Failure Analysis Report for ACCU Compressor Failure

Date: 22nd Sept. 2016

Objective:

To identify various causes of Failure of Bitzer Compressor installed in Gas Turbine / Steam Turbine
Building & Electrical Building

To identify Various measures / Steps to be taken to mitigate the failure.

System Introduction

Gas Turbine and Steam Turbine Buildings each are provided with 6 Nos. of AHU’s (Air Handling Unit),
with Each AHU having its own Air Cooled Condensing Unit (ACCU) (compressor). The AHU draws fresh
Air from outside the building, Filters & cools it and provides it to the Building at a temperature of about
28 Degrees. The Building Consist of opening at the roof top from where Hot air escapes. Hence this
system works as an Open loop.

Normally Five AHU units are running while one Unit is available as a stand by. Also ACCU of the
respective AHU run based on the temperature set point of 28 Degree. Once the Building temperature
reaches the set point, the ACCU stops and starts back again if temperature increases by 1 Degree

HVAC in Electrical Building is divided into two Sections. Each Section Consist of having 2 AHU’s and Each
AHU has Two ACCU’s. The AHU draws Air from the Building as Return Air and from Outside the building
as Fresh Air. Hence this system works are a Close Loop system.

Failures Observed:

1. Equipment KKS: 71SAM03AN002

a. Failure Date: Feb. – 2014 (During Commissioning)
b. Defect Description: Motor winding failure
c. Observations and Corrective action: ACCU Compressor was replaced.
d. Repair Time & cost: - Not known.
2. Equipment KKS: 81SAM05AN002
a. Failure Date: May 2015
b. Defect Description: MCC feeder tripping. Stator winding found failed / burned. (Ref. WD-869,
WO#9054)
c. Observations and Corrective action: Stator and Rotor was replaced.
d. Repair Time & cost: May 6, 2015-August 10,2015 & cost not known
3. Equipment KKS: 70SAM03AN002
a. Failure Date: October 2015
b. Defect Description: Abnormal sound observed. Bearings failed and replaced. (Ref. WD-942 and
1330, WO#13258 and 20919)
c. Observations and Corrective action: Compressor taken out and bearings were replaced.
d. Repair Time & cost: October 14,2015- November 1, 2015 and August 6, 2016-August 25, 2016 &
cost not known

1|Page
 Failure Analysis Report for ACCU Compressor Failure

4. Equipment KKS: 70SAM02AN002

a. Failure Date: November 2015
b. Defect Description: Abnormal sound observed. Compressor taken out for inspection. (Ref.
WO#13743)
c. Observations and Corrective action: Servicing done. Bearings, oil filter and pressure relief
valve replaced.
d. Repair Time & cost: November 16, 2015- April 20, 2016 & 17825 AED

5. Equipment KKS: 05SAB02AN003

a. Failure Date: March 2016
b. Defect Description: Compressor was tripped and motor IR found low. Inspection done and
found motor failed and mechanical component damaged. (Ref. WO#17439)
c. Observations and Corrective action:
 Bearings, Oil Filter, PRV replaced
 Male Rotor Machined due to scratches.
 Stator / Rotor Replaced.
 'The mechanical breakdown resulted in Axial Clearance Defect
 The STATOR damaged due to over voltage - SHORT CIRCUIT
d. Repair Time & cost: March 3, 2016- August 25, 2016 & 46500 AED

6. Equipment KKS: 71SAM04AN002

a. Failure Date: June 2016
b. Defect Description: ACCU was tripping frequently on Oil Flow Fault which occurs either due to
Voltage unbalance or High Motor Winding Temperature. Relay was replaced and fault was
attended. Further Compressor was observed with abnormal noise. Compressor was removed. .
(Ref. WO#19529) Observations and Corrective action: Servicing done. Bearings, oil filter and
pressure relief valve replaced.
c. Repair Time & cost: June 7, 2016- August 25, 2016 & 15815 AED

7. Equipment KKS: 71SAM01AN002

a. Failure Date: July 2016
b. Defect Description: ACCU was tripping on LP. Compressor motor was found failed. (Ref.
WO#20593)
c. Observations and Corrective action: Stator rewinding and repair was done.
d. Repair Time & cost: July 23, 2016- September 3, 2016 & 17865 AED

On May 2015, 81SAM05AN002 compressor failed during warranty period (WD-869, WO#9054). Stator
winding was found burnt which led to tripping of the MCC feeder of ACCU. Stator rewinding and repair
was done.

2|Page
 Failure Analysis Report for ACCU Compressor Failure

On October 2015, abnormal sound was observed from 70SAM03AN002 ACCU. EPC sent the
compressor for servicing and replacement of bearing under warranty (WD-942, WO#13258).

On November 2015, abnormal sound was also observed in 70SAM02AN002 compressor

(WO#13743). Compressor was taken out for inspection by OEM authorized service center. Some
mechanical components failure was observed. Servicing was done and replacement of bearings, oil filter
and pressure relief valve were replaced.

On March 2016, compressor for 05SAB02AN003 got tripped and motor IR was found low
(WO#17439). After checking, it was found that motor got burnt (due to short circuit) and some internal
mechanical damage was found. Servicing, stator rewinding and replacement of damaged components
were done.

On June 2016, 71SAM04AN002 ACCU was tripping frequently (WO#19529). Inspection was
carried out by authorized service center and some mechanical failures were found. Bearings, oil filter
and pressure relief valve were replaced and servicing was done.

On July 2016, 71SAM01AN002 was found tripping on low pressure fault and motor IR was found
low (WO#20593). Compressor was inspected and stator winding was found burnt. Expansion valve for
the AHU was also found damaged giving low pressure alarm for the unit. Stator was sent for rewinding
and repair and expansion valve was replaced.

Preventative Maintenance Plan:

System Observations:

 During Peak Summer GT/ST Building HVAC System are not able to meet the set point and due to
which ACCU compressors are continuously running. Continuous operation of compressor will
lead heat up and mechanical and Electrical Damage. Return gas temp. must be 55 degree.
 Temperature Element of Expansion valve not properly touching the return line. All Expansion
valves Temperature element has to be checked and aligned with the return line.


The ACCU compressors were operated as per O&M manual and as per manufacturer’s
recommendations. All the settings were kept as per design. Preventive maintenance is carried out as per
the manual. System has to be reviewed to determine the underlying root causes of such frequent
failures.

Action Plan

 Overhauling of Six Compressor Per year to cover total 30 compressors in Five years time
 Oil replacement of Compressor Once in two years.

3|Page
 Failure Analysis Report for ACCU Compressor Failure

 Train Manpower to enable opening of Screw Section of the Compressor which will enable Onsite
Repair works for Bearings.
 All Condenser FAN pressure Switch / HP/LP pressure switch calibration to be done.
 Discharge Gas Temperature Sensor for All Sensors to be Checked for calibration.
 Antifreeze protection to be provided. Option of Outlet temperature sensor installation
 Incase the ACCU Shutdown due to Flow Fault which may be due to any fault in the flow switch
or failure of AHU due to any reason, the ACCU is shutdown without pump down.
 ACCU is tripping after tripping seconds which may be too long and there are chances of Liquid
entering the compressor and further electrical and mechanical damage.
 Strategy For checking healthiness of the compressors during winter.

4|Page