DAR ES SALAAM INSTITUTE OF

TECHNOLOGY.

MECHANICAL ENGINEERING DEPARTMENT.

Module name: HVAC & REFRIGERATION MACHINERY
Module code: MET 06111.
Credit: 9.
 REFRIGERATION EQUIPMENT
Basic components parts of a mechanical refrigeration system are
common both for refrigeration and air-conditioning systems. They are;
• Compressor
• Condenser
• Expansion device
• Evaporator.
1. Compressor: Is a mechanical device used to compress the
refrigerant hence increases the pressure of the refrigerant (gas)
and raises its temperature.
The compressor receives low pressure refrigerant (gas) from the
evaporator and compress it to high pressure refrigerant (gas).
There are two different pressures in the refrigeration cycle;
• The evaporator / low pressure is being maintained by the
expansion valve.
• The condenser / high pressure being maintained by the
compressor.
Compressor consists of an arrangement in which an electric motor
drive it. When energized, it creates enough pressure difference to
circulate the confined refrigerant in the entire sealed system.
Because starting a compressor requires more torque and draws
at least three times the amperage of its normal running speed,
compressor motors are equipped with a starting winding and a
running winding and both compose the stator. At the instant of
starting, current flows through both windings. When motor
speed increases to about 75% of its normal running speed, a
starting relay disconnects power to the starting winding, and
the running winding continues operating the motor. Since
heavy wire is used in the starting winding, if it runs more than
a few seconds, it will overheat and possibly burn.
The relay has a coil and a set of normally closed contacts
where the starting capacitor is removed from the circuit after
the Compressor has started and has produced enough voltage
between the common terminal and the start terminal to
energize coil in the relay. This voltage that is produced in all
electric motors while running and is called Electro-Motive
Force ( EMF).
i. Starting capacitor is an electrical device that energizes the
starting winding for a brief time. The starting relay plays an
important role in the life of a compressor motor. Should the
relay not disengage from energizing the starting winding,
the starting winding (in the compressor motor) will burn,
and the compressor will have to be replaced. . Some relays
come with three openings that connect the starting relay to
the three terminals of the compressor.
ii. Running Capacitors are usually metal and are wired to the
Start and Run terminals all the time. This advances the field
inside the motor slightly which in turn reduces the
amperage draw lowering the heat produced in the motor.
Usually the Relay and Starting Capacitor should be replaced
first because the Running Capacitor very rarely fails.
Replacing the Relay and Starting Capacitor should always be
done before changing the compressor.
Overload - This is overheat/overload protection for the
compressor in the form of a bimetal, reusable safety fuse. If, for
any reason, the temperature of the compressor motor goes too
high, the bimetal strip within the overload protector will shut off
the power to the compressor until it cools sufficiently for safe
operation.
It is installed under the compressor terminal cover.
There are three compressor terminals: a run winding terminal
marked R, a start winding terminal marked S, and a common
terminal marked C. The overload protector is connected in
series with the common terminal of the compressor.
There are two types of machines:
(i) Positive displacement machines: Ensure positive
admission and delivery preventing undesired reversal of
flow within the machine as achieved by the use of valves
(reciprocating, rotary, scroll and screw compressors).
(ii) Non-positive displacement machines: Have no means to
prevent the reversal of flow (centrifugal compressors).
 TYPES OF COMPRESSORS
Types of compressors used in refrigeration are:
1. Reciprocating compressor - are one of the most widely
used types of compressors for refrigeration and air
conditioning applications. The reciprocating compressors
comprise of the piston and the cylinder arrangement similar
to the automotive engine. The reciprocating compressor
consumes electricity to compress the refrigerant. Inside the
cylinder the piston performs reciprocating motion which
enables the compression of refrigerant inside it.
• The reciprocating compressors are classified according to
their enclosing pattern as hermetically sealed, semi-sealed
and open-type. The hermetically sealed and semi-hermetic
compressors have their motor enclosed along with the
cylinder and crank-case inside a dome. The motor windings
are cooled by incoming suction vapours. These have the
advantage of no leakage, less noise and compactness.
 Working Principle of the Reciprocating Compressors
A reciprocating compressor has a piston that moves
downwards thus reducing pressure in its cylinder by creating a
vacuum. This difference in pressure forces the suction
chamber valves to open and bring gas or air in. When the
cylinder goes up, it increases pressure thus forcing the gas or
air out of the cylinder through a discharge chamber.
Apart from the piston and the cylinder arrangement, the
reciprocating compressor also comprises of the crankshaft,
connecting rod and other small connecting elements. The
crankshaft is connected to the electric motor directly by
coupling or by belt and driven by the pulley arrangement. The
rotary motion of the crankshaft is converted into the
reciprocating motion of the piston inside the cylinder via the
connecting rod.
 Advantages of Reciprocating Compressors
• They are very versatile and can handle a wide range of
pressures and flows.
• They are relatively simple and easy to maintain.
• They can be used in a wide range of applications including
refrigeration, air conditioning, and gas compression.
Disadvantages of Reciprocating Compressors
• They can be noisy and require a lot of space.
• They have a high initial cost compared to other types of
compressors.
• They are not suitable for continuous operation and may
require frequent maintenance.
 Types of Reciprocating Compressor.
i. Open type Compressor
An open type compressor is that in which the prime mover
drives the compressor by means of belt. In such a unit the prime
mover and compressor are separately serviceable. In this, the
compressor is enclosed in crank case and crank shaft projects
out through the compressor housing.
• The projected end of crank shaft is connected directly or
through the belt to the driving motor. The compressor and
motor can be mounted on the same base plate. A seal must be
used to prevent refrigerant leaking out or air from leaking in if
the crank case pressure is lower than the atmospheric
pressure. Because the open compressor lacks a seal around it,
there is risk of refrigerant leakage.
• An open compressor is designed to handle large-scale
refrigeration applications.
 Advantages of open type compressor.
• The compressor components are easily accessible for
maintenance.
• Designed to handle large-scale refrigeration applications.

Disadvantages of open type compressor.

• There are high chances of gas leaks from the compressor.
• Often fails due to dirt, debris, or chemicals.
ii. Hermetically Sealed Compressor
“hermetic” usually means an airtight seal. It refers to the way
the compressor is completely separated from the external
operating environment.
A hermetic compressor is a type of compressor sealed within a
welded casing. Therefore, it is entirely inaccessible for
maintenance or repair..
• In ordinary compressor the crank shaft extends through
compressor housing and it is connected to the driving motor.
A seal must be provided at the place where the shaft comes
out through the compressor housing.
• This is necessary to prevent the leakage of refrigerant outside
or leakage of air inside. To avoid this problem, the
compressor and motor are enclosed in one housing which
known as Hermetically sealed compressor.
• These types of compressors are normally used for small
capacity Refrigerating systems as house hold Refrigerator or
small capacity coolers.
 The advantages of hermetically sealed compressor.
• Usually restricted to smaller systems.
• The leakage of refrigerant is completely avoided
• It is less noisy,
• It requires less space.
• The motor is cooled more efficiently
Disadvantages of hermetically sealed compressor.
• Maintenance is not easy. The welded joints has to be broken or
cut for repairing the compressor.
• The pressure of moisture in the refrigerant may harm the
winding of the motor.
iii. Semi-Hermetic Compressor
• In a semi-hermetic compressor, the motor and the compressor
housing are located in a two piece shell. a semi-hermetic
compressor has both the compressor and the motor fully
protected from the environment within a sealed shell. The
covers are bolted together.
• Unlike the hermetic compressor, the semi-hermetic models are
designed so they can be opened for diagnosis and periodic
maintenance.
 Advantages of Semi-Hermetic Compressors
• Repairs and maintenance are possible, which can extend the
compressor's lifespan.
• It is commonly used in larger commercial and industrial
applications where higher cooling capacities are required.
Disadvantages of Semi-Hermetic Compressors
• More complex design and installation compared to hermetic
compressors.
• More potential leak points due to additional access points.
2. Rotary Compressor
Rotary vane compressors are positive displacement, direct-drive
machines. consist of a cylindrical casing, two openings - one
suction and one discharge - and a rotor positioned eccentrically
with respect to the casing. Compression occurs by refrigerant
flowing into the chamber where, due to eccentric rotation, there
is a reduction in the desired volume.
• There are essentially two designs of this compressor:
i. Rolling piston type. In the rolling piston type, the roller is
mounted on an eccentric shaft with a single blade, which is
always in contact with the roller by means of a spring.
ii. Rotating vane type. In the rotating vane type, with four
vanes, the rotor is concentric with the shaft. The vanes slide
within the rotor but keep contact with the cylinder. The
assembly of rotor and the vanes is off-centre with respect to
the cylinder.
In both designs, the whole assembly is enclosed in a housing
(not shown in the figures), filled with oil and remains
submerged in oil. An oil film forms the seal between the high-
pressure and the low-pressure sides. When the compressor
stops, this seal is lost and the pressure equalizes.
 The advantages of rotary vane compressors
• Low cost
• Compact dimensions,
• Lower noise
• Generate less vibrations
• Efficiency is also higher, on average over a wide operating
range, than scroll compressors. The highest efficiency of
rotary compressor technology is achieved when they are fitted
with brushless DC motors and driven by inverters.
• Wider range of applications, up to 50kW cooling capacity.
Task: Disadvantages of rotary vane compressors.
3. Scroll compressor
Scroll compressors use two scrolls, one fixed and the other moving
and coupled to the motor. The scrolls are interleaved so as to be in
contact with one another in various places and thus form a series of
gradually thinner pockets of air towards the center. The fluid is
compressed by rotation of the orbiting scroll around the fixed scroll
until being discharged in the center.
Figure shows the scroll compression process in a sequence of
suction, compression and discharge.
Fig.(a) The outermost pockets are sealed off. Suction gas is
trapped just before compression begins.
Fig.(b) At stage (b), orbiting motion moves the gas to the centre.
Pocket volume progressively reduces, and pressure rises, as
shown in (c).
Fig.(d) At (d), the gas reaches the discharge port in the centre,
and discharge takes place. Simultaneously, suction begins at the
outer periphery.
 Advantages of scroll compressors
• Low energy consumption. Research shows that the energy
usage in scroll compressors are around 25% lower than that of
reciprocating compressors.
• Smaller dimensions
• Lower weight than reciprocating compressors of the same
capacity, even if higher than rotary compressors.
• They also have very high efficiency at the design compressor
ratio, which however decreases at different working conditions.
High efficiency scroll compressors have been also developed
fitted with brushless DC motors and driven by inverters.
• The compressor gives low noise level. Reduced vibrations.
 Disadvantages of scroll compressors
• High Initial Costs. Generally, compressors that employ an oil-
free scroll mechanism are higher in price.
• Higher Repair Costs. Due to the design of the scroll
compressor, when a malfunction happens the unit is not
immediately serviceable.
4. Screw compressors
Screw compressors also belong to the category of positive
displacement compressors. The machine essentially consists of
two helically-grooved rotors which rotate in a housing.
Are based on a mechanism made up of two intermeshing screws,
called rotors.
As the rotors revolve, the fluid is drawn in through the inlet
port, filling the volume between two lobes. When the spaces
between the lobes are full of fluid, suction ceases, the fluid
between the lobes is then forced due to rotation into an
increasingly small space, causing compression. When the lobes
reach a certain position, the compressed fluid is completely
discharged through the outlet port. These compressors require
abundant lubrication due to the meshing of the two rotors.
5. Centrifugal compressor
• A centrifugal compressor is a type of dynamic compressor used
to increase the pressure of a gas by converting its kinetic energy
into potential energy.
• Commonly used in a variety of industrial applications to
compress gasses (such as air, natural gas, and refrigerants), its
main role is to move gas around. It thus provides compressed air
for a wide range of applications, such as pneumatic tools, or
manufacturing processes, as well as being key in many high-end
refrigeration applications.
• It can also be referred to as an impeller compressor, a radial
compressor or a turbo compressor
Centrifugal compressor mainly consists of the following components
below.
i. An inlet casing: to accelerate the fluid to the impeller inlet.
ii. An impeller: the rotating element of the centrifugal compressor
responsible to transfer energy to the fluid in the form of increased static
pressure (enthalpy) and kinetic energy and accelerating it outward
towards the periphery
iii. A diffuser: the high-speed gas enters the diffuser after leaving the
impeller, so that it converts the high-velocity gas into high-pressure gas
by reducing its velocity and increasing its pressure.
iv. A volute casing or scroll: a curved, stationary casing surrounding the
impeller and diffuser, which collects the high-pressure gas from the
diffuser and directs it to the compressor outlet and to further convert the
remaining kinetic energy into enthalpy resulting in further pressure rise.
v. Cooling and lubrication system: the first is crucial to maintain optimal
operating temperatures, while the latter ensures that bearings and other
rotating parts are properly lubricated to reduce friction and wear.
vi. Driver: in charge of providing the mechanical power to rotate the
impeller, they can be electric motors, steam turbines, gas turbines,
internal combustion engines
vii. Bearing and shaft: while the impeller is connected to the compressor's
shaft, it transfers the rotational energy from the driver to the impeller.
Bearings support the shaft and allow it to rotate smoothly.
viii.Seals: these are used to prevent gas leakages between the rotating and
stationary components.
ix. Balance drum: its role is to balance the pressure on both discharge and
suction sides
x. Coupling: in charge to transmit power from driver to compressor
The Principle of Centrifugal Compression: Aero-Dynamics
1. The air reaches the center of the impeller.
2. Air is forced outward by centrifugal force.
3. Diffuser gradually reduces the air velocity.
4. Velocity energy is converted to higher pressure.
 Advantages of Centrifugal Compressors
i. Large capacity and high flow rates.
ii. Compact structure gives good sealing effect thus less leakage
phenomenon.
iii. Suitable for continuous and high-pressure applications.
iv. Fewer wearing parts and simpler moving parts.
v. Low maintenance requirements.
 Disadvantages of Centrifugal Compressors
i. Higher initial cost compared to other types.
ii. High rotational speed may generate mechanical vibration
iii. Less efficient at lower flow rates.
iv. Limited turndown ratio (ability to operate at lower loads).