ICR07-B2-1485

WORK CHARACTERISTICS OF RECIPROCATING COMPRESSOR FOR

REFRIGERATION SYSTEM DEVELOPED WITH COMPUTER
SIMULATION
Risto Ciconkov1, Vasil Ciconkov2
1
Skopje University, Faculty of Mech. Eng., PO Box 464, Skopje, Macedonia
tel. +389 2 3064 762, fax: +389 2 3099 298, ristoci@ukim.edu.mk
2
Energija doo, Londonska 1 b, Skopje , Macedonia

ABSTRACT

In the operation of one refrigerating system in each moment there is a balance point of the system as
a result of interaction of main components: compressor, condenser, evaporator and expansion
device. In order to find a balance point, it is necessary to consider the performance of each
component separately.

The compressor has the biggest influence on the work of the refrigerating system. As the
reciprocating type is most used, in this paper a work characteristics (performances) of reciprocating
compressor is considered. The factors which have effect on the compressor performance are
analyzed, such as: re-expansion of gas from clearance volume, pressure drops, heat gain to
refrigerant, internal gas leakage and deviation from isentropic compression. Mathematical equations
are introduced in order to calculate the compressor volumetric efficiency.

For a given compressor, it means known design parameters, the work characteristics can be defined
as the refrigeration capacity depending of evaporating and condensing temperatures Qe = Qe (te, tc).
In addition, on a similar way, the effective power consumption is defined as Pe = Pe (te, tc). Using
equations for calculation of volumetric efficiency, refrigeration cycle and flows, a mathematical
model is created, which is used as a base for computer programme. It is applied on concrete
example on a compressor from known manufacturer and the results are compared with the technical
data declared by the manufacturer.

1. INTRODUCTION

There are four essential components of the compression refrigeration system: compressor,
condenser, evaporator and expansion device. The compressor circulates refrigerant through the
system in a continuous cycle.

In the catalogues of manufacturers there are tables or diagrams where refrigeration capacity and
input power of the compressor are presented depending to the evaporating and condensing
temperatures. But, in practice these capacity and power do not correspond, for example, to the water
chiller where the same compressor is built. The reason is that the performance characteristics of the
other components (evaporator, condenser) of the refrigeration system have a distinct influence on
each of the other components. So, the refrigeration system has to be treated as a whole [1, 2].

As it is described in [3], in a moment, under static operating conditions, there is an equilibrium of

the system so-called a balance point (or state of balance) with a corresponding refrigeration capacity.
This balance point could be found with a superimposing of the performance characteristics of all
components of the refrigeration system .

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There are several types of compressors: reciprocating piston, screw, scroll, vane rotary and
centrifugal compressor. The subject in this paper is related to the reciprocating compressor which is
the most applied type in various refrigeration systems.

2. MATHEMATICAL SIMULATION OF PERFORMANCE CHARACTERISTICS

As the performance of the compressor depends to the other components, on the Figure 1 the cycle
of the all system is shown. The compressor pulls the vapour from the evaporator trough suction
piping and compresses the refrigerant gas to a higher pressure and temperature (1-2).

Figure 1. Refrigeration cycle

1-2a: adiabatic compression, 1-2: polytropic (actual) compression

The capacity of a compressor at a given operating condition is a function of the mass flow of gas
compressed per unit time. Theoretically, the mass flow is equal to the product of the compressor
displacement per unit time and the gas density.
m& t = ρ1⋅ V&t (1)
where m& t and V&t are theoretical mass and volume flow of gas compressed, kg/s.

The actual compressor performance deviates from theoretical performance because of various
losses, with a resulting decrease in capacity and increase in power input. Depending on the type of
compressor, the following factors can have an effect on the compressor performance [3]:
- Reexpansion. The clearance volume (dead space) causes a reexpansion of the remained gas
during the suction cycle. Consequently, the volume flow of the discharged gas is less.
- Pressure drops within the compressor units. Through suction and discharge communications,
valves, across strainer/filter.
- Heat gain to refrigerant. From compression process, heat exchange within compressor,
lubricant pump, friction, hermetic motor (if hermetic type).
- Internal gas leakage
- Deviation from isentropic compression

These factors and deviations from theoretical performance are difficult to evaluate individually.
However, they can be grouped together and considered by category. Their effect on theoretical
compressor performance is measured by the following efficiencies:
volumetric efficiency (λ), compression efficiency (η ), mechanical efficiency (ηm), isentropic
(adiabatic) efficiency (ηt) and actual mass capacity ( m& ).

Volumetric efficiency

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Volumetric efficiency is the ratio of actual volume of gas entering the compressor to the theoretical
volume flow (displacement of the compressor).
λ = V& / V&t (2)
The theoretical volume flow is equal to the compressor displacement per unit time.
⎛ πD 2 ⎞ n
V&t = i ⎜⎜ s ⎟⎟ (3)
⎝ 4 ⎠ 60
The actual volume flow rate can be obtained by measurement or by calculating the volumetric
efficiency (λ) [4]:
λ = λc λp λq λl (4)

Many authors calculate the volumetric efficiency regarding to the clearance volume only (λc). Here,
it is included and other factors like a pressure drop, heat transfer between the cylinder and the
refrigerant, and refrigerant leakage.

- Volumetric efficiency, depending on the reexpansion of clearance volume (λc)

The volume of gas remaining in the compression chamber after discharge reexpands into the
compression chamber during the suction cycle and limits the mass of fresh gas that can be brought
into the compression chamber. This effect is comprised by λc which can be calculated by the
following equation:
⎡⎛ p ⎞ 1 / m ⎤
λc = 1 − c ⎢⎜⎜ c ⎟⎟ − 1⎥ (5)
⎢⎣⎝ p e ⎠ ⎥⎦
m≈1
m can be calculated with a greater precision by recommendations in [5].

– Volumetric efficiency which depends on the pressure drop in the suction side Δpe (λp):
1 + c Δpe
λp = 1 − (6)
λc pe
Δpe / pe = 0.02 ÷ 0.05 (recommended)

The multiplication of λc by λp represents the indicated volumetric efficiency, calculated by:

λi = λc⋅ λp (7)

p e − Δp e ⎡⎛ p + Δp ⎞
1/ m
pe − Δpe ⎤
λi = − c ⎢⎜⎜ c c
⎟⎟ − ⎥ (8)
pe ⎢⎣⎝ pe ⎠ pe ⎥⎦

- Volumetric efficiency which includes the influence of heat transfer between the cylinder and the
refrigerant (λq):
λq ≈ Te / Tc (9)

- Volumetric efficiency which includes the influences of refrigerant leakage through the cylinder
and piston clearances, as well as leakage through the suction and discharge valves (λl)

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λl = 1.00 ÷ 0.95 for a pressure ratio pc / pe = 3 ÷ 5. The coefficient λl can be improved with a
suitable compressor shape and increase of the number of revolutions.

The actual mass flow is:

m& = ρ1⋅ V& = V& / v1 , or (10)
m& = λ⋅ V&t / v1 (11)
The actual (refrigeration) capacity:
Qe = m& ⋅qe [kW] (12)
qe is a specific refrigeration effect:
qe = h1 – h4 [kJ] (13)
where h4 and h1 are enthalpies of the refrigerant at inlet and outlet of the evaporator.

With replacing of the equation (11) in (12):

Qe = λ⋅ V&t ⋅qe / v1 (14)

Defining a magnitude of “specific volume refrigeration effect” as:

qv = qe / v1 [kJ/m3] (15)

the actual refrigeration capacity of compressor is [6]:

Qe = λ⋅ V&t ⋅qv (16)

In fact, the last equation is one work characteristics of the reciprocating compressor. For a known
geometric displacement of compressor, the actual refrigeration capacity depends of the volumetric
efficiency (λ) and specific volume refrigeration effect (qv). The structure of λ is described above.
From the equations (13) and (15) it can be concluded that with the magnitude of qv is determined
the type of the refrigeration cycle in which the compressor works and the influence of the
thermodynamic properties of refrigerant.
For example, in a basic cycle with evaporating temperature 0oC and condensing temperature 40oC:
R134a R717
3
qv = 2050 kJ/m 3710 kJ/m3

This means, that to achieve the same refrigeration capacity, the compressor with R134a should have
(approximately) 45% more swept volume than the compressor with R717.

Indicated (compression) efficiency

On the Figure 1 a theoretical (ideal) cycle is presented where the compression is isentropic
(adiabatic). The actual discharge state of the gas is the point 2 where the entropy is bigger than in
the point 2a. There is an exception when is internal cooling of cylinders.
Indicated efficiency considers only what occurs within the compression volume. This is a measure
of the deviation of actual compression from isentropic compression. It is defined as the ratio of the
work required for isentropic compression of the gas to the work delivered to the gas within the
compression volume (as obtained by measurement).

The indicated efficiency is, by definition:

ηi = l t / l i (17)
The indicated efficiency can be calculated by [6]:
ηi = λql +b⋅ te (18)

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where:
λql = λq⋅λl.
b = 0.0010 - for ammonia; b = 0.0025 - for halocarbon refrigerants.

The above equation for ηi is used for an approximate calculation of the indicated efficiency. For a
small value of compression ratio and higher evaporating temperature it is practically unusable.
Orientational values of indicated efficiency are presented on diagrams [6] depending of
compression ratio.

Mechanical efficiency
Mechanical efficiency is the ratio of the work delivered to the gas (as obtained by measurement) to
the work input to the compressor shaft.
ηm = l i / l e (19)
The work input to the compressor shaft (le) is so called effective work.

Effective efficiency
Effective efficiency is the ratio of the work required for isentropic compression of the gas to the
work input to the compressor shaft. Some authors this efficiency call as isentropic efficiency of
compressor.
ηe = lt / le = ηi⋅ηm (20)

An equation for ηe can be derived from the manufacturer catalogues on the base of Qe and Pe
presented in tables. The following equation is one which gives acceptable values:

for Π = pc /pe ≤ 4
ηe = -0.0025153Π4 + 0.0387299Π3 - 0.2279675Π2 + 0.5772372Π + 0.2758929 (21)

for Π = pc /pe > 4

ηe = - 0.03Π + 0.892 (22)

The compressor manufacturers have more reliable values obtained by measurements. However,
they are many families of polynomials connected with models of product range.

Using the above equations, the actual shaft (effective) power of compressor is:
Pe = = m& ⋅le [kW] (23)
or
λ ⋅ V&t (h2 − h1 )
Pe = (24)
v1 ηe
The most useful measure of compressor performance is the coefficient of performance (COP). The
COP is a dimensionless number that is the ratio of the compressor refrigerating capacity (Qe) to the
heat equivalent of the input power (P).
COP = Qe / P (25)
For the open type compressor P is the input power to shaft, for hermetic and semihermetic P is the
input power to motor.

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 3. COMPUTER SIMULATION OF PERFORMANCE FOR A RECIPROCATING
COMPRESSOR

In the manufacturer’s catalogues, the performance of refrigerating compressors is presented

depending of evaporating and condensing temperatures. For a refrigerant with a temperature glide
(as R407C) it is suitable mid or saturated temperatures. So, the refrigeration capacity and power
input to shaft are in the forms [7]:
Qe = Qe (te, tc) (26)
Pe = Pe (te, tc) (27)
Although, on the first view the equations 1 to 27 seem simple, the calculations to achieve the
performances of compressor are large and complex. The reason is the big number of combinations
between evaporating (te) and condensing (tc) temperatures. Furthermore, for each combination of te
and tc the following refrigerant properties should be found: enthalpies at the inlet and outlet of the
evaporator and the compressor, evaporating and condensing pressures, the specific volume at the
suction of the compressor. This could be extended if the compressor works in the cycle with
superheating and subcooling as usually are applied.

Using the mathematical equations in the chapter 2, a simplified flow diagram is created and a
corresponding computer programme is composed which is one of the package “Refrigeration
Software” [8]. This is a universal programme independent to any manufacturers.

With a subroutine CYCL all thermodynamic properties are calculated on the base of Martin-Hou
equation by publications of the IIR [9] and ASHRAE [10] for ammonia, CFCs and HCFCs, and by
technical publications of I.C.I. [11] for HFCs. There are possibilities to choose the type of cycle in
which the compressor will work. These are: basic cycle, cycle with superheating and/or subcooling,
and cycle with a regenerator.

4. PERFORMANCE CHARACTERISTICS ON A CONCRETE EXAMPLE

In order to compare the results obtained by the computer programme with the performance data of
any manufacturer, the compressor model 46 of GEA Grasso is adopted [12].

Input data:
n = 1450 [rpm] – number of revolutions per minute,
ncyl = 4 – number of cylinders,
D = 85 mm – bore,
s = 66 mm – stroke,
c = 0.03 [%/100] – clearance ratio,
Δpo = 0.1 bar – pressure drop through the suction valve,
ηm = 0.95 – mechanical efficiency,
Refrigerant R717 (ammonia),
Results:
The results obtained by the computer programme are compared with the performance data of
Grasso catalogue (Selection software).

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The values of the refrigeration capacity (Eq. 16) are almost identical compared with Grasso
performance data that can be seen on the Figure 2.

The actual shaft (effective) power of compressor Pe is almost identical compared with Grasso data
for tc = 35oC for all evaporating temperature range. There are some deviations for tc = 30oC and
45oC where introducing a correction factor the deviations can be reduced to less than 1%. It is
obviously that an improvement of Eq. 20-22 is necessary because every percent of the energy
consumption is very important in the present time when the energy efficiency is a high level topic.

160

150

140

130

120 Qe_G

110 Qe
Qe, kW

100

90

80
tc=45
70

tc=40
60
tc=30
50
-20 -15 -10 -5 0 5 10
o
te C

Figure 2. Graphic presentation of performance characteristics,

Qe - by Eq. 16; Qe_G - by Grasso data

5. CONCLUSIONS

The performance characteristics of the compressor is in fact the refrigeration capacity and power
consumption depending of the evaporating and condensing temperatures. It is shown that it is
possible to create a mathematical model and corresponding computer simulation of the compressor
performance characteristics. The use of the computer programme is presented on a concrete
example with the reciprocating compressor model 46 of the GEA Grasso company. The results are
compared, and they are in acceptable ranges. Some improvements could be made for the indicated
efficiency, i.e. power consumption.

The use of the computer programme has many advantages. It is available for all reciprocating
compressors independent to any manufacturers, various dimensions and number of cylinders. Many
refrigerants are comprised: HFCs, HCFCs, CFCs and ammonia.

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It is very practical for engineering work. For example, in the manufacturers catalogues the
refrigeration capacity is given for condensing temperatures 30, 40 and 50o, but we need it to be
38oC. Usually the performance data are for a constant superheat suction temperature of 18 or 25oC
which are unusable conditions in practice. The computer programme enables calculations of the
compressor refrigeration capacity in all operating conditions for various suction superheating and
subcooling.

NOMENCLATURE

c clearance ratio, %/100 V& volume flow rate, m3/s

COP coefficient of performance v specific volume, m3/kg
D diameter, bore, m
Δ difference
f correction factor
h enthalpy, kJ/kg η efficiency
i number of cylinders λ volumetric efficiency
l specific work, kJ/kg Π compression ratio
m exponent of polytropic expansion ρ density, kg/m3
m& mass flow rate, kg/s
n number of revolutions per minute , rpm Subscripts
p pressure, bar
P power, kW 1 inlet, suction
Q heat capacity, kW
2 outlet, discharge
q heat per unit, kJ/kg
qv specific volume refrigeration effect, kJ/m3 c condensing
s stroke, m e evaporating; effective
T temperature absolute, K i indicated
t temperature, oC m mechanical
V volume, m3 t theoretical

REFERENCES

1. Fearon, J., Vapour compression systems, their complexities, control and equilibrium,
Refrigeration and Air Conditioning, 1980, no. 12, 28-34.
2. Rozenfeld, L., Vorobev, I., Equilibrium characteristics of refrigerating machines,
Holodilnaja tehnika, 1972, no. 1, 39-43.
3. ASHRAE, ASHRAE Handbook – Refrigeration, American Society of Heating,
Refrigerating, and Air Conditioning Engineers, Atlanta, 1994.
4. Bikov, A., Refrigerating Compressors, Legkaja i Pishtevaja Promishlenost,
Moscow, 1981.
5. Frenkel, M., Piston Compressors, Masinostroenie, Leningrad, 1969.
6. Ciconkov, R., Refrigeration : Solved Examples, University “Sv. Kiril and Metodij”,
Faculty of Mech.Eng., Skopje, 2000.
7. Ciconkov, R., Optimization of the Refrigerating Machines, Doctoral dissertation,
University “Sv. Kiril and Metodij”, Faculty of Mech.Eng., Skopje, 1986.
8. Ciconkov, R., Refrigeration Software (package of computer programmes), University
“Sv. Kiril and Metodij”, Faculty of Mech. Eng., Skopje, 1978-2001.
9. Chan, C., Haselden, G., Computer-based refrigerant thermodynamic properties, Part 1, 2
and 3, International Journal of Refrigeration, No. 1, 2 and 3, 1981.
10. ASHRAE, ASHRAE Handbook – Fundamentals, American Society of Heating,
Refrigerating, and Air Conditioning Engineers, Atlanta, 2001.
11. I.C.I., Technical documentation for HFC refrigerants.
12. GEA Grasso, Catalogues and Selection Software.

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13. Ciconkov, R., Hilligweg A., Kolbenverdichter – Simulation des Leistungsverhaltens beim
Einsatz in einem Verflüssigungssatz, Ki Kälte und Klimatechnik, Ki Luft- und Kältetechnik, No
3, 2003.

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