Automatic protection for compressors

and refrigeration Equipment

 Automatic protection
• Automatic protection is a must with the
serious performance of compressors and
other refrigeration equipment.

• Protection is done through:

o Stopping the compressor.
o Controlling equipment.
o Opening safety valves.
Reasons that lead to serious performance
in the field of refrigeration
 1-Protection from hydraulic thrust
• It is considered one of the reasons which leads to compressor failure.
• It is caused due to the compressor suction for wet refrigerant ( gas+ droplet of liquid)
• Protection is done through the control of liquid refrigerant flowrate to the evaporator.
• For medium and large refrigeration units, liquid separator is located in compressor suction
line.

Automatic liquid
refrigerant separation
• This is an automatic refrigerant liquid separation system.
• Liquid separator works on the separation of liquid from the refrigerant coming out of
the evaporator. The liquid is drained to the drainage receiver. When the liquid fill the
receiver, it send 2 signals to liquid controller (L.C) . The first one is send to (S.V) to stop
the refrigerant liquid flow coming from the condenser . The second one is send to
(S.V ) 2 to run the pump . The liquid is send to the evaporator through the expansion
devices. The non return valve prevents the back flow of refrigerant to the pump when
stopped.
 2-Protection from excessive discharge pressure
Excessive discharge pressure is created due to :
• Low cooling water mass flow rate.
• Leakage of air inside the condenser.
• Operating the compressor while discharge valve is closed.
• Compressors are prepared with a safety valve (HPC) which links the suction side
with the discharge side.
• If the difference between suction and discharge pressures increases above 16 atm
for ammonia and 10 atm for refrigerants, HPC [ High pressure controller] stops the
compressor through M.S
• When the discharge pressure increases above its limit, the HPC stops
the compressor through MS control method.
• It can be called as High pressure controller , Pressure Controller,
High pressure cut-out or High pressure relay.
• It must be located along the discharge line before the discharge
valve ???
 3-Protection from low Suction pressure
low Suction pressure is un preferable due to :
• It causes air leakage through the oil seal into the compressor .
• Air mixes with oil changing the properties of oil required for the lubrication of
cylinders and causes low performance for the oil pump .
• Low suction pressure must be to stop the freezing of salt solutions or the chilled
water inside the evaporator coils.

Air Leakage
When the suction pressure decreases below its limit, the LPC stops the
compressor through MS control method.
If the difference between suction and discharge pressures increases
above design pressure values, LPC [ low pressure controller] stops the
compressor through M.S.
It can be called as Low pressure controller , Pressure stat or Low
pressure relay

Crank Case Pressure Regulator

It is installed in suction lines before compressors to prevent suction pressure to be

higher than design level.
Low High pressure Controller
4-Protection from excessive vapor temperature after compressor

The increase of discharge temperature tends to increase the discharge

pressure.
The allowable discharge temperature for ammonia is 100 -130oC and
below 80oC for other refrigerants because the lubricating oil
decomposes at 120-180oC.
Causes:
• Too little refrigerant can cause the compressor to overheat. A properly
charged system allows suction gas to keep the compressor windings
cool.
• The oil is found in the crankcase of the compressor, which provides
lubrication to its moving parts. If a system loses its refrigerant and oil
then the compressor will cycle on its overload and this can cause the
mechanical parts to seize (Shrink) without causing any electrical
damage to the compressor's windings.

Cut open compressor with Cut open compressor with overheated

Cut open compressor with an
undamaged windings windings caused by a mechanical failure.
isolated point of failure (surge damage)
Locked rotor
• A situation called an acid burnout commonly occurs with improperly evacuated
systems or poor maintenance practices. Acid occurs in systems when the moisture-
contaminated refrigerant is compressed and circulated in the system over a period
of time or excessive heat causes the oil to breakdown which then causes the
unwanted chemical reaction.

Condenser and lines up to the liquid drier where full of black oil and big chunks of black powder
5-Protection from oil system failure & Lubrication Problems

• The control way for the

temperature of oil inside the
compressor. The sensor is
immersed in the oil inside the
compressor. If the oil temperature
decreases , the T.c stops the
compressor and a heater is started.
The oil temperature must not
decrease below 5-6 oC.

• PDC works on the presence of pressure

difference between oil lines after the oil
pump and compressor crankcase.
Compressor stops when the pressure
difference decreases below the
allowable limit which is 1-1.5 kg/m2.
 York reciprocating compressor detailed failure analysis
Screw rotors will become extremely hot, lose their critical
discharge end clearances and seize. Failures of this type are most
often due to a complete blockage in the oil flow such as a bad oil
stop valve or oil pump (where applicable), plugged oil filter
assembly, cooler, air end injection port or oil pipework
 6-Protection from lack of cooling water
• Water cooled Reciprocating compressors must be protected
against cooling water cutout . For case A , Flow controller ( F.C)
stopping the compressor in the case of the cooling water
cutout. For case B , Pressure controller stops the compressor in
the case of the decrease of cooling water pump pressure.

(A) (B)
 7-Protection from freezing of refrigerant in evaporator tubes:
• The freezing of cooling medium in the case of brine or water inside evaporator coil
tends to the failure of the evaporator and the refrigeration unit.
• When the suction temperature decreases below its limit, the TC limits decrease of
brine temperature and stops the compressor.
• When the suction pressure decreases below its limit, the LPC stops the compressor
through MS control method.
• When the refrigerant flow rate decreases across the evaporator below its limit, the
F.C stops the compressor through MS control method.
 8-Compression Ratio Problems
• Compression Ratio Problems can be caused by:
• Poor System Design :Undersized Condenser
• Poor Piping Design: High Head Pressure- Low Suction Pressure
• Low Air Flow: Dirty Filters, Coils, Fans
• Refrigerant Overcharge: Flooded Condenser

High Compression Ratios:

• Effects Of:
• Excessive Compressor Heat
• Excessive Component Wear
• Results:
• Motor Failure
• Compressor Bearing
Failure
• (Low COP)
 9-Refrigerant Slugging
Slugging is the result of trying to compress
liquid refrigerant and/or oil, in the cylinders.
Slugging indicates extreme flood back in air-
cooled compressors and severe flooded
start on refrigerant-cooled compressors.
When slugging occurs in a semi-hermetic
compressor, liquid is between the top of the
piston and bottom of the valve plate.

• Effect:
Oil Dilution-Oil Foaming-Hydrostatic
Compression
• Result in:
Bearing Wash And Failure &
Rusted valve components due to moisture in system
Compressor Valve Failure
 10-Refrigerant Restriction
Caused By:
• Broken TXV Sensing Bulb
• Loose TXV Sensing Bulb
• Wrong TXV Setting
• Undersized Piping
• System Contamination
• Low Evaporator Airflow
• Incorrect Orifice Plate

Effect:
• Motor Overheating
• Oil Loss
• Excessive Superheat
• Low Refrigeration Effect
• Low Efficiency
Moisture Presence in the cycle problems
 11-Superheat
• Superheat Is: The heat added to a refrigerant past point of
vaporization
Excess Superheat
causes motors to overheat and burn out
Inadequate Superheat
Causes Compressor Slugging and Valve Breakage
Evaporator Coil Refrigerant Level

Proper System Low Refrigerant Excess Refrigerant

Superheat Flow Flow
12 - 14 F High Superheat Low Superheat
(6 - 8 C) 20 - 30 F 0-1F
(11 - 17 C) (0 - 1 C)
Measuring Superheat
 12-Sub cooling
• Sub cooling is: the heat removed from a refrigerant
after it has reached its condensation point.
Excess Sub cooling:
Indicates refrigerant remaining In condenser too long
Effect on head pressure depends on the cause
Insufficient Sub cooling:
Causes flash gas to develop in the liquid line due to pressure
drop.
 Sub cooling
(Increased Liquid)
High Head Pressure
Less Condenser Surface

Sub cooling
(Cold Weather)
Low ambient temperature
causes liquid temperature
and head pressure to drop
Good Vs. Bad Coil Conditions

Pressure Drop Causes Flash Gas

 13-Under sized refrigerant suction line
• Hermetic compressors in refrigeration systems are cooled by the
suction gases coming back from the evaporator.
• When less vapor volume is returned to the compressor it not only
improperly cools the windings creating a potential burnout but it also
lowers the amount of refrigerant the compressor is pumping, lowering
the efficiency and capacity of the compressor and the system.
 14-Under sized condenser, oversized evaporator coil
• Example of this is a 2 ton condenser matched with a 3 ton or larger evaporator coil.
The condenser is not going to be able to pump enough refrigerant to properly feed
the coil, regardless of the metering device, causing a high superheat, high coil
temperature with little to no humidity removal, high supply temperature and
insufficient cooling of the compressor windings.
 Automatic signals in refrigeration systems
• Automatic signals may be warning signal, breakdown signal or execution signal.
• Warning signals give an indication that the controlled parameter had approached
from the hazardous value on the refrigeration unit.
• Warning signals often used with large refrigeration units.
• Execution signals are required in all refrigeration units
regardless the automatic control degree full or partial.
• Signals can be Light signals (lamps) or sound signals in the
case of breakdown. Lamps can be colored: yellow, green or
red. Green color for normal performance and red color for
hazardous performance
• If warning signals were not taken into account, controlled
parameters change and different protection ways operate
on stopping the compressors and giving breakdown
signals. Technician works on Repairing faults and
restarting the compressors .
Automatic control systems in refrigerating systems
Rename each part !!!
 LPC

BPV Discharge

M.S
T.C

F.C In

Brine Motor Compressor

Evaporator