The impact of evaporator fouling and filtration on the performance of packaged air conditioners

The goal of the study presented in this paper was to evaluate the impact of different filter types on the performance of three typical packaged air conditioners under both clean and fouled conditions. In a companion paper, combinations of six different levels of filtration and four different coils were tested under clean and fouled conditions. From the tests, it was found that fouling has a relatively small impact on air-side effective heat transfer coefficient, but can have a large impact on coil pressure drop. Data from the experimental study were used in developing simulation models for the three packaged air conditioners. Simulations show that the equipment cooling capacity is reduced with fouling primarily because of a decrease in air flow due to the increased pressure drop. In most cases, EER (energy efficiency ratio) was reduced with fouling primarily due to increased fan power. However, the changes in EER were relatively small, in the range of 1–10%. Equipment having low efficiency filters had higher EER after fouling than equipment with high efficiency filters, because high efficiency filters result in significantly higher pressure drops than low efficiency filters. The impact of the evaporator side fan efficiency was found to be significant. The energy penalty associated with high efficiency filters was reduced greatly when fan efficiency increased. Although high efficiency filters cause higher energy penalties they provide considerably better air quality. The quantity of dust passing through the coil with an MERV14 filter was approximately 30 times less than the dust passing the coil with an MERV4 filter. This difference was doubled when the MERV14 filter was compared to a case with no filter in place.     

An overall performance index for characterizing the economic impact of faults in direct expansion cooling equipment

Air conditioning is a non-critical application for fault detection and diagnosis (FDD) where decisions about servicing faults should involve the use of economics. Existing methods for evaluating impacts of faults on equipment performance only consider some individual factors such as the equipment coefficient of performance (COP) or cooling capacity. This paper develops an overall economic performance degradation index (EPDI) for air conditioning equipment that includes the combined effects of degradations in COP, cooling capacity, and sensible heat ratio (SHR). EPDI quantifies the performance degradation caused by faults based on economics so it can be used as part of the decision making process in an overall FDD system. Furthermore, EPDI can be used along with estimates of typical field performance degradations to assess the economic benefits associated with the application of automated FDD. A case study is presented where EPDI was applied to measurements for an existing unit where faults were artificially introduced.     

Design of a steady-state detector for fault detection and diagnosis of a residential air conditioner

This paper presents a general methodology for developing a steady-state detector for a vapor compression system based on a moving window and using standard deviations of seven measurements selected as features. The feature thresholds and optimized moving window size were based upon steady-state no-fault tests and startup transient tests. The study showed that evaporator superheat and condenser subcooling were sufficient for determining the onset of steady-state during the startup transient. However, they misidentified steady-state during indoor temperature change tests where evaporator saturation temperature and air temperature change across the evaporator were needed for proper steady-state identification. Hence, the paper recommends including all fault detection and diagnosis (FDD) features in the steady-state detector to ensure the robustness of the detector because different features may play key roles with different transients.     

Model-based Fault Detection and Diagnosis of HVAC systems using Support Vector Machine method

Preventive maintenance plays a very important role in the modern Heating, Ventilation and Air Conditioning (HVAC) systems for guaranteeing the thermal comfort, energy saving and reliability. Its key is a cost-effective Fault Detection and Diagnosis (FDD) method. To achieve this goal, this paper proposes a new method by combining the model-based FDD method and the Support Vector Machine (SVM) method. A lumped-parameter model of a single zone HVAC system is developed first, and then the characteristics of three major faults, including the recirculation damper stuck, cooling coil fouling/block and supply fan speed decreasing, are investigated by computer simulation. It is found that the supply air temperature, mixed air temperature, outlet water temperature and control signal are sensitive to the faults and can be selected as the fault indicators. Based on the variations of the system states under the normal and faulty conditions of different degrees, the faults can be detected efficiently by using the residual analysis method. Furthermore, a multi-layer SVM classifier is developed, and the diagnosis results show that this classifier is effective with high accuracy. As a result, the presented Model-Based Fault Detection and Diagnosis (MBFDD) method can help to maintain the health of the HVAC systems, reduce energy consumption and maintenance cost.     

Modeling the thawing of frozen foods using air impingement technology

With the continual growth in the use of frozen foods both in retail and in food service, there is a need to develop improved thawing methods. Current methods are often undesirably slow (still air) or are very expensive and cause uneven thawing (microwave). Air impingement technology is one possible method to improve the thawing of frozen foods. The objectives of this research were to develop a two-dimensional model for air impingement thawing frozen foods and to verify the model experimentally. Frozen products were thawed using a laboratory impingement system with a single impingement jet. A simulated meat product (Tylose gel) was used as the test material. Thawing of a Tylose disk (12.7 cm diameter, 1.98 cm thickness) with air at 6 °C without impingement required more than 12 h, while thawing under a single impingement jet took less than 3 h, over four times faster. Results from the finite difference model gave good agreement with experimental data. Moisture loss during thawing was typically over-predicted because moisture gain due to condensation was not modeled.     

A generalized coefficient of performance for conditioning moist air

The psychrometric chart is a useful tool for calculating the energy change between any two states and visually identifying the contribution of ‘sensible’ and ‘latent’ effects. However, the amount of work needed to move from one state to another is not read directly from the chart. In this paper, temperature and vapor pressure changes are cast into terms of minimum work relative to a dead state, and work contours are plotted on the psychrometric chart. These contours show the minimum work needed to move the state of the air further from the ambient conditions or the maximum work produced by letting a state approach the ambient conditions. A dividing line between heat pump and refrigeration operation is set on the basis total energy of the conditioned space relative to the ambient. Finally, an example is used to illustrate the implementation of the analysis.     

Experimental performance analysis and modelling of liquid desiccant cooling systems for air conditioning in residential buildings

The paper presents a new desiccant cooling cycle to be integrated in residential mechanical ventilation systems. The process shifts the air treatment completely to the return air side, so that the supply air can be cooled by a heat exchanger. Purely sensible cooling is an essential requirement for residential buildings with no maintenance guarantee for supply air humidifiers. As the cooling power is generated on the exhaust air side, the dehumidification process needs to be highly efficient to provide low supply air temperatures. Solid rotating desiccant wheels have been experimentally compared with liquid sorption systems using contact matrix absorbers and cross flow heat exchangers. The best dehumidification performance at no temperature increase was obtained in an evaporatively cooled heat exchanger with sprayed lithium chloride solution. Up to 7 g kg⁻¹ dehumidification could be reached in an isothermal process, although the surface wetting of the first prototype was low. The process then provides inlet air conditions below 20 °C for the summer design conditions of 32 °C, 40% relative humidity. With air volume flow rates of 200 m³ h⁻¹ the system can provide 886 W of cooling power.A theoretical model for both the contact absorber and the cross flow system has been developed and validated against experimental data for a wide range of operating conditions. A simulation study identified the optimisation potential of the system, if for example the surface wetting of the liquid desiccant can be improved.     

Methodology for uncertainty calculation of net total cooling effect estimation for rating room air conditioners and packaged terminal air conditioners

This article presents the general procedure for uncertainty calculation of net total cooling effect estimation for rating room air conditioners and packaged terminal air conditioners, by means of measurements carried out in a test bench specially designed for this purpose. The uncertainty analysis presented in this work looks for establishing a confidence degree or certainty of experimental results. It is particularly important considering that international standards related to this type of analysis are too ambiguous when treating this subject. The uncertainty analysis is on the other hand an indispensable requirement to international standard ISO 17025 [ISO, 2005. International Standard. 17025. General Requirement to Test and Calibration Laboratories Competences. International Organization for Standardization, Geneva.], which must be applied to obtain the required quality levels according to the Word Trade Organization WTO.     

Logic unconstrained multi-zone evaporator and condenser models

The multi-zone model is widely used in evaporator and condenser modeling. The basic two-zone evaporator model and three-zone condenser model might reduce to one-zone or two-zone model depending on the operating conditions. In the traditional multi-zone models, logic constraints are invoked to separate the possible running modes and trigger mode changes from one to another, which will lead to the complicated logic in implementation. A logic unconstrained multi-zone model has been developed in this paper. In the new model, all the logic constraints are transformed into continuously differentiable equations. As a result, all the equations can be solved simultaneously without any logic constraints. Numerical examples show that the new logic unconstrained multi-zone models are in good agreement with the traditional ones.     

Modelling of food transportation systems – a review

In 2002, over a million refrigerated road vehicles, 400,000 refrigerated containers and many thousands of other forms of refrigerated transport systems are used to distribute chilled and frozen foods throughout the world. All these transportation systems are expected to maintain the temperature of the food within close limits to ensure its optimum safety and high quality shelf life.Increasingly, modelling is being used to aid the design and optimisation of food refrigeration systems. Much of this effort has concentrated on the modelling of refrigeration processes that change the temperature of the food such as chilling, freezing and thawing. The purpose of a refrigerated transport system is to maintain the temperature of the food and appears to have attracted less attention from modellers. This paper reviews the work that has been carried out specifically on the modelling of food temperature, microbial growth and other parameters in the transportation of food.     

Modeling, identification and control of air-conditioning systems

In this paper, feedback controller design for the air-conditioning system is addressed through systematic modeling and identification. Particularly, the physical model of the system reveals the key parameter that dictates energy efficiency, and the identification procedure produces a low-order, linear model suitable for controller design. The feedback controller employed is multi-input–multi-output-based and possesses a cascade structure for dealing with the fast and slow dynamics in the system. To determine appropriate control parameters, conditions that establish performance and stability of the cascade design are given. Experiments show that the controller can simultaneously achieve satisfactory transient response in the indoor temperature, and improve energy efficiency at steady state.     

A vapour compression chiller fault detection technique based on adaptative algorithms. Application to on-line refrigerant leakage detection

The existence of faults in vapour compression chillers plays a significant role in terms of energy efficiency loss, performance degradations, and even environmental implications. In this paper, a dynamic model-based fault detection technique suitable for real-time implementation is proposed. The main objective is to obtain a reliable and automated tool for fault detection in vapour compression chillers, which can be applied in steady-state or transient operation. The fault detection methodology is based on comparing actual and expected performance using an adaptative model and operating variables dynamic thresholds. The technique has been successful applied for on-line refrigerant leakage detection with experimental tests involving the artificial introduction of the fault in a laboratory vapour compression plant, showing the results its capability of detecting incipient leakage failure conditions avoiding false alarms.     

Experimentation and modeling of refrigerant flow through coiled capillary tubes

Air-conditioners use spirally coiled capillary tubes as an expansion device to enhance compactness of the unit. However, most empirical correlations for predicting refrigerant flow rate through capillary tubes were developed for straight capillary tubes without consideration of coiled effects. The objectives of this study are to investigate the flow characteristics of the coiled capillary tubes and to develop a generalized correlation for the mass flow rate through the coiled capillary tubes. The mass flow rate of R22 through the coiled capillary tubes and straight capillary tubes was measured for various operating conditions and tube geometries. The mass flow rates of the coiled capillary tubes decreased by 5–16% more than those of the straight capillary tubes at the same operating conditions. A generalized correlation for predicting refrigerant mass flow rate through coiled capillary tubes was developed by introducing the parameter of capillary equivalent length. The present correlation showed good predictions with the present database for R22, R407C and R410A in the straight and coiled capillary tubes, yielding average and standard deviations of 0.24% and 4.4%, respectively.     

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.     

The reliable simple one-dimensional 64-CPWTR model applied to the two-dimensional heat transfer problem of an insulated rectangular duct in an air conditioning or refrigeration system

The heat-transfer characteristics of an insulated long rectangular or square duct are analyzed by using the one-dimensional plane wedge thermal resistance (PWTR) model and plate thermal resistance (PTR) model in this study. It is found that the errors generated by the PWTR model are all positive and the errors generated by the PTR model are all negative. Thus, the combined plate wedge thermal resistance (CPWTR) model generated by paralleling PWTR and PTR models with the proportion factors of α=0.6 vs. β=0.4 (64-CPWTR model) can neutralize the positive and negative errors and obtain very accurate results in comparison with the two-dimensional numerical solutions analyzed by the CFD software. The errors generated by the one-dimensional 64-CPWTR model are within 1% for practical sizes and practical insulated thickness in air conditioning and refrigeration systems. Thus, the engineer can obtain very reliable heat transfer results when applying the one-dimensional 64-CPWTR model to an insulated rectangular duct.     

Steady state CFD modeling of airflow, heat transfer and moisture loss in a commercial potato cold store

Storage loss beyond permissible limit is one of the most important problems in Indian potato cold stores, which has been hindering further growth of this industry. The losses in the stored potatoes have a direct relation to the intricate coupled transport phenomena of heat, mass and momentum transfer therein. Therefore, airflow, heat transfer and moisture loss was investigated in a potato cold store of commercial scale under steady state condition using the computational fluid dynamics technique. The developed CFD model was a two-dimensional simplification of the cold store. Heat and mass transfer at the cooling coils were not modeled, instead temperature and relative humidity in the air space were specified based on measured values. The model was validated in a commercial scale cold store and was found to be capable of predicting the air velocity as well as product temperature with an average accuracy of 19.5% and 0.5 °C, respectively and also the simulated average total moisture loss was found to be only 0.61% water (w.b.) higher than the experimental one for a storage period of 6 months. The main deficiencies of the airflow pattern which resulted in wide variations in temperature and moisture loss within the stored commodity can be investigated. The model located the probable zones of hot and cold spots, excessive product dehydration and moisture condensation within the storage facility, which might lead to qualitative and quantitative deterioration in stored product. This modeling tool could very well be applied to incorporate necessary design improvements with a view to improve the airflow distribution and heat transfer in order to limit the storage losses within the permissible limit.     

Applications and control of air conditioning systems using rapid cycling to modulate capacity

Rapid cycling the compressor of an air conditioning or refrigeration system can be used to modulate capacity, thus offering an alternative to a variable speed compressor. This paper explores design tradeoffs to optimize rapid cycling performance based on experimental results using two different evaporators and changing other components of an air conditioning system. Rapid cycling has inherent compressor lift penalties associated with larger mass flow rates, which need to be minimized. Preventing dryout (superheating) in the evaporator during the off cycle, a major penalty as cycles are lengthened, is also important. Evaporator dryout is minimized by increasing the refrigerant side area and reducing off cycle drainage. Combining a flash gas bypass with a suction line heat exchanger was found to maximize performance during the off cycle while allowing increased cycle lengths without incurring major penalties.     

Modeling and experimental investigation of accumulators for automotive air conditioning systems

A stream analysis model was developed to simulate the behavior of accumulators and their influence on the automotive air conditioning (A/C) systems. It allows a comprehensive steady state simulation with a set of input conditions such as refrigerant vapor mass flow rate and pressure at the inlet of an accumulator. In this study, the refrigerant/oil mixture is R134a/PAG oil which are totally miscible, but could be any air conditioning refrigerant/oil, including carbon dioxide (CO₂)/oil. The model accounts for all major effects inside the accumulator, such as friction, bends, sudden expansion, sudden contraction and heat exchange. The outputs are vapor quality, pressure and temperature at various positions of accumulator. In order to verify the mathematical model, experiments are performed in an experimental setup made up of real size automotive air conditioning components. The simulated results agree well with the experimental data. The simulation and experimental results show an important function of accumulators that is to determine the vapor quality into compressor, and thus has influence on the performance of whole automotive A/C systems.     

Performance analysis of air cycle refrigerator integrated desiccant system for cooling and dehumidifying warehouse

In this paper, the performance of air cycle refrigerator integrated desiccant system used to cool and dehumidify warehouse is analyzed theoretically. Simulation analysis is carried out to calculate the system coefficient of performance, cooling effects and the humidity change under different values of pressure ratio, storage zone temperature inside dock and outdoor air conditions. Also, the effect of the air cycle and the rotor parameters on the system performance is evaluated. From the simulation result it is found that, the desiccant system has the ability to supply air to the dock area at very low humidity. The system coefficient of performance increases due to the exhaust heat recovery on the desiccant system, and this enhancement can be more than 100%. The coefficient of performance of the proposed system is greater than that of a conventional system under the same operating conditions.