Refrigeration Cycle – Know All the Stages, Components & Diagrams

In this article, I am going to explain about refrigeration cycle in details like definition of Refrigeration, What are the 4 cycles of the refrigeration system? What is the principle of refrigeration? What are the parts of refrigerator? Refrigeration cycle diagram and working. Before starting first understand the term refrigeration.

What is Refrigeration ?

Refrigeration means cooling a space, substance or system to lower and/or maintain its temperature below the ambient one (while the removed heat is rejected at a higher temperature). In other words, refrigeration is artificial (human-made) cooling.

What is Refrigeration Cycle ?

Refrigeration cycle is a cycle of mechanical system in which transmission of heat flow from one place at a lower temperature (the source ) to another place at a higher temperature ( the sink or heat sink ) by continuously circulating, evaporating, and condensing a fixed supply of refrigerant in a closed system.

Refrigeration cycle is a thermodynamic cycle to generate refrigerating effect with the use of evaporator, compressor, condenser & expansion valve.

Refrigeration cycle name – It is also called heat pump cycle .

Thus, a heat pump is called as a “heater” if the objective is to warm the heat sink (as when warming the inside of a home on a cold day), or a “refrigerator” or “cooler” if the objective is to cool the heat source (as in the normal operation of a freezer).

In both cases, the working principles are same. Heat is removed from a cold place to a warm place. Below given is the refrigeration cycle diagram :

Refrigeration Cycle Diagram

Refrigeration Cycle working principle Diagram

Vapour Compression Cycle

Vapour Compression Refrigeration system is the most widely used refrigeration system.

Vapour compression refrigeration cycle is a process that uses the physics of phase change heat transfer and the unique properties of a refrigerant to transfer heat from a relatively cold source to a hot medium.

What is the Basic Refrigeration Cycle ?

The basic components of any refrigeration system working on the vapour compression cycle are the compressor, condenser, expansion valve and evaporator and the refrigerant fluid which is alternatively vaporized and liquefied during the refrigeration cycle.

The temperature at which a fluid boils or condenses is known as the saturation temperature .

Components of Refrigeration Cycle

The 4 main Components of Refrigeration cycle

1. Compressor
2. Condenser
3. Expansion valve
4. Evaporator

Refrigeration Cycle Working

Working of vapour compression refrigeration system has been explained step by step including the work done by each component in the cycle and can be seen in the refrigeration cycle diagram also.

1. Compressor

The compressor in a vapor compression cycle helps in raising the pressure of the vaporizer refrigerant, causing its saturation temperature to rise, so that it is higher than that of the the sea water or air, cooling the condenser. The compressor also promotes circulation of refrigerant by pumping it around the system.

Note :- Refrigerant enters the compressor as low-pressure, low-temperature gas, and leaves the compressor as a high-pressure, high-temperature gas.

Why compression takes place :- Compression takes place to raise the saturation temperature and refrigerant pressure.

2. Condenser

In the condenser of the vapour compression system the refrigerant is liquefied by being subcooled to below the saturation temperature relating to the compressor delivery pressure, by the circulating sea water or air for domestic refrigerator.

Latent heat, originally from the evaporator, is then transferred to the cooling medium. The liquid refrigerant, still at the pressure produced by the compressor, passes to the receiver and then to the expansion valve.

Note :- After condensing, the refrigerant is a high-pressure, low-temperature liquid, at the point it’s routed to the loop’s expansion device.

What happens in condenser :- Heat is transferred from the refrigerant to a flow of water

3. Expansion valve

The expansion valve is the regulator through which the refrigerant flow from the high pressure side of the system to the low pressure side. Its throttling effect dictates the  compressor delivery pressure which must be sufficient to give the refrigerant a saturation temperature which is higher than the temperature of the cooling medium.

The pressure drop through the regulator causes the saturation  temperature of the refrigerant to fall so that it boils at low temperature of the evaporator. In fact, as the liquid passes through the expansion valve, the pressure drop makes its saturation  temperature fall below its actual temperature.

Some of the liquid boils off at the  expansion valve taking latent heat from the remainder and causing it’s  temperature to drop.

The expansion valve throttles the liquid refrigerant and maintains the pressure difference between the condenser and evaporator, while supplying refrigerant to the evaporator at the correct rate. It is thermostatically controlled in modern systems.

What happens to refrigerant in Expansion valve :- When the refrigerant enters the throttling valve, it expands and releases pressure. Consequently, the temperature drops at this stage.

4. Evaporator

The refrigerant entering the evaporator coil at a temperature lower than that of the surrounding. Secondary coolant (air or brine ) receives latent heat and evaporates. Later the heat is given off in the condenser, where the refrigerant is again compressed and liquefied.

Note :- Refrigerant enters the evaporator as a low temperature liquid at low pressure, and a fan forces air across the evaporator’s fins, cooling the air by absorbing the heat from the spaces.

What happens to refrigerant in evaporator :- It evaporates and absorbs latent heat of vaporization.

For a small refrigerator the evaporator cools without forced circulation of secondary coolant. In larger installation, the evaporator cools air or brine which are circulated as secondary refrigerants.

Frequently Asked Questions

What is the refrigeration cycle called?

Refrigeration cycle is also called heat pump cycle

What are the 4 cycles to the refrigeration system?

The 4 main Components of Refrigeration cycle are :
1. Compressor
2. Condenser
3. Expansion valve
4. Evaporator

What Are the Different Types of Refrigeration Systems?

There are four main refrigeration cycle types :
1. Mechanical Compression Refrigeration System
2. Absorption Refrigeration
3. Evaporative Cooling
4. Thermoelectric Refrigeration

Which gas is used in refrigerator?

Tetrafluoroethane:

HFC-134a (1,1,1,2-Tetrafluoroethane) is one of the commonly used refrigerant gases which you can find in almost all the present time refrigerators.

we have covered all the required details of Refrigeration cycle ( vapour compression refrigeration system, vapour compression cycle, heat pump cycles ). This is the most basic refrigeration cycle and is known by many different names as mentioned. We got refrigeration cycle explained with the help of refrigeration cycle diagram and learned the thermodynamics of refrigeration.

For Better Explanation

Refrigeration Cycle Explained on YouTube

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Clarifier || Purifier || How to convert Purifier into Clarifier

In this Article ,I have mentioned How to convert purifier into clarifier ?

Beside it,you will also learn listed topic in this Article.

  • Difference Between Purifier and clarifier
  • Why Clarifier not converted into purifier
  • What is Blind Disc
  • What is sealing water line
  • What is gravity disc ?

Changing purifier into clarifier

  • Open the purifier and place the blind disk at the bottom of the disc stack.
  • The water outlet is blocked by a seal on the gravity disc.
  • Blank off the inlet line of sealing water.

For better understanding watch video:-
https://youtu.be/bdCiOitnjGA

Must read:- Purifier

Can Clarifier change into purifier

Answer is NoIt is because in clarifier there is no water outlet and sealing water line.

Difference between Puri fier and Clarifier

Purifier

  • There is holes in the upper disc .
  • It Separates water and solid particles.
  • It has two Outlet on top, a)Water outlet and b )pure oil outlet.
  • There is a Gravity disc on top of disk stack.
  • For starting of purifier ,Sealing Water required.
  • Top disk with neck

Clarifier

  • There is no holes in the lower disc.
  • It Separates only solid particles.
  • There is  No Gravity disc
  • Only cleaned Oil Outlet at the top
  • Sealing water does not required
  • There is Disk without neck

What is blind disc in the purifier ? What is it’s function ?

Blind Disc means the disc is blind.It means there is no holes in the disc.It is used to convert the purifier into clarify. It is inserted at the bottom of the disk stack, because there are no holes.

What is Gravity Disc ?

A ring fitted at the top of disc stack from where water is passing out is called gravity disc.Oil maybe of different densities,so the interface changes.To create the correct line of interface between water and oil it is very important to select correct gravity disc size.

The function of gravity disc are as follows

  • gravity disc in the purifier is one which controls the output of the quantity of fuel. It is responsible for creating the interface between the oil and water.
    Back pressure is maintained by gravity disc.

It is responsible for creating the interface between the oil and water.
Back pressure is maintained by gravity disc.

 

What is sealing water line?

In a purifier, water sealing is established before introduction of the oil, so that oil filling does not flow through the heavy liquid outlet.

Purpose :-
To seal the water outlet & also to prevent the overflow of oil through the water outlet.


For better understanding ,How purifier change into clarifier and why not clarifier change into purifier, please read full Article .

I am 100 percent sure,After reading this 5 minute article you have no Doubt.

Basic Principle of separation

Basic principle of separation of water and impurities from fuel is gravity difference.

  • Separation as a means of removing impurities from a fuel can be carried out by gravity in a settling tank or by centrifugation of the fuel.

  • Both methods work on the same principles that, by subjecting the constant force to fuel, the denser components of the fuel, i.e. water and soil, will be separated from the lighter components , i.e. the fuel itself.
  • The gravity acting on the fuel as it passes through the tank slowly separates the denser components from the fuel where they accumulate at the bottom of the tank. The contaminants can then be removed by sludging the tank.

Centrifuging

  • Centrifuging is a process by which the gravity effect  can be amplified by the use of centrifugal force to the extent that the separation process becomes rapid and continuous. Centrifuges operate, rapidly by spinning a bowl containing the liquid, thus producing the centrifugal force required for  separation.
  • Its  principle of operation of  is very simple.

When a bowl containing impure fuel is rotated, the centrifugal forces throw any item with a density greater than the density of fuel oil (solids and free water) to the bowl ‘s periphery.

Centrifugal separators used to separate two liquids with different densities (fuel and water) are known as purifiers, and clarifiers are those used to remove solid impurities.

Note:- Purifiers will also remove some solids, and clarifiers will remove small amounts of water as well.

Clarifier

In above figure,the addition of an inlet and an outlet connection forms a simple clarifier.

  • Rotational speeds vary by design and range from 7,000 to 9,000 rpm. Efficiency is increased by the inclusion of a number of dicks (up to 150) which increase the surface area and thus help in separation of impurities from fuel. The dicks are placed at a distance of 0.5-0.6 mm.
  • After passing through the central passage, the untreated oil is moved by centrifugal forces to the periphery of the bowl and then passes through the disk stack. Here is where the actual separation takes place, in a channel formed between two disks. Two forces are acting on each solid or liquid particle.

The particle is pushed upwards by the oil stream to the centre, while the centrifugal force directs it to the periphery.

The residual force on the denser particles (impurities) will drive them towards the periphery, while the less dense particles (oil) will be directed towards the center of the bowl and will rise to the outlet connection.

Purifier

When a centrifuge is configured as a purifier, the second outlet pipe is used  for the discharge of water as shown in figure.

In the fuel oil purifier, the untreated fuel contains a mixture of oil, solids and water, which is separated into three layers by the centrifuge.

While in operation, a quantity of oil remains in the bowl to form a complete seal around the underside of the top disk and, due to the difference in density, the oil is confined to the outer diameter of the top disk.

Because marine fuel oil usually contains a small amount of water , it is important to prime the bowl each time it runs, or otherwise,all the oil would passes over the side of the water outlet to waste.

The radius of the water outlet is greater than the fuel’s. There is a gravity disc within the water outlet, which did the work of controlling the radial position of the fuel- water interface.

As the fuel centrifuge operates, particulate matter accumulates on the bowl walls.

  • If the centrifuge is set as a clarifier, a mixture of water and solid material can form the particulate matter.
  • The free water is continually discharged if set as a purifier, thus the particulate matter must consist of solid material.

Notes:- In older machines it is important to stop the centrifuge to manually clean the bowl and the disc stack, but today most devices will discharge the contents of the bowl while the centrifuge operates.

Wikipedia

Safety Devices of All marine Equipment

What is Safety Device ?

Electrical Safety Devices

Dead front type switchboard, Fuses, Relays, Circuit breakers, Earth fault indicators, Under voltage relay, Reverse power trip, Preferential trip, Over current trip, Short circuit trip, Arc chute, Ebonite Rod ( to remove static charge).

Main Engine Safety Devices


General Safety Devices :-


 Insulated  hand  gloves,  dry  boiler  suits,  shoes  without  metallic  part,  Rubber  pad  in  front  of  switchboard,  0.6m  gap  behind  switchboard,  Panel  doors  to  be  earthed,  interlocked  handles  for opening doors.
 No water, oil, or steam pipeline in its vicinity.


Overhead crane safeties

1)  The most important safety feature of the crane is the electromagnetic fail safe brakes which do notallow the crane to fall with the load even when there is failure of power. For this:·        

Normally centrifugal brakes are used which are fitted inside the rotating drum.·       

The brake pads are always in applied state and pushed by magnetic springs when not in operation or when there is a power failure.·        

As the crane is operated or the power is supplied, the spring gets pulled inward or compressed due to the electromagnetic effect of the current. This allows the crane to be operated normally.

2) Emergency stop is provided in the remote so that the operator can stop the crane at any time.


3) The motor is fitted with distance limit switch in both transverse and longitudinal direction.


4) Mechanical stoppers are provided for both directions in case the electrical distance limit trips fail.


5) The up and down travel of the hook is also attaches with automatic stopper to avoid overloading of the motor.


6)  The motor is fitted with thermal protection trip. When the motor windings get overheated, trip will activate saving the motor winding from burning.


7)  Load limit switch is also fitted which will trip the motor if the load to be lifted is above the crane capacity.


8) It’s the responsibility of senior officers to operate the crane and to make sure all the personnel involve in any lifting operation are at a safe distance during operation of the crane.

9) Additional tools like i-bolts, shackle, wire sling, belts etc. used for lifting must be checked before use.


10) It should be noted that no one walks or stand below the crane when it is in the loaded condition.

Motor Safety Devices


Motor protection and safeties:

1.  Overcurrent and single phasing protection relays

2.  under voltage relay

3.  Short circuit relay (Trigger fuses for HV systems)

4.  Temperature sensor for motor insulation

Safety device on life boat


Mechanical brake (to prevent accident falling)

Centrifugal brake (to control life boat falling speed between 20 to 40 m/min)

Limit switch (to prevent over tightening of rope) (it is fitted arm of davit just before in limit)

Harbour safety pin (for davit)


Safety devices for steering system


@Hunting gear

@Buffer spring

@ Angle adjusting stop (Hand over position limit switch)

@ Double shock valve

@Relief valve

@ Tank level alarm (oil)

@ Over load alarm

STEERING GEAR SAFETIES
Hydraulic safeties:


  Level switch, low level, low low level alarm for hydraulic oil tank.·        

Relief valve.·        

Manual bypass valve.·       

Low pressure valve.·      

High lub oil temp. Cut out  

Low level cut out


Electrical safeties:


Electrical and mechanical stopper for rudder. 

Electrical motor overload alarm.·      

Power failure alarm.·      

High temp. Alarm.·   

Self starting after power failure.·    

Short-circuit trip.·      

Phase failure alarm.·       

 200% insulation in motor

Windless safety device·      

Cable stopper (chain stopper, bow stopper)·      

Overload trip·      

Overspeed trip·      

Hand brake·      

Slipping clutch for overload prevents any undesirable damage such hull damage due to anchor and rope broke out.


Scavenge Space Protection Devices
1)    Electrical temperature sensing device 

fitted within the trunking, which will automatically sound an alarm the event of an excessive rise in local temperature (above 200°C)
2)    Pressure relief valves

consisting of self-closing spring loaded valves are fitted and should be examined and tested periodically.


 3)  Fixed fire extinguishing system may be CO2, Dry Powder or Steam.


crankcase safety devices


1.     Breather pipe with flame trap

2.     Crankcase exhaust fan

3.     Oil mist detector

4.     Crankcase relief doors

5.     Bearing temperature sensor

6.     L.O return temperature sensor


Battery room safety arrangement


Safety is provided by

1)  Proper ventilation

2)  Prevention of heat source for ignition


Ventilation


 Independent exhaust fan provided·        

Inlet duct should be below battery level, and outlet at top of the compartment

Prevention of heat source for ignition
      

No naked light and no smoking·        

Uses of externally fitted light or flameproof light·        

Cables of adequate size and they are well connected·        

Never placed Emergency Switchboard in this room·        

Use insulated spanner and plastic jug for distilled water, to prevent short circuit·        

Room temperature, maintained at 15 ~ 25°C

Generator safety devices  ·      

Over speed trip·        

L.O low pressure trip

@ alarm·        

Low level sump trip·       

 F.O low pressure alarm·       

 Jacket water high temperature alarm·        

Thermometer·       

 Pressure gauge·       

 L.O high temperature alarm·        

Dip stick·        

Crankcase relief valve


ALTERNATOR  SAFETIES 


The three main type alternator protection are:

a. Over current protection.

b. Reverse power tripc.

c.Under voltage trip

Safety devices on starting air line

Î Spring loaded safety valve or bursting cap.(if bursting cap fitted, no need relief valve)

Î Flame trap.(At Joint where manifold to each cylinder startingline)

Î Starting air line drain valve (Inlet of automatic valve)

Π Turning gear interlock

Safety device on O.W.S

Pressure relief valve on discharge pipeO.D.M system with high ppm alarm and automatic pump stopping device.Test cock (level), drain valve


Incinerator Safety System

1)  The safety devices shut down the unit and give out alarms:a.  When the pilot and main burner fail to operateb.  When the flue gas temperature reaches above 400’Cc.  When the cooling fan fails to operate

2)  Emergency fuel shutdown valve

3)  Micro switch, fitted to hinged furnace door (Interlock)

AUTOMATIC MOISTURE DRAIN VALVE(Unloader)this reduced the starting torque for the machine and clear out any accumulated moisture and oil in the system


Safety devices on refrigeration system.

1)L. P cut-out on compressor suction side: Set at a pressure corresponding to 5°C below the lowest expected evaporating gauge reading

2)H.P cut-out on compressor discharge side:Set at a pressure corresponding to 5°C above thehighest expected evaporating gauge reading

3)  Lube oil low pressure cut-out: Oil pressure usually set at 2 bar above crankcase pressure

4)  Cooling water L .P cut-out in condenser side

5)  Safety spring loaded liquid shock valve on compressor cylinder head

6)  Bursting disc on cylinder head, between inlet and discharge manifold

7)  Bursting disc on Condenser, [if fitted]

8)  Relief valve on Condenser; air purging valve on condenser

9)  Master solenoid valve: to prevent liquid being entered into Compressor, when theplant is standstill, especially in Large Plant

COMPRESSOR

Relief valve:

Fitted after every stage to release excess pressure developed inside it. The setting of the lifting pressure increases after every ascending stage. Normally fitted between 1st stage and intercooler and 2nd stage – aftercooler.


Bursting disc:

A bursting disc is a copper disc provided at the air cooler of the compressor. It is a safety disc which bursts when the pressure exceeds over the pre-determined value due to leaky air tubes of the cooler (intercooler or aftercooler).

Fusible plug:

Generally located on the discharge side of the compressor, it fuses if the air temperature is higher than the operational temperature. The fusible plug is made up of material which melts at high temperature.

Lube Oil low pressure alarm and trip:

If the lube oil pressure goes lower than the normal, the alarm is sounded followed by a cut out trip signal to avoid damage to bearings and crank shaft.

Water high temperature trip:

If the intercoolers are choked or the flow of water is less, then the air compressor will get over heated. To avoid this situation high water temperature trip is activated which cut offs the compressor.

Water no-flow trip:

If the attached pump is not working or the flow of water inside the intercooler is not enough to cool the compressor then moving part inside the compressor will get seized due to overheating. A no flow trip is provided which continuously monitor the flow of water and trips the compressor when there is none.

Motor Overload trip:

If the current taken by motor during running or starting is very high then there is a possibility of damage to the motor. An overload trip is thus fitted to avoid such situation.

Boiler safety devices

1)  Safety valve

2)  Low / high water level alarm

3)  Too low water level alarm and shut down

4)  Water level indicators

5)  Pressure gauge

6)  Low fuel oil pressure alarm

7)  Low / high fuel oil temperature alarm

8)  Flame failure alarm

9)  Smoke density alarm

10)  Easy gear arrangement

11)  Air vent

12)  Force draught fan stop alarm

13)  Low / high steam pressure alarm

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