lilinoi! Institute
of Techiioiogy
UNIVBRSJTV LiBRARIES
.AT 244
Beerbaum, A. J. Test of a three ton refrigerating plant
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ILLINOIS INSTITUTE OF TECHNOLOGY PAUL V.GALVIN LIBRARY 35 WEST 33RD STREET CHICAGO. IL 60616
TEST OF A THREE TON
REFRIGERATING PLANT
A THESIS
PRESENTED BY
A.J.BEERRAUM
N.W.STRALE
P.L.KEACHIE
TO THE
PRESIDENT AND FACULTY
OF
ARMOUR INSTITUTE OF TECHNOLOGY
FOR THE DEGREE OF
BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING
HAVING COMPLETED THE PRESCRIBED COURSE OF STUDY IN
MECHANICAL ENGINEERING MAY 29, 191S
TilBLE OF C01JTEiI[rs.
Pill-.!i: I.
Introduotion • Pi-ge 1.
PAIiT II.
Preparation for Tests.
Indicator Seducing motions Page 3.
Insulating Boxes Pc.ge 3.
Mercury lianonieter • Page 3 .
Steam Condensing Apparatus Page 4.
Changes in the Piping 3;.'sterQ P^-ge ^:.
PAI-.T III.
Trying out the Apparatus P^<-ge 6.
PAKT IV.
The Tests.
Method of Procedure Page 9,
Outline of Theory Page 11 ,
Discussion Page 14.
Sample Compxitation of Results Page 16,
Sui-mnary of Average Results
Curves
Illustrations
Data
Drawins-s
8348S
TEST OF A Tm^EE-TOU REFEIGEHaTIITS PLALIT. IlITRODUCriOlI.
The subject of this report is an amiTionia- oorapression refrigerating plant of three tons refriger- ating capacity. The prohlem consists of a series of tests under different hack pressures, -his reqviiroc the taking of data relating to the efficiencies of the "boiler, engine, and compressor, "besides a large nunher of ohservaticns of the temperatures and pressures at various points in the steam, water and ammonia lines.
Before proceeding with the test, a con- siderable amount of installation and preparatory v;ork was necessary. This consisted chiefly in the install- ation of a steam concenaer and vacuum pump; the con- struction of reducing motions for the steam and com- pressor cylinders; the construction of a mercury man- ometer for measuring the ammonia back pressure; chan- ges and additions in the piping systems; the building of insulating boxes for the ammonia condenser and ex- pansion coils.
A general viev; of the -,lant is shown in Plate I. Its essential elements are a 25 K.?. Erie Economic boiler; a 6" x 6" vertical comTsressor direct- connected to a 6" X 6" horizontal engine; a double-tube ammoni':. condenser; double-tube expansion coils; an armnonia liquid receiver and an accumulator. The refrig- erating eciuipment was furnished by the York Maniifactur- ing Company. A Ylheelcv surface condenser and a Harsh vacuum pump enable the engine to be run condensing, and a closed heater makes possible the preheating of the water to -orevent too low a temperature being attained in the cooler or expansion cojls.
The operation of the plant may be more clearly under stood by following the amjuonia, steam, and water piping through a complete cycle.
The compressed ajnmonia gas passes from
'the coKiprecsor through an oil separator into the outer tubes of the condenser. The ammonia in the liquid state gravitates frora the condenser into the receiver helow. The liquid is then forced throup-h the accum- ulator (or by-passes it) into the outer tubes of the cooling coils. Here it vaporizes, absorbing its la- tent heat from the water in the inner tubes, and the gas -■ s drawn through the acciunulator into the com- pressor cylinder, where it is again comprecsed, and the process is repeated.
Water from the city main is weighed and then fed into the boiler. Steam from the boiler flov/s into the main header, v;hich supplies the engine, heat- er, and auxiliaries. The exhaust steam from the engine passes eitrifir into the cjonienser or the atmosphere as desired, the exhaust from the auxiliaries passing to the atmosphere.
Piesh water, instea of brine, is used in the expansion coils. Owing to the small pipe sup- plying Water from the city main, it was found neces- sary to havG a concrete sump to maintain a sufficient supply for operation. 'Yater is taken from the sump and forced through the ammonia condenser. From the ammonia condenser it may go to the cooler and then to the steam condenser, or go first to the steam con- denser and then to the cooler. In either case it may be sent through the heater before going to the cool- er. After lec-ving the r3team condenser or cooler, as the case may be, the water is weighed and returned to the sumio.
PREPAP.ATIOl!! FOR TEST.
IKDICATOP. REDUCING MOTIOIIS.
Plate II shows the indicator reducinf^- mo- tion for the steam cylinder of the refrigerating mach- ine. The panto graphic linkage was used since it gives a perfect straight line motion to the point to which the indicator cord is attached. The distance moved "by this point is also directly proportional to the distance moved "by the point of attachment to the crosshead. The pulley and fork at "C" permit the proper adjustment of of the indicator cord passing to the indicator. The proper height of the linkage can he adjusted hy moving the clamped rod "R" along the standard "S". All the parts except the small brass pulley are made of soft steel.
Plate III shows the reducing motion for the ammonia cylinder. The size of the linkage is the same as that for the steam cylinder. The position of the string can he adjusted \>-y moving the rod "B" within the hearing "A".
IlISULATINO BOZSS ?QR GO IIS.
Plate lY shows the insulating hox for the ammonia condenser. It is made of 7/8" tongued and groov- ed pine hoards held together hy 2' x 3/4" sticks. The top and hot torn sections have slots at "A" and "B" which fit over the side sections. This construction permits the removal of the top and sides in order to get at the coils. The space around the tuhes is packed v/ith mineral wool v/hich reduces the passage of heat to the contents of the tuhes.
Plate V shows the insulating hox for the ex- pansion coils. The constructiori is similar to that of the box for the condenser.
I£:RCURY IvIANOilETER.
Plate VI shows the mercury manometer which was constructed for measuring the ammonia back pi-essure on the compressor. By means of this manometer the pressure can he obtained with greater accuracy, than with the ordinary pressure guage and it also eliminates
V.
a calibration. The hose- oonnect ions shown at the top could not he used. One tap is left open to the atmosphere and into the other tap is screwed the pipe connected with the gas line returning to the compressor. The glass rods used are 5/8 ■' outside diameter, ''ith t}ie exception of the aluminmij hack, all the parts had to he made of steel so as not to be affected "by the ammonia. The manometer 7;>::s de- signed hy :,lr. ". L'. lihhy of the Ijlechanical Depart- ment.
STEillvI COlIliEJISIilG iiPPARATUS.
Plate VII shov/s the layout of the steam condensing apparatus. The condenser is a double flov; surface condenser manufactm-ed by the iTheeler Condenser and T^ngineering Company. There are 41 tubes in the first or lower pass and 53 in the second pass. The tubes are 1/2" inside dia- meter and 5/8" outside diameter with a length of 47 1/8'. The steam surface is 60.4 sq. ft. and the water sxirface 40.3 sq. ft. The condenser is sup- ported by tvifo 2 l/2" X 3/4" wrought iron supports imbedded 6" in the concrete foundation. The con- denser is used only in connection with the refrig- erating machine in order to determine its steam consumption. The cooling water inlet may come from either the ammonia condenser or the expansion coils as indicated on plate I. The Harsh vacuum pump has a 4" x 6" steam cylinder and 6" x 6" Vi/ater cylinder.
CHAIIGES III THE prPIEG SYSTEMS.
In order that tests may be made with and \7ithout the use of the accumulator a by-pass connection was made as indicated on Px^te I. The liquid ammonia from the receiver may pass directly to the expansion valve or first pass throixgh the accumulator coils where it would be cooled by the surrounding gas coming from the expansion coils. As formerly connected up, the liquid ammonia from the receiver v;ould always have to pass through the accumulator on its \my to the e::'j:cncion coils.
vrnen the steam oondenser was installed it was necessary to ohange the present water piping somewhat. ?here being very little space for more than one set of weighing tanks it v/as decdded that the same water "be used in the ammonia condenser, cooler, and steam condenser. As stated previously the water from the sump may take two routes. It may pass the ammonia condenser, througli the heater, thi-ough the cooler and then through the steam con- denser or after passing through the ammonia conden- ser the water may go through the steam condenser, througti the heater, and then tlirough the cooler. 1 1/4" tees were inserted in the lines on each side of the condenser so that the steam condenser could "be operated independent of the rest of the appara- tus.
TRYIIIG OUT THE .IPP^^.ATUS.
The first attempt to try out the ap- paratus Was made on 'Vednesday , May 1, 1912. On this occasion leaks \vere discovered at the manhole and one of the handholes of the holler, and the fire was drawn from the grate. These leaks were attended to and on Thiirfeday the compressor was run for the pur- pose of placing the system under air pressure. The discharge pressure did not rise, however, and steps were taken to locate the leak. It wus found that v7hon the valve in the water outlet from the ammonia condenser waS closed, the pressure rose. This in- dicated a leak betv/een the inner and annular space of the douhle tuhes.
The aminonia condenser was then talcen apart, and the two lower inner tuhes were found to he cracked, evidently due to the freezing of the water which V7a.s left in the coils during the winter. This water from the coils had gravitated into the receiv- er, about 2 1/2" being visible in the gauge glass. The water was drained out of the receiver and tv/o new 1 l/4" tubes were put in place, new gaskets be- ing used.
On the same day the lovi/ pressure side was pumped up to an air pressxxre of 160 lbs. gauge (142 lbs. corrected) and left there until the next day. After this run, leaks at the safety valve and at one of the joints in the steam leads from the boil- er v;ere repaired.
On Friday, May 3, it was found that the lov; pressure system liad held the pressure of the day before. The safety valve wus set by the boiler Inspector at 88 lbs. gauge (corrected). The gauge reading was 93 lbs., the intended blow-off pressure being 95 lbs. gauge.
After the ammonia condenser had been repaired, the high pressure system was tested out v/ith air pressure and found satisfactory. On the
'following !.Ior "ay a small charge of ammonia was fed into the system, while under air -oressure. The joints were then tried out for leaks "by the sulphur test. Sticks of suli^hur were lighted and moved a- round each joint. 7/liere ammonia was escaping, dense fumes of sal-am27ioniao would fona. The only leaks discovered were at the flanged joints. The holts on all the flanges were then dravm up and fiirther application of the sulphur sticks gave no indica- tion of oh jectionahle leaks.
The system was now given a larger charge of ammonia and on Tuesday, since no leaks appeared, the remainder of the charge was put in, making a total of chout 150 Ihs. of ammonia, \7hen charging the system the outlet valve on the receiv- er and all the valves between the receiver and the expansion valve were closed. Then the hlind flange just helow the expansion valve (see Plate I) was removed and a connection made to the ammonia drum. The gas v/as then drawn out of the drum, through the cooler and into the compressor. ?rom the compress- or the gas passed to the arniionia condenser where it was liquified. It then collected in the receiver below. The system now contained a rai::ture of ariimon- ia and air. The air was removed hy attaching small pet cocke to the purge pipes on th.e conc.enser and cooler. To these ecc!:s ruhher tubing was fastened. The other ends of tho .tubes v/ere placed into a bucket of Water. The acmonia gas being highly sol- uble in water dissolved, while the air escaped in bubbles to the surface of the water. ''.Taen no more bubbles appeared the system v;as free of air.
Indicator cards taken from the com- pressor cylinder were narrow and extended and indi- cated improper working of the discharge and inlet valves. The compressor cylinder head was removed and the valves taken out and thorovighly cleaned. The cards obtained now were still unsatisfactory and the valves were again removed and also the pis- ton. Burred edges were f^und on some of the piston rings and these were filed smooth, a better card v/as no\, obtained, although it v;as not the conven-
tlonal shape of an amnonia compressor card.
The inu-icator cards from the steam cylinder were Sc-tisfactory, showing a cut-off on both ends of ahoixt two-thirds of the stroke. The machine did not run very steadily at first, hut as it continued rixnning, conditions improved and the groan in the compressor cylinder was no longer audihle.
The circulating pump and vacuum pump were found to operate Sc.tisfaetorily. In charging the system, the steam condenser was not used, the e:diaust from tho engine and circulating pump going to the atmosphere.
THE TESTS.
"^he original intention was to run the refrigerating machine condensing and to run tests v/ith and v/ithout the use of the accumulator. Uhen prepared to "begin the tests, leaks v;ore discovered at the inlet and outlet of the v^ater heater and It was very difficult to get at the joints and solder them. It was therefore decided that the heater he out out entirely and so the fittings at the heater were hroken and the pipe rising from the amirionia condenser to the heater v;,as connected directly with the water inlet to the cooler, i'^urtherraore, it was found that tlie range of temperature produced in the cooler was not very great and conseruently v/hen us- ing the steam condenser, the v»ater leaving the cool- er and running hacl: into the sump was .uite warm and this water entering the ammonia condenser re- quired a higher pressure to condense the aoaonia than was thought dcsiratle. ]?or this reason the steam condenser was not used and the engine exhaust- ed to the atmosphere. After having started the first run on [Thursday evening, May 9, a severe leak was discovered around the thermometer cup on the liquid ammonia outlet of the accumulator. Drawing up the thermometer cup did not stop the leali. Since our tl"ie for testing was limited we decided tc run all our tests without the use of the accumulator. The mercury manometer for the use of measuring the ammonia back i ressure could not he used since the required length of glass tuhing could not he ob- tained in due time, so it was found necessary to use the gauge.
The first actual run was started on Friday morning. May 10, at 1:0C o'clock. The aver- age back pressure was 37.6 lbs. (corrected) Read- ings of the temperatures and nrecsures shown on the running log were taken every fifteen minutes for three hours. Indicator cards on the engine and com- pressor were also taken. The revolutions per min- ute vvere obtained from the continuous counter.
An attempt was made to make the next run v;ith 60 lbs. "back pressure but owing to the im- perfeot valve action it was impossible to maintain that pressuie any great length of time. It v/as then decided to ma^:e a run with 30 lbs. back pressure. This run was started at 6:30 A.ii. on the same day. Observations were taken every fifteen minutes, "lien the third reeding W...S taken it v/as noticed that the continuous counter v/as not recording properly, and all previous readings of the counter for this test had to be re.>:^cted. This necessitated counting the strokes for a minute to obtain the revolutions per minute. ?or some unknown reason the engine stopped a little after 9:00 A.il. and the run stopped half an hour earlier.
2he cards taken from the ammonia compressor were very pooi and showed th-.t the discharge valve w^.s not^^jrking properly. The cylinder head was removed and a^ discharge valve put in. The valve on the steam cylinder was tightened because from the cards it seemed as though the valve Wc^s loose. The engine was then otarted up again and appeared to run better than before except that one of the bearings became too warm and had to be loosened. The valves appeared to be working better than before but the cards still showed that it was not absolutely right.
The third rxin. was made Friday even- ing from 8:00 to 11:00 o'clock v/ith results as shown on the running log.
The test was resximed on Saturday morning at 11:00 o'clock. Owing to the lack of time it was decided to make runs of two hours duration. Four runs wore made with the back pressures at 11.4 lbs., 22.4 lbs., 2 lbs., and 32.9 lbs. (corrected valiafis)
Between every run it was found neces- sary to let the air out of tjie system by running rub- ber tubing from the purge outlets into a bucket of water.
The oirculating water, during a run, ■beoame very varm and this neoes;^ itated the pumping of the water from the sump and putting in fresh water.
After finishing the test, cards were taken from tlie compressor and engine cylinders with the engine running at lov; speeds.
OUTLIIIE OP THEORY.
The "boiler efficiency would he the same for all the runs. Hence in order to ottain as long a period of fuel consumption as possible, the efficiency was figured hy considering all seven runs as one and using the average values of all pressures and temperatures. Since t?ie thermodynamic efficiency of an injector is practically IOO70 the heat absorbed by the boiler is the amount required to evaporate the cold supply water. If then A' the total heat, t^ the supply v.-ater temperature, then the factor of e- vaporation P . X- (t^r - 32) 970.4
Let V/j ~ water evaporated per lb. of coal .
Then tho ecuivalent evaporation from and at
212"P^W X P.
Then the heat absorbed by boiler per lb. of
coal- ".7, {A -t^-'-SS)
Efficiency of boiler and grate J, (A -tj-SS)
BTU/lF coal
The ideal refrigerating machine is a reversible engine operating in a Carnot cycle in a re- verse direction from that of a steam or any other heat engine.- The eff:ic1ency of a Carnot engine when oper- ating as a heat engine -H-B^. v;here !!•=*■ the source of heat and I^ ^ that going H to the refrigerator. If the engine be run backward the "thermodjTiariic efficien- cy" would be Ey - E^ - T^ where T-fthe absolute temperature of H-H^' T-T^ the atirionia leaving the refrigerator and,Tr=:"ae absolute temperature of the ammonia entering the condenser.
The thermodynamic efficiency of an
engine working in a Garnot cyole is less than one, hence that in the refrigerating oycle must always "be greater than unity.
The object of the refrigerating pro- cess is tha removal of the heat Z^ In the cooler, so that this may he considered the useful work. Hence the actual efficiency of a refrigerating machine Kji -^ E ; where K ~ '^^\~%i ^ » ^ "being the water pass-
ing through the cooler per minute and tj and t^ are respectively the inlet and outlet temperatures. 77^= H.P. of the compressor cylinder and A M(^ its heat equivalent. The ahove efficiency gives a result greater than unity "because the em.-.onia receives heat from the wr.ter in the cooler and rejects heat into the condenser. That is, the •,7ork to he done hy the compressor is not the mechanical eruivalent of re- frigeration, hut only that necessary to supply the difference hetv/een the heat rejected hy the amnonia into the conlenser and that' received in the cooler.
The heat removed hy the condenser r- E-Q(t^-t, ) where Q condensing water per minute and t^and trthe outlet and inlet temperatures respect- ively.
The heat removed hy the jacket wat- errK rQ^ {t^-t^ where Q .- jacket water per minute and t^ and t - the outlet and inlet temperatures res- pectively.
The refrigerating ca-oacity in tons per twenty four hours Q("^ -W)^ 24 x 60. where
288,000 288,000 is the melting effect of one ton of ice in
B.T.U.
The thermal efficiency of the plant referred to the coal pile equals the refrigeration produced per Ih. of coal divided hy the B.T.U. val- ue of a Ih. of coal as fired.
The heat halanGe of the refrig- erating sj'-steKi is as follows: K-i»-A7^^ Eiil^ where X . the heat ahstracted (refrigeration); ?is.=^H.P, of^ compressor cylinder; Z-heat a^bstracted in the condenser; r^.r total sura of losses by radi- ation and convection, etc.
DISCUSS lOiJ.
The only steaixi consumption determin- ed in the test was that of the engine and circulat- ing pump together. In order to doterinine the water rate of the engine running noncondensing the punip would have to he connected up v/ith the condenser and its rteam consurapt ion determined. This oon- stunption suhtracted from the v/ater fed to the "boil- er would give the water rate of the engine. This determination co-aid net "b-e inade hecaiarje of lack of time.
The "boiler ^nd grate efficiency Is very low. "'e think this is partly due to the large eiccess of air parsing through the grate since there are no ash doors and the opening is very large. For a greater part of the time, however, sheet metal v;as set up In front of this opening. The holler was running at about tOfo of its normal rating and the efficiency is probably lower at this load.
The speed of the engine In the first run looks doubtful. At the beginning of the second run it was discovered tho,t the continuous counter was not recording properly. The speed recorded v/as too low. In all probabil:ty the r:.F.i.i. of 9i.7 in the first run is too low. This v/ould account for the low I.E. I. of tiie steam cylinder and the high refrigeration produced per minute per I.'-^.i . of both cylinders.
In several runs the heat removed by the condenser is less than the cold produced, V7hich is contrj-ry to theory and to results obtained in good practice.
In all the runs excepit the seventh the heat removed in the jacket T»"ater is greater than the indicated work of the compressor. This is cer- tainly due to the very 1)00t operation of the valves.
Curves #1 and ,;'S show that the II. P. increases with increase of back pressure up to a
maximum anu then decreases.
Curve fA shows the tonnage tc increase v/ith increase of back ressure as it should. There must however, he a turnin^r point in the curve because when the hack pressure became equal to the condensing piessure there would he no expansion and therfore no refr igerat Ion.
Curve \r5 shov/a the I.II.x . per ton to deciease with increase of back pressure as it sho'ild,
Ourve f7 sliows that tho temperc^ture of the gas entering the cooler (after passing the ejrpanoion valve) increases with the increase of back pressure. Tliis \vould be expected since the expan- sion is decreased and hence a less drop in temper- ature .
Ilhe shape of card v/hich should be ob- tained from the compressor when operating properly is shov/n in tho annexed diugram. The work required to open the compressor valves is indicated by small projections at the nressure and suction lines. The effect of clearance is sjhovm by a sloping of the curve "R". According to Siebel tho expansion and compression curves of tlie indicator cards obtained in the test shov; tliat the valves leal.ed verj- badly. During the entire time oT the test only two satis- factory cards were obtained.
On the ..hole we consider the results of the test very unsatisfactory. Tlie low mechanical efficiency is due to tjie leaking of the valves and these should be reground on to their p.eats and the entire machine should be given a thorough overhaul- ing. ;7e also think „hat some of the poor results were due to the incorrect readings of most of the thermometers. The therioometerc were calibre; ted a- galnst a standard thermometer which had been calibrat- ed at the U.S. Bureau of Standards, a few years before.
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