A guide to finding the causes of moisture temperature deviations in compressor air supply

1. Problem description and scope

This guide is intended to find the causes of moisture temperature deviations (dewpoint) in air compressor systems, especially in the conditions of industrial production in Ukraine. Deviation of the moisture temperature can occur due to an insufficient level of refrigerant, contamination of the heat exchanger, a malfunction of the exhaust valve, or an incorrect load ratio. Deviation from normal values ​​affects air quality, system efficiency, and production efficiency. The problem belongs to the critical class, because higher humidity can lead to corrosion, knocking out parts and knocking out production.

2. Security

Protective Equipment Requirements: Use impact protection (half boots, gloves), headgear, and chemical resistant clothing.
Lockout and tagout requirements: Before performing any operation, disconnect the compressor from power and install lockout and tagout to avoid unforeseen incidents.
Stored Energy Caution: Before accessing system components, ensure that all electrical supplies are disconnected and lock out accordingly.
Chemical caution: When using refrigerant or coolant, use chemical protection.

3. Necessary diagnostic tools

4. Initial evaluation

5. Systematic diagnostic flow

1. Symptom: Moisture temperature deviation above 3°C from the nominal value.
   1. Diagnostics: Measure the moisture temperature in the operating mode.
      1. Result: If the moisture temperature is above 3°C, do the following.
         1. Definition: Check the coldon level.
            1. Result: If the chladon level is high, do the following.
               1. Causes: Insufficient refrigerant level or leakage.
                  1. Diagnostic check: Perform a system pressure analysis.
                     1. Expected result: If the pressure is below nominal, do the following.
                        1. Recovery: Add hladon to the system.

6. Matrix of causes of malfunctions

7. Analysis of the causes of each malfunction

7.1. Insufficient refrigerant level

Reason: Insufficient refrigerant can be caused by a leak, lack of addition, or improper storage of the system. This leads to a decrease in cooling efficiency and an increase in moisture in the air.

Diagnosis: Measure the pressure in the system. If the pressure is below the nominal, this may indicate a refrigerant leak.

Message: If this problem is not addressed, high humidity will occur, leading to corrosion and reduced air quality.

7.2. Contamination of the heat exchanger

Reason: Contamination of the heat exchanger can occur due to the accumulation of dust, moisture or other contaminants. This leads to a decrease in heat exchange efficiency.

Diagnosis: Perform thermography of the heat exchanger. If uneven heating is observed, this may be a sign of contamination.

Message: If this problem is not resolved, the cooling efficiency will decrease, resulting in higher humidity in the air.

7.3. Malfunction of the exhaust valve

Cause: Exhaust valve failure can be caused by mechanical damage, corrosion or clogging. This leads to improper moisture release.

Diagnosis: Check the operation of the exhaust valve. If the valve does not open or close, this may indicate a malfunction.

Message: If this problem is not resolved, moisture will accumulate in the system, resulting in higher humidity in the air.

7.4. Incorrect load ratio

Reason: Incorrect load ratio can occur due to changes in the system, incorrect settings or lack of adjustment. This leads to uneven distribution of moisture.

Diagnosis: Analyze the load on the system. If the load exceeds the nominal, this may be a sign of a malfunction.

Message: If this problem is not resolved, moisture will accumulate in the system, resulting in higher humidity in the air.

8. Step-by-step recovery procedures

8.1. Insufficient refrigerant level

1. Measure the pressure in the system.
2. If the pressure is below nominal, add refrigerant to the system.
3. Check the pressure after adding refrigerant.
4. Recheck the moisture temperature.

8.2. Contamination of the heat exchanger

1. Perform thermography of the heat exchanger.
2. If uneven heating is observed, clean the heat exchanger.
3. Check the condition of the heat exchanger after cleaning.
4. Recheck the moisture temperature.

8.3. Malfunction of the exhaust valve

1. Check the operation of the exhaust valve.
2. If the valve does not open, replace the valve.
3. Check valve operation after replacement.
4. Recheck the moisture temperature.

8.4. Incorrect load ratio

1. Analyze system load.
2. If the load exceeds the rated load, adjust the load.
3. Check the system status after adjustment.
4. Recheck the moisture temperature.

9. Preventive measures

10. Production parts and components

For production parts, go to https://www.unitecd.com/e-catalog/.

11. Links

• DSTU 2507-97: Requirements for maintenance and repair of industrial installations
• EN 13780: Requirements for the air supply system
• ISO 8068: Requirements for diagnostics of industrial equipment
• UNITEC-D technical instructions