Refrigeration

Compressors
 Content

• Types of compressors
• Performance of reciprocating compressor
• Some construction details
• Safety features
 Function of compressor
Main function is to move refrigerant in
the system by:
• Remove gas from evaporator
• Raise the pressure of the gas
• Discharge gas to the condenser coil for
heat rejection

High-side pressure
Low-side pressure
 Compressor Types
• Positive displacement
- no reversal of flow
- transfer work by means of hydrostatic force
- e.g. reciprocating, screw, vane
• Non-positive displacement
- reversal of flow is possible
- transfer work by means of hydrodynamic force
- e.g. centrifugal
Types of compressors
Size range
 Reciprocating compressor

• Advantage
– Low cost
– Established technology
– Direct or belt drive
– Good part load and full load efficiency
– Simple control
• Disadvantage
– Many moving parts
– Small flow rate
 Reciprocating Compressors: Hermetic

• Hermetic
- motor-compressor unit is
total sealed, therefore non-
serviceable
- motor cooled by incoming
suction vapor
- use mainly for residential
appliance
 Reciprocating Compressors: Semi-
hermetic
• Semi-hermetic
- Partially sealed, therefore accessible for service
- motor cooled by incoming suction vapor
- larger size range (5-100kW)
 Reciprocating compressor- open
• Open
-External drive; motor separate
from compressor element
- burnt motor can be
easily replaced
- do not rely on suction
for cooling
- can incorporate more
cylinders and higher
output
 Semi-hermetic Reciprocating
Compressor
This is the common compressor
used offshore.
• No problem with shaft seal
leakage
• Runs cooler than open type
( higher service factor)
• Accessible for repair
• Compact
• No pulleys, belts or coupling
• Efficient at part-load and full
load Carlyle 6D/E Model
• Simple control, operation and
maintenance
• Less noise
Semi-hermetic Compressor

Source: Carlyle 06 Model Catalog

Work in Reciprocating Compressor
Work in Reciprocating Compressor
 Clearance Volume Reexpansion
• Clearance volume is
the volume between
TDC piston position
and the cylinder
head
• Expansion of this
volume occurs
initially during the
suction stroke
Effect of Clearance Volume

1-4 Re-expansion
4-3 Suction
3-2 Compression
1-2 Discharge

V c = Clearance volume
Effect of Increasing Clearance
Effect of Suction Pressure

Decreasing Suction Pressure

P1>P2>P3 (i.e. T1>T2>T3)
𝛈1> 𝛈2> 𝛈3 (i.e. efficiency drops)
Effect of Discharge Pressure

Increasing Discharge Pressure

P2>P1 (i.e. T2>T1)
𝛈2< 𝛈1(i.e. efficiency drops)
 Compressor Volumetric Efficiency
Volumetric efficiency
Volume flow rate entering compressor, m/s 3

Displacement rate of compressor, m/s 3
(This is a common measure of effectiven ess
of compressor )
Volume flow rate of refrigeran t
 Displacement rate of compressor x volume tric efficiency
 D x c
 Mass flow rate
M ass flow rate of refrigeran t
Volume flow rate

specific volume of vapor entering the compressor
Displacement rate of compressor x c

vs
Dc

s
where D  compressor displacement rate
 Refrigeration Capacity

The refrigerat ing capacity

 m (Refrigera ting effect)
 m (h1 - h4)
D
 v (h1  h 4)
s
where h1, h4 are enthalpies leaving and entering the evaporator
 Power Required
• The power requirement of a compressor is
= Mass flow rate x work of compression per unit mass
= m ( ∆ h c)

Power of compressor
v
 (D)( )(hc )
s
 Performance of Reciprocating
Compressors
Two important operating variables are:
• Evaporating temperature (pressure)
• Condensing temperature (pressure)
Two important performance characteristics are:
• Refrigeration capacity
• Power requirements
Effect of Evaporating temperature

As evaporating
temperature
decreases
•Volumetric efficiency
drops
•Mass flow rate also
drops
Effect of Evaporating Temperature

The curve of power

has a zero value at 2
points.
•When mass flow
is zero
•When ∆h c is zero

(most systems operate

on the left side of the
peak power)
Effect of Evaporating Temperature

Refrigerating capacity increases significantly with increasing evaporator temperature

Effect of condensing temperature

As condensing
temperature increases,
•Volumetric efficiency
drops
•Mass flow rate also
drops
Effect of condensing temperature

Power required by the

compressor increases
with increasing
condensing
temperature.
A low condensing
temperature is
desirable.
Effect of condensing temperature

Refrigerating capacity always

decreases with increasing
condensing temperature.
A low condensing
temperature is desirable.
manufacturer’s data
Performance Map
 Compressor Performance
•For any one compressor, volumetric efficiency is not a
constant. It changes with operating conditions of the system
•The refrigerant used also has an effect on efficiency value.

•Due to piston and valve leakage and heat loss, actual

efficiency drops by another 10-15%

• Approximately, actual compressor efficiency=actual

volumetric efficiency
Actual compressor efficiency

Source: Refrigeration & Air Conditioning by WF Stoecker

 Compressor Safety Control
• Low/high pressure switches
• Low and high temperature switches
• Low oil pressure switch
• Pump-down control
• Crankcase heater
• Motor overload protection
 Pressure Switches
• Low
– When suction pressure drops below a preset
value, compressor is stopped
• High
– When discharge pressure approaches a high level,
the cutoff pressure, compressor is stopped
 Temperature switches
• Low temperature at suction can result in
frosting
• High discharge temperature can result in
– Oil breakdown
– Excessive wear
– Reduce life of discharge valves
• Most compressor has limit on discharge
temperature (265 F for Carlyle compressors)
 Oil Pressure
• Compressors need lubricant for the following
reasons
• Lubrication of bearings
• Remove heat
• Assist with gas sealing
• Low oil pressure switch will stop the
compressor if oil pressure fails to reach a
predetermined level within a certain time
period
 Crankcase Heater

•To reduce the migration of refrigerant

to the crankcase
•Heaters are commonly fitted to
crankcase
•Remains in operation whenever the
compressor is idle
 Pumpdown Control
Pump-down control helps to prevent liquid
slugging during startup.
• When the system is shut down, the suction
solenoid valve is closed first.
• Compressor continues to pump the refrigerant
to the condenser.
• As the suction pressure drops below the cut-in
pressure, the compressor stops.
 Compressor Capacity Control
When the system load on the cooling coil
doesn’t match the full load capacity of
reciprocating compressor, the capacity
modulation is:
 On/off control
 Cylinder unloading
 Suction cutoff unloading (holding the valve open)
 Hot gas bypass
 Variable speed drive
Multiple Compressor ON/OFF
Cylinder Unload De-energized
Cylinder Unload Energized
Cylinder Unload
Suction Cut-off Unloading
 Hot Gas Bypass

Hot gas bypass valve

Evaporator Condenser
Bypass into evaporator inlet
Bypass into suction line
 Variable Speed Compressor
• Vary the speed to match precisely match the
load
• For reciprocating compressor, the lowest
speed shall not affect the oil lubrication
system
Why Compressor Failed?
Compressor Failure: Causes

•Is system design/

installation/ operation
OK?
•Are components
properly matched?
•Which component
malfunction?
 Causes of Compressor Failure
Mechanical issues
1. Liquid floodback
2. Dirt (acid or moisture)
3. Overheating
4. Lack of lubrication
Electrical unbalanced
1. Voltage
2. frequency
Refrigeration: What can go wrong?
Oversized
TXV

Non-condensable Liquid
slugging Low load

Dirt
High gas
Moisture return
temperatur
e
Contamination Refrigeration Overheating
(mechanical)
High
issues
discharge
temperatur
e
Low oil Loss of
pressure Lubrication

Poor oil
return
 Electrical: What can go Wrong?

Winding overheat

Unbalanced High
voltage Electrical Amperage Overheat
Motor failure Problem
Low dialectic
resistance
Low dialectic
resistance

Motor failure
 Solving the Problem
If the compressor is replaced
without attending to the root cause,
surely the new compressor will also
fail.
1. Identify the root cause
Lubricating oil analysis
Tear-down analysis
System diagnosis
2. Repair & Replace
3. Clean the system before restart
Seizure of bearing surfaces
At connecting rod and crankshaft

Broken fragments