1. Problem Description and Scope

This diagnostic guide addresses the issue of compressed air pressure drop, which may occur in various types of industrial equipment, including production, chemical processes, transportation, and energy. Depending on its severity, this may be a critical problem affecting productivity and efficiency of production. A pressure drop may lead to process stoppage, safety violations, and increased energy costs.

2. Safety and Protection

Important: Before starting diagnostic work, ensure complete disconnection of power and perform the lockout/tagout procedure. Use personal protective equipment (gloves, eye protection, helmets, work clothes) to protect against hazardous liquids, high pressure and electrical discharges.

3. Required diagnostic tools

Tool Name	Model/Specification	Measurement range	Objective
Ultrasonic Leak Detector	Ultrasonic Leak Detector Model 5000	20 Hz - 20 kHz	Leak Detection in Pipelines
Multimeter	Fluke 87V	0-2000 mA, 0-2000 V	Measurement of electrical parameters
Thermocamera	FLIR T1020	-20°C to 550°C	Anomaly detection in thermal imaging
Vibration Analyzer	Keysight V93000	0.1 Hz - 20 kHz	Mechanical anomaly detection
Pressure Gauge	Testo 510	0 - 100 bar	Pressure measurement in the system

4. Check before starting diagnostics

Step	Action
1	Record the operating conditions of the system: temperature, humidity, operating time
2	Determine whether there were changes in the system (repair, component change)
3	Check alarm history and errors
4	Make a photo or diagram of the system for tracking

5. Systematic Diagnostic Scheme

Symptom: Pressure spike in the system
1. Check the system pressure using a pressure gauge
2. If the pressure drops by 0.5 bar within 10 minutes — perform the following actions
Diagnosis: Leak Detection Using Ultrasonic
1. Use an ultrasonic leak detector with frequency selection 10 - 20 kHz
2. Check each node of the system, especially connection points, valves, filters
3. If noise is detected above 60 dB — this may be a leak
Confirmation: Pressure measurement with open node
1. Open the system node and measure the pressure
2. If the pressure drops by 0.3 bar in 5 minutes — leak confirmed
Визначення причини: Аналіз вимог та оптимізація мережі
1. Визначте максимальну потужність системи за допомогою манометра
2. Check whether the actions are carried out in consideration of the calculated capacity
3. If the power exceeds 1.5 kW per 100 m pipeline — perform optimization

6. Matrix of Causes of Defects

Symptom	Possible cause	Diagnostic test	Expected result
Pressure spike	Leak in the pipeline	Ultrasonic Leak Detection	Sound more than 60 dB
Pressure surge	Incorrectly set power	Power Measurement	Power exceeds 1.5 kW per 100 m
Pressure spike	Filter clogging	Filter Check	Contaminated filter

7. Analysis of the main causes of defects

7.1. Leak in the pipeline

Leakage in a pipeline may occur due to surface damage, incorrect installation, or material aging. This leads to pressure loss and reduced system efficiency. To confirm a leak, use an ultrasonic detector and measure the sound in the range of 10-20 kHz. If the sound is more than 60 dB, this confirms a leak.

7.2. Incorrectly Installed Power

Incorrectly set power may lead to energy consumption and pressure drop. To detect this cause, measure the power at a distance of 100 m pipeline. If the power exceeds 1.5 kW, perform network optimization.

7.3. Filter Clogging

Filter clogging may lead to a reduction in air flow and pressure loss. To check the filter, use a manometer and check the pressure difference before and after the filter. If the difference exceeds 0.3 bar, the filter needs to be replaced.

8. Problem-Solving Steps

8.1. Leak Repair

Block the system and perform the drainage
Use an ultrasonic detector for detecting leakage points
Remove the leak and install a new item (for example, fastening)
Check pressure up to 100 bar

8.2. Power Optimization

Measure the power at a distance of 100 m pipeline
If the power exceeds 1.5 kW — perform optimization
Install additional nodes or reduce costs
Check pressure up to 100 bar

8.3. Filter Replacement

Measure the pressure difference before and after the filter
If the difference exceeds 0.3 bar — remove the filter
Install a new filter with higher capacity
Check pressure up to 100 bar

9. Preventive Measures

Main cause	Preventive strategy	Monitoring method	Recommended interval
Leak in the pipeline	Regular ultrasonic inspection	Pressure gauge, ultrasonic detector	Monthly
Incorrect power	Network Optimization	Power Measurement	Quarterly
Filter clogging	Filter Replacement	Pressure difference check	Monthly

10. Spare Parts and Components

Component description	Specification	When to replace	Category UNITEC-D
Air filter	Pressure difference > 0.3 bar	Monthly	Filters
Pipe mounting	Leak detected	Depends on the conditions	Pipelines
Pressure sensor	Pressure > 100 bar	Annual	Sensors

You can find all the necessary parts on the UNITEC-D website: https://www.unitecd.com/e-catalog/

11. References

DSTU 2836-94 – Compressed Air Systems
EN 60519 – Compressed Air Business Systems
ISO 14644-1 – Cleanliness Control in Industrial Systems
UNITEC-D Maintenance Guide: Compression Systems

Conclusion

Diagnosis and resolution of pressure drop issues in compressed air requires a systematic approach, use of accurate tools and thorough analysis. Performing this manual will ensure effective problem resolution and increase system reliability.