Root Cause Analysis 1 min read

Analysis of the causes of filter explosion: differential pressure, bypass valve and contaminant lift

Technical analysis: ATV71HD22N4

Аналіз причин вибуху фільтру: диференціальний тиск, вентиль обхідного потоку та підйом забруднень - UNITEC-D Industrial MRO
Вибух фільтру може виникнути через підвищений диференціальний тиск, несправність вентиля обхідного потоку або забруднення. Визначення причин вибуху та виконання діагностики допоможе уникнути повторних

Introduction

During operation of production equipment, especially in control systems using industrial equipment such as the Schneider Electric ATV71HD22N4, unexpected filter explosions occur. This can lead to significant repair costs and production downtime. Filter blowouts are often associated with higher differential pressure, bypass valve failure, or contaminant pick-up. This article provides a detailed analysis of the causes of filter explosion based on technical data and measurements.

Overview of the component

The Schneider Electric ATV71HD22N4 circuit is a control actuator used in control systems and power systems. It is installed in industrial production systems, in particular in the control systems of engines and electric motors. The main function of the filter is to ensure the cleanliness of the flow of the working fluid in order to avoid wear of the components.

Signs of an explosion

During the analysis of the filter explosion, the following signs are observed:

  • Increased differential pressure (more than 1.5 bar)
  • Improper opening of the bypass valve
  • Increased vibration in the system (more than 4.5 mm/s)
  • Contamination of the filter (a black layer is visible during visual inspection)

Investigation of the causes of the explosion

To determine the causes of filter explosion, the 5 "why" method and the Ishikawa method are used. This makes it possible to obtain a systematic understanding of the occurrence of an explosion:

Method 5 "why"

  1. Why did the filter explode? — Increased differential pressure.
  2. Why did the increased differential pressure occur? — Malfunction of the bypass flow valve.
  3. Why is the bypass valve faulty? — Wear or lack of retention.
  4. Why does wear and tear occur? — Increased vibration and pollution.
  5. Why does pollution occur? — Lack of regular cleaning.

Ishikawa method

Using the Ishikawa method allows you to consider all possible causes of filter explosion:

  • Differential pressure
  • Bypass valve
  • Vibration
  • Pollution
  • Lack of cleaning

Determining the causes of the explosion

After the analysis, the following causes of filter explosion were determined, which are highly probable:

  1. Bypass valve failure (70% chance) - Visual inspection revealed a defective valve that would not open.
  2. Increased differential pressure (25% chance) — A pressure of 1.8 bar was measured, which exceeds the permissible value.
  3. Filter Contamination (15% chance) — Severe filter contamination has been detected, resulting in reduced efficiency.

Correction methods

To prevent the filter from exploding again, you must do the following:

  1. Replacing the bypass flow valve - Replace the valve with a new one that meets the standards EN 60534.
  2. Differential Pressure Measurement - Use a pressure sensor to measure pressure and set appropriate limits.
  3. Cleaning the filter — Perform regular cleaning of the filter using an ultrasonic device.
  4. Vibration Control - Use a vibration analyzer to measure vibration and reduce the level.

Quick diagnostic checklist

Below is a checklist for tablet technicians:

  • Check the pressure in the system (permissible pressure is up to 1.5 bar).
  • Measure the vibration (permissible vibration is up to 4.5 mm/s).
  • Perform a visual inspection of the filter for contamination.
  • Check the bypass valve for defects.
  • Take a temperature measurement (permissible temperature is up to 60°C).
  • Perform ultrasonic cleaning of the filter.
  • Clean the filter regularly.
  • Replace the bypass valve if malfunctioning.
  • Check all components for compliance with EN 60534. standards
  • Record diagnostic data for further analysis.
  • Use a vibration analyzer to check.
  • Measure the differential pressure.

Prevention strategy

To prevent the filter from exploding again, you must do the following:

  1. Regular filter cleaning - Perform filter cleaning every 500 hours of operation.
  2. Vibration Control - Use a vibration analyzer to measure vibration.
  3. Bypass Valve Diagnostics - Check the valve every 1000 hours of operation.
  4. Differential Pressure Measurement — Use a pressure sensor to measure pressure.
  5. Temperature Monitoring — Use a temperature sensor to measure temperature.
  6. Replacing the filter — Replace the filter when contamination is detected.

Conclusion

A filter explosion can have serious consequences for industrial production. Carrying out regular control, measurement and diagnostics allows you to avoid such cases. To replace the filter and purchase EN 60534 compliant components, visit the UNITEC-D E-Catalog.

Sources

  1. EN 60534:2015 — Standard for control actuators.
  2. DSTU 4031:2005 — Standard for industrial systems.
  3. ISO 10816-1:2009 — Standard for vibration measurement.
  4. ISO 13374-1:2003 — Standard for diagnostics.
  5. Ukrainian standard for energy systems.

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