COMPONENTS OF A REFRIGERATOR

REFRIGERATION COMPRESSORS
The compressors are one of the most important parts of the refrigeration cycle. The compressor
compresses the refrigerant, which flows to the condenser, where it gets cooled. It then moves to
the expansion valve, and the evaporator and it is finally sucked by the compressor again. For the
proper functioning of the refrigeration cycle, the refrigerant must be compressed to the pressure
corresponding to the saturation temperature higher than the temperature of the naturally available
air or water. It is the crucial function that is performed by the compressor. Compression of the
refrigerant to the suitable pressure ensures its proper condensation and circulation throughout the
cycle. The capacity of the refrigeration or air conditioning depends entirely on the capacity of the
compressor.
Types of Refrigeration and Air Conditioning Compressors
There are various types of compressors used in the refrigeration and air conditioning machines,
these are: reciprocating, rotary, screw, centrifugal and scroll. All these have been described below
briefly:
1. RECIPROCATING COMPRESSOR:
The reciprocating compressors are one of the most widely used types of the refrigerating
compressors. They have piston and cylinder arrangement like the automotive engine. The
reciprocating motion of the piston due to external power compresses the refrigerant inside the
cylinder. There are three types of reciprocating compressors: hermetically sealed, semi-
hermetically sealed and open type. The open of reciprocating compressors can be of single cylinder
type or multi-cylinder type.

1.1. Hermetic Compressor

In a hermetic sealed, compressor and driving motor coupled
to the same shaft, and are enclosed in a common rigid
casing made of welded steel. This type of compressor
eliminates the use of Crankshaft Seal, which is used to
prevent leakage. This makes whole the compressor and
motor as a single compact unit makes it easy to handle.
Basically, hermetically sealed compressors are air tight and
ensure no leakage of the working fluid to outside.
Hermetically sealed compressor widely used for small
motor compressor combination used in a domestic
refrigerator, freezer and air conditioner.
Figure 1(HERMETIC COMPRESSOR)
Advantages and disadvantages of hermetic seal compressor
Advantages
 Leak proof / completely sealed housing - There is no route for gas to leak out this system.
There are no shaft sales since both compressor and motor sealed in the same casing.
 Portable compressor and motor act as a single unit.
 No belt pulley coupling arrangement - No need disassembles the compressor from the
motor to move the system from one place to another.
 Since there is no belt coupling or crankshaft, cost involved with the maintenance is less.
 It is compact; they require small space.
 Lubrication is simple; there is no external lubrication is required.
 It is less noisy
 Installation of hermetic sealed compressor is very easy.
Disadvantages
 They are not intended to repairing since the moving parts are inaccessible if there is any
problem you need to do you replace the whole unit.
 Burnout winding can contaminate entire system.
 Only electric power sources can run this unit.
1.2. Semi-hermetic compressor
The semi-hermetic compressor also encloses the motor compressor by Common Housing. It
prevents the leakage of the fluid. In a semi-hermetic, the casing is bolted together instead of rigidly
welding. It offers limited serviceability; casing can be open to repair motor and other components.

1.3. Open compressor

In this type, compressor and motor working as two separate units, and they have a distinct casing
for both of them. The compressor is connected to the motor by a belt or crankshaft. Open type
compressors are not leak proof they are more susceptible to leak. They rely on shaft seals in order
to prevent leakage of working fluid and then to retain the internal pressure. The shaft seal required
to lubricate otherwise seals begins to leak.

Advantages of open compressor

 They can be driven from a non-electric power source such as turbine, IC engine.
 Compressor and motor are accessible to repair in case of failure.
  Servicing is easy and cheap
Disadvantages of open compressor
 Noisy operation
 Not leak proof they need shaft seals to prevent leakage lubrication required at sealing to
maintain Pressure.
 They are not compact.
2. SCREW COMPRESSORS:
The screw compressors comprise of the pair
of meshing screws between which the refrigerant gets
compressed. They can produce high pressure for
small quantity of gas. They consume less power than
the reciprocating compressors and are being used
widely. It can be used with refrigerants like R12,
R22, and others.

Figure 2(SCREW COMPRESSOR)

3. ROTARY COMPRESSORS:

The rotary compressors have two rotating elements,

like gears, between which the refrigerant is compressed. These
compressors can pump the refrigerant to lower or moderate
condensing pressures. Since they can handle small volume of
the gas and produce lesser pressure, they are used in fewer
applications.

Figure 3(ROTARY COMPRESSOR)

4. CENTRIFUGAL COMPRESSORS:
The centrifugal compressors comprise of the
impeller or the blower that can handle large quantities of
gas but at relatively lower condensing pressure. It is
suitable for working with refrigerants like R-11, R-113
etc.

Figure 4(CENTRIFUGAL COMPRESSOR)

5. SCROLL COMPRESSORS:
The scroll compressor comprises of two interleaved
scrolls of which one is fixed and the other orbits
eccentrically without rotating. During its motion
small gaps are created between the scrolls where the
refrigerant gets compressed. The scrolls can have
different shapes like involute, Archimedean spiral or
hybrid curve. In another arrangement both the scrolls
may be rotating eccentrically to produce the
compression. Figure 5(SCROLL COMPRESSOR)

EXPANSION DEVICES

Figure 6(DIFFERENT TYPES OF EXPANSION DEVICES)

Expansion valves are devices used to control the refrigerant flow in a refrigeration system. They
help to facilitate the change of higher pressure of liquid refrigerant in the condensing unit to lower
pressure gas refrigerant in the evaporator.
The term "low side" is used to indicate the part of the system that operates under low pressure, in
this case the evaporator. The "high side" is used to indicate the part of the system that operates
under high pressure, in this case the condenser.

Types of Expansion Devices:

There are basically four types of valves that are in used. These valves are also refer to as metering
devices.
1. Automatic Exp. Valves:
Automatic Expansion Valve regulates the flow of refrigerant from the liquid line to the evaporator
by using a pressure-actuated diaphragm. It maintains a constant pressure in the evaporator.
The setback is that it is not efficient if the load fluctuates hence this type is not suitable for use in
air conditioning as the load fluctuates a lot during its operation.

2. Thermostatic Exp. Valves:

Thermostatic Expansion Valve uses a valve mechanism to control the flow of liquid refrigerant
into the evaporator coil. The flow is controlled by the pressure in the evaporator.
This type of metering device is able to operate well when the load fluctuates and hence is suitable
for use in air conditioning system. When the evaporator warms, the valve provides a higher flow
rate and when it cools, it reduces the flow rate.
It is also commonly refer to as TXV, TEV or TX valve. There is a sensing bulb which detects the
temperature of the coil and is usually located at a higher temperature within the evaporator.
The bulb must be clamped firmly to the coil to ensure proper sensing. When the temperature of
the evaporator increases due to the demand for cooling, the pressure in the bulb will also increase
hence pushing the spring to open the valve.
Similarly, when the temperature of the evaporator reduces due to a lack of demand for cooling, the
pressure in the bulb will drop hence causing the spring to close the valve.

3. Capillary Tubes:
Capillary Tube is a tube with small internal diameter and could be coiled for part of its length. It
is installed to the suction line. A filter-drier is sometimes fitted before the tube to remove dirt or
moisture from the refrigerant.
This device is simple, does not have any moving part and lasts longer. In order to use this device,
the amount of refrigerant in the system must be properly calibrated at factory level.
Due to its lower cost compared to TXV, this metering device is used in units that are produced in
large quantity such as room or window air conditioners.
Depending on the capacity design of the system, the capillary tube internal diameter that is
commonly used range from 0.031" to 0.065" and the outer diameter from 0.083" to 0.130".

4. Float Valves:
Float Valve is actuated by a float that is immersed in the
liquid refrigerant. Both low-side float and high side-float are
used to control the flow of liquid refrigerant.
The low-side float helps to maintain a constant level of
liquid refrigerant in the evaporator. It opens when there is
no liquid in the evap. and closes when there is liquid in the
evap.
Figure 7(FLOAT VALVE)
The high-side float is located at the high pressure side of the
system and maintain a constant level of refrigerant in the condenser. When the compressor
operates, the condensed refrigerant flows to the float chamber and opens the valve.
This causes the refrigerant to flow into the evaporator where it is stored. As the liquid level falls
in the float chamber, the valve opening will close hence preventing the liquid from flowing to the
evap.

CONDENSERS
In systems involving heat transfer, a condenser is a device or unit used to condense a substance
from its gaseous to its liquid state, by cooling it. In so doing, the latent heat is given up by the
substance and transferred to the surrounding environment.
Types Of Condensers:
There are three types of condensers: air cooled, water cooled and evaporative. These have been
described below.
1. Air cooled condensers:
Air cooled condensers are used in small units like household refrigerators, deep freezers, water
coolers, window air-conditioners, split air-conditioners, small packaged air-conditioners etc.
These are used in plants where the cooling load is small and the total quantity of the refrigerant in
the refrigeration cycle is small. Air cooled condensers are also called coil condensers as they are
usually made of copper or aluminum coil. Air cooled condensers occupy a comparatively larger
space than water cooled condensers.
Air cooled condensers are of two types:
1.1. Natural convection:
In the natural convection type, the air flows over it in natural a way depending upon the
temperature of the condenser coil.
1.2. Forced convection:
In the forced air type, a fan operated by a motor blows air over the condenser coil.

2. Water cooled condensers:

Water cooled condensers are used for large refrigerating plants, big packaged air-conditioners,
central air-conditioning plants, etc. These are used in plants where cooling loads are excessively
high and a large quantity of refrigerant flows through the condenser.
Types Of Water Cooled Condensers:
2.1. Double Pipe Condenser:
These condensers, normally used in ammonia systems, consist of a pipe inside another pipe, or a
tube within a tube. The tubes are positioned horizontally to form a vertical bank. The whole unit
is fixed on a wall, and the water-ammonia mixture enters the sections at the bottom, flowing up
through the inner pipe. The compressed refrigerant vapor goes through the top section flowing
downward, due to which a counter flow is created.
2.2. Double Tube Condenser:
It is a version of the double type condenser in which water flows inside the tubes, and refrigerant
flows through the annular space between the two tubes. A compact condensing unit is created by
placing the compressor inside the condenser.
2.3. Shell And Coil Condenser:
It consists of a copper coil located in a steel shell. Water runs through the coil, and refrigerant
vapor is discharged from the compressor, condensing on the outside of the cold tubes. This type
of condenser is economical, but its maintenance is difficult. If a leakage occurs in the coil, it is
essential to remove the head of the shell, and withdrawal of coil from the shell.

2.4. Shell And Tube Condenser:

It is comprised of a large number of tubes located in a steel shell, with water flowing inside, and
vapor flowing around the tubes. The vapors condense on the exterior surface of the tubes, and
drops to the bottom of the condenser. A considerable amount of condensing surface is available in
a smaller place.
3. Evaporative condensers:
Evaporative condensers are usually used in ice plants. They are a combination of water cooled and
air cooled condensers. In these condensers the hot refrigerant flows through the coils. Water is
sprayed over these coils. At the same time the fan draws air from the bottom side of the condenser
and discharges it from the top side of the condenser. The spray water that comes in contact with
the condenser coil gets evaporated in the air and it absorbs the heat from the condenser, cools the
refrigerant and condenses it.
Evaporative condensers have the benefits of water cooled as well as air cooled condenser, hence
it occupies less space. However, keeping the evaporative condenser clean and free of scale is very
difficult and requires lots of maintenance. Hence they are not favored by HVAC designers.

EVAPORATORS
In the evaporator a very large amount of heat is absorbed from surrounding (the indoor air) causing
the liquid refrigerant to boil and turn into a gas phase, which is passed to compressor to repeat the
cycle again until the indoor air be comfortable and sufficiently cool.
The evaporator works at a constant temperature as long as the pressure remains constant.

Types Of Evaporators:
The evaporators may be classified into a forced convection type or natural convection type,
depending on whether the substance to be cooled lows naturally by difference in density through
the heat transfer surfaces of the evaporator or forced by pump or fan.
In some kinds of evaporator, the refrigerant flows in the tubes and substance to be cooled
surrounding it. But in other cases, substance to be cooled in the tubes and the refrigerant is in the
shell.
Evaporator are also classified into flooded type and dry expansion type, depending on whether the
refrigerant covers all the surface of heat transfer or some portion of heat transfer surface is having
gas being superheated.

1. Flooded evaporators
A flooded evaporator type with float control valve shown in fig. the liquid flow on low passages
passes the tubes upwards, and boils due to heat adsorption from the warmer substance, which is
cooled. The resulted vapor so formed on boiling bubbles up in flash chamber, where separates
liquid from vapor.
Separated vapor passes to compressor, and liquid flows back to the evaporator. The flash chamber
collects the vapor formed by liquid refrigerant boiling in the evaporator, and vapor obtained in the
expansion device.In a flooded type evaporator refrigerant liquid level is maintained. Float valve is
used as throttling device.
The heat transfer efficiency increases because the entire surface is in contact with the liquid
refrigerant. But the refrigerant charge is relatively large as compared to dry expansion type.
The accumulator or flash chamber is used to prevent liquid Cray over to compressor. The
evaporator coil is contacted to accumulator and the liquid flow from the accumulator to the
evaporator coil is generally by gravity. The vapor formed by the vaporizing of the liquid in the coil
being lighter rises up and passes on to the top of the accumulator from where it enters the suction
line.

In some cases liquid eliminators are provided in the accumulator top to prevent the possible carry
over of liquid to suction line. Also a liquid suction heat exchanger is used on the suction line to
superheat the suction vapor.

Figure 8(FLOADED EVAPORATOR)

2. Liquid Chiller:
The refrigerant in the shell and liquid to be chilled in the
tubes, When the refrigerant is in the shell, the refrigerant
liquid level is so kept that there is enough space on the top
portion of the shell for the liquid and vapor to separate.

Figure 9(LIQUID CHILLER)

Vapors are drawn from the top portion by the compressor. Liquid level must be maintained
constant as the chilled tubes are also immersed in the refrigerant liquid. Thus float control is
preferred. However thermostatic expansion valve is preferred, when the refrigerant is in the tubes
and the liquid to be chilled is in the shell.
The refrigerant gets superheat in the last portion of the set of tubes and is collected in the end
chamber from where it is sucked by the compressor. In order to facilitate proper contact of water
with the refrigerant tubes, baffles are provided to ensure larger circuit up and down for the water,
leading to increased turbulence and hence better overall heat transfer co-efficient. Thus, the first
fig. can be termed as loaded whereas second evaporator to be dry.

3. Direct Expansion Coil Evaporator:

Unlike the liquid chiller which the chilled liquid is fed to the
coils, which are used for cooling air, the evaporator is called
direct expansion evaporator if the coils of the evaporator with
refrigerant passing through them are used directly to cool air by
natural or forced convection.
To improve the lubricating oil return to the compressor, the
refrigerant feed comes through the thermostatic expansion
valve more often located at the top particularly for F12, F22.
Air is blown over the outside of the finned tubes.
Figure 10(DRY EVAPORATOR)
The direct expansion coil is preferred for air conditioning
purposes, where the evaporator is very near to the compressors. This is direct method of cooling
the substance and, therefore quite efficient. It is preferred to chill the water and pump it to the air-
cooling coil, when the coil has to be located very far away from the compressor.
There is possibility of refrigerant leakage for long distances, and the cost of the refrigerant would
be high. Also the pressure drop in the line would decrease evaporator coefficient of performance
and efficiency.
The expansion valve controls the rate of the refrigerant to evaporator in such a way that all the
liquid is vaporized and the vapor is also superheated to a limited extent. The inside of evaporator
is far from dry but wetted with liquid.
All the same, this type is called dry expansion to distinguish it from flooded system and also
probably because by the time the refrigerant reaches the evaporator outlet it from flooded system
and also probably because by the refrigerant reaches the evaporator outlet it is no more wet but
dry superheated vapor.