TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

ACTIVITY IN

ME 11L
MECHANICAL ENGINEERING LABORATORY 2

Submitted by:

Magsino, Mark Joseph G.

BSME 4D

Submitted to:

Engr. Manuel Europeo

 ACTIVITY NO. 3

Domestic Refrigeration System

Course Code: ME 11L Date Performed: December 5, 2016

Course Title: Mechanical Engineering Date Submitted: December 12, 2016
Laboratory 2
Section: BSME 4D Instructor: Engr. Manuel L. Europeo
Members: 1. Manalon, John Francis M.
2. Lara, Daniel Marc G.
3. Magsino, Mark Joseph G.
4. Salada, Joshuabel A.
5. Zamora, Joshua Mar M.

I. Objectives
 To have knowledge in refrigerants and its characteristics.
 To have knowledge in chlorofluorocarbon and its impact on the environment.
 To have knowledge in ozone; its characteristics, importance and condition.
 To have ideas in domestic refrigeration system.

II. Intended Learning Outcome

The students shall be able to:

2.1 Compare and discuss the different types and uses of refrigerants.
2.2 Know the History of Chlorofluorocarbon and why other alternative refrigerants are
made.

III. Dicussion
Required Properties of Ideal Refrigerant:
1. The refrigerant should have low boiling point and low freezing point.
2. It must have low specific heat and high latent heat. Because high specific heat
decreases the refrigerating effect per kg of refrigerant and high latent heat at low
temperature increases the refrigerating effect per kg of refrigerant.
3. The pressures required to be maintained in the evaporator and condenser should be
low enough to reduce the material cost and must be positive to avoid leakage of air into
the system.
4. It must have high critical pressure and temperature to avoid large power requirements
5. It should have low specific volume to reduce the size of the compressor.
6. It must have high thermal conductivity to reduce the area of heat transfer in evaporator
and condenser.
7. It should be non-flammable, non-explosive, non-toxic and non-corrosive.
8. It should not have any bad effects on the stored material or food, when any leak
develops in the system.
9. It must have high miscibility with lubricating oil and it should not have reacting properly
with lubricating oil in the temperature range of the system.
10. It should give high COP in the working temperature range. This is necessary to reduce
the running cost of the system.
11. It must be readily available and it must be cheap also.

Important Refrigerants:
Properties at -15o C
1. Ammonia (NH3)(R-717)
Latent heat = 1312.75 kJ/Kg
Specific volume = 0.509 m3 /kg
2. Dichloro–Difluoro methane (Freon–12) (R-12) [C Cl2 F2]
Latent heat = 162 kJ/Kg
Specific volume = 0.093 m3 /kg
3. Difluoromonochloro methane – or Freon-22 (R-22) [CH Cl F2]
Latent heat = 131 kJ/Kg
Specific Volume = 0.15 m3 /kg.

Chlorofluorocarbon
A chlorofluorocarbon (CFC) is an organic compound that contains only carbon,
chlorine, and fluorine, produced as volatile derivative of methane, ethane, and propane.
They are also commonly known by the DuPont brand name Freon. The most common
representative is dichlorodifluoromethane (R-12 or Freon-12). Many CFCs have been
widely used as refrigerants, propellants (in aerosol applications), and solvents. Because
CFCs contribute to ozone depletion in the upper atmosphere, the manufacture of such
compounds has been phased out under the Montreal Protocol, and they are being
replaced with other products such as hydrofluorocarbons (HFCs).

History of CFC
Carbon tetrachloride (CCl4) was used in fire extinguishers and glass "anti-fire
grenades" from the late nineteenth century until around the end of World War II.
Experimentation with chloroalkanes for fire suppression on military aircraft began at least
as early as the 1920s. Freon is a trade name for a group of CFCs which are used primarily
as refrigerants, but also have uses in fire-fighting and as propellants in aerosol cans.
Bromomethane is widely used as a fumigant. Dichloromethane is a versatile industrial
solvent.
The Belgian scientist FrédéricSwarts pioneered the synthesis of CFCs in the 1890s.
He developed an effective exchange agent to replace chloride in carbon tetrachloride with
fluoride to synthesize CFC-11 (CCl3F) and CFC-12 (CCl2F2).

Development of alternatives for CFCs

Work on alternatives for chlorofluorocarbons in refrigerants began in the late 1970s
after the first warnings of damage to stratospheric ozone were published.
The hydrochlorofluorocarbons (HCFCs)are less stable in the lower atmosphere,
enabling them to break down before reaching the ozone layer. Nevertheless, a significant
fraction of the HCFCs do break down in the stratosphere and they have contributed to more
chlorine buildup there than originally predicted. Later alternatives lacking the chlorine, the
hydrofluorocarbons (HFCs) have an even shorter lifetimes in the lower atmosphere. One of
these compounds, HFC-134a, is now used in place of CFC-12 in automobile air
conditioners. Hydrocarbon refrigerants (a propane/isobutane blend) are also used
extensively in mobile air conditioning systems in Australia, the USA and many other
countries, as they have excellent thermodynamic properties and perform particularly well in
high ambient temperatures.
One of the natural refrigerants (along with ammonia and carbon dioxide),
hydrocarbons have negligible environmental impacts and are also used worldwide in
domestic and commercial refrigeration applications, and are becoming available in new
split system air conditioners.
 Advantages and Disadvantages of Hydrochlorofluorocarbons
Advantages Disadvantages
 Replacement of the chlorine atom(s) with  Still contains
hydrogen atoms means that less chlorine atoms chlorine that
are released to the stratosphere --> ODP can attack the
decreased ozone layer.
 Extra hydrogen (H) dissipates almost all the  Can contribute
chlorine in the troposphere before the chlorine can to global
reach the ozone layer (the extra hydrogen makes warming (it’s a
them have a lower stability than CFCs) --> lower greenhouse
ODP than CFCs (only 2% - 10% of CFCs’) gas)
 More
expensive to
 Lower atmospheric lifetimes (2 - 25 years) than produce than
CFCs (100 years or more) CFCs
 Low toxicity; no or low flammability; do not
produce smog

5 possible HCFC alternatives for CFC refrigerants are HCFC-22, HCFC-123, HCFC-
124, HCFC-141b, and HCFC-142b.Their uses can be seen in the following table.

Applications of HCFC Compounds

HCFC Refrigerants Blowing Other
Compound Applications Agents Uses
Applications
Low temperature Polystyrene, Propellant.
and medium polyethylene,
temperature polyurethane,
applications; polyisocyanurate,
HCFC-22 household, commercial and phenolic
 (CHClF2) refrigeration and air
conditioning
applications.
Component in ternary
refrigerant blend.
Chillers. Polyurethane, Component
HCFC-123 polystyrene, in cleaning
(CF3CHCl2) polyisocyanurate, agent blend.
and phenolic
Chillers. Polystyrene,
Component in polyethylene,
HCFC-124 ternary blend for polyurethane,
(CHClFCF3) medium temperature polyisocyanurate,
applications and and phenolic
automotive air
conditioning service.
Polyurethane, Component
HCFC-141b
polyisocyanurate, in cleaning
(CH3CCl2F)
and phenolic agent blend
Polystyrene, Propellant.
HCFC-142b polyurethane,
(CH3CClF2) polyethylene,
polyisocyanurate,
and phenolic

Since HCFCs still have an ozone depletion potential (even though it is lower than
CFCs’), they are considered to be acceptable replacements only for a while as a
transitional plan.

Hydrofluorocarbonsare compounds that contain hydrogen, fluorine, and carbon

atoms. They are like CFC molecules, except hydrogen atoms have replaced the
chlorine atoms.
 Advantages and Disadvantages of Hydrofluorocarbons
Advantages Disadvantages
 Do not contain chlorine --> no  Can contribute to global warming
ozone depletion potential (it’s a greenhouse gas)
 Extra hydrogen (H) makes them  More expensive to produce than
have a lower stability than CFCs CFCs
 Lower atmospheric lifetimes (2 -
25 years) than CFCs (100 years or
more)
 Low toxicity; no or low
flammability; do not produce smog

4 possible HFC alternatives for CFC refrigerants are HFC-23, HFC-125, HFC-134a, and
HFC-152a. Their uses can be seen in the following table.

Applications of HFC Compounds

HFC Refrigerants Blowing Other Uses
Compound Applications Agents
Applications
HFC-23 Possible low Plasma
(CHF2) temperature etchant.
alternative.
HFC-125 Blend
(CHF2CHF3) component for
low temperature
and medium
temperature
applications.
HFC-134a Household Polystyrene, Propellant
(CH2FCF3) and commercial polyurethane, for aerosol
refrigeration polyisocyanurate, drugs/pharmace
systems, and phenolic uticals.
automotive air
 conditioning.
Medium
temperature food
cases and
chillers.
HFC-152a Component in Polystyrene, Propellant.
(CH3CHF2) ternary blend for polyurethane,
medium polyisocyanurate,
temperature and phenolic
applications and
automotive air
conditioning
service.

Considering the great drawback of HCFCs of having ozone depletion potential, the
usage of HFCs would be more ideal.

Ozone depletion potential

The ozone depletion potential (ODP) of a chemical compound is the relative amount
of degradation to the ozone layer it can cause, with trichlorofluoromethane (R-11 or CFC-
11) being fixed at an ODP of 1.0. Chlorodifluoromethane (R-22), for example, has an ODP
of 0.05. CFC 11, or R-11 has the maximum potential amongst chlorocarbons because of
the presence of three chlorine atoms in the molecule.

The first proposal of ODP came from Wuebbles in 1983. It was defined as a measure
of destructive effects of a substance compared to a reference substance.
Precisely, ODP of a given substance is defined as the ratio of global loss of ozone due
to given substance over the global loss of ozone due to CFC-11 of the same mass.
ODP can be estimated from the structure of a given substance. Chlorofluorocarbons
have ODPs roughly equal to 1. Brominated substances have usually higher ODPs in range
5 - 15, because of more aggressive bromine reaction with ozone. Hydrochlorofluorocarbons
have ODPs mostly in range 0.005 - 0.2 due to the presence of the hydrogen which causes
them to react readily in the troposphere, therefore reducing their chance to reach the
stratosphere. Hydrofluorocarbons (HFC) have no chlorine content, so their ODP is
essentially zero.
ODP is often used in conjunction with a compound's global warming potential (GWP)
as a measure of how environmentally detrimental it can be. GWP represents the potential
of a substance to contribute to global warming
Compound R No. ODP

Trichlorofluoromethane (CCl3F) R-11 1

R-
1,1,1,2-Tetrafluoroethane 0.055
134a

Chlorodifluoromethane (CClF2-H) R-22 0.05

Chlorotrifluoromethane (CClF2-F) R-13 1

Dichlorodifluoromethane (CClF2-Cl) R-12 1.00

Bromochlorodifluoromethane (CClF2-
7.9
Br)

Carbon tetrachloride (CCl4) 0.82

Nitrous Oxide (N2O) 0.017

Alkanes (Propane, Isobutane, etc) 0

Ammonia (NH4) R-717 0

Carbon Dioxide (CO2) R-744 0

Nitrogen (N2) R-728 0

 The chlorine is free to repeat the process of destroying more ozone molecules.
 A single CFC molecule can destroy 100,000 ozone molecules.
 CFC - chlorofluorocarbon: it contains chlorine, fluorine and carbon atoms.
 UV radiation breaks oxygen molecules (O2) into single oxygen atoms.
 Domestic Refrigeration Components and Operations
Capillary restrictor
Domestic refrigerators and freezers do not employ a
mechanical device as a refrigerant flow control. Instead
a capillary restrictor meters refrigerant liquid to
the evaporator and maintains a pressure differential
whilst the compressor is operating.
Basically the capillary restrictor is a small tube. The
refrigerant flow rate is determined by the length of the
tubing and the internal diameter of the bore. Refrigerant
will continue to flow through the capillary when the
compressor stops until the pressures in the system
(high side and low side) equalize.

The capillary is normally located after the filter drier; it is sometimes formed into a tight coil
around the suction line. Figure 56 shows a typical domestic refrigerator arrangement. It will
be noted that the capillary actually passes through the inside of the suction line to the
evaporator and thereby provides a heat exchange feature which improves compressor
performance.

Accumulator
Suction line accumulators are employed to prevent frosting back along the suction line after
off cycles. This is because the relatively small refrigerant charges in modern refrigerators
and freezers are difficult to control accurately, and some overspill from the evaporator
occurs when the compressor stops.

Freezer door heater and oil cooler

The figure shows a freezer system
diagram with door frame heater
and oil pre-cooler.
Hot gas defrosting
The figure shows the normal refrigeration and defrost cycles in an appliance using hot gas
defrosting.

Solenoid flow control for refrigerator/freezer

The figure shows the refrigeration system and Figure 60 the electrical circuit for solenoid
flow control.

When the refrigerator thermostat is made and the freezer thermostat is open circuit, the
relay is energized through contacts 1 and 3. The compressor operates but the solenoid is
not energized, and the refrigerant flows through the refrigerator evaporator and the freezer
evaporator.
When the freezer thermostat is made and the refrigerator thermostat is open circuit, the
compressor operates and the solenoid is energized through contacts 1 and 2. The
refrigerator evaporator is by-passed.

When the refrigerator thermostat makes whilst the compressor is operating, the relay is
energized. This opens contacts 1 and 2, and refrigerant will again flow to the refrigerator
evaporator as well as the freezer evaporator.

Procedures for Recharging Air Conditioning Systems with Refrigerant

Refrigerant charging might be the least understood practice in the air conditioning industry
next to setting airflow. Although there are several methods, typically there is only one
correct method for the type of unit you are working on. Information contained here is for
formally trained EPA Section 608 certified technicians.

Start with the basics for all systems

1. Makes sure the system been properly installed and evacuated. A proper
evacuation is critical to proper performance.
2. Clean the filters and the coils. You cannot charge or check the charge on a system
with dirty coils, filters, or blower. The condenser and the evaporator must be clean.
The blower must be capable of moving the correct amount of air. Visual inspection of
the evaporator can be aided with the use of a video scope by removing the high limit
of most furnaces and fishing the shaft up through the heat exchanger to the bottom
side of the coil.
3. Set the required airflow. You cannot charge a system without correct airflow. After
the system is confirmed clean, the airflow must be set to the manufactures
recommended settings. Typically this is 400 CFM/Ton +/- 10%.
4. Identify the type of metering device. You need to know what type of metering
device the system has as this may determine how the system will be charged.
5. Before installing your gauges, vent the hoses and the manifold with virgin refrigerant
(The same type as the system.) to avoid the introduction of air into the system.
6. Blends like R410a or 404a must be added to a system as a liquid. Pure refrigerants
like R22 can be added in liquid or vapor states. If adding liquid into the suction like,
throttle it in slowly to avoid slugging the compressor or diluting and washing out the
compressor oil.
 7. After the charge has been set, avoid installing the gauges as part of regular service.
The system should be sealed.

1. Total Superheat Method (Fixed Orifice / Piston / Capillary Tube / Non-TXV)

Temperature must be above 55°F outdoors and above 70°F indoors with a indoor
wet-bulb temperature above 50°F The evaporator coil cannot operate below freezing
or an overcharge and possible compressor damage could result.

When a system is equipped with a fixed metering device or capillary tubes, the total
superheat varies with the outdoor air temperature and the heat load on the evaporator (air
temperature and humidity). When properly charged the total superheat will be within 3ºF of
the target superheat for the current load conditions. Overcharging and undercharging both
have a considerable impact on efficiency and humidity removal so the correct charge is
critical to proper operation and creature comfort.

The total superheat method is the most accurate method of charging fixed orifice or
capillary tube systems. These systems are critically charged and require correct airflow and
accurate test instruments to properly and accurately charge the system.
An R410aand R22 charging calculator or the "Non TXV Charging Guide" are required to
determine the target total superheat. Because these systems do not "control superheat" it
is critical that the airflow be as close to possible to correct prior to charging as the system
will be charged to the airflow. The total heat in the air will be the driving factor for the
evaporator performance so low or high airflow will have a direct impact on the charge and
the system performance.

a. If not already in operation, assure that the system is leak free and a proper evacuation
has been performed to assure proper degassing and dehydration of the piping and the
evaporator coil.
b. Verify clean coils and correct airflow prior to charging.
c. Attach a high accuracy digital gauge like the iManifold, Testos, or Fieldpiece
SMANs to the service ports. Make sure the gauge has been zeroed, if required
barometric pressure offset adjusted to current conditions, and the proper refrigerant
type selected. Follow the gauge instructions.
 d. Attach temperature probes to their proper locations on the suction and liquid lines
assuring good contact to the line with the sensor at the 4-10 O-clock position, at least
6" from the compressor and attached to a horizontal section of line (suction only).
Typically installing the sensor on a straight section of line near the service valves is
perfect.
e. Measure the return air wet-bulb in the duct just before the coil, and outdoor dry-bulb
conditions with a digital psychrometer.
f. Determine the target superheat from the charging calculators or Table RD-2 on pages
RD7 and RD8 of the "NON TXV Charging Guide" (See example below, 95°F ODA and
67°F indoor wet-bulb, target superheat 12ºF.)

g. ADD refrigerant to DECREASE total superheat.

h. REMOVE refrigerant to INCREASE total superheat.
i. Allow approximately 10 to 15 minutes of operation after refrigerant has been added or
removed to determine final superheat.
j. Verify proper evaporator performance (temperature split) using page RD9 of the
"NON TXV Charging Guide".

2. Condenser Subcooling Method (TXV)

Temperature must be above 60°F outdoors and above 70°F indoors with a indoor
wet-bulb temperature above 50°F The evaporator coil cannot operate below freezing
or an overcharge and possible compressor damage result.
a. If not already in operation, assure that the system is leak free and a proper evacuation
has been performed to assure proper degassing and dehydration of the piping and the
evaporator coil.
b. Verify clean coils and correct airflow prior to charging.
c. Attach a high accuracy digital gauge like the iManifold or Testos or FieldPiece
SMANs to the service ports. Make sure the gauge has been zeroed, if required
barometric pressure offset adjusted to current conditions, and the proper refrigerant
type selected. Follow the gauge instructions.
d. Attach temperature probes to their proper locations on the suction and liquid lines
assuring good contact to the line with the sensor at the 4-10 o-clock position, at least
6" from the compressor and attached to a horizontal section of line (suction only).
Typically installing the sensor on a straight section of line near the service valves is
perfect.
e. From the manufactures label on the condenser or the manufacturers installation
instructions determine the required subcooling at the condenser outlet. If the
subcooling is not listed, 10-12°F is typically adequate provided the liquid line length
and lift are not excessive.
f. ADD charge to INCREASE liquid line subcooling
g. REMOVE charge to DECREASE liquid line subcooling
Note: When adding or removing refrigerant with a TXV equipped system, suction
pressure may remain relatively constant. Suction pressure is a function of the
evaporator load, and the TXV only controls the evaporator superheat. Low evaporator
pressure may be the result of low airflow, low load, air bypassing the coil, or in rare
cases a restricted dryer or TXV. Typically once the target subcooling is achieved,
additional refrigerant should not be added in attempt to increase suction pressure.
Adding additional charge will only stack refrigerant in the condenser and raise the
head pressure, current draw and lower the system efficiency.
h. Allow approximately 10 to 15 minutes of operation after refrigerant has been added to
determine final superheat
i. Verify proper evaporator performance (temperature split) using page RD9 of the
"NON TXV Charging Guide" Note: Split will work for any system regardless of
metering device.
 The TXV cannot control the superheat after the sensing bulb. Total
superheat (measured at the condenser) should be 8-20°F. If the total superheat
 is below 8°F check the TXV sensing bulb for proper installation, good contact
and insulation. If the total superheat is above 20°F check the evaporator
superheat. Evaporator superheat should be between 8-12°F To determine the
evaporator superheat, measure temperature and pressure at the evaporator
outlet or measure temperature, at the evaporator outlet and pressure at
condenser inlet, subtracting 3 psig for typical pressure drop before converting
to saturation temperature and determine the evaporator superheat. If
evaporator superheat is normal and total superheat is high, additional suction
line insulation may be required. Thermal expansion valves rarely fail if
properly installed.

3. Weight or "Weigh In" Method

Can be done correctly under any ambient conditions.

Charging by weight is one of the most accurate and fastest methods of charging a system
that has a known refrigerant charge. Typically this method requires an already evacuated
system that is ready for charge, or removal of the existing charge so the proper charge can
be weighed in. Because exact length of the line set is often hard to determine within a few
inches, we recommend the initial charge be determined by either the Total Superheat or
the Subcooling method. If the exact charge is known, use a high accuracy high
resolution digital scale to weigh in the entire charge.

4. Pressure and ODA Temp Method (Manufacturer's chart, and equipped with TXV or
at Fixed near design conditions)

If provided by the manufacturer and the system is new and or completely clean, the system
can be accurately charged by measuring the suction pressure, measuring outdoor air
temperature and then adding charge until the liquid pressure is at the chart requirement.
After the charge is complete, verify proper temperature split to assure acceptable system
airflow. This is the common method used by Rheem and Rudd and others for initial
charging. Because this method is pressure and temperature driven, cleanliness of the coils
is critical to your success. Typically the chart supplied with the equipment is specifically
for that piece of equipment and cannot be used with other models.
5. Commission the System (Verification of Capacity)

After the airflow and the refrigerant charge have been set, verify that the system is
operating at its rated capacity by measuring the actual airflow and measuring the change in
enthalpy across the evaporator coil. Enthalpy is determined by converting the return and
supply wet-bulb measurements using the enthalpy chart. Use the Commissioning
Worksheet to determine the capacity of the system.

IV. Conclusion

At the end of this activity, I learned that the ozone’s characteristics may be
altered there is no doubt that the problem of ozone depletion exists and deserves
extensive research and attention. With the release of each and every CFC, our
ozone layer takes one small step towards its destruction. The decision to ban
completely CFCs sooner than later cannot be decided by the United States or even
the United Nations. The entire world must unite in order to expel this problem
forever.

The effects of ozone depletion are real and of great global significance. Lower
ozone levels cause an increase in UV-B radiation reaching the earth’s surface
harming plant, animal, and marine life. Humans are adversely affected as well as
the risk of skin cancer and decreased immunity level becomes more serious. It is
only in the last few years that effects of previous legislation banning the use of CFCs
are becoming apparent. Speeding the process of reduction of CFCs can only help
the environment.

The domestic refrigerator serves the purpose of coolingfood items and such
other household requirements. Storingof cold water in the refrigerator needs more
no of openingsof the door. In the present work a refrigerator is modified to serveboth
purposes of refrigerator and also dispenser of coldwater.