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Power and Electrical Engineering Science and Technology Information Air Compressor Safety Operation Technology Analysis Zhang Enhua Hou Zhengzhou Gong Yuexiong (Zhejiang China Tobacco Industry Co., Ltd. Hangzhou Cigarette Factory Zhejiang Hangzhou Analysis of the type of air compressor failure and the cause of the failure, a brief description to avoid The technical measures taken by the air compressor to generate faults have guiding significance for its safe operation, improve the operating efficiency of the air compressor, and prolong the service life of the air compressor.
As a kind of power source, the application field of air compressors is more and more extensive, and it plays a vital role in the whole manufacturing. However, during the operation of the air compressor, due to the poor cooling heat transfer effect, abnormal pressure, insufficient exhaust volume, etc., the actual running time of the air compressor is short, the machine stops and starts frequently, and it cannot achieve efficient and safe operation. The requirements directly affect production and bring immeasurable losses to the company. Therefore, it is necessary to correctly identify the failure of the air compressor, analyze the cause, reduce the number of failures, and propose preventive measures to ensure the safe operation of the air compressor.
1 Air compressor failure type and cause analysis 1.1 Insufficient exhaust volume The main performance of the shortage is that the pressure does not reach the end pressure. From the fault phenomenon, it is likely to be caused by the following reasons: First, the inlet air filtration The failure of the device, when the fouling in the filter is blocked, will reduce the amount of exhaust; while the suction pipe is too long, the pipe diameter is small, and the suction resistance increases, it directly affects the displacement. Second, the low speed of the air compressor will reduce the exhaust volume: the air compressor is designed according to the specified sea height, intake temperature and humidity. If it is used on the plateau exceeding the above standard, it will be As a result, the suction pressure is reduced and the displacement is also reduced. When the conveyor belt slips, the air compressor speed is reduced, which in turn affects the exhaust gas volume. The third is caused by the wear of the air compressor due to the wear of the parts: the cylinder, the piston and the piston ring are seriously worn and out of tolerance, causing the relevant clearance to increase and the leakage amount to increase, which seriously affects the displacement. Fourth, the air compressor system is seriously leaking, mainly because the stuffing box is not tight and the air leakage is reduced to reduce the gas volume. The reason is: first, the stuffing box itself is not required to be manufactured; secondly, it may be the piston rod during installation. There is no good match with the center of the stuffing box, resulting in air leakage caused by abrasion, strain and the like. The fifth is the impact of the failure of the air compressor pressure valve on the displacement. It mainly refers to the metal fragments or other debris falling between the valve seat and the valve plate of the suction and exhaust valves, resulting in poor closure and leakage. In addition, the mismatch between the spring force of the valve and the gas force will also affect the displacement. If the spring force is too strong, the valve will be opened slowly. If the spring force is too weak, the valve will not close in time. This will not only affect the displacement, but also if it is serious. It will affect the increase of power and even affect the service life of valve discs and springs.
1.2 Exhaust gas temperature abnormal exhaust temperature is not higher than the design value, mainly caused by the failure of the cooling system. Theoretically, the factors affecting the increase in exhaust gas temperature are: intake air temperature, pressure ratio, and compression index (for air compression index K = 1.4). The actual situation affects the factors of high suction temperature, such as: low intermediate cooling efficiency, or the scale connection in the intercooler affects heat exchange, the inhalation temperature of the latter stage must be high, and the exhaust temperature will be high. The air valve leaks and the piston ring leaks, which not only affects the rise of the exhaust gas temperature, but also changes the level pressure. As long as the pressure ratio is higher than the normal value, the exhaust gas temperature will rise. In addition, water-cooled machines, lack of water or insufficient water will cause the exhaust temperature to rise.
1.3 Extraordinary vibration and noise Air compressors will make an abnormal sound if some components fail. Usually, the operator can discern abnormal vibrations and sounds by listening to the sample.
The drive motor is unstable, and the alignment of the shaft changes abnormal vibrations and sounds. The gap between the piston and the cylinder head is too small and directly impacts; the piston rod and the piston connecting nut are loose or tripped, the piston end face is blocked, the piston moves up against the cylinder head, the metal fragments in the cylinder and the water accumulated in the cylinder, etc. Both can make a knocking sound in the cylinder. The exhaust valve piece is broken, the valve spring is soft or damaged, and the load regulator is improperly adjusted, etc., and the impact sound can be generated in the valve cavity.
1.4 Overheating fault In the position where the crosshead and the sliding plate, the crankshaft and the bearing, the packing and the piston rod are in friction, the temperature is too high and exceeds the specified value, which is called overheating. The consequences of overheating: First, speed up the wear of the friction parts. The second is the overheating of the compressor unit's air intake mode. The improvement before the improvement is made to the exhaust air passage at the exit of the SCIENCE technology information to make a lot of heat.
Continuous accumulation of direct burnt surface and burning hugs caused major accidents in the machine. The main causes of bearing overheating are: uneven bearing or journal contact or too small contact area; bearing skewed crankshaft is distorted, lubricating oil viscosity is too small, oil circuit is blocked, oil pump is broken, oil is broken, etc. Leveling, no gap is found, the spindle and motor shaft are not aligned, and the two axes are tilted.
There are many reasons for the failure of the air compressor. There are both design and manufacturing reasons, as well as operation and maintenance and management reasons. Some effective solutions should be proposed through comprehensive analysis of these faults to extend the life of the air compressor.
2 Air compressor daily operation failure solution 2.1 Optimizing the cooling system temperature abnormality is the main cause of air compressor failure, so how to reduce the system temperature and maintain an efficient cooling system is essential to prolong the life of the air compressor. The air compressor cooling system can be optimized from the following aspects.
Reduce the air compressor temperature by improving the ventilation conditions in the compressor room. The working environment of mechanical sounding has a great influence on the use of mechanical sounding, and reduces the temperature of the sounding, which can reduce the adverse effects on the sound. As the unit's service life increases, the unit's heat generation also increases, and the original method of air intake from the intake duct to meet the gas production and cooling unit is not applicable. As shown in the figure, the Hangzhou Cigarette Factory reduces the air temperature of the ambient temperature from the lower part of the sounding and then discharges it from the upper exhaust fan by effectively transforming the left and right side doors of the unit into the louver form of the lower inlet air. The company's original unit cooling exhaust gas is directly discharged into the exhaust passage, and then discharged from the roof, but the power of the unit exhaust fan is small.
The air exchange rate in the channel is not high, which causes the temperature inside the channel to rise, which affects the cooling of the unit. By installing an exhaust fan at the exhaust passage port, as shown, the air flow rate in the passage is increased, and the number of air exchanges in the passage is increased, thereby improving the cooling effect of the unit.
Avoid scaling of the cooling system. The fouling of the cooling system is the main cause of the abnormal temperature of the air compressor, which makes the cooling water unable to effectively exchange heat with the cylinder wall, resulting in an increase in the operating temperature of the cylinder and causing an accident. To solve this problem, many scholars at home and abroad have done a lot of research work and obtained some research results. Mainly by strengthening the monitoring and management of the cooling water quality, the cooling water is modified and the air compressor is cleaned regularly to avoid the scaling of the cooling system. The cleaning and descaling method for the air compressor includes mechanical descaling and chemistry. Descaling method, etc., because the structure of the cylinder water jacket is relatively complicated, the mechanical descaling method is difficult to remove, so the current descaling method is mainly based on the chemical descaling method.
2.2 Maintenance of the equipment The basic maintenance of the air compressor includes: replacement and maintenance of the air filter; replacement of the oil filter, replacement of the air compressor oil; replacement and maintenance of the oil separation core; installation and maintenance of the coupling; Maintenance and maintenance, etc.
(1) Maintenance and maintenance of the air filter. The function of the air filter is to filter the dust and dirt contained in the air, and send the filtered clean air to the compression chamber for compression. It is best to maintain the air filter once a week, unscrew the gland nut, take out the air filter, and use 0.20.4MPa compressed air to blow out the dust particles on the outer surface of the air filter from the inner cavity of the air filter. Use a clean rag. The dirt on the inner wall of the air filter case is wiped clean. Refill the air filter, and pay attention to the tight seal at the front end of the air filter. The air filter new machine should be replaced after running for 500h in the running-in period, and replaced once in normal condition 3000h. When cleaning or replacing the air filter element, the parts must be combined one by one to prevent foreign matter from falling into the intake valve.
(2) Replacement of oil filter and replacement of air compressor oil. Under normal circumstances, it is recommended to replace the new filter element every 15002000h. It is best to replace the oil filter element when changing the oil. The air compressor oil has a decisive influence on the performance of the air compressor. After the new machine is running for 500 hours, the first oil product is replaced. After that, the new oil is generally replaced every 3000 hours. It is best to change the oil filter at the same time when changing oil. Whether it is oil filter or air compressor oil, use shortened replacement cycle in harsh environments.
(3) Replacement and maintenance of oil and gas separation cores. Replace the split core every year or when the monitor issues a maintenance number. The separation core can only be replaced and can not be used after cleaning.
(4) Installation and maintenance of the coupling. The coupling is related to the precision of the sound setting, and the assembly error is relatively high. After the axial deviation calibration, the axial deviation, the horizontal clearance and the angular deviation calibration are adjusted under the motor. To install bolts and lock washers.
2.3 The operation of the specification operation specification can improve the operation efficiency of the air compressor, reduce the number of failures, slow down the fatigue of the sound-setting parts, and prolong the service life of the air compressor. The operation of the specification should include the following aspects.
Before starting the air compressor, please make sure that the pipeline valve is in the normal position, the air compressor panel is displayed normally, and then press the start button to start. When shutting down, please press the stop button to stop, and the air compressor will automatically unload and stop. Non-emergency conditions Do not stop by pressing the red emergency stop button.
Every 500 hours of operation of the air compressor, the electrical wiring inside the air compressor must be re-inspected and tightened. The main parameters of the air compressor are recorded every day to provide a basis for analysis and processing after the sound has failed. Please check the oil level every day to ensure that the cold power and electrical engineering are adequate and observe the internal piping for leaks.
3 Conclusion As a machine to increase gas pressure and transport gas, the air compressor is inevitably faulty. The system analyzes several faults of the air compressor, finds the root cause of the fault, and through continuous improvement of the sounding facilities of the air compressor, strictly follows the operation procedures of the sounding operation, formulates maintenance plans, regularly maintains, and maintains The sound is cleaned, so that the air compressor can run safely for a long time under the best working condition, so as to improve the sound maintenance efficiency and the air compressor usage rate, and prolong the service life of the air compressor.
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