A major FMCG production facility in Enugu experienced a sudden failure of its ammonia compressor following repeated tripping of the main breaker. The issue was traced to a Danfoss VLT Automation Drive rated at 500 kW, which shut down unexpectedly while connected to the compressor motor.

Although a spare VFD of the same brand and power rating was available, the replacement unit also failed in December 2025 under similar operating conditions, prompting the client to engage the Teknifix team for urgent intervention. A comprehensive assessment was carried out to identify the root cause of the repeated failures. Diagnostics revealed that all main fuses and thyristors had been damaged.

The compromised components were replaced using Danfoss OEM-certified spare parts, restoring the drive to operational condition. One of the faulty drives was successfully repaired on-site by the Team Teknifix in December, 2025.

During the investigation, it was observed that the 500 kW VFD was powering an electric motor of equal rating, leaving no operational headroom. Based on this finding, Team Teknifix recommended an upgrade to a higher-rated VFD (560 kW or 630 kW) to improve reliability and prevent future failures.

The second VFD was subsequently repaired and fully restored in early January 2026, bringing the ammonia compressor system back to stable operation.

Project Scope Included:

• On-site fault diagnosis and emergency response
• Inspection of power components and protection devices
• Root cause analysis and system rating evaluation
• Replacement of damaged components with OEM-certified spares
• Functional testing and recommissioning of the VFD
• Technical recommendation for capacity upgrade

The intervention restored stable operation of the ammonia compressor, significantly reducing downtime and production losses.