3/12/22

} There are mainly two types of compressor’s are used in

Ammonia i.e. Screw and Reciprocating
Why Ammonia Compressor fails?

Dhananjay S. Deshpande

Mobile no: 09833889734 / 09769288737

Email: scorpioes1977@gmail.com
technexhvac@gmail.com

1 2

1 2

3 4

3 4

5 6

5 6

1
 3/12/22

} Compressor failure is a big, expensive problem in the
refrigeration & Air conditioning industry. Compressor
manufacturers, repairer are concerned about failure of
their product & services, since it can reflect negatively
on them.
} Most of the Compressors were still being “killed” by
system problems. System problems, if corrected, would
have saved the compressor.
} Replacement of compressors failed at a rate of
four times greater than that of original
compressors if we are not taking proper care.
} The Compressor
} Each compressor manufacturer specifies application limits in
which the compressor may be operated safely. The most
important limits are protected by safety controls and the
operator must make himself familiar with the operation, set
point and function of the following:
} A. Low (suction gas) pressure cut-out
} B. High (discharge gas) pressure cut-out
} C. Low differential oil pressure cut-out
} D. High oil temperature cut-out
} E. High discharge temperature cut-out
} F. Any additional safety controls which may be fitted

7 8

7 8

} Temperature or Pressure Changes

} Many factors such as mechanical malfunction, ambient temperature,
or product load can have an effect on the normal operating
temperatures/pressures of the refrigeration system. Every plant
operator should understand:
} 1. The normal operating pressures & temperatures in system
} 2. The causes and effects of a change in temperature or pressure in
system:
} The low pressure (low side) part of the system
} The intermediate pressure part of a two-stage system
} The high pressure (high side) part of the system
} 3. what action to take upon a change in temperature or pressure in
order to restore the system to normal

9 10

9 10

• Incorrect application
• Incorrect design, installation and operation.
• System component failures or application
• Malfunctioning, improperly applied or wrong settings in
controls.
• Improper maintenance
• Incorrect diagnosis

11 12

11 12

2
 3/12/22

• Most Failures are preventable! } Many compressors run thousands of hours with out oil
changes, new parts, a tune up or any other form of
• Compressor failures can normally be traced back to: maintenance.

o 1. Refrigerant Slugging / Flooded start } Preventative maintenance is the key to compressor

o 2. Flood back Longevity.
o 2. Lack of Lubrication
o 3. System Contamination
o 4. Overheating

13 14

13 14

} Slugging always occurs on startup, but a very rapid

change in system operating conditions can also cause
slugging.

} A loud knocking noise heard at the compressor start up

is evidence of slugging. The noise is produced by
hydraulic compression – the compressor is trying to do
something it wasn’t designed to do – compress a liquid.

15 16

15 16

} Refrigerant will condense in any cold part of a system

during the off cycle. The coldest parts of the system are
the evaporator and suction line. On the next start-up,
this liquid mixture will return to the compressor as a slug.
} Extremely high pressure will be reached in a cylinder. A
hole may be punched in the top of a piston. More often,
the suction, discharge, or both valve reeds will be bent
or broken.
} If a compressor continues to run with this damage, the
cylinder head will found very hot compared to any other
cylinders. Slugs can break connecting rods, even
crankshafts.

17 18

17 18

3
 3/12/22

} Improper setting / installation of level controllers or hand
expansion valve.
} Also liquid slugging can prevent by installing correct size
of accumulator or surge drum in suction line.
} Flooding is the continuous return of liquid refrigerant as
droplets in the suction vapor instead of all super-heated
vapor.
} This flood back washes oil off of piston and cylinder liner
surfaces.
} All bearing surfaces will prematurely wear. Resulting in
Overheating of compressor component.
} On a compressor with a crankcase sight glass, flooding
can be observed as constant foaming of the oil during
run.

19 20

19 20

} Avoid low load on the evaporator.

} Oversized Metering device
} Low flow through Evaporator

Liquid flooding
Causes radial
forces on the
rotors and lend
them to seize in
the housing on the
flange and slider

21 22

21 22

} Major cause of compressor failure could be Loss or lack Due to loss of

of lubrication, especially if we include flood back and the oil film from
flooded starts. Other causes of lack of lubrication could cylinder liner,
be as simple as not enough oil in the crankcase. rubbing
happens
} During operation, always oil leave should be visible in between piston
the crankcase, separate oil from ammonia in oil rings and
separator and returning to the compressor at the same cylinder liner
rate that it left the compressor. and cylinder
liner dimeter
increases.

23 24

23 24

4
 3/12/22

} Maintain adequate oil level in the compressor sump or in

oil separator in case of screw compressor.

} Reasons for oil carryover in the system is that the oil

separator mal functions, worn out piston rings.
} Oil pump failure or dirty oil filters in the compressor,
repair/replace the pump and oil filters.

25 26

25 26

} Contamination was found to be the major cause of

compressor failure.
} Refrigeration system should contains only two
things should be inside refrigeration circuit is
refrigerant and oil. Anything else is a contaminant!
} The presence of water in a system can lead to other
contaminations due to the formation of oxidation,
corrosion, the refrigerant decomposition.
} Chemical breakdown results from excessive heat ,
results in oil and refrigerant breakdown, Ferric oxide
(Fe2O3) - (Red iron oxide) or Ferrous oxide (Fe2O4) -
(iron oxide black), acid formation creates higher wear of
the bearing surfaces.

27 28

27 28

29 30

29 30

5
 3/12/22

• If the heat Is high enough, the oil breaks down

chemically.

• Compressors should operate within the safe limits of

the discharge temperature.

• Oil and refrigerant break down In severe overheating

and create CARBON and ACIDS, Which can cause
harm throughout the entire system.

31 32

31 32

33 34

33 34

Increased friction, resulting in excessive wear, excessive

energy consumption, and the possibility of premature
breakdown of equipment

Excessive wear on bearings and seals, leading to premature

failure

Premature shaft and coupling failure

Excessive lubricant leakage from shaft seal

Failure of coupling and foundation bolts

Increased vibration and noise

35 36

35 36

6
 3/12/22

Points to be checked on compressor are:

Drive end Male rotor bearing section, fe-male rotor bearing

section
Non-drive end Male rotor bearing section, fe-male rotor bearing
section
Oil injection point
Center of the compressor
Near shaft seal on rotor shaft

Effects of vibrations:

Premature failure of the compressor, bearings failure, screw

rotors failure, gas & oil leakage from mechanical joints on the
compressor and breakages on the pipes connected to the
compressor

37 38

37 38

} The most important factor contributing to a safe operation } Daily:

may be the operator's knowledge of preventive maintenance.
Each component of a system requires routine checking,
cleaning and possible replacement. } HP, LP & OP pressure
} Periodic checking / changing of oil
} Check pressure drops across condensers & evaporators } Refrigerant level and oil level
} Draining of oil from various components
} Purging of non-condensable gases } Water level in cooling tower / evaporative condenser
} Checking of safeties
} Removal of scales from condensers } Flow of media to be cooled
} Checking of Vibration levels in the compressor
} Annual checking of the compressors as per manufacturers } Specific gravity of brine.
guidelines.

39 40

39 40

} Weekly: } Monthly:

} Air purging
} Cleaning of filters, strainers of pumps, sump of the
cooling tower or evaporative condenser if required.
} Draining of oil

} Checking tension of compressor drive belts. } Sump cleaning of Cooling tower / evaporative
condensers
} Checking the proper oil return to the compressor from oil
separator. } Checking of oil filters, liquid line strainers.

41 42

41 42

7
 3/12/22

Quarterly:
}
} Half Yearly:
} De-scaling of condenser.

} De-scaling of water jacket of compressor head. } Checking of earth leakages.

} Cleaning of pump impeller.

} Cleaning of switch gear contacts and electrical
} Greasing of motors, pumps. panels.
} Adjust belt tension of compressor and motor if required.
} Checking of compressor and motor alignment.

43 44

43 44

} Yearly: To avoid repeated compressor failure, repair work on site may

only be carried out if the fault is exactly known other wise
serious damage to the compressor.
} Replacement/checking of internal parts of
compressor Possible Repair Works:
q Exchanging the check valve
} Pressure testing of receiver, oil separator &
condenser – factory act. q Exchanging the pressure relief valve

} Painting of equipments and pipelines as per q Exchanging oil flow switch / oil level switch
standard colour code with arrow mark.
q Repairing / replacement of shaft seal.
} Pipe line insulation repair / replacement. q Checking the thrust bearing clearance

45 46

45 46

m Oil Filter – & Replacement m Shaft Seal

m change after first 50...100 h (operating hours) recommended m Leakage tolerable up to 0,2 cm3 /h
m Inspection intervals -- depending on application
m check all 5.000 h (or yearly respectively)
l MT & LT all 10.000 h
l replace in case of pressure drop > 0.5 bar m Replacement after 20.000 .. 40.000 hrs. recommended

m Oil Change m Pressure Relief Valve

m With NH3 (unsoluble lubricants) m Maintenance free
l first change after 100 running hours (oil and oil filter)
l Opening pressure differential Dp = 28 bar
l Tightness check recommended after actuation
l topping when required -- change after approx. 3000 running hours (or
(è High pressure cut-out)
yearly respectively)
m Replacement after 100.000 h recommended

47 48

47 48

8
 3/12/22

Thank You

Technex HVAC&R Engg Works

Dhananjay S Deshpande

Email ammoniaindia@gmail.com
scorpioes1977@gmail.com

49

49