ISHRAE EDUCATION & RESEARCH FOUNDATION

WORKSHOP
ON
COIL DESIGN
BY
MR. A.K. AHLUWALIA

INTRODUCTION
The air Conditioning and refrigeration system uses a
variety of heat exchangers, mainly Evaporators and Condensers
in which heat transfer takes place between air, water, refrigerant
and any other body required to be cooled or heated. The heat
transfer is a very complicated phenomenon. Basically these heat
exchanges involve Shell and tube arrangements for water /
refrigerants, and tube for refrigerant / air system. Some are
confused with term tube and coil, are they same or different.
Tube is a straight passage through which fluid flow in a one
direction between given inlet and outlet. But to increase the flow
time between inlet & outlet the tubes are arranged in zig-zag
passage which is known as coil so that more time is available for
heat transfer. The designing of coil is an important part in
refrigeration System as they are used in different conditions,
shapes, sizes, materials as per the requirements.
2

Heat transfer
There are three modes of heat transfer conduction, convection
and radiation.
i)
Conduction- Heat transfer rate in conduction is given by
Fouriers law.
q = - KAdT/dx
Where K is coefficient of thermal conductivity
ii)
Convection Heat transfer rate in convection is given by
Newtons law
q = - hAdT
h is convective heat transfer coefficient

Overall heat transfer coefficient for single pipe

In a pipe as shown in fig.1, inside and outside a film of fluid is
formed in which temperature variation takes place. For this
case heat transfer rate (q) is
Fig.1

(T1 T4)
q =
(1 / hi Ai) +{ln (ro/ri )} / 2 l K + (1 / ho Ao)

l is length of pipe, hi & ho is convective heat transfer coefficient

corresponding to inside and outside surface
Hence, 1 / UoAo = (1 / hi Ai) +{ln (ro/ri )} / 2 l K + (1 / ho Ao)
Uo is overall heat transfer coefficient corresponding to outer
surface area (Ao = 2rol) which is easy to measure
So, 1 / Uo = (Ao / hi Ai) + roln (ro/ri ) / K + (1 / ho)
Since a high rate of heat transfer through the evaporator walls is
desirable, so U factor should be as high as possible. Metals,
because of their high conductance factor (K),
are always used in evaporator construction. However metal
which will not react with refrigerant must be selected.

i) Iron & steel do not react with common refrigerants, but rust is
formed in the presence of moisture in the system.
ii) Brass and copper can be used with any refrigerant except
ammonia, which dissolve copper.
iii) Aluminium may be used with any refrigerant except methyl
chloride.
iv) Magnesium alloys can not be used with fluorinated
hydrocarbons or with methyl chloride.

Importance of Metallic wall

Let inside is refrigerant and outside is air.
hi = 1000 W/m2K, ho = 10 W/m2K, K (for copper) = 383.559
W/mK,
ri = 0.075 m,
ro = 0.08 m, l = 1 m
Ai = 2 x 0.075 x 1 = 0.4712 m 2 , Ao= 2 x 0.08 x 1 = 0.5027 m2
1 / UoAo = (1 / hi Ai) +{ln (ro/ri )} / 2 l K + (1 / ho Ao)
Resistance = 1 / UoAo
= 1 / 471.2 + 1 / 37037 + 1 / 5.027
= 0.002122 + 0.000027 + 0.198925
= 0.201074
= 1 / 4.97329

Contribution to resistance of inner side =

0.002122 x 100 / 0.201074 = 1.055%
Contribution to resistance of wall

= 0.000027 x 100 / 0.201074

= 0.013%

Contribution to resistance of outer side = 0.198925 x 100 /

0.201074
= 98.93%
Which indicate that contribution of wall in resistance is 0.013%
which is least significant in comparison of other two. In the
above example if we use different metals, there contribution can
be given as
8

Metals
Aluminium
Brass
Copper
Iron

K(Watt / mK)
203.403
85.429
383.559
62.764

% Contribution inResistance
0.025
0.06
0.013
0.082

So contribution towards resistance of all metals are

approximately negligible, specially Aluminium and Copper, in
comparison of other two.
Hence this example suggests that use cheap material which
should be non-reacting with refrigerant.
9

Logarithmic Mean temperature difference (LMTD)

If the temperature of the fluid varies during heat transfer, the
heat transfer rate is given by
q = U A Tmean
Here, Tmean is the arithmetic mean temp. of the fluid. But it is
observed that temp of the fluid does not vary linearly, so above
equation gives wrong result. This variation is logarithmic.
Hence, q = U A x LMTD
LMTD is known as logarithmic mean temp difference.
10

Fig.2

From fig.2
(tho tco) - (thi tci)
LMTD for parallel flow =

ln{(tho tco) / (thi tci)}

(thi tco) - (tho tci)

LMTD for Counter flow =

ln{(thi tco) / (tho tci)}

(LMTD is also known as mean effective temp difference)

11

If refrigerant is at constant temp = 200C

Air temp varies from 400C to 300C
Arithmetic mean temp difference
Temp. diff. at outlet + temp diff. at inlet
=

= (30-20) + (40-20) / 2 = 150F

(30-20) (40-20)
LMTD (parallel)

= 14.430F
ln {(30-20) / (40-20)}

12

(40-20) (30-20)
LMTD (counter)

= 14.430F
ln {(40-20) / (30-20)}

So there is difference between LMTD and arithmetic mean. LMTD gives

more accurate result.

13

Fouling Fouling or scaling is a layer deposited on the internal or

external surface of the tube and acts as insulation, so resistance is
produced in the way of heat transfer resulting reduced heat transfer rate.
It is not possible to measure the thickness and thermal conductivity of
the scale formed. So the effect is considered in terms of convective heat
transfer coefficient (h). The reciprocal of scale heat transfer coefficient is
called fouling factor
Hence eq is changed to
1 / UoAo
= 1 / hiAi + 1 / hfiAi + ln (ro/ri) / 2 l K + 1 / hfoAo + 1 / hoAo
Hence, hfi and hfo are fouling heat transfer coefficient of inside and
outside surface respectively.
1 / hfi and 1 / hfo is fouling factor.
14

Fouling on External surface

In air cooling applications, fouling on external surfaces is mainly due to
accumulation to dust and lint from the air which adhere to the wet coil
surface or by frost accumulation on the coil surface
In liquid cooling application, fouling of the external tube surface usually
results from scale formation and corrosion.
Fouling Internal surface
Fouling of internal surface is usually caused by excessive amount of oil
and low refrigerant velocity. At low velocity, vapour bubbles formed by
boiling, tends to cling to the tube wall, which works as an insulator so as
heat transfer is reduced. By increasing refrigerant velocity, produces a
scrubbing action on wall of the tube, which carries away the oil and
bubbles and improves the rate of heat transfer. But velocity is limited by
allowable pressure drop through the coil.
15

Why fins are required (Bare tube, Inner fins, Outer fins)
As we have shown that for a combination of tube wall, refrigerant
inside, air outside, overall heat transfer coefficient (U) can be given as

1 / UiAi =1 / UoAo

= 1 / 471.2 + 1 / 37037 + 1 / 5.027

= 1 / 4.97329

Which indicates that overall value (UA) is 4.97329 which is less than
minimum value (5.027). So lower side coefficient is the controlling
coefficient. It means there is no use to increase higher side coefficient
(refrigerant side). UA value will increase when lower side coefficient
(air) improves.
Heat transfer rate (q) = UAT
16

Hence, this equation shows, heat transfer rate can be improved by two
ways (i) by improving ho (here h can be improved such as by increased
velocity) but it is fixed for a particular fluid for a given conditions (ii) or
by increasing Ao which can be increased by using fins at outer surface.
The increase in fins area is only beneficial till outer heat transfer is equal
to inner heat transfer after that no use of extra area.
Inside fins are used when inside heat transfer is less than outside heat
transfer.
When both side are the fluid of same order heat transfer, no fins are
required. In such a case we can use bare tubes.
In some applications, external air velocity is very high, so that outer heat
transfer becomes more than inner heat transfer. In such cases inner fins
are beneficial to improve the capacity of the system.
17

Selection of Fins
Fins are thin metallic plates firmly bonded to the tubes, and so will be at
the same temp as the evaporator and make an integral part of the tube.
Fins are usually of copper, aluminium or stainless steel. The bonding
between the tube and fins must be good, otherwise with loose bonding,
the evaporator capacity falls down substantially because evaporator will
not have sufficient area to heat transfer for vapourizing the refrigerant
and even liquid refrigerant may go in compressor.
Fins are slipped over the tube and positioned at a definite pitch and the
tube is expanded to make perfect bond for good thermal contact. The
expansion of the tube is accomplished by filling the tube with oil and
building up high hydraulic pressure. Another method is to force an
oversized rod through the pipe, which will be expand the tube. In some
method, fins are soldered directly to the tubing.
18

Small tube requires small fins. Fin spacing varies from 1 to 14 fins
per inch, depending on the operating temp of the coil. For the application
of air conditioning where coil operates at temp high enough so that no
frost accumulation may have 12 to 14 fins per inch. Evaporators
designed for low temp application must have wide fin spacing 2 to 3 fins
per inch in order to minimize the danger of blocking air circulation. Coil
with 6.5 fins per inch are used for cold storage.
In the application of evaporator, fin temp at tip is equal to air temp and
decreases continuously upto base at refrigerant temp, so heat transfer rate
is reduced. Hence efficiency or effectiveness of the fin can be defined as
the ratio between actual heat transfer from the fin surface and theoretical
heat transfer when held at a constant temp equal to the refrigerant. The
efficiency is around 80%.
19

Hence overall heat transfer coefficient eq becomes

1 / UoAo = 1 / hiAi +{ ln (ro/ri) / 2 l K }+ 1 / hfo (Ap + Ae )
Here, Ap = Prime area of tube between fins.
Ae = extened area of the fin having efficiency
Evaporator
The evaporator is a component of a refrigeration system in which heat is
removed from air, water or any other body required to be cooled by the
evaporating refrigerant.
Evaporators can be divided into two sections(A) Air Cooling Evaporator
(B) Liquid Chilling evaporator.
20

(A) Air Cooling Evaporator In air cooling evaporator, low temp

refrigerant vaporizes in the cooling coils to extract the heat from hot air
passes over the coils. Now we shall discuss the different types of air
cooling evaporators
Evaporators fall into two general categories according to their operating
conditions
(i) Flooded Evaporator
(ii) Dry or Direct Expansion (D- X) Evaporator

Fig.3

21

The flooded evaporator is completely filled with liquid refrigerant, the

liquid level being maintained with a float valve as shown in Fig. 3. The
vapour accumulating from the boiling action of the refrigerant is drawn
off the top by the action of the compressor. The principal advantage of
the flooded evaporator is that the inside surface of the evaporator is
always completely wetted with liquid, which is a condition that produces
a very high rate of heat transfer. The principal disadvantage of the
flooded evaporator is that it is usually bulky and is more expensive to
operate because it requires a relatively more refrigerant charge.
The vapour formed is always in saturated conditions and they never
reach in super heated state because they are always in contact with liquid
refrigerant. The baffle plate arrests any liquid in vapour to save
compressor.
Flooded evaporator find application in chemical and food processing
units.
22

In a dry or direct expansion ( D-X) evaporator, the liquid refrigerant is

fed by an expansion device ( thermostatic expansion valve for large units
and capillary tube for small units) which meters the liquid into the
evaporator a rate such that all the liquid is vaporized by the time it
reaches the end of the evaporator coil as shown in fig 4. And also a part
of the heat transfer surface is used to superheat the vapour.

Fig.4

23

One important point about these two is the amount of liquid refrigerant.
Off course, the amount of refrigerant supplied in both cases depend on
load, higher the load, higher the rate of supplied refrigerant. The flooded
evaporator is always filled with liquid refrigerant, so gives greatest
efficiency always. But D-X evaporator require more and more liquid
refrigerant with increase of load to accommodate the load, so has larger
liquid wetted surface at higher load. Therefore D-X evaporator has
greater efficiency at greatest load.

24

(A) AIR COOLING EVAPORATORS

According to the types of Construction:Three principal types of evaporator are
(i)Bare tube (ii)Plate surface (iii)Finned tube
Bare tube and plate surface evaporators are also known as prime
surface evaporators because entire surface is more or less in contact
with the vaporizing refrigerant inside. With the finned evaporator, the
refrigerant- carrying tubes are the only prime surface and fins are
secondary surface because they are not filled with the refrigerant and
their functions is to pick up heat from the surrounding air and conduct
it to the refrigerant-carrying tubes.
Although, prime surface evaporators of both bare-tube and plate
surface give satisfactory service in all temp range, but they are most
frequently applied to the applications where (i) the space temp is
maintained below 34oF (ii) the front accumulation on the evaporator
25
surface cannot be readily prevented

Frost accumulation on prime surface evaporator does not effect the

evaporator capacity to the extent that it does on finned coils.
Furthermore, prime surfaces can be easily defrosted manually by either
brushing or scraping off in comparison of finned tubes.
Bare Tube evaporator: Bare tube evaporators are usually
constructed of either steel pipe or copper
tubing. Steel pipe is used for large
evaporators and with the applications
with ammonia, where as copper tubing is
utilized with smaller evaporator having
refrigerant other than ammonia. The
common shapes for bare tube coils are
(a) flat zig-zag and (b) oval from bone as
shown in fig.5. Spiral bare tube coils are
often used for liquid Chilling.

Fig.5

26

Plate Surface evaporator

Plate surface evaporators are of several types.
(i) Some are constructed of two flat sheets of metal so embossed and
welded together as to provide a path for refrigerant flow between the two
sheets (fig.6). This particular types of plate surface evaporator is widely
used in house hold refrigerators and some freeze because it can be easily
cleaned, economical to manufacture, and can be readily formed into one
of the various shapes required.

Fig.6

27

(ii) Another Type of plate surface evaporator consists of formed tubing

installed between two metal plates which are welded together at edges
(Fig 7). To maintain good thermal contact between plates and refrigerant
carrying tubes, the space between the plates is either filled with a
eutectic solution or evacuated so that the external atmospheric pressure
holds the plates firmly against the tubing. Those containing the eutectic
solution are especially useful where a hold over capacity is required,
specially refrigerated truck. Because at night plant is stopped
refrigerating capacity stored in eutectic solution is used during night. The
temp of the plates is controlled by the melting point of the eutectic
solution.
Fig.7

28

Plate type evaporators may be used singly or in banks. The plates may be
manifolded for parallel flow of the refrigerant or they may be connected
for series flow ( Fig. 8 & Fig 9).
Plate type evaporators are very useful for
periodical peak load Conditions because
during light load, and ice bank is build up
on the surface of the plate which provide
holdover refrigerating capacity for heavy
or peak condition. This allow the use of
smaller capacity equipment than would be
required by the peak load.

Fig.8

Fig.9

29

Finned evaporators
Finned evaporators uses bare tube upon which metal plates or fins have
been installed (fig.10). The fins work as a secondary heat absorbing
surfaces, thereby improving its efficiency. In the bare tubes, much of the
air circulates through the open spaces between the tubes and does not
come in contact with the coil surface. When fins are added to a coil, fins
extend into the open space between the tubes and act as a heat collectors.
Fin size, spacing, no. of fins, types of fins material of fins effect the heat
transfer rate. Generally, a finned coiled will occupy less space the either
a bare tube or plate surface evaporator of the same capacity.

Fig.10

30

According to the mode of heat transfer

Evaporators are (i) Natural Convection evaporators (ii) Forced
convection evaporators
Natural Convection evaporators
Natural convection evaporators are frequently used in applications where
low air velocities and minimum dehydration of the product are desired.
Typical installations are household refrigerators, display cases and large
storage rooms.
The circulation of air over the cooling coil by natural convection is
proportional to the temperature difference between the evaporator and
the space. The circulation of air is greatly influenced by the shape, size,
location of the evaporator, the use of baffles, the placement of the stored
product etc.
31

(i) Shallow coils (one or two rows deep) should be used because with
more number of rows, resistance to the free circulation or air increases
which reduces the coil capacity.
(ii) As warm air is lighter than cold air and tend to rise to the roof, so
evaporators should be located as high as possible.
(iii) Baffles are used with natural convection coils to assume good air
circulation.

32

Forced Convection evaporator

Forced Convection evaporators, commonly called unit coolers or
blower coils, are essentially finned coils encased in a metal housing
and equipped with one or more fans (propeller or contribution) air
circulation. They are more efficient than the natural convection
evaporators. They are suited for air cooling units as well as for
refrigerator cabinets used to store bottled beverages or foods in sealed
containers.
Low air velocity 60 m/min to 90 m/min is recommended for comfort air
conditioning where low noise is required. Medium air velocity 150
m/min to 240 m/min is for refrigerator and freezers where noise is not a
problem. High velocity above 240 m/min for quick pull down of temp is
required for blast freezers as special product refrigerators.

33

The Effect of Air Quantity on Evaporator Capacity

Besides the heat transfer equations, there are other factors, which effect
the coil performance
(a) Circulation of air
(b) Velocity of air
(c) The distribution of air over the coil.
Except the case of liquid cooling and where product is in direct contact
with the evaporator, in most of the cases, heat is carried from product to
evaporator by air circulation. If air circulation is not adequate, heat is not
carried to the evaporator at a rate sufficient to allow the evaporator to
perform at peak efficiency.

34

Uneven distribution of air over the coil surface causes some parts of the
surfaces to function less efficiently than other resulting lower evaporator
capacity. The velocity of air passing over the coil influence the value U
and LMTD and play an important role in determining the evaporator
capacity. High air velocity tends to break up the thin film of stagnant air
adjacent to coil surface. As this film acts as a heat flow barrier that
means produces resistance to heat flow. By breaking the film, heat flow
resistance is decreased so overall value of U increases. When air velocity
is low, the air passing over the coil, stay in contact for a longer period
over the coil surface and cooled through a greater range resulting low
LMTD so low heat transfer. As the air velocity increases, the period of
contact with coil surface decreases so cooled through a smaller range
resulting high LMTD so high heat transfer rate.

35

Surface Area
q = UA x LMTD
This eq. shows that heat transfer rate
is proportional to the surfaces area,
this is possible only when U and
LMTD remains contact. But in actual
practice they are also effected, so that
heat transfer rate does not increases or
decrease indirect proportion to the
change in surface area.
Fig.11 shows coil B and C have twice
surface area than A. But C has face
area twice than A and B. C will have
twice the capacity than A, but not B.
Area of B will be more than A.
Fig.11

36

LMTD so effected when surface area increased by using more number

of rows. The drop in air temp. is much more in 1st row (fig.12) and
diminishes as air passes over the successive rows (2 nd and 3rd ). The
reason of this is that temperature difference between inlet air and
refrigerant decreases. Due to this phenomenon heat transfer in 1 st row is
maximum and it reduces in 2nd and 3rd row. Hence 1st row works most
efficiently. Therefore increasing in area by using more no. of rows like B
is not so effective as in case C where whole increased area lies in 1st row.

Fig.12

37

Hence, for same total surface area, a long wide flat coil is more efficient
than a short narrow coil have more number of rows. But sometimes,
space available is limited forces to use compact coil. In such a case loss
in capacity can be compensated to some extent by increasing the air
velocity over the coil.
Evaporator Circuiting
Excessive pressure drop in the evaporator decreases the suction pressure
inlet to the compressor, which reduces the capacity and efficiency of the
compressor. But (i) some minimum pressure drop is necessary to
maintain the flow rate of refrigerant because velocity is proportion to the
pressure drop. (ii) And also velocity should be sufficient to sweep the
tube surface free of vapour bubbles so results in high heat transfer rate
(iii) oil may be carried back to compressor. Hence evaporator circuiting
should be such that minimum pressure drop may cause sufficient
velocity to provide high heat transfer rate and good oil return.
38

Pressure drop in the evaporator circuit depends on: size of tube (dia), length of the circuit and circuit load.
(i) larger size (dia) gives low pressure drop.
(ii) Longer length gives more pressure drop
(iii) Circuit load means, heat transfer. If circuit load increases,
more refrigerant mass has to supply. Hence velocity will increase,
resulting more pressure drop.

Evaporator TD
Most important factor for selection of evaporator (or chiller) is
Temperature Difference (TD) which is defined as the difference in temp
between the temp of air entering the evaporator and the saturation temp
of the refrigerant corresponding to the pressure at the evaporator outlet.
39

The relationship between evaporator capacity and TD is shown

by the curve in fig.13 which shows capacity (Btu/hr) is proportional with
TD. (it means capacity at 10oF TD is 10 times that capacity at 1oF TD).
To get same required cooling effect. We can choose either a coil with
higher TD with smaller surface area or a coil with larger surface area.
But in actual practice, we can not follow this because TD has
considerably effect on the stored product and efficiency of entire system.
Hence to select an evaporator, first decide TD according to the
requirement then calculate sufficient area to give required cooling effect.

Fig.13

40

The effect of coil TD on Space Humidity

The preservation of food not only required proper temp in the space but
also upon space humidity. When the space humidity is too low, excessive
dehydration occurs, on the other hand, when the humidity is too high, the
growth of mould, fungus and bacteria is encouraged. But space humidity
is of little importance, when the product is in bottles, cans or other
vapour-proof containers.
Space humidity is controlled by the TD. Higher the TD, more
dehumidification will take place resulting lower humidity in the space
and vice versa. The TD value is given in table 11.2 for natural and forced
convection for required space humidity.
If space humidity is of no importance, the factor governing evaporator
selection are (i) System efficiency and economy or operation (ii) the
physical space available for evaporator installation (iii) initial cost.
41

The effect of air velocity on product condition

The velocity of air not only increases the heat transfer rate but also
effect the rate of moisture evaporation from the product surface. Higher
velocity increases the dehydration of the product, which reduces the
quality, shortens the life and reduces the weight of the food. So desired
air velocity is an important factor in point of view product condition.
Air velocity and space humidity are closely associated. Low velocity has
same effect on product as high humidity. And high velocity has same
effect as low space humidity. So combination off these two should be
used properly. For example, higher air velocity can be used without
damaging the product by maintaining higher space humidity.

42

Case 1
Chilled water coil selection for air cooling
Data given :
Load = 30 ton
Fresh air dry bulb temp. (taf ) = 950F
Fresh air supply (maf ) = 879 cfm
Return air dry bulb temp. (tar ) = 750F
Return air supply (mar ) = 13500 cfm
Apparatus dew point (tadp ) = 570F
GSHF = 0.79
43

Solution
i. Assumption The following assumptions are taken to fulfill above
requirements
Water inlet temp. (twi ) = 440F
Water outlet temp. (two ) = 520F
Bypass factor = 0.1
ii. Choose a coil with following data
Copper tube of 5 / 8 inch OD, 22 G thick ( ID = 0.6 inch)
Staggered arrangement with pitch (p) = 1.5 inch
Aluminium fins (8 fpi)
Coil length (tube length) = 75 inch
Coil height = 52.5 inch

44

For this configuration

Outside surface area (Ao) = 22 sq ft / row / unit face area
Inside surface area (Ai) = 1.2 sq ft / row / unit face area
No. of circuit = 35 (that means 35 tubes in first row)
iii. Find LMTD
Temp. of air inlet to chiller (tain) = mixed air dry bulb temp.
= (maf x taf + mar x tar) / (maf + mar)
= (870 x 95 +13500 x 75) / (870 + 13500) = 76.210F
BF = (tao tadp) / (tain tadp)
0.1 = (tao 57) / (76.21 57)
Temp. of air outlet to chiller (tao) = 58.920F

45

LMTD = {(tain two) - (tao twin)} / ln{(tain two) / (tao twin)}

= {(76.21 52) - (58.92 44)} / ln{(76.21 52) / (58.92 44)}
= 19.190F
iv. Find overall heat transfer coefficient (Uo)
1/ Uo = (Ao / hi Ai) + (Ao / hfi Ai) +{roln (ro/ri )} / K + (1 / hfo ) + (1 / ho)
here, Ao / Ai = 22 / 1.2 = 18.33
ro / ri = OD / ID = (5 / 8) / 0.586 = 1.042
K = conductivity of tube (copper) = 220 Btu/hr.ft. 0F
1 / hfi = Fouling factor for water = 0.0004 ft2.hr. 0F / Btu
1 / hfo = Fouling factor for air = 0.00009 ft2.hr. 0F / Btu
hi of water for given inside dia depend velocity of water flow.

46

As q = m.cpdt
q = 30 x 200 = 6000 Btu/min
cp = 1 Btu/lb. 0F
dt = 52 44 = 80F
Mass flow rate of water (mw) = 6000 / (1x8)
= 750 lb/min
(for 0.6 inch ID)
Vw (fps)
1
2
3
4
6
8

hi (Btu/hr.sq ft.oF)
230
400
550
720
1000
1250

For dry coil

Va (fpm) ho (Btu/hr.sq ft.oF)
100
4.1
200
6.3
300
8.0
400
9.6
500
11.0
600
12.3
47

No. of circuit = 35
Density of water = 62.4 lb/ cu.ft
Water velocity =
(mw / density) / (no. of circuit x inside cross section area of each tube)
from table for this velocity, hi = 550 Btu/hr.sq ft.0F
ho of air depends on face velocity
Total air flow rate = maf + mar
= 870 + 13500 = 14370 cfm
Face area of coil = (75 / 12) x (52.5 / 12)
= 27.343 sq ft
Air velocity (Va) = flow rate / area

48

From table for this velocity, ho (for dry coil) = 11 Btu / hr.sq ft.0F
Tube is wet coil, ho = ho (for dry coil) / GSHF = 11 / 0.79 = 13.92 Btu /
hr.sq ft.0F
Hence 1 / Uo = (18.33 / 550) + 0.0004 x 18.33 + [{0.6 / (2 x 12)}/ 220] x
ln 1.042 + 0.00009 + (1/13.92)
Uo = 8.882 Btu / hr.sq ft.0F
As q = Uo x total outer area x LMTD
q = 30 x 12000 Btu / hr
Total outer surface area = (30 x 12000) / (8.882 x 19.19) = 2112 sq ft
Ao x no. of rows x face area = total outer surface area
22 x no. of rows x 27.433 = 2112
No. of rows = 3.499 4

49

v. Pressure drop in tubes

Water velocity (Vw) = 2.92 fps
For this velocity pressure loss = 8.95 ft of water column / 100 ft of tube
Equivalent length = tube length between inlet and outlet + bend loss in
length term
= (75 / 12) x 4 + 3 x 0.4 = 26. 2 ft.
[ 4= no. of rows, 3 = no. of bends, 0.4 ft loss at each bend]

Pressure drop = (26.2 / 100) x 8.95 = 2.3449 ft of water column

= 2.3449 / 2.31 = 1.015 psi
[1psi = 2.31 ft]

50

Case 2
Select a natural convection coil for the mixed vegetable storage cooler
with the following data available.
Inside dimensions of the cooler = 17 ft. length x 9 ft. width
Average hourly cooling load = 8500 Btu / hr
Solutioni. From the available table, the desired space humidity for mixed
vegetable is 87% (and permissible range is 85-90%)
From table 11-2, for natural convection, design TD for 87% RH is
between 14 to 160F. For cost consideration take TD = 140F
ii. Allow 1 ft. on each end of evaporator for working space, then overall
length of evaporator will be = 17 (1+1) = 17 ft.
51

iii. According to manufacturers specification (Table R-1), the overall

length of the evaporator is 7 inch longer than the actual finned length.
So finned length desired = 15 ft. 7 in. = 173 in.
iv. Required cooling capacity (Btu / hr/ 0F TD / in finned length)
= 8500 / (14 x 173) = 3.51 Btu / hr/ 0F / in
v. From Table R-1, for single row selection, above cooling capacity can
be obtained by using nearer model K-1.12 (2 fins/in.) and PK-16 (2
fins/in.)
Fig. R-1 shows that model K-1.12 single section evaporator of 42 inch
width and model PK 16 uses two sections evaporator each having 18.5
inch width.

52

For available width (9 ft.), PK-16 will give better result for even
distribution (for more than 8 ft. width use more than one evaporator).
This model has capacity = 3.65 Btu / hr/ 0F TD / in
Capacity required (Btu / hr/ 0F)
So required finned length =
Capacity of the model (Btu / hr/ 0F / in)
= (8500 / 14) / 3.65
= 166.34 inch 167 inch
vi. The overall length of the evaporator = finned length + 7 in. = 167 + 7
= 174 inch
Inside length is 204 inch
So margin on lengthwise from each wall = (204-174) / 2 = 15 inch

53

vii. The widthwise distance from the wall should be taken by

manufacturers recommendations. Fig. R-1
Distance from wall (A) = 12 inch.
Shown in fig.14

Fig.14

54

Case 3
Determine the approximate quantity of air (cfm) circulated over a unit
cooler having a capacity of 20,000 Btu / hr, if the sensible heat ratio is
0.7 and the design evaporator TD is 150F and also select the required
model for this purpose.
Solutioni. Due to temp drop sensible heat is removed. Actual temp drop for a
well designed unit cooler is 0.9 of the TD.
cfm = (Total capacity x sensible heat ratio) / (TD x 1.08)
= (20000 x 0.7) / {(15 x 0.9) x 1.08}
= 960 cfm
ii. Air velocity across the face of unit cooler is maintained between
300 to 500 ft./min
So face area = cfm / velocity = 960 / 350 = 2.75 sq ft. (Let V = 35055fpm)

iii. From Table R-8, for required total capacity 20,000 Btu/hr with TD150F, select the model UC 180 which has capacity 27000 Btu/hr
iv. Since in unit cooler, fan motor operates inside the refrigerated space.
So it is also supplying the heat
Heat given by motor (from Table R-8) for this model = 25200 Btu/24 hr.
Since the fan operates 24 hrs for air circulation while load is based on a
16 hr running time.
Hence average Btu/hr from fan motor = 25200/16 = 1575 Btu/hr
Hence net load per hr base = 20000 + 1575 = 21575 Btu/hr
Selected model is giving higher capacity (27000 Btu/hr) than required
capacity (21575 Btu/hr), hence ok.
This fan is supplying 2550 cfm, hence ok.
56

(B) Liquid Chilling Evaporators

In liquid chilling evaporators, refrigerant vaporizes in the cooling coils
to extract heat from the hot water passes over the coils. General types of
liquid chillers are as follows.
Double pipe coolersDouble pipe cooler consists of one tube inside
another tube. The liquid to be cooled (chilled fluid)
flows in one direction through the inner tube while
the refrigerant flows in the opposite direction
through the annular space between the inner and
outer tubes (fig15). In this design outer tube is
welded to vertical refrigerant header while inner tube
passes through the header and are connected together
by removable return bends. They may be dry
expansion type or flooded type. This requires more
space, so used for special applications as wine
making, and in petroleum industry for chilling of

Fig.15

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Bandelot CoolersThe Bandelot coolers (Fig.16) consists of a series of horizontal pipes

which are located one under the other. For either dry expansion or
flooded operation, refrigerant passes through the tubes while chilled
liquid flows in a thin film over the outside from top to bottom from a
distributor located at top and collected at bottom. Bandelot chillers are
used for the cooling of milk, wine and for chilling of water for
carbonation in bottling plants.

Fig.16

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Shell and Coil chiller

Shell and Coil Chiller is usually made up of one or more spiral shaped,
bare tube coils enclosed in a welded steel shell. Fig 17. Chiller having
chilled liquid in tubes is not recommended for any application where it is
required to chill the liquid below 38oF. They are used to cool drinking
water.

Fig.17

59

Shell and tube chillers

Shell and tube chillers (fig.18) have relatively high efficiency, required
minimum of floor space and available for any types of liquid-chilling
applications. Shell and tube chiller consists a cylindrical steel shell in
which a number of straight tubes are arranged in parallel and held in
place at the ends by tube sheets. These are available for both dry
expansion type and flooded type. Chilled liquid is circulated by means of
liquid circulating pump, usually of the centrifugal type.

Fig.18

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Dry Expansion Vs flooded chillers

(i)
As a general rule, the chiller is operated dry expansion
with the refrigerant in the coils and chilled liquid in the shell. The chiller
is operated flooded when refrigerant is in the shell and the chilled liquid
passes through the tubes
(ii)
Dry expansion chiller has the advantage of providing a hold
over capacity so ideal for small applications having high but infrequent
peak loads. Hence used for the chilling of water for drinking and other
purpose.
(iii)
Flooded chillers is commonly referred to as an
instantaneous liquid chiller as fluid is cooled suddenly as it come in
contact with refrigerant one of the disadvantage of flooded chillers is that
is no hold over capacity. Since the liquid is not recirculated, it must be
chilled instantaneously as it passes through the coil.
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(iv) Another disadvantage of flooded chiller is that the danger of

damaging the tubes or coils in case if chilled fluid is freezed up in coils,
the possibility of this problem is very less in case of dry expansion
chiller. Therefore flooded chillers are not recommended for any
application where it is required to chill the liquid below 38oF.
(v) Dry expansion chillers are employed in small and medium tonnage
installations (2 to 250 tons) while flooded chillers are used for large
tonnage installations (10 to thousands tons).
(vi) The principal advantages of dry expansion chiller over the flooded
type are smaller refrigerant charge required and the assurance of positive
oil return to the compressor due to high velocity in tube of refrigerant.
(vii) Flooded chillers have high efficiency as surface is completely
wetted with liquid refrigerant.
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Case 4
It is desired to cool 50 gpm of water from 540F to 460F with a refrigerant
temp as measured at the cooler outlet of 450F using R 134a.
Solutioni. Total chiller load in tons = (gpm x 8.33) x Cp x temp range / 200
= 50 x 8.33 x 1 x (54-46) / 200
= 16.66 tons

(tho tco) - (thi tci)

LMTD

=
ln{(tho tco) / (thi tci)}
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ii.
thi= 540F, tho= 460F, tci= tco= 400F
(46 40) - (54 40)
LMTD

=
ln{(46 40) / (54 40)}

= 9.47 0F
thi tci = 54 40 = 14 0F
tho tco = 46 40 = 6 0F

From table 11-1

We get LMTD = 9.47

64

iii. Select the trial chiller (Shell diameter and baffles spacing) from
Fig. R-9
For flow rate 50 gpm, we can select following chillers which can fulfill
our cooling requirement of 16.66 ton.
10 M, 12 L, 8 M, 12 K, 10 K and 8 L
(number indicated shell diameter and letter indicates baffle spacing)
We have to select small chiller diameter with minimum pumping loss
against baffles (M baffling produces minimum and K produces
maximum pumping loss). So logical choice is 8 M first and 8 L second.
Upper part of the figure shows for 8 M choice at 9.47 0F LMTD, loading
is 1200 Btu/hr/sq ft.
Surface area

= Capacity (Btu/hr) / Loading

= 16.66 x 200 x 60 / 1200
166.6 sq ft.

65

Table R-9 shows that model DXH 8 in. shell dia, does not have 166.6 sq
ft. surface area. So we can not select 8 M, similarly 8 L also. Next choice
goes to 10 M which having loading at 9.470F LMTD = 1110 Btu/hr/sq ft.
Surface area = 16.66 x 200 x 60 / 1110 = 180.2 sq ft.
Table R-9 gives model for our requirement is DXH 1014 which has 10
in. chiller dia x 14 ft length and has surface area 184 sq ft.
iv.
Now find water pressure drop through the chiller, from fig. R-9
corresponding
to 10 M, on M scale the value is 0.155 ft of water column
Pressure drop = length (ft.) x pressure drop per ft.
= 14 x 0.155
= 2.17 ft of water of water column
= 2.17 x 62.4 / (12 x 12)
= 0.94 psi

66

Defrosting
Evaporators for cold storage and low temp applications works at a temp
lower than 320F, the freezing point of water. Therefore the moisture from
the air freeze on the coil surface which is known as frosting. Lower the
evaporator temp, greater will be the frost formation. In case of finned
coils, frost formation between the fins obstruct the air flow over the coil.
So heat transfer rate is reduced which lower the evaporator temp leads to
thicker frost formation. If frost is allowed to accumulate, liquid
refrigerant may go in compressor. The frost exerts greater pressure on the
fins which may even move from its place and thus loosen the bond
between fins and tubes. If this happens, it becomes necessary to change
the coil.

67

So it becomes necessary to remove this frost by some means. The

process of removing the frost by melting, is called defrosting. Large bare
tube evaporators, such as those employed in breweries, cold storage
plants etc., are usually defrosted only once or twice a month. On the
other hand finned blower coils are frequently defrosted as often as once
or twice each hour. In some low temp applications defrosting is a
continuous process by brine spray or some antifreeze solutions.
All defrosting methods can be classified as either natural defrosting or
supplementary heat defrosting. Natural defrosting is also called shut
down or off cycle defrosting, utilizes the heat of the air in refrigerated
space to melt the frost from the evaporator. In supplementary heat
defrosting, heat from other source is utilized which may be as follows.
(i) Spraying warm water over the frost (water defrost)
(ii)Using electric heating element embedded in the evaporator (electric
defrost)
(iii)Circulating hot discharge gas from the compressor (hot gas defrost)
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THANKS FOR
SPARING YOUR VALUABLE TIME

69