12. PRECAUTIONS TO PREVENT
FAILURES ON COMPRESSORS
Our analysis of 'Field Failures' has shown that 98% of failures
on KC compressors have occurred due to 'SYSTEM DIRT'
entering the compressor and thereby damaging the bearings,
connecting rods, pistons, crankshaft, valves etc.
12.1 SOURCE OF ENTRY:
(i) The dirt enters from the inter connecting pipe lines,
various joints, condensers, chillers coils etc. and consists
of metallic sand in fine and coarse condition, welding slag,
copper powder etc.
(ii) The contractor/erection staff do not clean the various pipes
thoroughly before welding, complete draining of water
from condenser, chiller after these are pressure tested,
flanged joint are kept open during other masonry work or
digging of trenches for cable laying etc, in the vicinity of
AC/ refrigeration plant.
12.2 PREVENTION:
(i) Source of entry has to be avoided.
(ii) The system has to be thoroughly flushed off before
connecting pipes to compressor suction and discharge
line.
(iii) In addition it is preferable to put a cloth bag inside the gas
strainer (The cloth bag should be slightly oversize than
the strainer ID) to catch very fine dirt particles coming
from the system. This bag should fit tight at the place
where '0' ring of strainer fits.
Note: (a) cloth must be fine cotton cloth/Mulmul.
(b) This cloth should not be fitted on External
OD of gas-strainer, as this will enter in the
compressor suction zone.
12.3 PREVENTION FOR COMPRESSOR :
(i) Before the very first start of compressor do not forget to
fill oil in shaft seal through the plug provided on shaft
seal cover and suction and discharge oil filter chambers.
(ii) After initial run of compressor (with refrigerant in
system and correct brand of refrigeration oil) for 4 hrs.
duration, pump down the system and stop the
compressor.
(iii) Drain oil from compressor.
(iv) Open side covers/inspection covers.
(vi) Open liquid line strainer, clean and refit.
(vii) Open additional suction line gas strainer, check, clean
and refit.
(viii) Open compressor suction gas strainer, check, clean and
refit
(x) Open compressor suction oil strainer, check,
clean/replace by new.
(xi) Open compressor delivery oil strainer, check,
clean/replace by new.
(xii) Check oil strainer housing/chamber for metallic sand,
paste, etc.
Depending on the quantum of dirt found, and quality of oil etc.
at above check points, operator/site staff has to use his 'own
discretion' for frequency of checking above point and change
oil at intervals till the oil is completely clean.
12.4 RESTART:
(i) Use new oil (Do not use same old oil) as per required
level, reassemble covers, strainers filters etc. Do purging
and start the compressor.
(ii) Oil should be suitable for refrigeration and should be
always free from water contents.
(iii) Never bye-pass oil cut out and discharge cut out which
should be set at minimum 1 kg/cm2 difference and 17.5
kg/cm2 respectively. If compressor is tripping on oiL
clean oil passages, charge fresh oil. If the problem still
persists, call compressor manufacturer's representative.
We are sure that a small amount spent on above exercise will
benefit your company by achieving long trouble-free
performance on our compressors.
Kindly ensure that this is followed by your
maintenance/operational staff.
KEEP YOU SAFE
WHILE COMPRESSOR IN OPERATION
lDo not touch hot surfaces (portions) of
compressor (cylinder heads, discharge
header/piping).
lDo not remove belt/coupling, safety guards.
lDo not insert fingers/body parts/tools in
safety guards.
lDo refer instruction and operation manual of
compressor as well as total plant carefully.
lOnly authorised trained staff should handle
compressor.
lDo respect the safety of self, society,
environment and nation.
CAUTION
CAUTION
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