Refrigeration compressor common 5 kinds of failure and failure analysis
DATE:2024-07-18
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1. liquid return
Definition: Liquid return refers to the phenomenon of liquid refrigerant entering the compressor directly. Under normal circumstances, the refrigerant should be completely vaporized in the evaporator, but when the evaporator temperature is too low or the refrigerant charge is too much, the liquid refrigerant may be sucked into the compressor without being completely vaporized.
Mechanical damage: liquid refrigerant is not compressible, when it is sucked into the compressor, it will impact on the internal parts of the compressor (e.g. piston, valve) like a “hammer blow”, this phenomenon is known as “liquid shock”, which may cause serious mechanical damage.
Reduced efficiency: liquid refrigerant occupies the volume of the compressor, reducing the amount of gas actually compressed, thus reducing the efficiency of the compressor.
2. Liquid compression
Definition: Liquid compression is a condition that occurs when a compressor compresses liquid refrigerant. This is usually due to a failure of the evaporator to completely vaporize the refrigerant, or improperly regulated refrigerant flow.
High Pressure Hazard: Liquid refrigerant can heat up dramatically during compression, resulting in an abnormally high system pressure that may trigger a high pressure protection switch or safety valve.
Loss of efficiency: Liquid compression reduces the compressor's compression ratio and efficiency because it takes more energy to compress liquid refrigerant than gas.
3. Poor lubrication
Definition: Poor lubrication means that the lubrication system inside the compressor is unable to supply enough lubricant to the various moving parts, such as bearings, crankshafts and pistons.
Overheating: Lack of lubricating oil increases friction, leading to overheating and accelerated wear of compressor components.
Mechanical failure: Excessive friction and wear can reduce the reliability of the compressor and eventually lead to mechanical failure, such as burnt out bearings or seized pistons.
Loss of efficiency: Poor lubrication increases the power consumption of the compressor and reduces its overall efficiency.
4. High temperature carbonization
Definition: High temperature carbonization refers to the phenomenon of solid carbon deposits formed by the decomposition of hydrocarbons in the lubricant under high temperature conditions.
Lubrication failure: Carbon deposits will adhere to the internal surface of the compressor, destroying the original lubrication layer, resulting in reduced lubrication.
Overheating and failure: The accumulation of carbon deposits will aggravate localized overheating, which may lead to premature failure of compressor components such as piston rings and bearings.
Blockage of oil passages: Carbon deposits may also block oil passages, further affecting the lubrication and cooling of the compressor and ultimately leading to a reduction in system performance.
5. System uncleanliness
Definition: System uncleanliness refers to the presence of various impurities in the refrigeration system, such as dust, metal shavings, welding slag, oxides, etc., which may originate from the installation, maintenance process or system aging.
Clogging: Impurities can clog filters, expansion valves or heat exchangers, resulting in a blockage of refrigerant flow and reduced system efficiency.
Wear and corrosion: when circulating in the system, impurities can accelerate wear and corrosion of pipes and components, shortening system life.
Performance degradation: heat exchange efficiency is reduced, cooling effect is weakened and energy consumption is increased.
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Definition: Liquid return refers to the phenomenon of liquid refrigerant entering the compressor directly. Under normal circumstances, the refrigerant should be completely vaporized in the evaporator, but when the evaporator temperature is too low or the refrigerant charge is too much, the liquid refrigerant may be sucked into the compressor without being completely vaporized.
Mechanical damage: liquid refrigerant is not compressible, when it is sucked into the compressor, it will impact on the internal parts of the compressor (e.g. piston, valve) like a “hammer blow”, this phenomenon is known as “liquid shock”, which may cause serious mechanical damage.
Reduced efficiency: liquid refrigerant occupies the volume of the compressor, reducing the amount of gas actually compressed, thus reducing the efficiency of the compressor.
2. Liquid compression
Definition: Liquid compression is a condition that occurs when a compressor compresses liquid refrigerant. This is usually due to a failure of the evaporator to completely vaporize the refrigerant, or improperly regulated refrigerant flow.
High Pressure Hazard: Liquid refrigerant can heat up dramatically during compression, resulting in an abnormally high system pressure that may trigger a high pressure protection switch or safety valve.
Loss of efficiency: Liquid compression reduces the compressor's compression ratio and efficiency because it takes more energy to compress liquid refrigerant than gas.
3. Poor lubrication
Definition: Poor lubrication means that the lubrication system inside the compressor is unable to supply enough lubricant to the various moving parts, such as bearings, crankshafts and pistons.
Overheating: Lack of lubricating oil increases friction, leading to overheating and accelerated wear of compressor components.
Mechanical failure: Excessive friction and wear can reduce the reliability of the compressor and eventually lead to mechanical failure, such as burnt out bearings or seized pistons.
Loss of efficiency: Poor lubrication increases the power consumption of the compressor and reduces its overall efficiency.
4. High temperature carbonization
Definition: High temperature carbonization refers to the phenomenon of solid carbon deposits formed by the decomposition of hydrocarbons in the lubricant under high temperature conditions.
Lubrication failure: Carbon deposits will adhere to the internal surface of the compressor, destroying the original lubrication layer, resulting in reduced lubrication.
Overheating and failure: The accumulation of carbon deposits will aggravate localized overheating, which may lead to premature failure of compressor components such as piston rings and bearings.
Blockage of oil passages: Carbon deposits may also block oil passages, further affecting the lubrication and cooling of the compressor and ultimately leading to a reduction in system performance.
5. System uncleanliness
Definition: System uncleanliness refers to the presence of various impurities in the refrigeration system, such as dust, metal shavings, welding slag, oxides, etc., which may originate from the installation, maintenance process or system aging.
Clogging: Impurities can clog filters, expansion valves or heat exchangers, resulting in a blockage of refrigerant flow and reduced system efficiency.
Wear and corrosion: when circulating in the system, impurities can accelerate wear and corrosion of pipes and components, shortening system life.
Performance degradation: heat exchange efficiency is reduced, cooling effect is weakened and energy consumption is increased.