Refrigeration condenser fouling detection

Background

A food storage and processing facility depends on refrigeration to maintain its operating conditions. As the condenser fouls, the compressor has to work harder to provide the same cooling. Our review follows that relationship over time, using the refrigeration load as the context for the pressure reading.

The problem

The system can continue operating while its electricity demand rises. A cleaning schedule based only on the calendar gives the team little connection between the planned work and the condenser’s current condition. The increasing effort can therefore remain part of everyday operation until someone looks at pressure alongside the load.

How we found it

We use a head pressure transducer on the refrigeration circuit and monitor compressor current. The dashboard follows the ratio of head pressure to load, with a threshold for cleaning. A rising ratio while load remains constant makes the developing fouling visible and connects the maintenance question to the measured operating penalty.

What changed

The cleaning decision follows the measured penalty rather than the calendar alone. The team can review the pressure and load trend to see why the condenser needs attention. That gives maintenance a specific condition to act on and an operating record to use when discussing the timing of the work.

The lesson

We keep the load beside the pressure reading so a change has context. For this system, the useful signal is increasing pressure for the same cooling duty. Continuing to follow the ratio after cleaning gives the team a way to review the effect of maintenance and watch for renewed drift, with the next cleaning decision tied to the equipment’s measured condition.