1. Problem description and scope

This guide is intended for diagnosing and solving problems associated with water hammer in systems with hydraulic automatic valves. Water hammer occurs due to a sudden change in pressure and speed of fluid movement in pipelines, which can lead to explosions, damage to pipelines, valves, pumps and other equipment. The problem can arise in systems of the food industry, energy, chemical industry, as well as in cooling and air conditioning systems. The importance of this issue is classified as critical, as water hammer can result in the failure of valuable equipment and hazardous conditions for personnel.

2. Safety and Warnings

Use personal protective equipment (PPE): glasses, gloves, means to protect against noise and higher pressure.
Perform lockout/tagout procedures: be sure to turn off power and system pressure before performing any diagnostic actions.
Be careful when working with high pressure: high pressure can cause an explosion or leakage of liquid, which requires additional protection.
Check for stored energy: in systems using springs or electromagnets, storing energy can lead to unpredictable movements.

3. Necessary diagnostic tools

4. The first inspection with filling out the report

5. Systematic diagnostic scheme

1. Symptom: Unpredictable noise and explosions during valve operation
   1. Check: Fluid leakage or vibration
      1. If vibration is high: Check valve closing speed
         1. If closing speed is higher than 1.5 m/s: Check valve parameters and selection damper
            1. If the damper does not match: Select the correct damper
2. Symptom: High system pressure
   1. Check: Leaks or improper connections
      1. If leakage is found: Check valve and piping for tightness
3. Symptom: Unstable operation of the valve
   1. Check: Presence of clogging or malfunction in the system
      1. If clogging is detected: Clean the pipeline and valve

6. Matrix of causes of malfunctions

7. Analysis of the reasons for each malfunction

7.1 Closing speed > 1.5 m/s

A valve closing speed greater than 1.5 m/s may result in water hammer, causing explosions and pipeline damage. This is caused by an insufficient closing speed of the valve, which does not meet the recommended parameters.

How to check: Measure the closing speed of the valve with a flow rate tester. If the value is higher than 1.5 m/s, this indicates a problem.

Consequences: Explosions, valve, pipeline and pump damage.

7.2 Wrong choice of damper

Incorrect damper selection can result in insufficient vibration reduction resulting in water hammer. The damper must be selected taking into account the flow rate and pressure in the system.

How to check: Check the damper parameters and compare with the recommended values.

Consequences: Unstable operation of the valve, explosions, pipeline damage.

7.3 Low level of pipeline diameter

A small pipe diameter can lead to high flow velocities that cause water hammer. This occurs due to the insufficient size of the pipeline for the working volume.

How to check: Measure the diameter of the pipeline and compare with the design values.

Consequences: Explosions, pipeline damage, reduction of system efficiency.

8. Step-by-step solution methods

8.1 Correction of valve closing speed

1. Measure the valve closing speed
2. If the speed > 1.5 m/s, install a control system
3. Set the closing speed to 1.2 m/s
4. Check for explosions

8.2 Choosing the right damper

1. Determine the flow rate and pressure in the system
2. Choose a damper according to the recommended parameters
3. Install the damper in the system
4. Check for explosions

8.3 Change in pipeline diameter

1. Measure the diameter of the pipeline
2. If the diameter is smaller than the design, replace the pipeline
3. Install a new pipe
4. Check for explosions

9. Preventive measures

10. Spare parts and components

To order components, please follow the link: https://www.unitecd.com/e-catalog/

11. Links

Additionally use:

• Standards: EN 12238, ISO 5199, DSTU 4185-2018
• Original manufacturers: Catalogs of manufacturers of valves and pipelines
• Specialized guides: UNITEC-D additional materials on hydraulic systems

1. Problem description and scope

This tutorial is intended to solve problems related to insufficient capacity of the hydrocooling system in industrial installations. Problems can occur in any industry that uses cooling systems, including airfields, food processing plants, chemical plants, and energy facilities. The threat is classified as critical because insufficient cooling flow can cause the equipment to overheat and fail.

2. Safety precautions

Ensuring power cut and blocking of mechanical working parts before performing any actions.

Use special equipment to protect against electric current, moisture and high pressure.

Before starting work, check the presence of residual energy in the system.

3. Necessary diagnostic tools

4. First assessment

5. Systematic diagnosis

1. Symptom: The cooling system does not remove enough heat.
   1. Measure the temperature at the inlet and outlet of the system.
   2. If the difference is more than 10°C, check the cooling flow.
2. Symptom: Temperature increase in key nodes.
   1. Use thermography to detect high temperature areas.
   2. Check for dirt build-up.
3. Symptom: Pressure mismatch in the system.
   1. Measure the pressure at the inlet and outlet.
   2. If the pressure is higher than 80% of the nominal, check the filters.

6. Matrix of causes of malfunctions

7. Analysis of root causes

7.1 Contamination of filters

Contamination of the filters can reduce the cooling flow. This occurs due to dust accumulation, clogging or high levels of pollution. If the filters are not cleaned regularly, they can cause the system to overheat and increase energy consumption.

7.2 Contamination of the heat exchanger

Contamination of the heat exchanger reduces the efficiency of heat exchange. This can be caused by deposits, moisture or high levels of pollution. Improper ventilation or high humidity can damage the heat exchanger.

7.3 Refrigerant leak

Refrigerant leakage can occur due to damage to pipelines, filters or components. This leads to a decrease in the efficiency of the cooling system and can lead to overheating of the equipment. Re-introduction of chladon without diagnosis can cause a repeated leak.

8. Step-by-step decision procedures

8.1 Removal of contamination of filters

1. Turn off the system and disconnect the electrical power.
2. Open the filters and remove the dirt.
3. Check inlet and outlet pressure to ensure correct flow.

8.2 Cleaning the heat exchanger

1. Use thin fluids to clean the heat exchanger.
2. Check for moisture and high levels of contamination.
3. Measure the inlet and outlet temperatures again.

8.3 Recovery of the khladon solution

1. Turn off the system and disconnect the electrical power.
2. Measure pressure and temperature.
3. Add the appropriate amount of refrigerant and check the pressure.

9. Preventive measures

10. Spare parts and components

For more information on spare parts, please visit: https://www.unitecd.com/e-catalog/

11. Links

• DSTU 4787:2017 – Requirements for maintenance of industrial equipment
• EN 13790:2016 – Requirements for cooling systems
• ISO 14617:2019 – Diagnostics of industrial systems
• UNITEC-D Maintenance Manual