MECHANICAL ENGINEERING A Project Report on ENERGY EFFICIENT REFRIGERATION Submitted to „MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION‟ In partial fulfilment for the award of Diploma in Mechanical Engineering Submitted by MR.KADUKAR ASHUTOSH G. MR. KAKADE MAYUR J. MR. KOLI SANDESH N. MR. KUMBHAR VINAY S. Under the guidance of PROF. D. M. PATIL DEPT. OF MECHANICAL ENGG. NEW POLYTECHNIC, KOLHAPUR 2013-14
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MECHANICAL ENGINEERING
A
Project Report on
ENERGY EFFICIENT REFRIGERATION
Submitted to
„MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION‟
In partial fulfilment for the award of
Diploma in Mechanical Engineering
Submitted by
MR.KADUKAR ASHUTOSH G.
MR. KAKADE MAYUR J.
MR. KOLI SANDESH N.
MR. KUMBHAR VINAY S.
Under the guidance of
PROF. D. M. PATIL
DEPT. OF MECHANICAL ENGG.
NEW POLYTECHNIC, KOLHAPUR
2013-14
MECHANICAL ENGINEERING
SHRI PRINCE SHIVAJI MARATHA BOARDING HOUSE‟S
NEW POLYTECHNIC, KOLHAPUR
CERTIFICATE
This is to certify that
1) MR. KADUKAR ASHUTOSH G. 2) MR. KAKADE MAYUR J.
3) MR. KOLI SANDESH N. 4) MR. KUMBHAR VINAY S.
of final year of diploma in Mechanical Engineering
have satisfactorily completed their project work entitled
“ENERGY EFFICIENT REFRIGERATION”
Under my supervision and guidance
Towards the partial fulfilment of award of
Diploma in Mechanical Engineering as laid by the
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,
MUMBAI
During academic year 2013-14.
Date:
Guide External Examiner HOD Principle
MECHANICAL ENGINEERING
ACKNOWLEDGEMENT
We would like to place on record our deep sense of gratitude to Prof. D. M. Patil Sir for
his excellent guidance, help and constant encouragement during the completion of this project.
Our sincere thanks to Mr. Saiprasad Bondre, for his timely guidance and help.
We are thankful Prof. G. N. Munishwar (Head of Mechanical Dept.) and all staff
members for giving us the proper and constant guidance during this project. Without their
guidance it was really impossible task for us to complete this project.
Finally, we wish to thank all of our friends and those who directly and indirectly helped
us a lot during this course of project work.
Thank you,
Students‟ Names
Mr. Kadukar Ashutosh G.
Mr. Kakade Mayur J.
Mr. Koli Sandesh N.
Mr. Kumbhar Vinay S.
MECHANICAL ENGINEERING
INDEX
CHAPTER NAME OF CONTENT PAGE NO.
1 Introduction 1
2 Field survey
3
Design
3.1. Conventional design
3.1.1. Vapour Compression Cycle
3.1.2. Vapour Compression Refrigeration System
3.2. Modified Design
3.2.1.Sub-cooling
3.2.2. Methods and Effects of Sub-cooling
3.2.3. Design Details
3.3. Details of parts of system
3.3.1. Compressor
3.3.2. Condenser
3.3.3. Capillary tube
3.3.4. Evaporator
3.3.5. Helping Condenser
4
Manufacturing Activities
4.1. Fabrication
4.1.1. Water Tank
4.1.2. Insulation
4.1.3. Box Mounting
4.1.4. Temperature Indicator
4.1.5. Water Cooled Condenser
MECHANICAL ENGINEERING
4.1.6. Pressure Gauges
4.2. Machines/Tools Used
4.2.1. Hand Shear
4.2.2. Portable Drilling Machine
4.2.3. Fly Press
4.2.4. Riveter
4.2.5. Tube Cutter
4.2.6. Spring Pipe Bender
4.2.7. Flare
4.2.8. Gas Torch
4.2.9. Soldering Gun
4.2.10. Vacuum Pump
5 Testing
6 Results and Analysis
7 Conclusion and Scope For Future
MECHANICAL ENGINEERING
MECHANICAL ENGINEERING
CHAPTER NO.1
MECHANICAL ENGINEERING
1. INTRODUCTION:
The fossil fuels and the petroleum fuels are depleting very fast and the human race has to
hunt for newer resources for energy. Similarly energy has to be saved and used very
economically because saving is earning. As such, we engineers working in several branches as
well as the end users of the machines/gadgets who are playing role of energy consumers should
think of the gadgets which are energy efficient.
Our project is endeavouring to save energy in our house by developing a gadget which utilizes
the heat coming out from the condenser. As such besides working to cool the milk, fruits,
vegetables, the refrigerator will also work as a heating device for some useful work.
The electrical energy consumption for a typical 200 lit. refrigerator is …. Kwh and the
approximate expenditure of running is …. The total amount of heat coming out of condenser is
… Kcal and this can be used for heating of 38 liters of water.
The various design parameters considered for developing this gadget are:
-Ease of manufacturing
-Low Cost
-Ease of adaptability/Installation
-High efficiency
-Compactness
The results obtained are fantastic and we hope that in the coming few years, this product will be
developed better than ours and be used on large scale.
MECHANICAL ENGINEERING
CHAPTER NO.2
MECHANICAL ENGINEERING
2. FIELD SURVEY:
Our field survey started with location where we were about to execute the entire project
regarding activities. We visited such locations and found four workshops for our project. The
two of which were located in Belbag near Gokhale College named „Viky Refrigeration‟ and
„Som Refrigeration‟ and one in Shivaji Udyamnagar named „Car Refrigeration‟ but due to
convenience of travelling and transportation, we finalized „Sai-Vabhav Refrigeration‟ located in
Uchgaon.
Next major part of our project was to buy a second-hand refrigerator. We finalized the
specification of the refrigerator as 190 liters with R134a refrigerant. We visited different
electronics shops and refrigeration industries in different locations around city. We selected a
good working refrigerator of specification of 200 liters and refrigerant R134a; near „Tatakadil
Talim Mandal, Rankala‟ from Mr. Juned Bagwan.
For fabrication of sheet metal boxes we visited two places. A shop in Shahupuri near the
Bagal Chowk and another shop in Belbag near Gokhale College. We fabricated sheet metal
boxes from the shop in Belbag.
For pressure gauges we visited „Kadam Refrigeration‟ in Shivaji Udyamnagar. Also for
temperature indicator and thermocouples we visited „Bombay Furnace‟ in Shivaji Udyamnagar.
Also for the rest of the materials like electrical wires, cables and piping materials, we visited
local shops in Uchgaon in the vicinity of our workshop.
MECHANICAL ENGINEERING
CHAPTER NO.3
MECHANICAL ENGINEERING
3. DESIGN:
3.1. CONVENTIONAL DESIGN:
The conventional design of any refrigeration system is based on the „Vapour
Compression Cycle‟ (VCC) and the system working on Vapour Compression Cycle is called
as „Vapour Compression Refrigeration System‟.
3.1.1. VAPOUR COMPRESSION CYCLE:
The Vapour Compression Cycle is as represented in the p-h diagram below. The diagram
represents Pressure (p) on X-axis and Enthalpy (h) on Y-axis.
P (Bar)
h (kJ/kg)
Pe
Pc
h3 = h4 h2 h1
Qa
Qr
W
MECHANICAL ENGINEERING
i. Compression Process (1-2):
Vapour at evaporator pressure (Pc) enters into the compressor at state point 1. It is
compressed isentropically (reversible adiabatically) upto the discharge condenser pressure (Pc)
and vapour is assumed to become dry-saturated.
ii. Condensation Process (2-3):
Dry-saturated vapour at state point 2 enters the condenser where it rejects heat Qr at constant
pressure (Pc) to surrounding. It is assumed that the vapour is completely condensed and it
becomes saturated liquid.
iii. Expansion Process (3-4):
Saturated liquid at state point 3 and condenser pressure (Pc) is now passed through an
expansion device having restricted opening and it is throttled down to the evaporator pressure
(Pe). This process of throttling is constant enthalpy or isenthalpic process.
iv. Vaporization Process (4-1):
Slightly evaporated refrigerant enters into evaporator at state point 4, where the refrigerant
absorbs the heat (Qa) from space to be cooled. This effect of heat absorption is called as
„Refrigerating Effect‟. Now vapour refrigerant leaves the evaporator in vapour state as entry to
compressor at state point 1. Hence the cycle is completed.
MECHANICAL ENGINEERING
3.1.2. VAPOUR COMRESSION REFRIGERATION SYSTEM:
The vapour compression refrigeration system by far is the most popular and widely used
system in refrigeration and air conditioning both for industrial and domestic applications.
In this system the working substance is a refrigerant like NH3, R-12, R-22, R-134a, etc.
A refrigerant readily evaporates and condenses depending upon the pressure and
temperatures during the cycle therefore; refrigerant undergoes a change of phase alternatively
between liquid and vapour phases without leaving the system.
Any vapour compression refrigeration system consists of four basic parts: