Guide to Correcting Undercapacity in Industrial Cooling Systems: Heat Load Calculation, Flow Balance, Contamination Assessment, and Fluid Inspection

1. Problem description and scope

This guide is intended to solve problems related to insufficient capacity of industrial cooling systems. This includes identifying and correcting when the system cannot provide the required temperature, withstand the heat load or is experiencing low efficiency. Cooling systems used in aerospace, chemical production, energy, and food production are suitable. Severity: critical — leads to production interruption, risk of explosion, or equipment damage.

2. Safety during diagnosis

Requirements for protection:

• Use additional personal protective equipment (PPE): gloves, glasses, respirator.
• Perform the Shutdown and Lockout (LOTO) procedure before operating the equipment.
• Disconnect power and open air vents before accessing the system.
• Do not work on equipment that has residual energy or chemicals.
• Use insulated tools when working with electrical circuits.

3. Necessary diagnostic tools

4. Initial assessment and marking

5. Systematic diagnostic flow

1. Symptom: The system does not provide the required temperature.
   1. Check the inlet and outlet temperatures.
      1. If the inlet temperature is higher than the outlet:
         1. Check the flow rate.
            1. If the flow is higher:
               1. Check for contamination in the heat exchanger.
            2. If flow is lower:
               1. Check fluid level.

6. Matrix of possible causes

7. Analysis of root causes

7.1. Clogging of the heat exchanger

Reason: The accumulation of impurities in the heat exchanger reduces the surface area for heat exchange, which leads to a decrease in the efficiency of the system.

Diagnosis: Measure flow and temperature at inlet and outlet. If the temperature is higher than appropriate and the flow is higher than the higher values, there may be a blockage.

Potential consequences: Improper cooling, higher temperature of production equipment, risk of damage.

7.2. Insufficient flow

Reason: Flow reduction may be due to valve opening, clogging, or lack of fluid.

Diagnosis: Measure the flow on the input and output circuits. If flow is less than 20% of design, check valves and fluid level.

Potential consequences: Insufficient cooling effect, higher temperature, possible explosion.

7.3. High level of vibration

Reason: Uneven load distribution or clogging in working parts.

Diagnosis: Measure the vibrations. If the value is above 10 mm/s, check the vibration level and fluid level.

Potential consequences: Vibration can lead to wear of parts, higher temperature, or explosion.

8. Step-by-step repair procedure

8.1. Clogging correction

1. Disable system (do LOTO).
2. Turn off the power supply.
3. Open access to the heat exchanger.
4. Remove pollution.
5. Check the cleanliness of the heat exchanger.
6. Return the system to working mode.
7. Check the temperature at the inlet and outlet.

8.2. Low flow fix

1. Disable system (do LOTO).
2. Turn off the power supply.
3. Check for contamination.
4. Open the valves.
5. Check the fluid level.
6. Return the system to working mode.
7. Check the temperature at the inlet and outlet.

8.3. Fix for high level of vibration

1. Disable system (do LOTO).
2. Turn off the power supply.
3. Check the vibrations.
4. Remove pollution.
5. Check the fluid level.
6. Return the system to working mode.
7. Check the temperature at the inlet and outlet.

9. Prevention

10. Information about spare parts

For parts, visit: https://www.unitecd.com/e-catalog/

11. Links

• DSTU 2811-94 – Electrical cooling equipment
• EN 1434 - Rules for using cooling systems
• ISO 21469 – Cooling systems
• UNITEC-D technical documentation
• Original manufacturer's instructions