acting vertically upwards below the diaphragm.
iii. Bulb Pressure (PB) acting vertically downwards on the top of diaphragm.

For equilibrium PB = PS + PE
Normal operation: The valve maintains equilibrium between the bulb pressure PB acting
vertically downwards and evaporator pressure PE & spring pressure PS acting vertically upwards
and maintains a certain opening of the valve to allow the flow of refrigerant through it.
Note: TEV maintains constant level of superheat at evaporator exit as per the setting of the
spring pressure.
Operation under increased refrigeration load: Any increase in refrigeration load increases the
superheat level of vapour refrigerant and hence the bulb pressure increases This moves the
needle valve downwards, opening the valve orifice and thus increasing the refrigerant mass
flow.
Operation under reduced refrigeration load: Any decrease in refrigeration load decreases the
superheat level of vapor refrigerant and hence the bulb pressure decreases. This moves the
needle valve upwards, closing the valve orifice and thus decreasing the refrigerant mass flow.

Advantages of Thermostatic Expansion Valve (TEV):

a) Suitable for systems subjected to fluctuating refrigeration loads.
b) Efficient operation under varying load conditions.
c) It avoids compressor damage due to entry of liquid refrigerant.
d) It helps in producing optimum cooling effect.
e) Capacity and temperature ranges are very good.

Disadvantage of Thermostatic Expansion Valve (TEV):

a) TEV does not work well, if its feeler bulb is not in a good thermal contact with the
refrigerant tube.
b) If there is very small superheating, TEV cannot be used.
c) Necessity of superheating steals heat transfer area from the evaporator.

SELECTION OF EXPANSION DEVICES

The commonly used expansion devices are:
a) Capillary Tube: For small capacity constant load applications
b) Expansion Valves:
o Thermostatic Expansion Valves
For small to medium capacity fluctuating load applications.
o Automatic Expansion Valve
For constant load applications
c) Float Valves: For large capacity installations with varying load conditions
3.5 Explain the construction & working principle of Thermostatic Switch or
Thermostat. S-18, 17, W- 22, 16
Function: Thermostatic switch is a device that controls the temperature in various household items like
refrigerators, air conditioners and adjusting them to just the right level.
It is a regulating device which senses the temperature of a physical system and performs
actions so that the system's temperature is maintained near a desired set point..

Construction: Fig above shows the sketch of thermostatic switch. It consists of:
o Lever ‘AB’ whose movement is controlled by Spring on one side and Bellow on the
other side. Bellow pressure is the pressure in the Thermal Bulb, located in the space
where temperature control is required.
o Lever ‘CD’ having electrical contacts. The end of this lever moves in a slot of the first
lever with the help of Sliding Pin.
o Range Adjustment & Differential Adjustment Screws.
o Toggle Jack Mechanism or Magnet
o Limiting Plate.

Working:
When temperature increases, Bellow/blub pressure increases resulting in expansion of bellow
which pushes the lever ‘AB’ but the second lever ‘CD’ does not move as its end (sliding pin)
slides in the slot. At cut-in temperature the second lever ‘CD’ reaches the edge of slot and
moves such that electrical contacts are made to start the compressor motor. This results in
cooling to bring down the temperature.
When temperature decreases, Bellow/blub pressure decreases and the bulb gets compressed.
The spring pushes the lever ‘AB’ but the second lever ‘CD’ does not move as its end slides in
the slot. At cut-out temperature the second lever ‘CD’ reaches the edge of slot and hence
moves such that there is break in electrical contacts stopping the compressor motor. Thereby
cooling is stopped and temperature rises again.
The length of the slot decides the difference between cut- in and cut-out temperatures. The
length can be changed by changing the position of limiting plate with the help of differential
adjustment screw. The cut- in and cut-out temperatures can be adjusted by adjusting spring
pressure with the range adjustment screw.
A Toggle Jack Mechanism or Magnet ensures electrical contacts are made or broken quickly to
prevent spark.
State the function, location and types of drier/strainer in VCR system. State the sources in
moisture in VCR system.
Function & Location of Drier/Strainer (Filter): It is used in a refrigerating system in the liquid line
just before expansion device in order to-
a) Remove moisture as frozen moisture in the expansion device clog the system.
b) Remove minute dust particles which may clog the system
c) Prevent corrosion of system components.
d)
Note: Drier/Filter is an auxiliary safety device for proper functioning of VCR system. Any
moisture present in the system
Types of Drier/Strainer (Filter): Two types of drier/strainer are used-
o Throw-away type - thrown away after use and replaced with a new one.
o Refill type – Refilled with new charge of desiccant and reused again.

Sources of Moisture: The moisture may enter the VCR system due to-
o Improper evacuation
o Leakage of air in low pressure side
o Leakage of water from condenser side
o Wet charging equipment
o Wet oil, etc.

Why is hermetically sealed compressors preferred for domestic refrigerators, water coolers and
room air – conditioners?
Hermetically sealed compressors are preferred for domestic refrigerators, water coolers and
room air – conditioners because of the following reasons:
i Less noise and vibrations are produced.
ii Leakage of refrigerant is totally eliminated.
iii These units are compact and light weight.
iv These units are moisture and dust free.
v These units are do not require frequent servicing and repair

Explain the construction and working of Drier/Strainer (Filter) with the aid of a neat sketch.
The drier/filter unit consist of a shell containing desiccant granules. This shell is called a
cartridge and can be refilled again when required. At the exit, a perforated pipe is provided