Fault diagnosis and refrigerant leak detection in vapour compression refrigeration systems

The environmental impact of refrigeration systems can be reduced by operation at higher efficiency and reduction of refrigerant leakage. Refrigerant loss contributes both directly and indirectly to global warming through inefficient system operation, increased power consumption and greenhouse gas emissions and higher maintenance costs. Existing sensor-based leak detection methods are limited by the inability to detect gradual leakage and the need for careful sensor location. There is a requirement for a real-time performance monitoring approach to leak detection and fault diagnosis which overcomes these disadvantages.This paper reports on the development of a fault diagnosis and refrigerant leak detection system based on artificial intelligence and real-time performance monitoring. The system has been used successfully to distinguish between faulty and fault free operation, steady-state and transient operation, leakage and over charge conditions. Work currently underway is aimed at testing additional fault conditions and establishing further rules to distinguish between these patterns.     

Non-linear predictive control of a vapour compression cycle

A potential energy saving can be obtained by a global optimal setting of each actuator in a vapour compression cycle. This paper describes a predictive optimal control algorithm applying this strategy. At each step, an optimal command profile is computed, upon predictions of variables system evolution, using a simple non-linear model of a vapour compression cycle. Choice of this profile is based on a multiple criterion including cycle efficiency and technological constraints. The approach is experimentally validated on a pilot scale refrigeration plant with variable speed compressor. Trials have been performed and showed a meaningful energy saving.     

Real-time measurement of mixing ratio of refrigerant/refrigeration oil mixture

The mixing of refrigeration oil with refrigerant in a refrigeration cycle has great influence on cycle performance. A sampling method is the most general way to measure the mixing ratio of refrigerant and refrigeration oil. Since the sampling method is time-consuming and reduces the amount of refrigerant and oil in the cycle, a real-time measurement is desirable. In this study, a refractive index measurement was applied to measure the mixing ratio of refrigerant/oil mixture. A laser displacement sensor was used to detect any change in optical path which results from changes of the refractive index of refrigerant/oil mixture. For the practical application of real-time measurement of the oil circulation ratio (OCR) in the refrigeration cycle, a correlation between the refractive index and the mixing ratio was developed. In addition, the changes of the refractive index in a range of a few percentages of the oil concentration and under subcooled conditions were measured. Finally, a transient measurement of the OCR in a practically operating refrigeration cycle was carried out successfully.     

Experiment and simulation on the performance of an autocascade refrigeration system using carbon dioxide as a refrigerant

The main purpose of this study is to investigate the performance of an autocascade refrigeration system using zeotropic refrigerant mixtures of R744/134a and R744/290. One of the advantages of this system is the possibility of keeping the highest pressure of the system within a limit by selecting the composition of a refrigerant mixture as compared to that in the vapor compression system using pure carbon dioxide. Performance test and simulation have been carried out for an autocascade refrigeration system by varying secondary fluid temperatures at evaporator and condenser inlets. Variations of mass flow rate of refrigerant, compressor power, refrigeration capacity, and coefficient of performance (COP) with respect to the mass fraction of R744 in R744/134a and R744/290 mixtures are presented at different operating conditions. Experimental results show similar trends with those from the simulation. As the composition of R744 in the refrigerant mixture increases, cooling capacity is enhanced, but COP tends to decrease while the system pressure rises.

Résumé

The main purpose of this study is to investigate the performance of an autocascade refrigeration system using zeotropic refrigerant mixtures of R744/134a and R744/290. One of the advantages of this system is the possibility in keeping the highest pressure of the system within a limit by selecting the composition of a refrigerant mixture as compared to that in the vapor compression system using pure carbon dioxide. Performance test and simulation have been carried out for an autocascade refrigeration system by varying secondary fluid temperatures at evaporator and condenser inlets. Variations of mass flow rate of refrigerant, compressor power, refrigeration capacity, and coefficient of performance (COP) with respect to the mass fraction of R744 in R744/134a and R744/290 mixtures are presented at different operating conditions. Experimental results show similar trends with those from the simulation. As the composition of R744 in the refrigerant mixture increases, cooling capacity is enhanced, but COP tends to decrease while the system pressure rises.     

A low data requirement model of a variable-speed vapour compression refrigeration system based on neural networks

In this work a model of a vapour compression refrigeration system with a variable-speed compressor, based on a black-box modelling technique, is presented. The kernel of the model consists of a full customized radial basis function network, which has been developed to accurately predict the performance of the system with low cost data requirement in terms of input variables and training data. The work also presents a steady state validation of the model inside and outside the training data set, finding, in both cases, a good agreement between experimental values and those predicted by the model. These results constitute a first step to go through future research on fault detection and energy optimisation in variable-speed refrigeration systems.     

A novel concept of rapid cooling method of refrigeration system

This paper describes a novel cooling method of enhancing refrigeration capacity during short time (order of 1 min) by storing low-temperature liquid refrigerant. This method actively controls the refrigerant mass flow rate for the evaporator. The compressor of the refrigerator, therefore, does not have to be oversized to cope with intermittent large cooling load of the system. During a short period of time, a higher cooling capacity than that of the steady operation is achieved by the increased mass flow rate of liquid refrigerant. An experimental apparatus was designed and fabricated to validate the proposed cooling methodology. Two reservoirs as temporary sequential storages of the refrigerant were set up before and after the evaporator. Several on/off solenoid valves were installed to control the refrigerant flow. From the experimental results, we confirmed a successful operation of rapid cooling process as designed. This rapid cooling methodology shall be useful for temporarily enhancing the refrigeration capacity in other low-capacity refrigeration systems. The practical system must optimize the design of refrigerant reservoirs to reduce the whole system size.     

Measurements of the surface tension for R290, R600a and R290/R600a mixture

The surface tensions of R290, R600a and R290/R600a mixture have been measured by the modified differential capillary-rise method. Twenty-two data points for R290 and 21 data points for R600a were obtained in the temperature range between 273 K and 354 K, and 43 data points for R290/R600a mixture on three isotherms of 278 K, 300 K and 320 K were obtained. The experimental uncertainties of temperature and surface tension are estimated to be within 20 mK and 0.2 mN m⁻¹, respectively. Surface tension correlations as a function of temperature for pure R290 and R600a were formulated in the temperature range between 253 K and critical temperature, and the correlation as a function of the composition for R290/R600a mixture was discussed at 278 K, 300 K and 320 K. It is found that the surface tension for R290/R600a mixture can be reproduced by the simple mixing rule by mole fraction with the correlations of both pure components.     

A novel hybrid absorption–compression refrigeration cycle

When used in traditional pool-boiling type refrigeration cycles, non-azeotropic mixed refrigerants tend to result in a reduced efficiency compared to pure refrigerants. This results from the composition shift effect, which distributes the mixture components: concentrating the more volatile component in the high pressure part of the cycle, and the less volatile component in the low pressure part. The obvious effect of this is to increase the compression ratio relative to a single component. This article investigates a way of manipulating the composition change of a refrigerant mixture, using two components of similar volatility, in order to reduce the compression ratio. Counter-current vapour–liquid contact is used in a “refrigeration column”, which is combined with a distillation column. The cycle is able to exploit heat sources below 100°C as input to the distillation column and the designer is able to optimise the consumption of compressor power and distillation heat input.     

Study of capillary tubes in a transcritical CO2 refrigeration system

Capillary tubes have been used in refrigeration systems for many years, but not with a transcritical CO₂ system. In this article, the effects of capillary tubes in a transcritical CO₂ refrigeration system have been investigated experimentally and theoretically. Different types of capillary tubes with different lengths (0.5–4 m) and diameters (1–2 mm) have been tested. The result of this work is a static model, which is used in the further work to make a simulation model (static) of a complete refrigeration system. The model is based on Friedel's and Colebrook's pressure drop correlations.

The behaviour of an adiabatic capillary tube in a refrigeration cycle has been investigated theoretically. The conclusion is that the COP of a system with capillary tubes generally is better than when a fixed high pressure is used, but not as good as when variable optimal high pressure is used. Capillary tubes are especially interesting in applications where the evaporation pressure is constant and the temperature out of the gas cooler varies no more than ±10 K from the design condition. The reduction in COP is more significant at low temperatures out of the gas cooler.     

Simulated performance and cofluid dependence of a CO2-cofluid refrigeration cycle with wet compression

Recent experiments demonstrate the viability of a low-pressure CO₂-cofluid compression refrigeration cycle in which CO₂ and a non-volatile cofluid are circulated in tandem and co-compressed in a compliant scroll compressor. This work explores the theoretical performance limitations of such a cycle operating under environmental conditions representative of automotive air conditioning and studies the dependence of this performance on the properties of the CO₂-cofluid mixture. The vapor–liquid equilibrium and thermodynamic properties of the mixture are described using a previously reported activity-coefficient model. A coupled system of physically based equations that allows for consideration of both ideal and real hardware components is used to represent the system hardware and its interaction with the environment. The system efficiency is analyzed in terms of entropy generation rates in the various hardware components; entropy generation in the internal heat exchanger—a component required to achieve sufficiently low cooling temperatures—strongly influences overall system efficiency. The vapor pressure of the CO₂-cofluid mixture and the heat of solution of CO₂ in cofluid have large and somewhat independent contributions to the system performance: lower saturation pressure lowers the optimal operating pressures at fixed CO₂ loading, while increasingly negative heat of solution contributes to higher specific refrigeration capacity and efficiency.

Résumé

Recent experiments demonstrate the viability of a low-pressure CO₂-cofluid compression refrigeration cycle in which CO₂ and a non-volatile cofluid are circulated in tandem and co-compressed in a compliant scroll compressor. This work explores the theoretical performance limitations of such a cycle operating under environmental conditions representative of automotive air conditioning and studies the dependence of this performance on the properties of the CO₂-cofluid mixture. The vapor–liquid equilibrium and thermodynamic properties of the mixture are described using a previously reported activity-coefficient model. A coupled system of physically based equations that allows for consideration of both ideal and real hardware components is used to represent the system hardware and its interaction with the environment. The system efficiency is analyzed in terms of entropy generation rates in the various hardware components; entropy generation in the internal heat exchanger—a component required to achieve sufficiently low cooling temperatures—strongly influences overall system efficiency. The vapor pressure of the CO₂-cofluid mixture and the heat of solution of CO₂ in cofluid have large and somewhat independent contributions to the system performance: lower saturation pressure lowers the optimal operating pressures at fixed CO₂ loading, while increasingly negative heat of solution contributes to higher specific refrigeration capacity and efficiency.     

Numerical simulation and experimental validation of vapour compression refrigeration systems. Special emphasis on CO2 trans-critical cycles

A numerical and experimental comparative study of a carbon dioxide trans-critical refrigerating system and a conventional sub-critical refrigerating cycle is presented. Attention is focussed not only on the whole refrigeration cycle, but also on the behaviour of the hermetic reciprocating compressors used in these systems. The comparative cases presented have been specially designed for small cooling capacity units with an evaporation temperature around 0 °C. A detailed numerical simulation model for hermetic reciprocating compressors performance, widely validated under conventional fluid refrigerants, has been extended to numerically obtain the CO₂ compressor prototypes behaviour. Two CO₂ compressor prototypes working with CO₂ have been experimentally tested in a specific unit, specially designed and built to analyse high-pressure single stage vapour compression trans-critical refrigerating equipments. This set-up has allowed validating a detailed numerical simulation code for the thermal and fluid-dynamic behaviour of single stage vapour compression refrigeration system working with CO₂ as fluid refrigerant. The numerical results and the experimental data obtained to validate compressors, heat exchangers and whole cycle behaviour have shown a really good agreement. Finally, the numerical and experimental comparison between the carbon dioxide system and the sub-critical conventional cycle has shown the possibility of CO₂ as fluid refrigerant under the studied working conditions.     

The optimum high pressure for CO2 transcritical refrigeration systems with internal heat exchangers

The system performance of a CO₂ refrigeration system is greatly affected by the compressor discharge pressure. An internal heat exchanger (IHX) with high effectiveness is an important factor to achieve high system performance. The expression traditionally used to describe the heat exchange effectiveness is not suitable for CO₂ systems. As a result a practical effectiveness expression for IHX, based on enthalpy difference, has been derived and is reported in this paper. Detailed analysis on the relationship between the optimum high pressure P_k,opt and other systematic parameters was performed. Evaporating temperature has little influence on P_k,opt; and IHX can minimize the sensitivity of the system to the refrigerant quality x at the evaporator outlet. Based on simulation data, a correlation of P_k,opt was developed that predicts the simulation values with a deviation of less than 3.6% in the whole range and 0.94% when the evaporating temperature t₁=5.3 °C. The results reported in this paper can be used in optimum control and performance evaluation of the whole system.     

Experimental results for a hydraulic refrigeration system using n-butane

The hydraulic refrigeration system (HRS) is a vapor-compression system that accomplishes the compression and condensation of the refrigerant in a unique manner, by entraining refrigerant vapor in a down-flowing stream of water and utilizing the pressure head of the water to compress and condense the refrigerant. A multi-stage HRS was designed, fabricated, and tested using n-butane as the refrigerant. In general, both the refrigeration rate and the coefficient of performance (COP) increased with a corresponding decrease in the compression fluid temperature of the third and final stage. The refrigeration rate and COP were also found to increase with a corresponding increase in evaporator temperature. The predictions of an enhanced model incorporating two-phase hydraulic losses show excellent agreement with the experimental data with a maximum error of ±20%. The results of the experimental investigation indicate that the HRS offers an attractive and feasible alternative to conventional vapor-compression systems, especially in applications where direct-contact heat exchange in the evaporator is desirable.     

Modeling absorption of pure refrigerants and refrigerant mixtures in lubricant oil

This paper addresses the problem of absorption of refrigerant vapor in a stagnant layer of lubricant oil. The bulk motion of the solute is described in terms of apparent diffusion coefficients that encompass both molecular diffusion and possible macroscopic motion induced by liquid density instability and surface tension. In absorption of refrigerant mixtures, diffusion in the vapor and liquid phases are coupled with a thermodynamic model for interfacial equilibrium. Results are compared with experimental data available in the literature for absorption of several refrigerants in polyol ester oil (POE68). The adequacy of the formulation is assessed in the light of its basic assumptions and performance of the model.     

Theoretical evaluation of trans-critical CO2 systems in supermarket refrigeration. Part I: Modeling, simulation and optimization of two system solutions

Using CO₂ trans-critical system solutions in supermarket refrigeration is gaining interest with several installations already running in different European countries. Using a computer simulation model, this study investigates the performance of two main system solutions: centralized with accumulation tank at the medium temperature level and parallel with two separate circuits for low and medium temperature levels. Both system solutions are presented and the simulation model is described in details. Calculations have been performed to design the systems and optimize their performances where basic layout and size of each solution have been defined. For ambient temperature range of 10–40 °C, the reference centralized system solution shows higher COP of about 4–21% than the reference parallel solution. Using two-stage compression in the centralized system solution instead of single stage will result in total COP which is about 5–22% higher than that of the reference centralized system and 13–17% higher than that of the improved two-stage parallel system. The two-stage centralized system solution gives the highest COP for the selected ambient temperature range.     

Effects of flash gas generation at the expansion device inlet on the dynamic characteristics of a refrigeration system

The flash gas generation at the expansion device inlet in multi-air-conditioners causes rapid reduction of refrigerant mass flow rate and irregular distribution of refrigerant into multi-indoor units. The objective of this study is to evaluate the influence of the flash gas generation on the dynamic characteristics of a refrigeration system. The dynamic characteristics of a refrigeration system with an electronic expansion valve (EEV) were measured with time at various levels of flash gas generation, which were expressed as flash gas ratio. In addition, the averaged operating parameters and system COP were investigated with the variation of flash gas ratio. As the EEV inlet condition changed from the subcooled to the two-phase state, the refrigerant flow rate decreased rapidly due to the flash gas generation at the EEV inlet. At two-phase inlet conditions, the system operating parameters, such as mass flow rate, suction and discharge pressures, fluctuated periodically with time. As the flash gas ratio increased, the average COP decreased and the discharge temperature increased, degrading the system performance and reliability more severely.     

Influence of the objective function on the optimisation of a steam ejector cycle

Optimisation is a design method to search the best value of the defined system's goal that can be expressed by an objective function to be minimised or maximised. A set of unknowns subject to constraints controls the values that the objective function can assume. A multi-variable approach enables one to address the optimisation of a thermodynamic system: the best working conditions of the system are different from those corresponding to component optimisation. Then we have to model the complete system to find an optimumty.

Different objective functions are presented as optimisation criteria of the design data of a steam ejector cycle, keeping the same boundary conditions and convergence limits and using a numerical optimisation of the cycle published by the authors. The comparison between the results obtained with different objective functions is presented to show the influence of the function chosen on the system design.

The comparison also shows that the choice of the objective function decisively influences the robustness of the numerical code results and the convergence performances of the code.     

A year-round dynamic simulation of a solar-driven ejector refrigeration system with iso-butane as a refrigerant

In this paper, the performance of the solar-driven ejector refrigeration system with iso-butane (R600a) as the refrigerant is studied. The effects that both the operating conditions and the solar collector types have on the system's performance are also examined by dynamic simulation. The TRNSYS and EES simulation tools are used to model and analyze the performance of a solar-driven ejector refrigeration system. The whole system is modelled under the TRNSYS environment, but the model of the ejector refrigeration subsystem is developed in the Engineering Equations Solver (EES) program. A solar fraction of 75% is obtained when using the evacuated tube solar collector. In the very hot environment, the system requires relatively high generator temperature, thus a flat plate solar collector is not economically competitive because the high amount of auxiliary heat needed to boost up the generator temperature. The results from the simulation indicate that an efficient ejector system can only work in a region with decent solar radiation and where a sufficiently low condenser temperature can be kept. The average yearly system thermal ratio (STR) is about 0.22, the COP of the cooling subsystem is about 0.48, and the solar collector efficiency is about 0.47 at T_e 15 °C, T_c 5 °C above the ambient temperature, evacuated collector area 50 m² and hot storage tank volume 2 m³.     

Performances d'une machine tritherme à éjecteur utilisant des mélanges de fluides frigorigènesPerformance analysis of a jet cooling system using refrigerant mixtures

The optimisation of a jet cooling system using refrigerant mixtures as substitutes of pure refrigerants has been investigated. A steady-state simulation program, for given temperatures of the sources, integrating simple models of each component has been developed. A Peng-Robinson equation of state assuming equality of the fugacities of the two phases was used to model the thermodynamic properties of the vapour and liquid-vapour equilibrium. The refrigerants investigated in this study are: the pure refrigerants R142b, R152a, RC318, R124, R134a, R22 and the binary refrigerants R22/RC318, R22/R142b, R22/R124, R22/R152a, R22/R134a, R134a/R142b, R152a/R142b and R134a/R152a. Results show that the use of a binary mixture does not always increase the performance of system. Generally, when the mixture is strongly zeotropic (e.g.: R22/RC318), the cooling efficiency of the system decreases. However, when the mixture is mildly zeotropic (e.g. R134a/R142b) or almost azeotropic (e.g. R134a/R152a), efficiency and energetic efficiency increase.