Support and fix humidity problems in dry air: detect and fix exceptions in dew point

1. Problem description and scope

This is a guide to diagnosing and correcting dry air dew point exceptions that can occur in dry air systems. The problem can arise in industrial installations, including the transportation, aviation, food, chemical and energy industries. Dew temperature exceptions can be considered critical because they lead to corrosion, explosions, product degradation, and loss of system efficiency. The task is to identify the causes of exceptions and correct them.

2. Safety precautions

Warning: The use of electrical equipment can lead to electric shock. Use appropriate personal protective equipment.

Warning: Before performing any diagnostic actions, perform the lockout and tagout (LOTO) process to avoid unexpected events.

Warning: Dry air systems may contain liquids or high pressure. Check for accumulated energy or fluids before diagnosis.

3. Necessary diagnostic tools

4. Initial assessment: checklist

5. Systematic diagnostic flow

1. Symptom 1: Moisture in the system, higher dew point values
   1. Check the dew point with a thermal camera
   2. If the dew point is above 0°C, continue with the diagnosis
   3. Check the pressure in the dry air system
   4. If the pressure is higher than 7 bar, check the filters and fan
   5. Check the vibration analyzer for abnormalities
   6. If anomalies are detected, check the wiring connection
2. Symptom 2: Change in dew point temperature without known changes in the system
   1. Check the stability of the system parameters
   2. Diagnose whether the dew point temperature meets the standard values
   3. Perform a vibration diagnostic study analysis
   4. Check the condition of the filters
   5. Perform resistance and voltage measurements
   6. If deviations are found, check the drain valves
3. Symptom 3: Decreased system performance
   1. Check system pressure
   2. Perform a vibration diagnostic study analysis
   3. Check the condition of the filters
   4. Perform resistance and voltage measurements
   5. Check the drain valves
   6. If deviations are found, check the refrigeration unit

6. Matrix of occurrence of defects

7. Detailed analysis of the reasons for exceptions

7.1. Incorrect amount of refrigerant

An incorrect amount of refrigerant can lead to moisture in the system. The determination is made by measuring the pressure and temperature of the refrigerant. If the coolant pressure is higher than 10 bar, this may indicate excessive coolant. An incorrect amount of refrigerant leads to a decrease in the efficiency of the system, the appearance of moisture and possible leaks.

7.2. Lubrication of the heat exchanger

Lubrication of the heat exchanger leads to a decrease in the efficiency of heat exchange, which can cause the appearance of moisture. The determination is made by analyzing the surface temperature of the heat exchanger. If the surface temperature is higher than 30°C, this may indicate oiling. Lubrication of the heat exchanger can lead to a decrease in the efficiency of the system and the appearance of moisture.

7.3. Malfunction of the drain valve

A malfunction of the drain valve leads to grease in the system, which can cause moisture. Drain valve testing is performed using diagnostic tools such as a vibration analyzer. If the valve does not open, this may indicate a malfunction. A malfunction of the drain valve can lead to a decrease in the efficiency of the system and the appearance of moisture.

8. Step by step repair procedure

8.1. Correcting the wrong amount of hladon

1. Measure the pressure and temperature of the refrigerant
2. If the pressure is higher than 10 bar, restore the refrigerant to the recommended level
3. Check the recovery of the refrigerant using a multimeter
4. After restoring the refrigerant, check the pressure and temperature
5. Diagnose system performance

8.2. Correction of oiling of the heat exchanger

1. Perform an analysis of the surface temperature of the heat exchanger
2. If the surface temperature is higher than 30°C, clean the heat exchanger
3. Check the condition of the heat exchanger using a thermal camera
4. After cleaning the heat exchanger, check the surface temperature
5. Diagnose system performance

8.3. Drain valve malfunction correction

1. Check the condition of the drain valve
2. If valve does not open, repair or replace
3. Check valve recovery using a vibration analyzer
4. After restoring the valve, check its operation
5. Diagnose system performance

9. Prevention methods

10. Spare parts and components

Please refer to our e-catalog: https://www.unitecd.com/e-catalog/

11. Links

• Standards: DSTU, EN, ISO
• Reference materials: Manufacturers' catalogs
• Links to other UNITEC-D manuals