Test of a three ton refrigerating plant

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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