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MINI ICE PLANT TRAINING MODULE

CHAPTER III

METHODOLOGY

3.1 INTRODUCTION

The study mainly focuses on the improvement of the performance of the mini-ice plant
module. The module had been developed by the past Mechanical Engineering students. In order
to attain the best performance of the module, recommendations of the past researchers are
considered.

3.2 FLOW PROCESS

INSPECTION

PLANNING

COMPONENTS AND
DESIGN

CANVASSING

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3.2.1 INSPECTION

The researchers inspected the existing mini ice plant training module. The
following images show the current state of the training module.

The photo below shows rusted brine tank. It is not properly maintained or used for
over a year and the leaked brine from the tank may also have been the cause of corrosion.
The base of the training module is partially rusted caused by the exposure to the
surrounding and also the leak from the tank.

Figure 3.1: Photo showing Mini Ice Plant Training Module

Some devices in the mini ice plant need to be change. The evaporator coil is full
of rust and is in a bad condition. The gauges cannot be able to test if it is still useful
because the mini ice plant is not working anymore. The gauges need to be changed to
make sure the modified ice plant can give an exact reading when used in experiments.

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Figure 3.2: The photos above shows the evaporator coils (left), and the gauges (right)

3.2.2 PLANNING

Planning is focusing on the restoration and modification of the Mini-Ice Plant


Training Module. There are things that need to be restored in the mini ice plant especially
the problems that has already been recognized by the previous researchers. Due to the
inactivity of the training module, the base, evaporator coils and the brine tank are now
rusted which causes the leak. Also the gauges need to be replaced, to make sure it gives
accurate reading.

3.2.2.1 TIME FRAME

Since theres an existing mini-ice plant, the restoration and the replacing
of several parts of the machine is our only focus. To reinforce the plans, setting
time frame is very important. The project is only good for one semester. The first
two weeks is for canvasing of the parts for the module. Another two weeks is
allotted for the fixing and repainting of the base. For the replacement of the brine
tank and evaporator coils, the estimated time is about two weeks. Two weeks for
the replacement of the parts and the addition of the recommended parts. The
remaining weeks is allotted for the testing and gathering of results. The
modification of the parts, if theres something wrong in the data or the results
gathered.

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Activities Number of Weeks from the Date of Start

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1. Canvassing

2. Fixing and
Repainting

3. Acquisition of
Equipment

4. Fabrication

5. Testing

6. Gathering of
results

7. Paper Works

Figure 3.3: Gantt chart

The chart illustrates the start and finish dates of the terminal and summary elements of the Mini Ice Plant Training Module
Project.

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3.2.2.2 SCHEMATIC DIAGRAM OF MINI-ICE PLANT

Figure 3.4: Schematic Diagram of Mini-ice Plant

3.2.3 COMPONENTS AND PARTS OF MINI-ICE PLANT TRAINING MODULE

3.2.3.1 BRINE TANK/ICE TANK

Brine tank or ice tank contains the direct expansion coils, equally
distributed throughout the tank and these coils are submerged in brine. The brine
in the tank acts as a medium of contact only.

Source: plastic-mart.com

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Figure 3.5: Brine Tank

3.2.3.2 CONDENSER

A device or unit used to condense a substance from its gaseous to


its liquid state, by cooling it. It provides a heat transfer surface through which heat
passes from the hot refrigerant vapor to the condensing media.

Source: mcdanielcontrols.com

Figure 3.6: Condenser

3.2.3.3 COMPRESSOR

A mechanical device that increases the pressure of a gas by reducing


its volume. It removes the vapor from the evaporator and raises the temperature
and pressure of the vapor to a point that the vapor can be condensed with
normally available condensed media such as water or air.

Source: img.tradeindia.com

Figure 3.7: Compressor

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3.2.3.4 EVAPORATOR COILS

A device used to turn the liquid form of a chemical into its gaseous form.
It provides a heat transfer surface through which heat can pass from the
refrigerated space or product into evaporating refrigerant.

Source: Alibaba.com

Figure 3.8: Evaporator Coils

3.2.3.5 EXPANSION VALVE

A component in refrigeration and air conditioning systems that controls


the amount of refrigerant flow into the condenser thereby controlling
the superheating at the outlet of the evaporator. Thermal expansion valves are
often referred to generically as "metering devices".

Source: ranommachinery.com

Figure 3.9: Expansion Valve

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3.2.3.6 OIL SEPARATOR

A device designed to separate oil and water by centrifugation. It generally


contains a cylindrical container that rotates inside a larger stationary container.
The denser liquid, usually water, accumulates at the periphery of the rotating
container and is collected from the side of the device, whereas the less dense
liquid, usually oil, accumulates at the rotation axis and is collected from the
center.

Source: static.grainger.com

Figure 3.11: Oil Separator

3.2.3.7 PRESSURE GAUGE

A instrument for measuring the condition of a fluid (liquid or gas) that is


specified by the force that the fluid would exert, when at rest, on a unit area, such
as pounds per square inch or newtons per square centimeter.

Source: mcdanielcontrols.com

Figure 3.12: Oil Separator

3.2.3.8 SOLENOID VALVE

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Solenoid valve is an electromechanically operated valve. The valve is


controlled by an electric current through a solenoid: in the case of a two-port
valve the flow is switched on or off; in the case of a three-port valve, the outflow
is switched between the two outlet ports.

Source: static.grainger.com

Figure 3.13: Solenoid Valve

3.2.3.9 Ammeter

An ammeter is a measuring instrument used to measure the current in


a circuit. Electric currents are measured in amperes (A), hence the name.
Instruments used to measure smaller currents, in the milliampere or microampere
range, are designated as milliammeters or microammeters.

Source: reuk.co.uk/

Figure 3.14: Ammeter

3.2.3.10 Voltmeter

A voltmeter, also known as a voltage meter, is an instrument used for


measuring the potential difference, or voltage, between two points in an electrical

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or electronic circuit. Some voltmeters are intended for use in direct current (DC)
circuits; others are designed for alternating current (AC) circuits.

Source: 3.imimg.com

Figure 3.15: Voltmeter

3.2.3.11 Condenser Fan

A condenser fan is part of a heat pump or central air conditioning system


that circulates air across the system's condenser coil to increase the transfer of
heat. The function of the condenser fan is to cool the highly-pressurized, hot
refrigerant gas to the point where it will condense inside the condenser coil to a
sub-cooled liquid.

Source: tommyji.en.made-in-china.com/

Figure 3.16: Condenser Fan

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3.2.3.12 Flow Meter

A flow meter is a device used to measure the flow rate or quantity of a gas
or liquid moving through a pipe. Flow meters are referred to by many names, such
as flow gauge, flow indicator, liquid meter, etc. depending on the particular
industry; however the function, to measure flow, remains the same.

Source: atctrain.com

Figure 3.17: Flow Meter

3.2.4 CANVASSING

The researchers conducted a canvassing through online market to know the prices
and availability of the material based on the recommendation of the past researchers and
based on the inspection performed by the group. The table below shows the material with
their prices including the shipping rate of an estimated rate of one cubic meter or 21
kilograms of package.

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TABLE 3.1: Shows the summary of the materials needed and prices

Source
Materials Price/ Cost
Plastic-Mart 2014
*Brine plastic tanks (9.5 in x 9 in H) Php 1200.00 (www.plastic-mart.com)
OLX Philippines 2016
*Evaporator Coil Php 1500.00 (www.olx.ph)
www.alibaba.com
*High Side Meter Php 500.00
www.alibaba.com
*Low Side Meter Php 500.00
www.olx.ph
*Ammeter Php 250.00
www.alibaba.com
*Voltmeter Php 250.00
www.grainger.com
*Solenoid Valve Php 4400.00
www.alibaba.com
*Oil Separator Php 1350.00
www.alibaba.com
*Flow meter Php 3500.00
www.alibaba.com
*Compressor Php 4800.00
tommyji.en.made-in-
*Condenser with Fan Php 2400.00
china.com

Total Shipping Fee Php 10000.00

TOTAL Php. 26330.00


* indicates shipping fee is excluded

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References

Poortvliet, P., 2015, " Health check: do ice cream and cold drinks cool us down?" retrieved from:
http://theconversation.com/

Yadav and Singh, 2011, A Study on Analysis and Fabrication of an Ice Plant Model

Castillo, Enriquez et al., 2015, Mini Ice Plant Training Module Modification

Dequito, R., 2016, Price List of Materials retrieved from: alibaba.com

Whitman, et. al 2009, Refrigeration & Air Conditioning Technology

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