Maintenance Guides 1 min read

Guide for diagnosing insufficient capacity of the industrial cooling system

Technical analysis: Troubleshooting industrial cooling system insufficient capacity: heat load calculation, flow balance

Guide for diagnosing insufficient capacity of the industrial cooling system

1. Description of the problem and scope of application

This guide is intended for diagnosing and correcting problems associated with insufficient capacity in an industrial cooling system. Cooling systems are used in a variety of manufacturing facilities, including refrigeration plants, bearing cooling systems, engine cooling systems, and heat exchangers. Compliance with DSTU, EN, ISO standards and use of CE, UkrSEPRO certifications are critical to ensure safety and efficiency.

2. Safety and measures

Requirements for equipment: Reliability of insulation, electrical insulation, disconnection of power supply, use of appropriate equipment and personal protective equipment (insulation, gloves, glasses, separation mask).
Warning: Before performing any diagnostic procedures, install a lockout and tag on the electrical outlets to avoid unexpected situations. When using chemical liquids, use appropriate protective equipment.

3. Necessary diagnostic tools

Name of the tool Model/specification Measuring range Purpose
Multimeter Fluke 434 II 0–600 V, 0–200 mA Measurement of electrical parameters, compliance with standards.
Thermographic camera FLIR T1020 -20°C to 650°C Detection of thermal anomalies in the cooling system.
Vibration analyzer Brüel & Kjær 3580 0–100 kHz Detection of mechanical faults in nodes.
Thermometer Testo 816 -50°C to 300°C Temperature measurement at system points.

4. Inspection before diagnosis

Overview action
System temperature Measure the temperature at the inlet and outlet of the cooling system.
Pressure in the system Measure the pressure in the ascending and descending pipelines.
Filters Check the condition of the filters for contamination.
Previous answers Please note previous deviation notices.

5. Systematic diagnostic scheme

  1. Symptom: The cooling system does not feel the temperature drop.
    1. Measure the temperature at the outlet of the system.
    2. If the temperature is higher than 45°C, continue the diagnosis.
  2. Symptom: Increased pressure in the system.
    1. Measure the pressure in the riser.
    2. If the pressure is higher than 10 bar, diagnose the filters and distribution valves.
  3. Symptom: Incorrect flow allocation.
    1. Measure the flows in each branch.
    2. If the difference is more than 15% from the nominal, check the control valves.
  4. Symptom: Excessive vibration.
    1. Measure the vibration at the nodes.
    2. If the vibration is greater than 4.5 mm/s, check the suspension and hinges.
  5. Symptom: Insufficient refrigerant level.
    1. Measure the refrigerant level.
    2. If the level is below nominal, perform an additional measure.

6. Matrix of compliance reasons

Symptom Reasons (probably) Diagnostic test Expected result
The system does not cool 1. Insufficient refrigerant level Measure the refrigerant level The level is below the nominal level
The system does not cool 2. Incorrect flow distribution Measure the flows in each branch The difference is more than 15%
Increased pressure 1. Contamination of filters Check the filters Increased pollution
Increased pressure 2. Insufficient flow distribution Measure flows The difference is more than 15%
Wrong vibration 1. Insufficient suspension Measure the vibration Vibration more than 4.5 mm/s
Wrong vibration 2. Incorrect setting Check the settings Incorrect parameters

7. Analysis of the causes of failure

7.1. Insufficient refrigerant level

An insufficient level of refrigerant causes improper cooling, since refrigerant is responsible for heat transfer. High pressure or low pressure can be symptoms of an insufficient level of chladon. To confirm, measure the refrigerant level. If the level is below nominal, perform an additional measure.

7.2. Incorrect flow distribution

Incorrect flow distribution leads to uneven cooling. Measure the flows in each branch. If the difference is more than 15%, check the control valves.

7.3. Contamination of filters

Contamination of the filters leads to a decrease in cooling efficiency. Check the filters for dirt. If contamination is high, clean or replace the filters.

7.4. Insufficient suspension

Insufficient suspension leads to system vibration. Measure the vibration at the nodes. If the vibration is greater than 4.5 mm/s, check the suspension and hinges.

7.5. Incorrect setting

Improper adjustment can result in incorrect flow distribution and vibration. Check your system settings. If the settings are incorrect, take an additional step.

8. Step-by-step correction procedures

8.1. Insufficient refrigerant level

  1. Measure the refrigerant level.
  2. If the level is below nominal, perform an additional measure.
  3. Add refrigerant to the system to the recommended level.
  4. Measure the temperature at the outlet of the system.
  5. Check that the desired temperature is reached.

8.2. Incorrect flow distribution

  1. Measure the flows in each branch.
  2. If the difference is more than 15%, check the control valves.
  3. Open or close the control valves according to the recommended values.
  4. Measure the flows again.
  5. Check whether the desired uniformity is achieved.

8.3. Contamination of filters

  1. Check the filters for dirt.
  2. If contamination is high, clean or replace the filters.
  3. Measure the pressure in the system.
  4. Check that the desired temperature is reached.

8.4. Insufficient suspension

  1. Measure the vibration at the nodes.
  2. If the vibration is greater than 4.5 mm/s, check the suspension and hinges.
  3. Restore the suspension or install a new one.
  4. Measure the vibration again.
  5. Check that the desired stability is achieved.

8.5. Incorrect setting

  1. Check your system settings.
  2. If the settings are incorrect, take an additional step.
  3. Reset the settings to the recommended values.
  4. Measure the temperature at the outlet of the system.
  5. Check that the desired temperature is reached.

9. Preventive measures

The reason Precautionary measure Tracking method Recommended interval
Insufficient refrigerant level Periodic measurement of the refrigerant level Multimeter, thermographic camera monthly
Incorrect flow distribution Periodic inspection of control valves Thermographic camera, flow meter Quarterly
Contamination of filters Periodic cleaning or replacement of filters Multimeter, thermometer monthly
Insufficient suspension Periodic inspection of the suspension Thermographic camera, vibration analyzer monthly
Incorrect setting Periodic check of settings Multimeter, thermometer monthly

10. Spare parts and components

Component description Specification When to replace UNITEC-D category
Filter Material: stainless steel, size: 50 mm After 1000 hours of operation Category 15
Control valve Material: stainless steel, size: 30 mm After 500 hours of operation Category 16
Suspension Material: stainless steel, size: 20 mm After 1000 hours of operation Category 17
Cold Type: R-134a, volume: 5 l After 1000 hours of operation Category 18

Learn more about our spare parts, visit our e-catalog: https://www.unitecd.com/e-catalog/

11. Links

  • Standards: DSTU 3013-95, EN 12725, ISO 5149
  • Maintenance manual: UNITEC-D maintenance catalog
  • Additional resources: UNITEC-D maintenance catalog

Contacts: UNITEC-D GmbH, Augsburg, Germany. Phone: +49 821 123 45 67

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