Maintenance Guides 1 min read

Guide for diagnosing the high temperature regime of the discharge of the script compressor compartment

Technical analysis: Troubleshooting screw compressor high discharge temperature: oil level, cooler fouling, thermostat f

Гід для діагностики високого температурного режиму висипу відсіку скріптового компресора - UNITEC-D Industrial MRO
Гід для діагностики високого температурного режиму висипу в скріптовому компресорі. Високий температурний режим може призвести до вибуху, зношування деталей та небезпечних умов роботи. Гід включає діа

1. Problem description and scope

This guide is intended for diagnosing a high temperature rash in a script compressor. If the discharge temperature exceeds the permissible limits (eg 100 °C for standard oil-cooled compressors), it can lead to explosion, wear of parts, loss of efficiency and dangerous operating conditions. The threat is considered critical because the high temperature regime can lead to a stoppage of production or an explosion of the compressor.

2. Safety nets

Disconnecting power and blocking the unit before diagnosis: Before any technical diagnostic actions, disconnect the power supply to the compressor and install blocking strips. Use PPE (protective gloves, goggles, protective weapons) to protect against liquids, high pressures and electrical discharges.
Hazardous Energy: Perform a lockout and isolation procedure before diagnosis to avoid unexpected explosions or equipment damage.

3. Necessary diagnostic tools

Name of the tool Model/Specification Measuring range Purpose
Multimeter Fluke 87V 0–2000 Ω, 0–600 V, 0–20 A Measurement of electrical parameters and resistance
Thermal camera FLIR T1030sc –20 °C to 550 °C Determination of the temperature regime of the rash
Vibration analyzer BBE 3020 0–10000 Hz Detection of vibrational deviations
Manometer Testo 2050 0–200 bar Pressure measurement in the system

4. First assessment and filling in the checklist

action Description
Record the temperature of the rash Record the current temperature of the rash and compare with the permissible values
Pressure measurement in the system Use a pressure gauge to determine system pressure
Checking the oil level Determine if the oil is at the proper level
Checking the condition of the cooler Determine if there is flaking or clogging on the cooler
Measurement of the vibrational state Use a vibration analyzer to determine deviations

5. Systematic diagnostic flow

  1. Measure the temperature of the rash using a thermal camera
    1. If the temperature exceeds 100 °C, go to the next step
    2. If the temperature is within acceptable limits, check other factors
  2. Check the oil level in the compressor
    1. If the oil level is below 50%, perform an additional analysis
    2. If the level is normal, check the cooler
  3. Measure the pressure in the system
    1. If the pressure is higher than 150 bar, perform diagnostics for the absence of clogging
    2. If the pressure is normal, check the thermostat
  4. Perform a vibrational state analysis
    1. If the vibration exceeds 4.5 mm/s — carry out diagnostics for the absence of malfunctions
    2. If the vibration is within acceptable limits, check the ventilation and ambient temperature

6. Compensation and reasons matrix

Symptom Probable causes (by level of probability) Diagnostic testing Expected result
High temperature rash
  1. Low oil level
  2. Clogging of the cooler
  3. Thermostat malfunction
  4. Excessive ambient temperature
  1. Measure the oil level
  2. Perform a coolant analysis
  3. Check the thermostat
  4. Measure the ambient temperature
  1. The oil level is below 50%
  2. The cooler is clogged
  3. The thermostat does not meet the technical specifications
  4. The ambient temperature exceeds 40 °C

7. Analysis of the reasons for each malfunction

7.1. Low oil level

A low oil level can be due to leaks, oil consumption, or a malfunction in the power system. An oil leak can lead to an increase in the temperature of the rash due to insufficient cooling. If the oil level is below 50%, it can cause explosion or wear of parts.

7.2. Clogging of the cooler

Clogging of the cooler can reduce the cooling efficiency. If the cooler is blocked or dirty, the discharge temperature may exceed the permissible limits. It is necessary to clean the cooler and check its efficiency.

7.3. Thermostat malfunction

A malfunctioning thermostat can result in improper rash temperature control. If the thermostat does not meet specifications, it may not turn off the system or turn it on in time. This leads to a high temperature rash.

7.4. Excessive ambient temperature

Excessive ambient temperature can affect the cooling efficiency of the compressor. If the ambient temperature exceeds 40 °C, the rash can withstand the high temperature, resulting in an explosion.

8. Step-by-step reimbursement procedures

8.1. Low oil level

  1. Measure the oil level in the compressor
  2. If the oil level is below 50%, add oil to the specified level
  3. Check the power system for leaks
  4. After adding the oil, measure the temperature of the rash

8.2. Clogging of the cooler

  1. Determine the condition of the cooler
  2. Clean the cooler of dirt or accumulated substances
  3. Check the cooling efficiency
  4. Measure the temperature of the rash after cleaning

8.3. Thermostat malfunction

  1. Check the thermostat for compliance with technical specifications
  2. If the thermostat does not work, replace it
  3. Measure the temperature of the rash after installing the new thermostat

8.4. Excessive ambient temperature

  1. Measure the ambient temperature
  2. If the temperature exceeds 40 °C, take additional cooling measures
  3. Measure the temperature of the rash after the ambient temperature has decreased

9. Preventive measures

The reason Preventive strategy Monitoring method Recommended interval
Low oil level Regular oil level measurement Manometer, thermal chamber Weekly
Clogging of the cooler Cleaning the cooler Thermal camera, manometer Monthly
Thermostat malfunction Checking the thermostat Multimeter, thermal camera Every quarter
Excessive ambient temperature Measures to reduce the temperature Thermal camera, manometer Monthly

10. Spare parts and components

Description of the component Specification When to replace UNITEC-D category
Compressor oil ISO 46, 68, 100 Oil level below 50% Oil
Cooler Material: stainless steel Clogging Coolers
Thermostat Temperature: 85–100 °C Malfunction Control devices
Liquid for cooling Water, glycine solution Clogging Coolers

Please refer to our e-catalog to select the appropriate parts: https://www.unitecd.com/e-catalog/

11. Links

Note: This guide complies with CE and UkrSEPRO requirements. All diagnostic procedures are performed in compliance with safety rules.

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