Compressor

Capacity Control
Prof. Dr. Gamal I. Sultan

Mansoura University, Faculty of Engineering

Mechanical Power Dept.,
EGYPT.
Contents

i. Crankcase Pressure Control

ii. Discharge Temperature Control with Liquid
Injection
iii. Compressor Capacity Control
iv. Reverse Flow Control
v. Auxiliary Valves.
 REFRIGERATION SYSTEM
 There are two pressures existing in compression
refrigeration system:
1. Evaporating or low pressure
2. Condensing or high pressure
The refrigerant acts as a transportation medium to
move heat from the evaporator to the condenser
where it is given off to the ambient air
 The change of state from liquid to vapor and back
to liquid allows the refrigerant to absorb and
discharge large quantities of heat efficiently
COMPRESSOR
It Compresses the refrigerant from a low pressure side to
a high pressure side
✓ First, it removes the refrigerant vapor from the
evaporator and reduces the pressure in the
evaporator to a point where the desired evaporating
temperature can be maintained.
✓ Second, the compressor raises the pressure of the
refrigerant vapor to a high level enough so that the
saturation temperature is higher than the
temperature of the cooling medium (air or water)
used for condensing the refrigerant vapor to a liquid
refrigerant.
The Evaporator Pressure Regulating (EPR)
Evaporator Pressure Regulating Valve prevents the
evaporator pressure from falling below the
predetermined value.
By controlling the evaporator pressure, the evaporator
temperature is also controlled.
The EPR valve modulates from fully open to fully closed.
It Located in the suction line near evaporator outlet

Some typical applications :

• Multiple evaporator applications where each evaporator
is intended to operate at a different temperature
 The Evaporator Pressure Regulating, EPR (Cont…)
Two-temperature operation
Two evaporators are operating on
one compressor. One evaporator
operates at 20°F (18.4 psig), the
other at 30°F (26.1 psig).
 EPR is needed in the suction line
of each evaporator except the
lowest temperature coil
 EPR valves are equipped with
Schrader valves to read
evaporator pressure.
 Multiple EPRs can be set at
different pressures so each
evaporator can be maintained at
a different temperature.
The Evaporator Pressure Regulating, EPR (Cont…)

 Evaporators piped together

and one compressor used to
maintain a suction pressure
for the lowest pressure
evaporator.
 Evaporators that have a
pressures higher than the
true suction pressure of the
lowest evaporator all have
EPR valves set to their
individual needs
 Pressure Regulators in Multiple Evaporators

✓ Solenoid valve installed in the external line allows the regulator to function as a
suction stop valve as well as an evaporator pressure regulator.
✓ This feature is particularly useful on a flooded evaporator to prevent pumping
refrigerant out of the evaporator, which occurs when the thermostat is satisfied
and the compressor continues to operate to cool other evaporators.
The Electronic Pressure Regulating, EEPR (Cont…)

The electronic pressure regulator provide more

accurate control.
– It is located at the evaporator outlet
– It is used in single or multiple systems
Microprocessor senses the discharge temperature and
is designed to maintain discharge air temperature in the
refrigerated space.
– It is controlled by a bipolar step motor
 Crankcase Pressure Regulator
The Crankcase Pressure Regulator
Valve (CPR) limits the suction
pressure at the compressor below a
preset limit to prevent overloading
of the compressor motor
The CPR valve modulates from fully
open to fully closed.
This valve responds to outlet
pressure, closing on a rise in outlet
pressure.
A CPR valve is typically used to
prevent motor overloading on low
temperature units during start-up
after a defrost cycle .
Crankcase Pressure Regulating (Cont…)
✓There will be a pressure drop
across the valve when the
evaporator is too warm.
✓The CPR valve can be set to
throttle the suction gas to the
compressor and prevent a
high suction pressure on the
compressor side of the valve
and will not allow the
compressor to overload.
✓When the refrigerated box
temperature is pulled down to
the design range, the suction
gas in the evaporator will be
the same as the pressure at
the compressor because the
valve is wide open.
Relief Valves
Its function is to release refrigerant
from a system when a high-
pressure condition exists.

Spring-loaded type
• Located in the vapor side
• Resets after opening
Refrigerant Check Valves
• Allows refrigerant to flow in only one direction and can be either the
ball type or magnetic type.
• Must be installed with the arrow pointing in the direction of
refrigerant flow
• Installed at outlet of the lowest temperature coil on multi-
evaporator systems.

Suction Line Accumulators

Located in the suction line, close to the
compressor to prevents liquid refrigerant
from entering the compressor.
 Gives liquid a place to boil off before
entering compressor.
 Sometimes, the liquid line is routed
through the accumulator to boil away
any liquid
 Compressor Control Methods
There are several control methods for air compressors, which affect
the overall operating efficiency of the compressor.

Inlet Valve Modulation / Inlet Throttling

 Inlet valve modulation throttles off the inlet gas to the
compressor as pressure rises above the setpoint pressure. This
causes the compressor to draw in less gas, matching
compressor capacity with gas usage for relatively steady
pressure control.
 This causes part load performance to be very poor (machine
that modulates to 0 capacity uses about 70% of its full load
power).
 The modulation controlled machines can be adjusted to fully
unload or “blow down” if capacity reduces to a certain level,
such as 40%. .
 Compressor Capacity Control
 It is the method by which the quantity of refrigerant
gas supplied by the compressor is regulated to
provide, as efficiently as possible.
 The ideal governing arrangement would be to obtain
such infinite control that the compressor capacity
would be exactly equal to the fluctuating demand of
the plant at all times.
Capacity regulation can be divided into three basic modes:
1.Stepped Control
2.Step less Control
3.Composite Control
 Speed Control
 In this method, the capacity is regulated in steps by using
variable speed motor. For example, three steps control
means that the compressors can deliver 100 %, 50 % & 0 %t
of its capacity. Because of its simplicity and reliability in use,
this method is the most common choice.
 This limits these prime movers to not allow speed reduction of
more than 70 %, thus imposing the range of continuous capacity
variation between 100 % to 70 % only.
 It is the simplest method of controlling the capacity of the
compressor. If the speed of the driver can be varied, this will give
an excellent means of loss free capacity control of compressor.
The refrigerant mass flow rate is given by:

𝒅 Cylinder diameter
𝑳 Stroke length
𝒏 No. of compressor cylinders.
𝑵 Compressor speed (Hz, V, I)
𝒛 =1 for single acting
=2 for double acting
𝜼𝒗𝒐𝒍 Volumetric efficiency
𝒗𝒔𝒖𝒄𝒕𝒊𝒐𝒏Specific volume at suction, function of (P, T).
Variable frequency drive for refrigeration compressor
 The control of suction pressure by varying the speed of
refrigeration compressors provides many advantages.
 If the installation is designed correctly, important considerations
such as improved quality of stored goods, energy saving,
improved performance at light refrigeration loads and
increased working life can be easily achieved.
 With speed control, refrigeration compressors are operated
outside the normal area of operation defined by the manufacturer.

The following abbreviations may be used in this article:

VSC: Variable speed Compressor
FSC: Fixed speed Compressor
VFD: Variable Frequency Drive
 Reverse Flow Control

✓ Stepless capacity control by Reverse flow through suction

valves is one of the most efficient means of capacity control
while operating the Compressor with a constant speed driver.
✓ Capacity control is achieved by unloading device, fitted to
each suction valve, which delays the closing of the suction
valve in a controlled way during compression stroke.
✓ Thus gas already filled in the cylinder will flow back into the
suction piping. This becomes possible to vary the compressor
capacity continuously.
✓ From the point of view of efficiency, the power reduction is
directly proportional to the capacity reduction apart from the
losses due to the flow of gas in both the directions through the
suction valves.
ON/OFF Control
 It is the most efficient control mode for small compressors.
 The compressors in this process shut itself down when the
demand is low & automatically restarts on an increase of gas
requirement.
 This is advantageous in case where demand for compressed
gas fluctuates widely, particularly, when there are sudden
large demands followed by periods of very small demand or
no demand at all.
 This method provides completely no loss capacity control
and thus almost 100 % energy is saved.
 This system can also be used in large installation when
there are several units working in parallel.
 When an increase in output is required, one or more unit is
brought into operation.
Loader / Unloader capacity Control

Figure ( ) Loader/Unloader Valve

 By-Pass Control
Stepless control by using a by-pass from discharge to
suction is one of the most common and easy means of start-
up and stepless capacity control. This control is based on the
principle of connecting the discharge side of the compressor
with the suction side via a throttle valve.
However, by-pass control is a 100 % loss system. This
method involves wastage of power and as such should be
used preferably in combination with other means of
stepped control, such as, valve unloaders and clearance
pockets.
By-pass Control may also involve a by-pass cooler to ensure
that suction temperature does not go beyond acceptable
limits.
Vapor Compression Refrigeration with Hot Gas
Bypass Arrangement

Condenser

Hot Gas bypass

Evaporator
Suction Valve Unloader Control
In this system, the valve lifting device keeps the suction
valves open during the compression stroke. By keeping these
valves open by means of valve lifter, the cylinder capacity is
zero during this stage. And when the valve lifter withdraws,
suction valve again comes to normal position and capacity
rises to maximum.
 This method is generally used in all process industries.
 From the point of view of efficiency, the power reduction is
almost directly proportional to the capacity reduction. If two
double acting cylinders are available, capacity regulation
of 100 %, 75 %, 50 %, 25 % & 0 % can be achieved.
 Fixed Volume Clearance Pocket Control (FVCP)

✓ A FVCP is used to add additional clearance volume to the

head end of a cylinder.
✓ The clearance pocket, when open, increases the cylinder
clearance volume, which causes the compressor capacity
to decrease.
✓ An indicator card taken from a cylinder end with a 50 per
cent capacity reduction shows this effect more clearly.
✓ From the point of view of efficiency, the power reduction is
almost directly proportional to the capacity reduction if
allowance is made for losses due to throttling through the
valves.
Fixed Volume Clearance Pocket Control (cont…)

Control
Pressure
Unit
Transducer

Directional Discharge
Valve

Hydraulic
Actuator

Suction
 Stepless Capacity Control
This method allows the continuous regulation of the capacity of
the compressor. The following methods of Stepless Capacity
Control are widely used. Fit the non-return valve in the
discharge line after the compressor.

Check that the solenoid valve is fitted with the flow arrow
pointing from the high pressure to the low pressure side. A
wrongly fitted valve or a leaky valve will lead to overheating and
breakdown of the compressor. In a few cases a delaying relay
must be used, keeping the solenoid valve open until the motor
has reached its max. number of revolutions.
(A) Controlled operation: With the solenoid valve energized,
the suction port in the corresponding cylinder head is shut
off by means of a servo valve; the pistons of this cylinder
row run idle without gas pressure.

(B) Normal operation: With the solenoid valve de-energized,

the gas ports in the valve plate and cylinder head are open.

Note:
Stop the compressor and check that the solenoid valve works
correctly. At a current impulse to the solenoid valve the
characteristic valve stroke must be heard!
Compressor Operating Curve of
Dynamic Compressors

Pressure Surge point

Head
Operating point

Stonwall point

Maximum Flow
rate

Flow
rate
Operating Terminology
Surge
✓ It is occurrence of back flow of the refrigerant in a
centrifugal or axial compressor.
✓ Surge is bad because it can damage the compressor.
Stonewall point
The point that represents the maximum flow rate and
minimum pressure head.
Operating point
The compressor operates between the stonewall and the
surge point.
Compressure Operation Problems
1. Surge1.
It can occur when the mass flow of gas to the compressor falls
below a critical level with a high pressure difference (i.e. when
there is not enough gas to replace that being pushed).
✓ Forward discharge gas will flow backwards through the
compressor towards the suction side, this back flow will tend to
decrease the speed of rotation while the speed controller will try
to maintain the correct speed.
✓ It means, maximum discharge pressure is obtained at minimum
flow rate.
✓ Now, surge is the operating point, where Maximum head and
minimum flow capacity is reached.
Surge results in:
• High vibration
• Abnormal noise
• Temperature increases
• Rapid changes in axial thrust that can damage
compressor internals and driver

Surge may be prevented by:

• Increase flow (recycling)
• Increasing speed
• Increasing differential head
How surge occurs?
Tank Receiver
C

Spill back
valve

 The pressure in the receiver is greater than the pressure at

compressor outlet (receiver will explode due to pressure build up)
and excess refrigerant flows back into the compressor causing a
surge.
 At the surge point, the flow rate is minimum and pressure head is
maximum.
How to prevent?
This can be done by two ways:
(i)Install a spill-back valve
During surge, Preceiver > Pcompressor, this valve is open and back flow excess
fluid flows back into the tank, reducing compressor pressure.
(ii) Reducing tendency to surge during design stage using analytical skill
The change in pressure is directly proportional to compressor head x density
of gas.

We can reduce tendency of surge by changing the factors affecting the

change in pressure by:
 Increasing density by increasing compression suction.
 Decreasing gas temperature.
For compressor head:
 Increase the number of impellers.
 Increasing rotating speed.
Chocking (stonewall)
 This can be prevented by
maintaining minimum flow
resistance to the fluid flow by
providing Anti-choke valves at
discharge which closes to
restrict the flow and hence
preventing Choke.

 The stonewall limit of the performance defines the flow at

which the gas velocity at one of the impellers approaches
the velocity of sound.
 Compressor operates, somewhere between Surge point
and Stonewall Point (Choking Point).
When stalling takes place on all the blades , this leads to choking
of the flow. Sometimes even reversal of the flow may take place.
Heavy vibrations also occur.
Three Way Valves
CONDENSER PRESSURE CONTROL
THE CONDENSER AND LOW-AMBIENT CONTROLS
• Condensing temperatures drop when the outside ambient
temperature drops
• For air cooled condenser,
P(Ts)  ambient air temperature +15oC
• The condensing pressure must be at least 75 psig higher than
the evaporator pressure in order for the metering device to
operate properly
• Low ambient controls
– Designed to maintain the desired head pressure
– Needed on systems that operate year-round
CONDENSER CONTROL
Fan Speed Control for Controlling Pressure

QH = (N1 2VR)(h2 – h3)

Where N1 is the no of fans, VR air volume flow rate of each fan
✓ As the outside temperature drops, the fan slows down to
reduce the amount of airflow through the condenser coil.
✓ As the outside temperature rises, the fan speeds up to
increase airflow through the condenser.
✓ Can utilize variable frequency drives (VFD)
✓ Some condensers have more than one fan
– Some fans remain on all the time
– Others cycle on and off to maintain proper pressure
– Can be controlled by pressure or temperature
CONDENSER PRESSURE CONTROL (Cont…)

AIR SHUTTERS OR DAMPERS

• Located at the inlet or outlet of the condenser which opens and
closes by a pressure-controlled piston and controls air flow
through the condenser coil
• As ambient temperature drops, the dampers close to reduce
the amount of airflow through the coil
• As ambient temperature rises, the dampers open to increase
the amount of airflow through the coil
HIGH PRESSURE CONTROL (Cont…)
CONDENSER FLOODING
In large capacity air cooled condenser, a suitable liquid receiver is
installed to the condenser to collect liquid refrigerant during any
repair in the cycle and ensure stable operation.
• The valve (High pressure float valve) is installed in parallel
with the condenser.
• The valve closed when the ambient temperature is high
• The Valve opens as the ambient temperature drops
• During very cold weather, the liquid receiver will be almost
completely filled with liquid refrigerant
• Systems become more efficient since they operate at lower
pressures.
Why Compressor Control?
– Primary: to control the suction pressure;
– Secondary: reliable compressor operation (start/stop, etc.)

How ?
– Control the compressor capacity according to the refrigeration
load by means of bypassing hot gas from the high pressure side
back into the low pressure side, compressor ON/OFF step
control or controlling the rotating speed of the compressor;
– Install check valve (Non-return valve) on the discharge line in
order to prevent reverse flow of the refrigerant to the
compressor;
– Keep pressures and temperatures on the inlet and outlet of the
compressor within the working range.
Solenoid Valve
 Step control of compressor capacity

Step control solution for

compressor capacity can be
achieved by using a step
controller EKC 331 ➀.
EKC 331 is a four-step controller
with up to four relay outputs.

It controls the loading/unloading of the compressors/pistons or control the

electric motor of the compressor according to the suction pressure signal
from the pressure transmitter AKS 33 ➁ or AKS 32R. It can control a pack
system with up to four equally sized compressor steps or alternatively two
capacity controlled compressors (each having one unload valve).
 Compressor capacity control by hot gas bypass

✓ Hot gas bypass can be used to

control refrigeration capacity of
compressor for fixed capacity.

✓ The pilot-operated servo valve ICS ➁ with a CVC pilot valve is used to control
the hot gas bypass flow according to the pressure on the suction line.
✓ The CVC is a back pressure controlled pilot valve, to open the ICS and increases
the flow of hot gas when the suction pressure is below the set value.
By this way, the suction pressure ahead of the compressor is kept constant,
therefore the refrigeration capacity satisfies the actual cooling load.
Compressor variable peed capacity control
 Discharge Temperature Control with Liquid Injection

Compressor manufacturers generally

recommend limiting the discharge
temperature below a certain value to prevent
overheating of values, prolonging their life
and preventing the breakdown of oil at high
temperatures.
From the log p-h diagram, it can be seen that the discharge temperature may be high when:
✓ the compressor runs with high pressure differential.
✓ the compressor receives highly superheated suction vapor.
✓ the compressor runs with capacity control by hot gas bypass.
There are several ways to reduce the discharge temperature. One way is to install water cooled heads in
reciprocating compressors, another method is liquid injection, by which liquid refrigerant from the
outlet of the condenser or receiver is injected into the suction line, the intermediate cooler, or the side
port of the screw compressor.
When the discharge temperature rises above the set value of the thermostat RT 107 ➄, RT 107 will
energise the solenoid valve EVRA ➁ which will start liquid injection into the side port of the screw
compressor. The thermostatic injection valve TEAT ➂ controls the injected liquid flow according to the
discharge temperature, which prevents the discharge temperature from rising further.
 Liquid injection with motor valve

An electronic solution for liquid injection control can be achieved with

the motorized valve ICM ➂. An AKS 21 PT 1000 temperature sensor ➅
will register the discharge temperature and transmit the signal to the
temperature controller
EKC 361 ➄. The EKC 361 controls the ICAD actuator which adjusts to
opening degree of the ICM motor valve in order to limit and maintain
the required discharge temperature.
Crankcase Pressure Control
During start-up or after defrost, the suction pressure has to be controlled, otherwise it can be
too high and the compressor motor will be overloaded. The electric motor for the compressor
may be damaged by the overloading. There are two ways to overcome this problem:
i. Start the compressor at part load (Capacity control by unload cylinders in reciprocating
compressors or by-pass some suction gas for screw compressors with slide valve).
ii. Control the crankcase pressure for reciprocating compressors (installing a back pressure
regulating valve in the suction line drops below the set valve).

In order to control the crankcase pressure during start-up after defrost or in others cases when
the suction pressure may run too high, the pilot-operated servo valve ICS(1) with the back
pressure controlled pilot valve CVC is installed in the suction line. The ICS will not open
until the downstream suction pressure fall below the set value of the pilot valve CVC. In this
way, the high pressure vapor in the suction line can be released into the crankcase gradually,
which ensures a manageable capacity for the compressor.
✓ The maximum suction pressure allowed is set on the CVP pilot valve. When the compressor
starts after an Off cycle, the suction pressure will be high.
✓ As long as the suction pressure remains above the set point, the CVP pilot valve will be open.
✓ The main ICS valve is kept closed as the high pressure vapor on the servo piston is released
into the suction line of the compressor via the CVP valve.
✓ After operating for a very short period of time, the compressor reduces the pressure in the
suction line below the CVP pilot valve set point. When this has happened, the CVP pilot
valve will close. During normal operation the ICS valve will be completely open.
✓ The manual regulating valves REG (2) and (3) shown are set for an opening which results in a
suitable opening and closing time on the ICS main valve.