August 2005
Compressor Overheating
Still Today’s Most Serious Field Problem?
By Dave Demma, Senior Application Engineer – Supermarket Refrigeration, Sporlan Division of Parker Hannifin.
More than 20 years ago an application bulletin enti- compressor sump or the lubrication passages in the
tled “Compressor Overheating: Today’s Most Serious crankshaft. Each of these will have the same devas-
Field Problem” was published by a major compressor tating consequence: loss of lubrication, and ultimate-
manufacturer. At first look, it might seem that com- ly failed bearings.
pressor overheating would not be a major factor in
the many refrigeration compressors that fail on any Oil breakdown deposits can also attach themselves to
given day. Closer inspection, however, would reveal the internal surfaces of the refrigeration system. The
that many compressors suffering mechanical/electri- inner walls of the piping, compressor, and control
cal failures have their roots in overheating. valves are all subject to this problem. While this will
cause TEVs to stick/plug, and restrict the lubrication
Why does overheating have such a devastating affect passages, oil breakdown on the interior walls of the
on a compressor? The answer is twofold: piping may remain undisturbed for years (Figure 1).
1. Loss of lubrication film: Refrigeration oils have Converting a system such as this from R-22/mineral
been highly refined in an effort to elevate the tem- oil to R-404A/POE oil will awaken the oil breakdown
perature at which chemical decomposition will like a sleeping giant. With POE’s solvent-like abili-
occur. As such, they are vulnerable to losing the ties, its presence in the system will literally clean
lubrication film necessary to prevent metal to these deposits from the interior surfaces and bring
metal contact between bearings and journals, or them back into circulation. One can expect contami-
piston rings and cylinders, prior to the tempera- nant problems after a refrigerant retrofit where the
ture at which decomposition begins. With mineral mineral oil has been replaced by POE oil: the new oil
oil this will occur approximately between 310ºF that was added to the compressor will likely be dark
and 330ºF. When these temperatures are the next morning, and the odds are that a few TEVs
achieved, the probability of extreme piston and will plug. Several filter-drier/oil filter/oil changes
ring wear is imminent. may be necessary before the problem is resolved.
While unpleasant, it is simply a natural consequence
2. Chemical decomposition: This happens at elevat- of excessive discharge temperatures causing oil
ed temperatures, and is accelerated in the pres- decomposition, and the solvent-like properties of POE
ence of other contaminants such as air or water. bringing it back into circulation.
18 is an important number to remember, for the
rate of chemical reaction doubles with every 18ºF Figure 1 — Oil Breakdown Deposits on Inner Walls of
temperature increase.* For example, a chemical System Piping
reaction that takes 10 years to complete at 100ºF,
will only take 5 years to complete at 118ºF. At
136ºF it would be complete in 2-1/2 years, and so
forth. The process by which the refrigerant and/or
oil chemically breaks down can occur in a matter
of seconds if there have been enough 18° tempera-
ture increases.
both ends of the bore. In addition, the piston may hit excessive discharge temperatures, and ripe for oil
the bottom of the valve plate at the end of each com- decomposition. After some period of time, what used
pression cycle. to be clean looking straw colored oil in the crankcase
will become thick and black. Some of this oil break-
Figure 2 — Worn Wrist Pin Bore down will be deposited on the valve plates (Figure 4),
preventing the reed valves from sealing properly.
wrist pin and wrist pin bore continue to shift from the This is most certainly a mechanical failure. A review
top to bottom in this manner, as it allows the clear- of the steps that led to this failure will reveal that its
ance to shift as well. Without the clearance shifting, roots are in excessive discharge temperatures.
the ability to lubricate the top and bottom of the wrist
pin and bearing would be compromised. 1. High suction vapor temperature, resulting from
underfeeding TEVs. The higher suction tempera-
Figure 5 — Connecting Rod Wrist Pin Bore ture increases the discharge temperature.
Figure 6 — Normal Lubrication of Wrist Pin/Wrist Pin Bore Figure 7 — Loss of Lubrication to Lower Portion
of Wrist Pin/Wrist Pin Bore
Wrist Wrist
Pin Pin
heat added to the refrigerant between the evapo- entropy), the higher the heat of compression.
rator outlet and the compressor discharge. A large
amount of this can be attributed to the compres- For example, the system in Figure 8 represents an
sion process. While the amount of heat added will R-22 low temperature system operating at -20ºF
vary depending on the refrigerant and system saturated suction temperature (SST) and 100ºF
conditions, this “heat of compression” cannot be saturated condensing temperature (SCT), with an
eliminated by any procedure. It is inherent in the open drive compressor. The refrigerant vapor tem-
compression process. perature at the evaporator outlet is -15°F (5°
superheat) The orange line reflects 40º of super-
The compression process somewhat follows the heat at the compressor inlet, and the heat of com-
constant entropy line on the P-H diagram (Figure pression (HOC) is 27 Btu/lb. The discharge
8). The constant entropy lines extend at an angle temperature is 215ºF.
from the saturated vapor line, and become less
vertical with each succeeding (or increasing value) The system in Figure 9 represents a system with
line. So, the greater the value of the constant the same operating conditions, using a suction
entropy line, the farther it will travel horizontally cooled hermetic compressor. The cool suction
between two pressure points. It is this horizontal vapor must now travel across the warm compres-
travel that represents the increase in the refriger- sor motor windings, experiencing an approximate
ant’s heat content in Btu/lb. The entropy of a 80ºF temperature increase in the process. The
vapor will increase as its temperature increases. vapor temperature entering the cylinders is 100ºF
Therefore, it is the vapor’s temperature (which, is (120º of superheat). The resulting discharge tem-
partially influenced by the amount of suction perature is 295ºF.
superheat) that will determine the constant
entropy line from which the compression process Note that the suction temperature of the system
follows. The laws of physics in this scenario never in Figure 9 was 80ºF higher than that of the sys-
change: the higher the suction vapor temperature tem in Figure 8. This translated into an 80ºF
entering the compressor (resulting in a higher increase in the discharge temperature. For every
SCALE CHANGE
14 15 16 17 18 19 20 21 22 23
12
13
0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2
0.
0.
5000
0.01 0.018 0.020 0.022 5000
0.017 0.2
5
4000 0.025 6
4000
3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
0.05
200
0
Open Drive Compressor 50
52
0 0.2
8
180
0.10 1000
1000
215°F Discharge Temp. Heat of
0
44
160F
800 800
0
Compression
42
0.14
200 –
0
40
600 600
0
180 –
Co
38
180 0.2
0
ns
36
160 – 160 –
tan
0
34
140 – 140 –
t Te
320
m pe r
120 – 120 –
215°F Discharge Temp.
280
0.5
100 – 200
ature (°
200
260
80 – 0.7
or
80 –
240
140
Vap
Pressure (psia)
140
220
F)
60 – 60 – 1.0
ted
200
id
100 100
iq u
ura
180
80 40 – 40 – 1.4 80
dL
Sat
160
ate
60 20 – 20 – 2.0 60
tur
140
Sa
120
40 0– 0– 3.0 40
100
30 4.0 30
80
20 20
7.0
40
-40 – -40 –
14 14
20
10.0
10
0
-60 – -60 – 14
8.0 8.0
-20
) 6.0
6.0 -F 20
-40
4.0 (B 4.0
30
py
ro
-80
3.0
E nt 3.0
40
-100 – -100 – nt
s ta
50 Specific Volume (ft3/lb)
2.0
C on 2.0
37 38 0.
39 .40
5 36 0. 0. 0
1.4
1.4 .3 0. 70
34
0
33
0.
2
-120 – -120 –
0.
1.0
1
0.3
1.0
0.3
0
0.3
9
0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2
0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE
SCALE CHANGE
14 15 16 17 18 19 20 21 22 23
12
13
0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2
0.
0.
5000 0.020 0.022 5000
0.01 0.017 0.018 5
0.025 0.2 4000
4000 6
3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
Hermetic Compressor 0.05
200
52 0
8
50 0 0.2
180
1400 40°F Suction S.H. @ Comp. Inlet 0.07 0 1400
48
160F
0
295°F Discharge Temp.
46
1000 0.10 1000
0
44
800 800
0
42
0.14
200 –
0
40
600 600
Co
0
180 –
38
180 0.2
ns
0
36
160 – 160 –
tan
0
34
400 400
0.3
t Te
0
140 – 140 –
320
300 300
m pe
0.4
30 0
120 – 120 –
280
0.5
rature
200
100 – 295°F Discharge Temp. 200
260
80 – 80 – 0.7
por
240
(
140 140
°F)
Pressure (psia)
220
d Va
60 – 60 – 1.0
200
uid
100
rate
100
Liq
180
80 40 – 40 – 1.4 80
u
Sat
d
160
ate
60 20 – 20 – 2.0 60
tur
140
Sa
120
40 0– 0– 3.0 40
100
30 4.0 30
80
-20 – -20 – 5.0
60
20 20
7.0
40
-40 – -40 –
14 14
120°F Suction Superheat, 80°F Vapor Temperature
20
10.0
10
increase from hermetic motor windings
0
-60 – -60 – 14
8.0 8.0
-20
) 6.0
6.0 -F 20
-40
4.0 (B 4.0
py 30
ro
-80
3.0 E nt 3.0
40
-100 – -100 – nt
s ta
50 Specific Volume (ft3/lb)
2.0
C on 2.0
37 38 0.
39 .40
5 3 6
0. 0. 0
1.4
1.4 .3 0. 70
34
0
33
0.
2
-120 – -120 –
0.
1.0
1
0.3
1.0
0.3
0
0.3
9
0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2
0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE
1ºF increase to the suction temperature, you can 3/8” wall thickness insulation. This should be
expect an approximate 1ºF increase in the dis- avoided. On long piping runs, or where the suc-
charge temperature. Simply stated, any system tion piping is routed through an attic, 1/2” or 1”
condition that causes an increase in suction tem- wall thickness is recommended.
perature will result in a nearly equal increase to
the discharge temperature. C. Liquid to suction heat exchangers. This is the
classic “rob Peter to pay Paul” situation. The
Some of the more common system conditions that cool suction vapor subcools the liquid, which
are cause for increased suction temperatures are: will ensure vapor free liquid feeding the TEV. It
does so at the expense of higher suction vapor
A. High TEV superheat setting. This should temperatures. Not only does this lead to
always be checked at startup and set to the increased discharge temperatures, the higher
equipment manufacturer’s specification. The suction vapor temperatures reduce compressor
system TEV is not designed to regulate refrig- efficiency. This cancels any efficiency gained
erant vapor temperature at the compressor from the subcooled liquid.
inlet. Allowing the system TEV to operate at a
flood-back condition to ensure proper vapor 2. Insufficient Condenser Capacity: On rare occa-
temperature at the compressor inlet is danger- sions this might be the result of an undersized
ous (the potential for compressor damage) and condenser. However, for every undersized con-
inefficient (refrigerating the suction line adds denser in service, probably thousands more have
operating expense, yet has no effect on product not been maintained. As the condenser fins
temperature). When set properly, the system become restricted with dirt, the airflow necessary
TEV will maintain the lowest compressor suc- to deliver the condenser’s rated capacity is com-
tion temperature without sacrificing compres- promised.
sor safety or system efficiency.
Figure 11 shows the system mentioned previously,
B. Ineffective or missing insulation (Figure 10). but with a dirty condenser. The condensing tem-
There may be a temptation to use the lower cost perature has increased from 100ºF to 120ºF, and
Page 6 / Form 10-207
14 15 16 17 18 19 20 21 22 23
12
13
0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2
0.
0.
5000 0.01 0.018 0.020 0.022 5000
0.017 0.2
5
4000 0.025 6
4000
3000
REFRIGERANT 22 0.03 60
0.2
0 7
3000
58 0.2
0.04 56 0
2000 54 0 2000
0.05
200
52 0
Dirty Condenser - 120°F Cond. Temp 50 0 0.2
8
180
1400 0.07 0 1400
Hermetic Compressor
48
0
46
1000 0.10 1000
0
120°F S.H. @ Cylinder Inlet
44
160F
800 800
0
42
0.14
200 –
0
40
600 600
0
180 –
Co
38
180 0.2
ns
36
160 – 160 –
tan
0
34
400 0.3 400
0
140 – 140 –
t Te
320
300 0.4 Temp.
320°F Discharge 300
30 0
m pe
120 – 120 –
280
0.5
rature
100 – 200
200
260
0.7
or
80 – 80 –
240
140
Vap
(
Pressure (psia)
140
° F)
220
60 – 60 – 1.0
ted
200
100 100
ura
180
80 40 – 40 – 1.4 80
Sat
160
60 20 – 20 – 2.0 60
140
120
40 0– 0– 3.0 40
100
uid
30 4.0 30
80
Liq
60
20 20
rate
7.0
40
u
-40 – -40 –
Sat
14 14
20
10.0
10
0
-60 – -60 – 14
8.0 8.0
-20
)
6.0 -F 20 6.0
-40
4.0 4.0
y 30
op
tr
-80
3.0 n 3.0
n tE 40
-100 – -100 – ta
2.0 ns 50 Specific Volume (ft3/lb) 2.0
Co
37 38 0.
39 .40
36 0. 0. 0
1.4
1.4 35 0. 70
0.
34
33
0.
2
-120 – -120 –
0.
1.0
1
0.3
1.0
0.3
0
0.3
9
0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2
0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE
Figure 12 — Typical Cycle With Dirty Condenser and Lowered Suction Pressure
SCALE CHANGE
14 15 16 17 18 19 20 21 22 23
12
13
0. 0. 0. 0. 4
0. 6 0. 0. 0. 0. 0. 0.2
0.
0.
0
Dirty Condenser - 120°F Cond. Temp 50
52
0 0.2
8
180
800 800
0
42
0.14
Suction Pressure lowered
200 –to 20 psia (-29°F) Discharge temperature lowered
0
40
600 600
0
180 –
Co
38
0.2
180 to 280°F with liquid injection
0
ns
36
160 – 160 –
ta n
0
34
400 400
0.3
0
140 – 140 –
t Te
320
m pe r
120 – 120 –
280
0.5
100 – 100 – 200
ature (
200
260
80 – 80 – 0.7
or
240
140
Vap
140
Pressure (psia)
°F )
220
60 – 60 – 1.0
ted
200
100 100
ura
180
80 40 – 40 – 1.4 80
Sat
160
60 20 – 20 – 2.0 60
140
120
40 0– 0– 3.0 40
100
id
30 4.0 30
iqu
80
60
20 20
te
ura
7.0
40
-40 – -40 –
Sat
14 14
20
8.0
-60 – -60 – inlet with Y1037 TREV 14 8.0
-20
) 6.0
6.0 -F 20
-40
/ lb
-80 – -80 – tu
-60
4.0 (B 4.0
y 30
op
tr
-80
3.0 3.0
t En 40
-100 – -100 – an
n st 50 Specific Volume (ft3/lb) 2.0
2.0
Co
37 38 0.
39 .40
5 36 0. 0. 0
1.4
1.4 3 0. 70
0.
34
33
0.
2
-120 – -120 –
0.
1.0
1
0.3
1.0
0.3
0
0.3
9
0.8 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.8
0.2
0.6 0.6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
SCALE CHANGE
Evaporator
Y1037
Y1037 Condenser
Compressor Receiver
the resulting discharge temperature has increased lowered from 10 psig to 5.5 psig, while maintain-
to 320ºF. ing a condensing temperature of 120ºF. The result
is a higher discharge temperature; 365ºF. It is
Figure 3 shows an example of this condition; it’s a important to operate the system with the highest
compressor waiting to fail. Sadly, this is possible suction pressure.
easily…and completely…preventable.
4. Refrigerant Type: Many criteria are used in the
Figure 10 — Missing Suction Line Insulation selection of a refrigerant for a given application:
cost, availability, performance, and environmental
issues. When R-502 joined the endangered species
list, and suitable replacements for refrigeration
applications were needed, it seemed logical to
enlist R-22 as a replacement. It had been used for
Missing
Insulation refrigeration applications before R-502 was devel-
oped in the 1960s.
running per design...meaning that the condenser There is no equalizer connection, and pressure does
is sized correctly AND is clean, the TEV super- not influence its operation. The sensing bulb should
heat is set correctly, the suction line is well insu- be securely attached 6 inches from the compressor
lated, and the suction pressure is operating at service valve for accurate control. Insulating the bulb
the highest possible level, it will still operate is recommended to eliminate ambient temperatures
with high discharge temperatures. This is simply from influencing the bulb temperature. The Y-1037
due to the physical properties and characteristics inlet should be connected to a vapor free source of liq-
of R-22. uid refrigerant; the outlet should be piped to the suc-
tion line 12”-18” from the compressor suction service
Because of this limitation, if R-22 is chosen as a valve. Because of the Y-1037s positive shut off capa-
low temperature refrigerant, something must be bility, an additional solenoid valve is not typically
done to neutralize its “natural” high discharge required.
temperature problem. A compressor body cooling
fan motor is a start, as it can reduce the discharge Liquid injection can be used to reduce excessive dis-
temperature perhaps 15-25 degrees. charge temperatures on a single stage compression
process, or to control the interstage temperature on a
The real “something” will be to attack the problem at two stage compression process.
the compressor inlet. Recall that for every 1ºF change
in the suction vapor temperature, there will be an Conclusion: As stated more than two decades ago,
approximate corresponding 1ºF change in the dis- compressor overheating IS today’s most serious field
charge temperature. This can either be an increase problem. Many system problems and compressor fail-
OR a reduction. Knowing this, it becomes rather easy ures can be directly traced to high discharge
to control the discharge temperature by controlling temperatures.
the suction temperature. Hence, the birth of the liq-
uid injection valve. Several causes exist for this condition and most can be
remedied by proper diagnosis and action. Condensers
Figure 13 shows the application of a liquid injection should be cleaned as needed to keep them operating at
valve; a Sporlan Y-1037 Temperature Responsive their rated capacity. The suction vapor temperature
Expansion Valve. Its function is quite simple: to mon- should be kept within acceptable limits by setting the
itor the compressor discharge temperature via a sens- system TEV correctly and insulating the suction line
ing bulb. As the discharge temperature exceeds the properly. Compressors should not be allowed to oper-
setting of the Y-1037, it injects a mixture of saturated ate at abnormally low suction pressures, as this will
liquid and vapor into the suction line. This will lead to higher discharge temperatures.
decrease the suction vapor temperature, which in
turn reduces the discharge temperature. Knowing With some refrigerants and applications, additional
that the sensing bulb location is 50-75 degrees less methods are required to alleviate high discharge
than the actual discharge temperature, a technician temperatures. This can be accomplished to a degree
can easily select a Y-1037 setting based upon the with a compressor body cooling fan motor. For com-
desired maximum discharge temperature. If the plete control in preventing this problem, a
desired point for the valve to start injecting is a 280ºF Temperature Responsive Expansion Valve, which
discharge temperature, then the Y-1037 setting monitors the discharge temperature, can be used.
would be 205ºF (280 – 75). The system in Figure 12 Injecting saturated liquid/vapor into the suction line
illustrates the benefit of liquid injection. will reduce the temperature of the superheated suc-
tion vapor, and in turn reduce the excessive dis-
The Y-1037 TREV responds to temperature only. charge temperatures.