Maintenance Guides 1 min read

Guide to detection and correction of insufficient capacity of industrial cooling systems

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

Гід по виявленню та виправленню недостатньої потужності промислових систем охолодження - UNITEC-D Industrial MRO
Цей гід допоможе технікам виявити та виправити недостатню потужність промислових систем охолодження. Він включає діагностичні методи, матриці причин, а також рекомендації щодо профілактики та вибору к

1. Problem description and scope

This guide is intended to identify and correct insufficient capacity in industrial cooling systems. The problem can occur in various types of equipment: production plants, cooling systems of modern factories, refrigeration plants, as well as in industrial cooling systems using freons. According to the classification, this problem is considered critical due to the possible impact on productivity, product quality, and personnel safety.

2. Security

Important: Before starting diagnostics, turn off the power supply and perform a lockout/tagout (LOTO) procedure for all system components. Use special clothing, including work gloves, goggles, and safety helmets. Refrigeration systems may contain refrigerants that are toxic and also responsible for the potential release of energy.

3. Diagnostic tools are required

Name of the tool Model/Spec Measuring range The goal
Multimeter Fluke 289 0–1000 V, 0–200 A, 0–2000 Ω Measurement of voltage, current, resistance
Thermography FLIR T650 –20°C to +650°C, resolution 0.05°C Detection of uneven heating
Vibration analyzer Keysight 35670A 0–100 kHz, 0–100 mm/s Detection of vibrational deviations
Thermometer Testo 835 -50°C to +120°C Temperature measurement at workplaces
Manometer Testo 510 0–100 bar Measurement of refrigerant pressure

4. First review

Point Description
1 Record the operating conditions of the system: ambient temperature, humidity, load
2 Record the changes that have been made to the system in the last 24 hours
3 Record the history of alarms if they are displayed
4 Check the condition of all filters and valves
5 Fix the pressure level in the system

5. Systematic diagnostics

  1. Symptom: The system does not provide the required level of cooling
    1. Diagnosis: Measure the temperature at the system outlet
      1. Result: If the temperature is higher than 50°C, check the pressure in the system
    2. Diagnosis: Measure the refrigerant pressure
      1. Result: If the pressure is above 120 bar, check for leaks
  2. Symptom: Uneven heating of components
    1. Diagnosis: Use thermography
      1. Result: If the temperature on different components varies by more than 15°C, check the filtration
  3. Symptom: Increased refrigerant consumption
    1. Diagnosis: Measure the current on the compressor
      1. Result: If the current is higher than 10 A, check the system ventilation

6. Matrix of causes of defects

Symptom Reasons (probably) Diagnostic test Expected result
The system does not provide the required level of cooling
  1. Insufficient refrigerant level
  2. Contamination of the system
  3. Insufficient refrigerant flow
  1. Measure the refrigerant pressure
  2. Measure the temperature at the outlet
  3. Check the filters
  1. If the pressure is higher than 120 bar, there is a leak
  2. If the temperature is higher than 50°C, there is an insufficient level of refrigerant
  3. If the filters are dirty, there is a decrease in flow
Uneven heating of components
  1. Insufficient refrigerant flow
  2. No filtering
  3. Insufficient ventilation flow
  1. Use thermography
  2. Measure the temperature on different components
  3. Check the filters
  1. If the temperature on different components varies by more than 15°C, uneven heating occurs
  2. If the filters are dirty, there is a decrease in flow
  3. If ventilation is insufficient, uneven heating occurs
Increase in refrigerant consumption
  1. Insufficient refrigerant level
  2. Insufficient refrigerant flow
  3. No filtering
  1. Measure the refrigerant pressure
  2. Measure the current on the compressor
  3. Check the filters
  1. If the pressure is higher than 120 bar, there is a leak
  2. If the current is higher than 10 A, insufficient flow occurs
  3. If the filters are dirty, there is a decrease in flow

7. Analysis of the main causes of defects

7.1. Insufficient refrigerant level

Reason: A decrease in the amount of refrigerant in the system can occur due to a leak, incorrect replacement, or incorrect measurement.

Diagnosis: Measure the refrigerant pressure. If the pressure is higher than 120 bar, a leak occurs. If the pressure is below 80 bar, the level may be insufficient.

Confirmation: Measure the outlet temperature. If it is higher than 50°C, this confirms an insufficient level.

Summary: An insufficient level of refrigerant leads to a decrease in the efficiency of the cooling system, which can cause overheating and leakage.

7.2. Contamination of the system

Reason: Contamination can be caused by the lack of filters or high humidity.

Diagnosis: Use thermography. If the temperature on different components varies by more than 15°C, this confirms contamination.

Confirmation: Check the status of the filters. If they are contaminated, this confirms the cause.

Summary: Contamination of the system leads to a decrease in the flow of refrigerant, which can cause uneven heating and the appearance of leaks.

7.3. Insufficient refrigerant flow

Cause: Insufficient flow can occur due to lack of filtering, leaks, or insufficient level.

Diagnosis: Measure the current on the compressor. If the current is higher than 10 A, this confirms insufficient flow.

Confirmation: Measure the refrigerant pressure. If the pressure is higher than 120 bar, a leak occurs.

Summary: Insufficient refrigerant flow leads to a decrease in the efficiency of the cooling system, which can cause overheating and leaks.

8. Step-by-step repair procedure

8.1. Correction of insufficient refrigerant level

  1. Measure the refrigerant pressure
  2. If the pressure is below 80 bar, add refrigerant
  3. Measure the temperature at the outlet
  4. If the temperature is higher than 50°C, do the dosage
  5. Check the system for leaks

8.2. Correction of system contamination

  1. Use thermography
  2. If the temperature on different components varies by more than 15°C, perform cleaning
  3. Check the condition of the filters
  4. If the filters are dirty, replace them
  5. Check the system for leaks

8.3. Correction of insufficient refrigerant flow

  1. Measure the current on the compressor
  2. If the current is higher than 10 A, do the dosage
  3. Measure the refrigerant pressure
  4. If the pressure is higher than 120 bar, top up
  5. Check the system for leaks

9. Prevention

The main reason Prevention strategy Control method Recommended interval
Insufficient refrigerant level Periodic dosing of cold Pressure measurement Monthly
Contamination of the system Filter cleaning Use of thermography Quarterly
Insufficient refrigerant flow Periodic dosing of cold Current measurement Monthly

10. Relevant components

Description of the component Specification When to replace UNITEC-D category
Filter for the cooling system Maximum 100 mm, 1000 l/h Pollution Category 3
Compressor Maximum 2000W, 1000RPM leak Category 2
Manometer 0–100 bar Change measurement Category 5
Thermometer -50°C to +120°C Change measurement Category 4
Thermography 0.05°C Change measurement Category 1

Go to our e-catalog to find the components you need.

11. Links

  • DSTU 3016-95 – Methodology for determining heat loads
  • EN 378:2009 – Safety when working with refrigerants
  • ISO 14644-1:2015 – Purity control in industrial systems
  • UNITEC-D Maintenance Manual – Complete description of maintenance of cooling systems

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