8 Most Common Problems Found in Ship’s Refrigeration System

One of the few machinery systems which needs to run continuously on ships is its refrigeration plant. As
a lifeline for all perishable food items and temperature sensitive cargo, refrigeration plant is one of the
most important systems on ships which requires utmost attention of engineers at all times.

However, just like all other machinery on ships, the refrigeration system can also get into some trouble
from time-to-time. Some of these problems are common but require immediate attention. Mentioned
below are eight most frequently seen problems in the ship’s refrigeration plant:

1. Compressor Starts But Stops immediately

When the compressor in the reefer circuit starts and suddenly stops, it can be because of the following
reasons:

Reasons

Solutions

Low pressure cut out gets activated

Ensure that all the suction line valves are in open condition, the refrigeration is properly charged and
the low pressure cut out is not defective

Defective oil pressure cut out

Check for proper functioning of oil pressure cutout and replace the defective cutout

Defrosting timer is getting activated frequently

If the defrost timer is getting activated frequently, leading to cutout of compressor, check and repair
defrost timer

The lube oil level is below required level

This can be because of leakage of lube oil from seal or carry over of oil. Rectify the leakage and refill the
oil level

Foaming of oil leading to reduced oil pressure

Ensure no foaming takes place, renew the oil if required

Motor overload cutouts are activating

Ensure that electrical motor trips are working properly

2. Compressor Start and Stops Frequently

If while maintaining the correct temperature of the ship’s provision room or reefer cargo, the reefer
compressor is frequently cutting-in and out, then such problem needs to be sorted out immediately. The
most normal causes for such operation are:

Reasons

Solutions

Wrong Setting of Cutouts: It may be because the high pressure (HP) cutout is set too high or LP cutout is
set too low

Check and change the setting to advisable limit

Differential Setting Span is Small: The low pressure (LP) cut out is provided with starting and stopping
pressure setting. If the setting span is too small, it will lead to frequent cut-in and cut-out of the
compressor

Change the setting and increase the span between starting and stopping compressor pressures.

Defective Valves: If the compressor discharge valve is leaky or the line solenoid valve is not closing
properly, this will lead to variation in sensor pressure and result in frequent cut-in and cut-out of
compressor

Replace all the defective valves

Clogged Suction Filters: Compressor is provided with a filter in the suction line. If that is clogged, it will
lead to frequent LP cut out

Clean the filter

3. Compressor is Running Continuously

The function of compressor in a refrigeration system is to act as a pump to circulate the refrigerant in
the cooling circuit. It can happen that to maintain the cooling temperature in the rooms, the compressor
is running continuously. If this happens following can be the causes for the same:

Reasons

Solutions

Refrigerant not sufficient for cooling evaporator

Ensure thermostatic expansion valve is working properly and clean the filters inside TEV

Thermostat low pressure cut-out not activated at low temperature/ pressure

Correctly set the LP cut-out to correct setting

Refrigerant charge is low in the circuit

Check for leakage of refrigerant and charge with required refrigerant

4. Unusual Sound from Compressor

One of the most common problems in any machinery is abnormal sound coming from some of its parts.
This may be due to trouble with mechanical components inside the compressor or due to the reasons
stated below:

Reasons

Solutions

The capacity control setting is too high, leading to knocking sound during starting

Reduce the capacity control setting

The oil pressure is low

Ensure that the oil level is maintained and no foaming of oil is developed. Replenish or refill the lube oil
if required

Incorrect alignment of compressor and motor

Check the alignment and set motor and compressor in one line

Loose foundation

Ensure that the compressor foundation is secured and all foundation bolts are checked for tightness

Loosening of driving belt

Ensure to check the elasticity of the belt and renew if the belt is slack

5. High Compressor Discharge Temperature

It may happen that all the provision rooms or cargo holds are maintained at correct temperature, but in
doing so the discharge temperature of the compressor is going above the limit. This problem may arise
due to following reasons:

Reasons
Solutions

Excessive suction temperature due to less refrigerant in the circuit

Recharge the circuit to maintain refrigerant quantity in the circuit. Ensure TEV is set properly and
supplying enough to the evaporator, else degree of superheat will result in increase of suction and
discharge temperatures of the compressor

Leak in the discharge valve leads to generation of heat

Renew the leaky valve

Leak in the safety valve

Renew safety valve

Open bypass between suction and discharge

Control the bypass to avoid this

6. Evaporator Coil Icing

Another common problem in reefer system is icing of the evaporation coils which may happen due to:

Reasons

Solutions

Too low temperature setting

Increase the coil temperature by adjusting TEV or it’s sensor

The coil capacity is less

Install large capacity evaporator coils

Defrost is not operational

Check if the defrost system is functioning at regular intervals

7. Reduced Cooling Capacity

If the cooling capacity of the plant has reduced and it is not being able to maintain the provision room or
cargo hold temperature, following may be the causes:

Reasons

Solutions
Inadequate refrigeration

Charge refrigerant in the circuit

Insufficient or damaged insulation in the room

Check and renew the insulation

Room or hold is over packed

Ensure that the room is not filled above its capacity

Malfunctioning solenoid or TEV

Check the functioning of these valves and renew if not functioning properly

Poor thermostat location that senses cold temperatures

Place the sensor of the TEV in proper location i.e discharge of the evaporator

Room door is kept open

Ensure to close the door while exiting the provision room

8. Reducing oil level in compressor

If the oil level in the compressor crank case of the refrigeration system is reducing within short intervals,
this indicates leakage or increase in consumption of lube oil due to following reasons:

Reasons

Solutions

Nozzle or filter clogged

Ensure that the nozzle in oil return line or filter in solenoid valve is cleaned and not choked

Foaming of oil due to liquid in suction line

Foaming of oil may arise due to liquid refrigerant entering the crankcase. Replenish oil and troubleshoot
cause of liquid in suction of compressor

Drive side seal leaking

The compressor is provided with oil seal at the drive side. Ensure it is not leaking and renew it if required

Worn out piston rings/ liner leading to oil carryover in the system
Renew the compressor piston rings or liner

Do you know about any other common problems seen in ship’s refrigeration plant? Let us know in the
comments below.

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View Comments (12)

Capt Mukul Chaturvedi says:

October 30, 2013 at 1:45 am

Found very good Information and shared with Engine staff on board mainly for juniors knowledge and
training to TME .

Many Thanks and heartily appreciate .

RANJIT SIDHU says:

October 30, 2013 at 7:17 am

Very good technical information in a capsule from.

Waiting more similar information in near future,

Keep it up Marine In Sight.

Ranjit

Elect Supt

Eagle International Shipping USA

Anish says:

October 30, 2013 at 10:49 am

Dear Ranjit,

Thank You for commenting. Please do check our free ebook on "Marine Electro-technology" by
subscribing to marine insight here:https://marineinsight.com/subscribe/

SAJEEVAN says:
October 30, 2013 at 1:21 pm

Thanks for the healthy technical tips

keep it up

vishal says:

November 4, 2013 at 4:13 pm

Very nice info about refrigeration system...thanx a lot nw i will follow this sit daily

FABIO PANTOJA says:

November 19, 2013 at 12:48 am

Very good technical information.

Today I read many articles in the Marine Insight and now, I will share information and I will indicate to
my maritime engineer friends this website.

Thanks.

1st Eng. Fabio Pantoja

ECO, Brazilian Division

Anish says:

November 19, 2013 at 12:26 pm

Dear Fabio,

Appreciate your comment and support.

Cheers

Dr.Alan Profke says:

March 16, 2014 at 5:55 am

Hi I have a Danfoss compressor that runs fine but does not cool Gas levels fine but when I switch on it
immediately draws 18 amps of power 240v. It is shorting somewhere????? Can you advise and if so
what do I need to replace. Thanks Alan.

adrian says:

August 24, 2014 at 4:29 pm

Really good stuff. Thank you.

Chief Keith says:

October 24, 2014 at 7:24 am

Can you recommend an on line course or another course for ships refrigeration trouble shooting and
repair for marine engineers?

thabiso says:

January 17, 2016 at 10:55 pm

Hello.. Please help me i need to know courses of high pressure trip in refrigeration

H.E.D says:

March 5, 2018 at 2:32 pm

thanks for good remarks about refrigeration system faults.

but Im doubt about icing on suction line of compressor.if its an indication of under charge or over
charged system?pls leave your comments

LEAVE A COMMENT

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Simple Steps to Troubleshoot a Frozen Evaporator Coil

JULY 28, 2015 | ARTICLES

Simple Steps to Troubleshoot a Frozen Evaporator Coil

Troubleshooting a frozen evaporator coil in your Savannah-area home's central air conditioner just
might get the cool air flowing again. More likely it will help you take immediate steps necessary to
prevent more damage while you arrange for professional HVAC service to repair the problem. What’s
definitely not recommended is continuing to operate the system and hoping the malfunction will simply
resolve itself. Irreparable harm to expensive components like the compressor or blower or even water
damage to your home could be result.

Why an Evaporator Coil Freezes

The first concept to understand while troubleshooting a frozen evaporator coil is that the coil is
supposed to be cold but not freezing. In a properly functioning system, the evaporator circulates
refrigerant vapor at about 40 degrees — the optimum temperature to extract heat from the airflow
passing through the coil but never frigid enough to produce ice.
The presence of ice on the coil tends to trigger formation of still more ice until the entire coil may
become encased in a block of ice. Damage may occur as the blower fan strains to pull air through the
ice-obstructed coil, often overheating, or the compressor is dangerously overstressed as the A/C runs
continuously, never cycling off.

Eventually, overload protections may shut down the system or a circuit breaker may trip. What follows
next may be more headaches, however, as the oversized block of coil ice rapidly melts. Gallons of water
may spill outside the air handler, soaking structural components of the house or leaking through a
ceiling.

What You Can Do

While troubleshooting a frozen evaporator coil can be accomplished in a limited way by a handy
homeowner with average DIY skills, most repairs for this problem will require qualified HVAC service. If
your evaporator coil ices up, here’s how to get the process started:

First turn off the A/C at the thermostat to minimize further damage. Turn the fan switch to "fan only" to
blow warm air over the coils and hasten melting. If ice accumulation on the coil extends beyond the
dimensions of the condensate drip pan beneath the air handler, be ready with containers to catch the
dripping water and prevent water damage as the ice melts.

Next, check the air filter. Low system airflow is one cause of coil icing, and a clogged filter definitely
reduces airflow. When system airflow drops below specs, refrigerant circulating through the coil can't
extract sufficient heat energy. Refrigerant temperature plunges into the range below 32 degrees. As the
coil continues to condense water, ice inevitably forms on freezing coil surfaces.

If the filter appears extremely dirty or clogged, install a new filter. Wait for the ice to melt off the coil,
then restart the system. If icing recurs, shut down the system and call in professional help.

Another possible reason for low or no airflow could be an extremely dirty blower or malfunctioning
blower fan. If you don’t feel airflow when you activate the "fan only" switch at the thermostat, the
blower drive belt may be broken or the motor may be defective. Further diagnosis and repair by an
experienced service tech is indicated.

What You Can’t Do

Dirt or dust accumulation on coil surfaces also inhibits heat transfer, causing the coil to run too cold and
freeze. Most evaporator coils are sealed and not a good project for do-it-yourself methods. Coil
inspection and cleaning is a standard part of regular annual maintenance by an HVAC service provider.
Low refrigerant level in the system frequently causes coil icing. As the volume of circulating refrigerant
declines below specifications, refrigerant temperature initially drops below freezing. Air conditioners
don’t use refrigerant like a high-mileage car consumes oil. Low refrigerant usually indicates a leak in the
system that must be tracked down by a professional utilizing leak detection equipment, then properly
sealed. Simply topping up a low refrigerant level by adding more without pinpointing and fixing the leak
is not a competent repair.

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