Fault Analysis Fault Diagnosis and Maintenance of Air Compressor Abnormal Abnormality Mao Yunyan Zhejiang Institute of Air Compressor and Pneumatic Tools Product Quality Inspection Center, Zhejiang Cangzhou 324022.
The abnormal suction and exhaust of the air compressor is a common fault in the use of the air compressor, but the causes are also various. The following are some of the following reasons for the abnormal suction and exhaust, and the corresponding maintenance measures. .
1 Abnormal intake and exhaust temperature due to poor suction of the stage suction valve, the stage suction line is heated, and the level of suction temperature rises abnormally. The treatment measures to replace the new parts and remove the high temperature machine close to the suction pipe; 2 the intermediate stage suction valve has a bad backflow and the front stage cooler has low efficiency, and the intermediate stage suction temperature rises abnormally. Handling measures Check the air tightness of the suction and exhaust valve and whether the work is sensitive and reliable. Replace the new parts, ensure the cooling water volume, and clean the cooler. 3 The reverse flow is caused by the poor suction and exhaust valve of the front stage, so that the air pressure between the stages is lowered. If the suction and exhaust valves are bad, the air pressure between the stages will increase, and the resistance of the connecting line will be large, and the exhaust temperature will rise abnormally. Treatment measures Check or repair new valves, check and clean the pipelines; 4 Before the secondary suction, the exhaust pressure drops due to leakage to the outside of the machine, and the intermediate exhaust temperature is abnormally low. Treatment measures Check the leakage site and take measures to stop the leakage; 5 due to scale or dirt, the cooling efficiency of the cooler is low, the resistance of the connected secondary pipeline is large, and the temperature between the stages is abnormally increased. Treatment measures ensure the amount of cooling water, clean the cooler, replace the new parts, check and clean the pipeline; 6 discharge valve, the bypass valve is not closed tightly, and the intermediate stage suction temperature is abnormally low. The treatment measures completely close the discharge valve and the bypass valve; 7 due to deformation of the valve piece, the valve seat surface is poor, the valve is attached to the inclusion valve, the sealing surface is poorly fitted, the valve spring is broken, and the valve spring is damaged. abnormal. Treatment measures Replace the valve plate, mechanically or re-spin the valve seat surface; clean the valve, remove the inclusion tightening valve, re-learn, replace the gasket, make the valve completely fit; replace the valve spring and other measures.
2 Absorption and exhaust pressure abnormality 2.1 Power consumption exceeds the design requirement 1 The gas valve resistance is too large. Handling measures Check whether the valve spring force is qualified, whether the valve passage area is large enough; 2 the suction pressure is too low. Treatment measures the pipes and coolers to eliminate excessive resistance; 3 internal leakage between compression stages. Treatment measures Check whether the suction and exhaust pressure is normal, whether the gas discharge temperature of each level is increased, and take corresponding measures.
2.2 Exhaust pressure abnormality The exhaust valve has a large resistance to the check valve and the exhaust line is abnormal. Handling measures Check the check valve, and check the troubleshooting of the full open exhaust valve process.
The 2.3-stage suction pressure is abnormally increased. The first-stage suction and exhaust valve is poor, and the suction is insufficient. Disposal measures to remove new parts; 2 high-pressure gas flows into the suction line, abnormal treatment of the suction line completely close the bypass valve, check the procedure, eliminate the fault, and pay attention to prevent overload.
2.4 The intermediate stage suction pressure is abnormally increased. 1 The suction and exhaust valve of this stage is defective. Handling measures Check the air valve and replace the damaged parts; the 2nd stage suction pressure is too high. The treatment measures are checked and eliminated; 3 piston ring leakage causes insufficient exhaust gas, and the treatment measures replace the piston ring; 4 the front stage cooler has insufficient cooling capacity. Treatment measures Check that the front stage exhaust pressure of the cooler 2.5 is abnormally increased. 1 The intake air temperature is low, the intake pressure is high, and the stage cooler is inefficient. The treatment measures are checked and eliminated; 2 the secondary suction and exhaust valves are poor, and the inhalation is insufficient. The treatment measures are checked and replaced, and new parts are replaced; the resistance between the three stages is large. Handling measures Check the repair line to reduce the resistance. 2.6 Intermediate stage exhaust pressure is abnormally increased 1 The cooling capacity of the cooler is poor. Handling measures Check and repair and pay attention to prevent overload; 2 lower suction and exhaust valve is bad, insufficient suction, treatment measures air valve, removal of fault to replace new parts; 3 lower level pipeline resistance, treatment measures check cleaning pipeline, open suction Valve 2.7 suction pressure is abnormally low, and the suction line has large resistance. The treatment measures the cleaning pipeline and opens the suction valve.
2.8 Intermediate stage suction pressure is abnormally low. The 1st stage intake and exhaust valve is defective, causing insufficient exhaust gas and excessive leakage of the first stage piston ring. Treatment measures Check the air valve, the piston is broken, replace the new parts; 2 The leakage treatment measures after the front stage discharge are checked for leakage and elimination; 3 The suction line has large resistance, and the treatment measures the cleaning line to make it 2.9 class exhaust pressure Abnormally low 1 intake pipe resistance is large. The treatment measures the cleaning pipeline to make it smooth; the 2nd inlet and outlet valves are inspected for bad treatment and replaced with new parts; the 3rd stage piston ring leaks too much. Handling measures to check the replacement of the piston ring; 4 leakage valve bypass valve lost. Remedy Close the drain valve and the bypass valve.
2.10 Intermediate stage exhaust pressure is abnormally low. Before inhaling, the machine leaks to the outside of the machine. The treatment measures the leaked part and takes measures to repair it.
3 The exhaust gas volume does not meet the design requirements. 3.1 The filter resistance increases. 1 The filter is blocked by freezing or fouling in winter, and the resistance increases, which affects the air intake. The treatment measures to replace or clean the filter according to the prescribed cycle; 2 the filter device is improperly positioned, is sucked by the unclean gas and is blocked, and the resistance is increased. Treatment measures When installing the air filter, it is necessary to select a suitable position to ensure that the clean gas is sucked in. 3 The suction pipe is installed too long or the pipe diameter is too small, and the resistance is increased. The treatment measures the diameter and length of the suction pipe according to the amount of displacement of the compressor.
Disposal measures for the repaired compressor after the cylinder, reconfigure the appropriate piston or piston ring 3.3 suction and exhaust valve failure 1 suction and exhaust valve improper assembly, the position of each other reverse, not only affect the displacement, but also When the pressure is abnormal, the temperature will change. The treatment measures immediately exchange the misplaced suction and exhaust valves and reinstall them; 2 metal fragments or other debris are dropped between the valve seat and the valve plate, and the sealing is not strict, forming a leak, affecting the displacement, affecting the interstage Pressure and temperature treatment measures Check the suction and exhaust valve. If the suction valve cover is hot, the suction valve is faulty. If other valves are hot, there are also faults, repairing the faulty air valve; 3 valve seat and valve plate are not in strict contact, A leak is formed, which affects the amount of exhaust gas. Handling measures to scrape the contact surface or replace the new valve seat or valve; 4 Inhalation valve spring elastic is not appropriate, the elastic force is too large, the suction is slow to open, the elastic force is too small, the compression is not timely, affecting the displacement . Handling measures Check the spring, select the spring according to the elastic force specified by the technology; 5 When the suction valve spring is broken and compressed, it will also cause the closure to be not tight and the closing is not timely, affecting the displacement. Treatment measures to check the replacement spring; 6 valve seat and valve plate wear, the seal is not strict, forming a leak, affecting the displacement, treatment measures to check the wear and tear parts or replace the new seat and valve; 7 suction valve opening height is not enough The gas flow rate is increased, the resistance is increased, and the displacement is affected. The treatment measures adjust the rise limiter to form the opening height; 8 the valve assembly is not correct, causing air leakage, affecting the exhaust volume, and the treatment measures to check whether the intake and exhaust valve seat and the valve port on the cylinder block are biased, if any, should be reinstalled 9 valve spring stuck or tilted, so that the valve plate is closed, the treatment measures to use the spring to reverse the head or replace the new spring; the valve is too charred, affecting the switch. Treatment measures open the gas compressor technology valve cleaning ash, the exhaust valve is faulty, the exhaust volume is reduced, the exhaust valve cover is overheated, the treatment measures to disassemble the special hot valve cover to check and repair; 12 the exhaust volume is reduced, the middle The pressure in the cooler drops below the normal pressure, and the exhaust valve cover of the foreline cylinder is overheated. The exhaust valve of the pre-stage cylinder is faulty. Disassemble the inspection and repair, and pay attention to whether the gasket is damaged or not. Good; 13 the exhaust volume is reduced, the pressure in the intercooler is higher than the normal pressure, the rear cylinder is faulty, the inspection is repaired, and the gasket is damaged or not padded; 14 the exhaust volume is reduced, in the intercooler The pressure is higher than the normal pressure, but the exhaust valve of the front-stage cylinder is not particularly hot, and the suction valve of the rear-stage cylinder is heated. The suction valve of the rear-stage cylinder is faulty. Unpack the inspection and repair, and pay attention to whether the gasket is Damaged or not padded; 15 the amount of exhaust is reduced, but the front and rear valve covers are not overheated. The small piston that meets the adjustment system pressure to open the intake valve device fails, and the valve is pressed open so that the compressor can not breathe. Handling measures Check the gap unloading valve on the cylinders of the front and rear stages. The valve should be in good contact with the valve seat and must not leak.
3.4 Failure of the piston ring 1 The piston ring is poor in the quality of the lubricating oil or the injection volume is insufficient, so that the temperature inside the cylinder is too high, causing a seizure phenomenon, which reduces the displacement and may cause the pressure to be redistributed in each stage. Disposal measures remove the piston to check the piston ring, and clean the groove on the piston. If the qualified piston is damaged, it can continue to be used, and the damage is severely replaced. Check the oiler and oil pipeline to ensure good lubricating oil in the cylinder; 2 the gap between the piston ring and the piston is too large, including the radial axial clearance treatment measures should be selected when assembling; 3 piston ring is installed in the cylinder The opening gap is too small and is caught by thermal expansion. When the assembly piston is broken, the opening clearance should be checked according to the technique; 4 the piston ring is used for a long time and the wear is too large, and the treatment measures to replace the new piston ring.
3.5 Compressor speed reduction 1 Diesel engine horsepower is insufficient, the speed does not reach the rated speed, affecting the normal rated speed of the compressor, and reducing the exhaust volume. The treatment measures check and adjust the diesel engine to reach the rated speed. 2 When the motor is driven by the motor, the angle belt is too loose, and the transmission is lost. The exhaust gas treatment measures check the tightness of the angle belt to prevent the loss of the number of revolutions.
3.8 clearance unloading valve leakage 1 valve body assembly tilt, gap unloading valve and cylinder wall cone surface sealing failure = treatment measures to check whether it is positive, not inclined; 2 wide and 1 cylinder wall dimension roundness and surface roughness not enough. The treatment measures the grinding valve and the cone surface of the cylinder wall; 3 valve body rod sealing plate root plug wire is not tightly treated. When assembling, the sealing plate root plug wire should not be leaked. 3.9 Safety valve leakage gas 1 Safety valve spring is not pressed Or the elastic force is invalid. Treatment measures to adjust or replace the spring; 2 there is impurity between the safety valve and the valve seat, the valve surface contact is not strict. Treatment measures to clean impurities or re-grind the valve to the valve seat contact surface; 3 safety valve connection thread damage, treatment measures check replacement; 4 sealing surface damage, treatment measures can be repaired and repaired; 5 valve spring bearing surface is not perpendicular to the spring center line Deviation after the spring is pressed, causing uneven force on the valve, causing warpage and causing air leakage or oscillation. Handle the inspection check to make it vertical and note that a qualified spring should be used.
3.10 Excluded gas is not pure, contains more oil droplets and water 1 oil water separator failure, treatment measures to repair oil water separator; 2 scraper ring and piston rod contact is not tight, the lubricant in the fuselage is brought into the cylinder treatment Measures grinding repair scraping oil or replacement parts; 3 small compressor cylinder without crosshead, bad wear of piston, serious clearance, large lubricating oil, too much treatment, replacement of cylinder sleeve, scraping oil, piston ring and other parts. 4, the conclusion of the air compressor suction and exhaust failure can not be underestimated, therefore, for the air compressor suction and exhaust failure must find the real reason, plug-in technology, twin screw compressor, often fault characteristics and diagnosis Zhang Jiandong Jiang Meng Song Haiyan 21 PetroChina Dalian Petrochemical Company, Dalian 6031, Liaoning; 2. Zhonghe Desalination Engineering Co., Ltd., Tianjin 300457 solution and rationalization proposal.
1刖 twin-screw compressor is a large-scale key equipment for ketone-benzene dewaxing and deoiling equipment in the production of paraffin and lubricating oil. Its operation status is not only related to the quality and yield of the product, but also affects the whole device and other devices. There are more than ten screw freezers. Therefore, it is very important to reduce the consumption of the freezer.
2The characteristics of the screw compressor The screw type refrigeration compressor is a kind of rotary refrigeration compressor, and has the characteristics of both the piston type and the power type speed type. The screw compressor has a simple structure and the root of the parts avoids serious consequences. At the same time, it is necessary to pay attention to the maintenance of the air compressor. If there is a fault, it needs to be solved as soon as possible, so as to effectively extend the service life of the air compressor and achieve safe production.
1 Li Zonggen. Air compressor operating process. Beijing China Labor and Social Security issued a model number of motor power, medium ammonia refrigeration capacity 3, condensing pressure, according to the practical experience of the work, combined with the actual situation of the critical unit management of the device, the common failure of the twin-screw machine was analyzed. Less, there are no wearing parts such as gas valve piston rings, its main friction parts such as rotor bearings, etc., the strength and wear resistance are relatively high, and the lubrication conditions are good, so it runs reliably and has a long service life, and the overhaul interval can reach 48. Easy to operate and maintain. The screw compressor has a high degree of automation, and the operator does not have to go through long-term professional training to achieve the unattended safety and stability program. Reciprocating compressor technology Q & A. Beijing Sinopec Publishing House, Wang Yinxue. Piston air compressor use and maintenance. Shaanxi Science and Technology Press, 2001.
Performance testing of materials and mechanical equipment products, director of Zhejiang Province air compressor and pneumatic tool product quality inspection center.
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