Diagnosis and correction of pressure drop in the compressed air system: effective work with ultrasonic equipment, analysis of requirements and optimization of the pipeline network

1. Problem description and scope

This diagnostic guide is dedicated to detecting and correcting pressure drops in the compressed air system. Finding a pressure drop can affect production equipment, reduce process efficiency, and increase energy costs. Depressurization can be critical in systems with high stability requirements, such as aerospace installations, chemical reactors, and automated production lines. Determining the cause of the pressure drop is critical to ensuring uninterrupted production.

2. Safety precautions

Requirements for protective equipment: Use work gloves, headgear and noise protection during diagnosis.

Lockout and Tagout Requirements: Before performing any diagnostic actions, lockout power, set the dash, and disconnect power to the compressed air system.

Stored Energy Warning: Turn off the compressed air system before starting the diagnosis to avoid leakage or electrical shock.

3. Necessary diagnostic tools

4. First examination: Check before starting diagnostics

5. Systematic diagnostic scheme

1. Symptom: Pressure drop in the compressed air system.
1. Use a manometer to measure the pressure at the measurement points.
2. If the pressure rises during system operation, check the measurement range.
3. If pressure remains low, use an ultrasonic leak detector.
2. Symptom: Leak detection.
1. Use an ultrasonic detector to detect leaks.
2. If a leak is detected, record the location and intensity.
3. Record the leakage value in dB.
3. Symptom: Airflow change.
1. Use a multimeter to measure power and current.
2. Determine if airflow is increasing or decreasing.
3. Compare with normative values ​​of costs.
4. Symptom: Uneven pressure distribution.
1. Use thermography to detect uneven temperature distribution.
2. Record the temperature at each point.
3. Compare with standard values.

6. Matrix of reasons for failure

7. Analysis of root causes

7.1 Air leakage

An air leak is the most likely cause of the pressure drop. It occurs due to damage to pipelines, hoses, faucets or nodes. Leakage can occur due to physical damage, wear, or improper installation of components.

To confirm a leak, use an ultrasonic detector that will detect a leak in the 40-120 dB range. If a leak is confirmed, it can lead to reduced system pressure, increased air flow, and energy loss.

7.2 Incorrect source settings

Incorrect adjustment of compressed air sources can lead to pressure changes in the system. This may be due to the selected power, source selection or the use of inappropriate components.

To confirm the source setting, use a pressure gauge to determine the pressure range. If the pressure changes during the operation of the system, this may indicate incorrect settings.

7.3 Clogging in the pipeline

A blockage in the pipeline can lead to a decrease in pressure, especially if it occurs in critical places. This may be due to deposits, wear or incorrect installation of components.

To confirm blockage, use thermography to detect uneven temperature distribution. If a blockage is found, it can lead to reduced pressure, increased air flow and energy loss.

7.4 Change in air flow

A change in air flow can occur due to an increase or decrease in system requirements. This may be due to a change in the production regime, the selection of the wrong equipment or an increase in system requirements.

To confirm the change in airflow, use a multimeter to determine the change in power. If the flow rate changes, it may indicate a change in system requirements.

7.5 Incorrect operation of the compressor unit

Incorrect operation of the compressor unit can lead to a decrease in pressure. This could be due to compressor failure, incorrect settings, or component failure.

To confirm the operation of the compressor unit, use a pressure gauge to determine the pressure range. If the pressure changes during the operation of the system, this may indicate a malfunction of the compressor unit.

8. Step-by-step repair procedure

8.1 Air leakage

1. Use an ultrasonic detector to detect leakage in the 40-120 dB range.
2. Record the location of the leak and its intensity.
3. Use special tools to fix the leak.
4. Measure the pressure again with the pressure gauge.
5. Check for leakage in the 40-120 dB range.

8.2 Incorrect source settings

1. Check the settings of the compressed air sources.
2. Change the configuration parameters as required.
3. Use a manometer to measure pressure.
4. Check the change in pressure range.
5. Record the results and perform the check.

8.3 Clogging in the pipeline

1. Use thermography to detect uneven temperature distribution.
2. Record the location of the blockage and its intensity.
3. Use special tools to correct the blockage.
4. Measure the pressure again with the pressure gauge.
5. Check for uneven temperature distribution.

8.4 Change in air flow

1. Use a multimeter to determine the power change.
2. Record the change in airflow.
3. Change the airflow parameters as required.
4. Use a multimeter to measure power.
5. Check the change in power range.

8.5 Incorrect operation of the compressor unit

1. Use a pressure gauge to determine the pressure range.
2. Check the operation of the compressor unit.
3. Change the configuration parameters as required.
4. Use a manometer to measure pressure.
5. Check the change in pressure range.

9. Protective measures to prevent reoccurrence of failure

10. Appropriate components and spare parts

Refer to UNITEC-D e-catalog for spare parts: https://www.unitecd.com/e-catalog/

11. Links

• DSTU 2831-94 – Technical conditions for compressed air
• EN 12021 – Compressed air standards
• ISO 14644-1 – Cleanliness control in aerotechnical installations
• UNITEC-D Technical Manual for Compressed Air Systems
• UNITEC-D Maintenance Guide for Industrial Compressed Air Systems