Refrigerator Gas Charging Unit

SUBMITTED FOR THE PARTIAL FULFILMENT OF DEGREE OF BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING 2010-2014

Submitted to: Department of Mechanical Engg. FET, Gurukula Kangri Vishwavidyalaya

Submitted by: Ankit Gupta Sumit Kumar Sharma Suryaprakash Singh

Under the guidance of Mr. Sunil Sharma (Asst. Professor, ME Department) FACULTY OF ENGINEERING AND TECHNOLOGY GURUKULA KANGRI VISHWAVIDYALAYA HARDWAR-249404

CERTIFICATE
Certified that this project report titled Refrigerator Gas Charging Unit is a bonafide work of Ankit Gupta, Sumit Kumar Sharma and Suryaprakash Singh who carried out the project work under my supervision, for the fulfillment of requirements for the award of degree of Bachelors of Technology in Mechanical Engineering.

Place: Hardwar Date: MR. SUNIL SHARMA

Assistant Professor Department of Mechanical Engineering Faculty of Engineering and Technology Gurukula Kangri Vishwavidyalaya Hardwar

COUNTERSIGNED

MR. SUNIL LAMBHA

Head of the Department Department of Mechanical Engineering Faculty of Engineering and Technology Gurukula Kangri Vishwavidyalaya Hardwar

ACKNOWLEDGEMENT

It is a matter of great pleasure to make this project report towards the fulfillment of Minor project of Mechanical Engineering. We feel great pleasure in expressing our sincere and profound gratitude to our guide Mr. Sunil Sharma who has guided and made us useful suggestion for undertaking this project work. We also want to express our profound gratitude to Mr. Sanjeev Lambha who rendered the valuable help from time to time. We are very thankful for providing us necessary facilities for this project work. We offer our cordial thanks to our teachers. Finally we express our regards to our parents who inspired us throughout our studies and completion of our project work. We are also very thankful to our friends who gave us constant support and help us for improving and testing project.

Team Members

ABSTRACT
Refrigerator being a common household appliance nowadays in homes as well as industries, sometimes faces problems related to gas filling, leaking etc. In order to make the process of refrigerator gas charging easy and efficient a Refrigerator Gas Charging Unit (RGCU) can be used. The principle of this method is that whenever a charging is carried out by this set, the amount of gas supplied to the refrigeration or air conditioning unit is calculated with the help of spring balance and also determine the pressure of the gas flowing through the charging line with the help of compound pressure gauge. This set being portable, is easy to carry and can be used at homes by regular persons.

CONTENTS
CERTIFICATE.1 ACKNOWLEDGEMENT...2 ABSTRACT3 CONTENTS...4 INTRODUCTION

INTRODUCTION
Refrigeration is defined as any process of heat removal. More specially, refrigeration is defined as the branch of science that deals with the process of reducing and maintaining the temperature of a space of material below the temperature of the surroundings.

Multipurpose charging set is a single arrangement for charging the refrigeration and air conditioning unit. This charging set is different than other methods. This is a portable device which can be transferred from one place to another its construction is simple and portable. This set is multipurpose device; with charging the unit it can also achieve the vacuum in unit. The weight of gas and pressure of gas going to the unit is directly measured at the time of charging on this set so it is very useful device for charging the refrigeration and air condition unit in laboratories.

PRINCIPLE OF PROJECT Evacuation: Removing of fully air present in the refrigeration unit is known as evacuation. The main purpose of evacuation process is that for charging the refrigeration unit. The air should not be present in it. If evacuation is not carried out some amount of air is present in the refrigeration unit carried out properly. The leakage problems are rising in it. Definition of Charging: Charging is the process of filling the gas in the refrigeration and air-conditioning system. Principle of charging set: This is a new method used for the charging of refrigeration unit differ than the other method. The principle of this charging set is that whenever a charging is carried out by this set how many amount of gas is supply to the refrigeration or air conditioning unit is calculated with the help of spring balance and also determine the pressure of the gas flowing through the charging line with the help of compound pressure gauge.

Isometric View of evacuation and charging set

PART LIST

Sr.no. 1 2 3 4

Part 3 way valve 2 way valve Charging line

Quantity 2 1 3 1

Material Bronze Bronze Rubber

Compound pressure Gauge

5 6 7 8

Spring balance Refrigerant gas Vacuum Pump Compressor

1 1 kg 1 1 R-12

VACUUM PUMP A vacuum pump is a device that removes gas molecules from a sealed volume in order to leave behind a partial vacuum. The first vacuum pump was invented in 1650 by Otto von Guericke, and was preceded by the suction pump, which dates to antiquity.

Root Blower Root Blower: It is also called a booster pump, has highest pumping speeds but low compression ratio.

TYPES Pumps can be broadly categorized according to three techniques

Positive displacement: pumps use a mechanism to repeatedly expand a cavity, allow gases to flow in from the chamber, seal off the cavity, and exhaust it to the atmosphere.

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Momentum transfer pumps, also called molecular pumps, use high speed jets of dense fluid or high speed rotating blades to knock gas molecules out of the chamber. Entrapment pumps capture gases in a solid or adsorbed state. This includes cryopumps, getters, and ion pumps.

Positive displacement pumps are the most effective for low vacuums. Momentum transfer pumps in conjunction with one or two positive displacement pumps are the most common configuration used to achieve high vacuums. In this configuration the positive displacement pump serves two purposes. First it obtains a rough vacuum in the vessel being evacuated before the momentum transfer pump can be used to obtain the high vacuum, as momentum transfer pumps cannot start pumping at atmospheric pressures. Second the positive displacement pump backs up the momentum transfer pump by evacuating to low vacuum the accumulation of displaced molecules in the high vacuum pump. Entrapment pumps can be added to reach ultrahigh vacuums, but they require periodic regeneration of the surfaces that trap air molecules or ions. Due to this requirement their available operational time can be unacceptably short in low and high vacuums, thus limiting their use to ultrahigh vacuums. Pumps also differ in details like manufacturing tolerances, sealing material, pressure, flow, admission or no admission of oil vapor, service intervals, reliability, tolerance to dust, tolerance to chemicals, tolerance to liquids and vibration.

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Uses of vacuum pumps Vacuum pumps are used in many industrial and scientific processes including:

Composite Plastic moulding processes (VRTM) Driving some of the flight instruments in older and simpler aircraft without electrical systems. The production of most types of electric lamps, vacuum tubes, and CRTs where the device is either left evacuated or re-filled with a specific gas or gas mixture Semiconductor processing, notably ion implantation, dry etch and PVD, ALD, PECVD and CVD deposition and soon in photolithography Electron microscopy Medical processes that require suction Uranium enrichment Analytical instrumentation to analyze gas, liquid, solid, surface and bio materials Mass spectrometers to create an ultra-high vacuum between the ion source and the detector Vacuum coating on glass, metal and plastics for decoration, for durability and for energy saving, such as emissivity glass Hard coating for engine components (as in Formula One) Ophthalmic coating Milking machines and other equipment in dairy sheds Vacuum Impregnation of porous products such as wood or electric motor windings. Air conditioning service - removing all contaminants from the system before charging with refrigerant

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GAUGE, ABSOLUTE, AND VACUUM

DIFFERENTIAL,

COMPOUND

It is important to understand the type of pressure that is required for an application. The terms Vacuum, absolute and compound are usually the basis for this misunderstanding; often Demonstrated by incorrectly combining terms such as absolute vacuum or compound Vacuum. First, lets identify and define the 5 basic pressure types. Dial gauge configurations will be referenced for each pressure type because they serve as the best means of illustration.

1) Gauge Pressure. Because gauge pressure gauges allow the surrounding ambient pressure to effect both sides of the sensing element, the effects of barometric pressure are essentially negated. Therefore, a gauge pressure gauge with an open inlet port will start with the pointer at zero, which means that the gauge is indicating no pressure in excess of barometric.

2) Vacuum. Vacuum gauges measure negative pressures, i.e. the removal of atmospheric pressure. Using gauge pressure zero as the starting point, the gauge will indicate the vacuum level in positive numbers as more pressure is removed. Vacuum gauges usually position zero at 5:00 on the dial and rotate counter clockwise. Most vacuum gauges are rated to a full scale of 30 In Hg or 15 psi. Remember that since

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vacuum is simply the removal of atmospheric pressure, the highest level of vacuum that can be achieved on a given day is equal to the barometric pressure. (You can only remove whats there to remove in the first place!). Customers often comment that they cannot get the gauge to read all the way down to 30 In Hg, therefore the gauge is not working properly. In most cases, the reason that they cannot achieve a 30 In Hg vacuum reading is that the existing barometric pressure is less than 30 In Hg, thus a 30 In Hg vacuum reading is unachievable.

3) Compound Pressure. Starting at gauge pressure zero, a compound gauge simply combines the vacuum indication of the straight vacuum gauge with the gauge pressure indication of a gauge pressure gauge. The position of the zero is dependent upon the full scale rating of the pressure side. The pointer will travel in the counterclockwise direction for vacuum indications, and clockwise for pressure indications.

4) Differential Pressure. Starting at gauge pressure zero, a differential pressure gauge simply measures the difference between 2 input pressures. A differential dial gauge looks like a gauge pressure gauge, except it has a second inlet port.

5) Absolute Pressure. Unlike gauge pressure, an absolute gauge does not allow ambient pressure to affect both sides of the sensing element. To achieve a true

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absolute reading, an absolute pressure gauge must have the atmosphere removed from around one side of the sensing element (referred to as an evacuated reference). The result is that an absolute gauge with an open inlet port will indicate the barometric pressure (which is usually between 14 and 15 psi). This will allow the user to either apply pressure causing the gauge to read above the barometric pressure value, or remove pressure (pull vacuum) causing the gauge to read below the barometric reading. Absolute zero should be achievable under full vacuum, since the starting point is the actual barometric reading, and a full vacuum will remove all of this existing pressure. On absolute dial gauges, the zero point will be positioned at 7:00 on the dial and the pointer will rotate clockwise when pressure is applied and counterclockwise when pressure is withdrawn. Many customers will refer to absolute gauges as vacuum gauges because they are using them in vacuum applications, so there is likely to be confusion regarding which pressure type is required. Also, please keep in mind that Torr is a unit of measure equal to millimeters of mercury (mm Hg) absolute. Please note that although all of illustrating the different pressure types can be accomplished much easier by depicting a dial gauge for each example, even if the focus of the inquiry is a digital indicator or transducer.

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TYPES OF PRESSURE GAUGES

PRESSURE GAUGE: - a gauge to measure and indicate pressure using ambient pressure as a datum point.

VACUUM GAUGE A gauge used to measure and indicate pressure below ambient, using ambient pressure as the datum point.

COMPOUND GAUGE A gauge used to measure and indicate pressure both above and below ambient pressure, using ambient pressure as the datum point. Ambient pressure equals pressure surrounding the measuring element, generally Atmospheric pressure.

ABSOLUTE PRESSURE GAUGE A gauge used to measure and indicate pressure above zero absolute pressure, using absolute zero pressure as the datum point.

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GAS COMPRESSOR A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible; while some can be compressed, the main action of a pump is to pressurize and transport liquids. TYPES OF COMPRESSOR 1. Centrifugal Compressor Centrifugal compressors use a rotating disk or impeller in a shaped housing to force the gas to the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section converts the velocity energy to pressure energy. They are primarily used for continuous, stationary service in industries such as oil refineries, chemical and petrochemical plants and natural gas processing plants. Their application can be from 100 horsepower (75 kW) to thousands of horsepower. With multiple staging, they can achieve high output pressures greater than 10,000 psi (69 MPa). Many large snowmaking operations (like ski resorts) use this type of compressor. They are also used in internal combustion engines as superchargers and turbochargers. Centrifugal compressors are used in small gas turbine engines or as the final compression stage of medium sized gas turbines.

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2. Diagonal or mixed-flow compressor Diagonal or mixed-flow compressors are similar to centrifugal compressors, but have a radial and axial velocity component at the exit from the rotor. The diffuser is often used to turn diagonal flow to an axial rather than radial direction. 3. Axial-flow compressors Axial-flow compressors are dynamic rotating compressors that use arrays of fan-like airfoils to progressively compress the working fluid. They are used where there is a requirement for a high flow rate or a compact design. The arrays of airfoils are set in rows, usually as pairs: one rotating and one stationary. The rotating airfoils, also known as blades or rotors, accelerate the fluid. The stationary airfoils, also known as stators or vanes, decelerate and redirect the flow direction of the fluid, preparing it for the rotor blades of the next stage. Axial compressors are almost always multi-staged, with the cross-sectional area of the gas passage diminishing along the compressor to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1 design pressure ratio, variable geometry is normally used to improve operation. Axial compressors can have high efficiencies; around 90% polytropic at their design conditions. However, they are relatively expensive, requiring a large number of components, tight tolerances and high quality materials. Axial-flow compressors can be found in medium to large

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gas turbine engines, in natural gas pumping stations, and within certain chemical plants. 4. Reciprocating compressor Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or portable, can be single or multi-staged, and can be driven by electric motors or internal combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are commonly seen in automotive applications and are typically for intermittent duty. Larger reciprocating compressors well over 1,000 hp (750 kW) are commonly found in large industrial and petroleum applications. Discharge pressures can range from low pressure to very high pressure (>18000 psi or 180 MPa). In certain applications, such as air compression, multi-stage double-acting compressors are said to be the most efficient compressors available, and are typically larger, and more costly than comparable rotary units. Another type of reciprocating compressor is the swash plate compressor, which uses pistons moved by a swash plate mounted on a shaft (see axial piston pump).

Household, home workshop, and smaller job site compressors are typically reciprocating compressors 1 hp or less with an attached receiver tank.

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APPLICATIONS Gas compressors are used in various applications where either higher pressures or lower volumes of gas are needed:

In pipeline transport of purified natural gas from the production site to the consumer, a compressor is driven by a gas turbine fuelled by gas bled from the pipeline. Thus, no external power source is necessary. Petroleum refineries, natural gas processing plants, petrochemical and chemical plants, and similar large industrial plants require compressing for intermediate and end-product gases. Refrigeration and air conditioner equipment use compressors to move heat in refrigerant cycle. Gas turbine systems compress the intake combustion air. Small-volume purified or manufactured gases require compression to fill high pressure cylinders for medical, welding, and other uses. Various industrial, manufacturing, and building processes require compressed air to power pneumatic tools. In the manufacturing and blow moulding of PET plastic bottles and containers. Some aircraft require compressors to maintain cabin pressurization at altitude. Some types of jet enginessuch as turbojets and turbofans)compress the air required for fuel combustion. The jet engine's turbines power the combustion air compressor. In SCUBA diving, hyperbaric oxygen therapy, and other life support devices, compressors put breathing gas into small volume containers, such as diving cylinders.

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In surface supplied diving, an air compressor frequently supplies low pressure air (10 to 20 bar) for breathing. Submarines use compressors to store air for later use in displacing water from buoyancy chambers to adjust depth. Turbochargers and superchargers are compressors that increase internal combustion engine performance by increasing the mass flow of air inside the cylinder, so the engine can burn more fuel and hence produce more power. Rail and heavy road transport vehicles use compressed air to operate rail vehicle or road vehicle brakesand various other systems (doors, windscreen wipers, engine, gearbox control, etc.). Service stations and auto repair shops use compressed air to fill pneumatic tires and power pneumatic tools. Fire pistons and heat pumps exist to heat air or other gasses, and compressing the gas is only a means to that end.

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REFRIGERANT The substance, which carries the heat from low temperature region and discharge, the same to the higher temperature region is known as refrigerant. Refrigerant removes the heat in the form of sensible heat as in case of air refrigeration or in the form of latent heat as in the case of vapour refrigeration. The refrigerants, which carry the heat in the form of latent heat and also dissipate in the form of latent heat, are more efficient than the refrigerant, which carry the heat in the form of sensible heat.

REFREGERANT IN COMMON USE 1. Ammonia (NH3): Ammonia is one of the oldest refrigerant uses in refrigeration system. Its excellence thermal property make it an idea refrigerant for ice plant, cold storage etc. Ammonia has the highest refrigerating effect per unit refrigerant capacity. It is much less expensive compare with any other refrigerant. Any moisture, which may enter the system, will be dissolved in ammonia and it attacks many foods, therefore it is not used for domestic refrigerant or where there is danger of exposing foods to leaking ammonia. It attack non-ferrous metal, brass and bronze, but it is non-corrosive to iron and steel. It is widely used in vapour absorption refrigerant system as it soluble in water and easily expelled when heated.

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2. Freon 12 or Discholorodifluro methane ( CCL2F2) : It is commercially term as F-12 or R-12. It is used for domestic refrigerator. It is colourless odourless and nontoxic. Therefore it is best suitable for domestic refrigerator. It is used with all types of condenser, aircooled and water cooled. The boiling point is 29.80c at atmospheric pressure make it suitable for high, medium and low temperature application with any types of compressor. It is soluble in oil; therefore, it is simplifies the problem of lubrication. But its disadvantage is that it is costly and leak cannot be detected easily. Its leak detected with the halides torch.

3. Freon -22 Difluromonochloro Methane (CHCIF2) : It has a boiling Point -400C at atmospheric pressure. It is used for low temperature production. It is also used in packaged air conditioners, where, because of space limitations, relatively small compressor displacement required with R-22 water-cooled Condensers are used. When air-cooled condenser is used with R-22 is not used. The main advantage of R-22 over R-12 is the smaller compressor displacement required for same capacity.

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4. Carbon dioxide (CO2): It is the oldest refrigerant used. Carbon dioxide is Odourless, nontoxic, non-flammable, non-explosive and non-corrosive Refrigerant. It used in hospitals, theaters, hotels and marine service where safety is prime consideration? Now days its use is limited for production of dry ice. But the power required for 002 refrigerants is high.

5. Sulphur dioxide (S02): In olden days it was used in domestic Refrigerator. It is now replaced by freon-12. It is colourless and suffocating fluid. In presence of water it forms sulphurous acid, it has low refrigerating effect Compared with other refrigerant and it is heavy irritating and high toxic in nature.

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PROPERTY OF IDEAL REFREGERANT

1 2 3 4 5 6 7 8 9

The boiling point should be low. The condensing pressure should not be more. Critical temperature should be high. The latent heat of vaporization should be high. Specific heat of liquid should be low. It should not have corrosive action. It should not be flammable and explosive. It should be non-toxic. It should be easily detectable for leaks.

10 It should have satisfactory heat transfer coefficient. 11 It should be easily available at low cost.

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5. CONSTRUCTION This is a simple arrangement for charging the refrigeration and air conditioning unit. The main feature of this charging set is that the whole assembly is carried on a rectangular base. This is portable device, which can be transferred from one place to another its construction is simple land decorative one. A vacuum pump is fitted on the base plate. In front vacuum pump a vertical rectangular angle set is attached on which spring balanced is attached and the plywood and valve are attached with the help of nut-bolt. A vacuum pump is mounted for creating the vacuum in the unit. An arrangement of spring balance is to be made for calculating how many amount of gas is filled in unit. For calculating the amounting of the gas refrigerant the refrigerant cylinder is attached tom hook of spring balance with the help of into cylinder hanger arrangement. On the front side of this charging set a panel board is fixed for mounting 2 three way valves and compound pressure gauge. Three charging lines are required for this set. One charging line is joined between the vacuum to connector disconnect the vacuum pump. The second charging line is connected between the cylinder and valve V1 and end of valve V2, which is always open. The third charging line is connected between the refrigeration unit and common end of valve V2 for the purpose of connect or disconnect the unit whenever required. One end of valve V2 is connected to the compound pressure gauge with the help

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of flare nut. These two 3-way valve V1 and V2 are connected with the help of copper tube and flare nut. So this is a simple arrangement of charging set.

6. WORKING After assembling it is required to charge the system with refrigerant gas. Many times charging is necessary after repair and maintenance of the system.

Before charging the system evacuation of system is done. With the help of vacuum pump air in the system is removed and vacuum is achieved.

For this purpose the vacuum pump is joined to the common end of valve V1 and connection between cylinder and valve is turned off from cylinder itself. Then turn the valve V2 on for the purpose of removing oxygen and nitrogen from the unit. The vacuum created in the system should be below 300 mm of Hg.

After vaccumisation of the system, the vacuum pump is disconnecting immediately with the help of valve V1 by turning it at off position. In this way at the vacuum side connection is off and remaining two connections is on state. The hand shut-off valve is used during change of line.

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Before charging the system, calculate the amount of gas required for the system. Then place the refrigerate cylinder with the help of cylinder hanger arrangement on the spring balance to refrigerant into evacuated system to exact quantity required. The purging should be done before admitting the gas into system.

What amount of pressure present in the system is indicated by compound pressure gauge. The amount of pressure is required inside the system is controlled by valve V2.After completing the process, pinch the process tubes and seal it.

Circuit diagram

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7. ADVANTAGES AND APPLICATION

Advantages: -

The weight of gas and pressure of gas going to the unit is directly measured at the time of charging. It is multipurpose device. The connection of vacuum pump to the unit is directly connected with the help of valve and charging line. So separate arrangement is not required for achieving the vacuum in unit. Simple in construction. It is portable device, which can be transferred from one place to another. Less maintenance. Time is saved due to whole accessories are mounted on one table. The initial and working cost is less.

Application: -

In refrigeration and air-conditioning industries. In refrigeration shops and laboratories. It is used for charging of ice plant domestic refrigerator etc.

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8. HINTS BEFORE CHARGING

Use clean & moisture free drums for transfer & charging purpose. The system should be evacuated particularly when it is new.

The charging lines must be purged & it must be made sure that all connections are tight air is not drawn in the system with the refrigerant. The suction pressure may not be allowed to rise above 2 Kg.sq.cm. when charging. The pressure may be controlled with the cylinder valve.

The refrigerant in the liquid from should under no circumstances to the compressor. The charging lines should not be flexible.

The head pressure must be watched for indications of over charge.

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9. TESTING OF CHARGING SET (LEAK DETECTION) Before charging the refrigeration unit, the whole system must be tested for the purpose of arising leakage problem. If it is not done, the leakage problem is created & the charging is not done properly i.e. evacuation is not done properly. For this test a high-pressure compressed air is drawn through a charging set. Before entry of the high-pressure compressed air, a soap bubble are placed on v/v port, connection of charging lines & copper tubes & compound pressure gauge for the purpose of to detect the leakage. Then a compressed air is pass through the system if leakage is find, tight the connection with Teflon tape properly. This process is carried out up to the leakage problem is minimized. Then the system is ready form charging. Method Commonly Used For Leak Detection are: 1) Bubble Method 2) Halide Torch Method 3) Electronic Leak Detector 4) Special Method for detection of Ammonia and Sulphur dioxide.

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1) Bubble Method: This method of leak detection is the oldest one and is universally used with all the refrigerants. A solution of soap or some other leather forming liquid detergent is applied with the brush over the subjected area or joint. The leaking gas forms bubble, which can be easily been seen. This method of leak detection can only be used when the system has positive pressure. If there is vacuum present in the system, it will pull in the moisture or stop bubble, which will be quite harmful. 2) Halide Torch Method: A carbon element is heated by methyl alcohol or hydrocarbon flame in the halide torch. A rubber tube attached to the refrigerator. A refrigerant going on the tube combines with the Flame to cause Perceptible change in the Flame Colour. This method of leak detection is slow and insensitive and in brightly lighted area it is almost impossible to locate small leaks. 3) Electronic Leak Detector: An electronic leak detector is more sensitive and faster responding. The electronic detector contains an internal pump, which draws, and air leaking gas through a probe and hose as the probe is passed over leaking joints. A leak-detecting lamp Flashes at this moment. By adjusting a knob on the Electronic detector the magnitude of the leak can also be found.

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4) Special Method For detection of Ammonia and Sulphur dioxide: Ammonia leak can be detected by bringing a burning candle of sulphur near the suspected spot. The candle will give a cloud of white smoke if ammonia vapour is present there A solution of hydrochloric acid brought in the vicinity of ammonia leak will also give white smoke. The moistened strip of phenol Phalein Paper turns pink when faintest trace of ammonia vapour comes in contact with it. Presence of sulphur dioxide can be detected by bringing aqueous ammonia near the suspected area. It will give white smoke in the presence of Sulphur dioxide. When no ammonia is available leak may located by the soap bubble or oil test.

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10. METHODS OF CHARGING By using this set the methods of charging are as follows: There are three methods of charging as given below:

1. Charging through the suction valve: A small installation, which needs to few kilograms of refrigerant, is usually charged through the suction service valve gauge port. For this method of charging the system is fully evacuated and charged a follows. Charging line is connected to the suction valve gauge port. Attach a gauge to the discharge valve and open half turn. The other end of the charging lines us connected to a refrigerant cylinder, which should be standing up right. The cylinder valve is opened slightly and to flare nut is loosened at the compressor end. This operation removes air from the line, when the sound of escaping gas is heard, the nut is tightened. Suction valve is turned into close the suction line, thus drawing the gas directly from the cylinder by the compressor. Compressor is started drawing the requisite quantity of refrigerant. The suction pressure should not be allowed to exceed 2 kg/sq.cm. Gauge. The cylinder valve is closed and the compressor is allowed to run sufficient time to reduce the pressure in charging time to 0 kg/sq.cm.gauge.

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 Compressor is stopped and the suction valve is back seated. The charging line is detached and compound gauge attached. The valve is turned in one half turn. The system is thus ready for testing and normal operation. The refrigerant quantity to be charge is often weighted. In that case the cylinder may be on the weighing platform, or suspended from spring scale. The tubing should be coiled and long enough to get true weight. The cylinder may be kept in warm water to quacked the process of charging.

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2. Charging through discharge valve: The method is used for certain conditions where it is impossible or impracticable to add refrigerant by the other methods. This is the least used to the three methods. The refrigerant is caused to flow by difference in pressure between cylinder and high side. The compressor is not operated while the unit is being charged. In order to save time when charging by this method, it is imperative to weight into an empty cylinder the exact amount of charge required by the system. If this is known, all contents of cylinder transferred. The system is evacuated and following procedure adopted:

The discharge and suction service value are backseated. The gauge port of each valve is plugged or otherwise kept closed until the valves are wide open. Compound gauge is attached to the suction valve and the valve is turned in one-half turn. A pipe-toflare adapter is installed to the discharge valve port and the charging line is connected to the adapter.

The other end of the charging line is connected to the cylinder. The air is removed from line by losing flare nut. The nut is tightened. The valve A is turned in about half way.

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 The cylinder is placed bottom side up since the refrigerant will flow into the condenser in liquid form.

After the refrigerant has flowed into the condenser, the discharge valve is back-seated cylinder valve is closed and the charging line is removed. The pressure gauge is attached and the valve is ready for testing and operation.

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3. Charging through the charging valve: Large machine normally have charging valve located in the liquid line between the receiver valve and the filter or dehydrator. This valve is always located in Ammonia installation and is becoming more popular in other installations requiring large quantities of refrigerants it cuts upon the charge time. The charging refrigerant cylinder acts as received when connected to the charging valve. The refrigerant enters the system in liquid form expanding the liquid control valve before it enters the compressor. This avoids the danger of liquid to enter the compressor and eliminates high vacuum, which may cause the oil to leave the crankcase. The procedure is described below. System is evacuated and a pressure gauge attached to the discharge valve port and a compound gauge to the suction valve port. Both valves are opened wide and then turned in one half turn so that the gauge will read. The receiver valve is closed. Refrigerant cylinder is connected to the charging valve by tubing. The cylinder valve is opened slightly and the flare nut is loosened at the charging valve to purge the air from the line. When the sound of escaping gas is hard the nut is lightened.

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 The cylinder is tipped to ensure liquid at the valve and then charging and cylinder valves are opened wide. Compressor is started and the system is charged with required quinsy. When cylinder becomes empty, frost will form on the bottom of the cylinder and the charging line.

After completing the charging close the cylinder valve and run the compressor for some time to empty the charging line. Then close the charging valve C, and remove the line. The charging valve is capped to prevent leakage. The receiver valve R is opened, the system is ready for testing and operation.

When charging refrigerant into an ammonia plant using the above method. It is necessary to lay the cylinders have an internal gooseneck which makes this necessary. Charging connections for ammonia should be made rigid steel pipe and fittings. For other refrigerants use copper tubing Flexible connections, in the authors opinion are dangerous.

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Charging through the charging valve

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11. CONCLUSION AND MODIFICATION

Conclusion: In the end we concluded that by using this instrument we could evacuate and charge the refrigeration and air conditioning system simultaneously.

This means that we can save a time by connecting and disconnecting of the charging line. It is used in the charging of refrigeration and air conditioning system in an industries, laboratories etc.

Modification: -

1. It is possible to weight a refrigerant, which is supplied to the system.

2. From the system we can evacuate and charged the refrigeration and air conditioning system very fast.

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References:1. Refrigeration and air conditioning, S.C Arora , S. Domculwar 2. Refrigeration and air conditioning system, S.L. Gavhale 3. Refrigeration and air conditioning system, S.T. Ghan, R.M. Naphade.

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