Since air compressors have important uses, the stability and continuity of their working state directly affect the production efficiency of enterprises. Therefore, in order to ensure the normal operation of air compressors, common faults should be judged and handled in time, and the maintenance and management of air compressors should be strengthened to avoid abnormal operation of air compressors or even major safety accidents.
Air compressors are the most basic industrial equipment, which are widely used in various industries such as mining, petrochemicals, metallurgy, textiles, machinery manufacturing and electricity, especially in mining work. It is an extremely important auxiliary design. Since air compressors have important uses, the stability and continuity of their working state directly affect the production efficiency of enterprises. Therefore, in order to ensure the normal operation of air compressors, common faults should be judged and handled in time, and the maintenance and management of air compressors should be strengthened to avoid abnormal operation of air compressors or even major safety accidents.
1. Overview of air compressors
Air compressors (Air Compressor) are a main gas source device that converts the mechanical energy of the prime mover into gas pressure energy, and increases the gas pressure or transports the gas by highly compressing the gas. It belongs to power machinery equipment. Air compressors are widely used in different industries such as mining, textiles and metallurgy. They are widely used as general basic equipment. They can provide sufficient pressurized gas at the work site to ensure the continuous production. Air compressors have very obvious performance characteristics such as convenient delivery of pressurized air, abundant air medium resources for transmitting pressure, good compressibility and elasticity, safe and fast energy delivery and no fire hazards.
The following mainly introduces the performance advantages of several common air compressors. Screw air compressors have the advantages of high speed, good dynamic balance performance, high degree of automation and high gas transmission efficiency; piston compressors are easy to cause gas pressure loss, low mechanical efficiency of the compressor itself, low safety performance and short life, and the application range in most areas is getting smaller and smaller; screw air compressors have the characteristics of high reliability, increased compression efficiency, simple mechanical structure and convenient and safe maintenance; vortex air compressors are new air compressors developed in the past two decades or so, with excellent performance, especially small size, low noise and high efficiency. With the rapid development of my country's economy, the demand for air compressors in the domestic and foreign markets will surely increase, and its future development prospects are very optimistic. However, due to improper installation, improper operation and imperfect daily maintenance, air compressors are prone to some failures, delaying the production of enterprises. Therefore, it is necessary to do a good job in the maintenance and maintenance of air compressors.
2. Maintenance and maintenance content of air compressors
Since the working environment of air compressors is very harsh and they operate under high temperature and high pressure conditions for a long time, their maintenance and maintenance work is particularly important. In order to prevent the aging or wear of parts and adverse effects on the stable performance of air compressors, relevant staff are required to do a good job in the daily maintenance of air compressors, so as to reduce the failure rate of air compressors and prevent major safety accidents. Air compressor operators should strictly follow the relevant documents on air compressor maintenance and maintenance to maintain and maintain air compressors, find problems in time and solve them, so as to ensure the normal work of relevant departments of the enterprise and ensure the economic benefits of the enterprise.
(I) Daily maintenance and care of air compressors
Daily maintenance and care of air compressors is crucial to ensure the normal operation of air compressors, mainly including the following contents: First, the relevant operators should conduct a comprehensive inspection and test before the equipment is put into operation. This is the basic step to ensure that the air compressor can work normally and stably. We should strive to do a good job in daily maintenance and inspection, and make comprehensive inspections without omissions. We should formulate detailed and comprehensive daily maintenance rules and regulations, establish and improve the supervision mechanism, and strive to improve the skills and comprehensive quality of operators.
Before starting the air compressor, the operator should conduct a comprehensive inspection of the equipment, including checking whether the amount of lubricating oil in the oil pool and the oiler is sufficient; checking whether the protective device is reliable and safe; checking whether the oil and gas pipelines are unobstructed; checking whether the operating parts are flexible, etc. The focus of daily maintenance work should be to observe whether the readings of various instruments of the air compressor are normal when it is running, whether there are abnormal sounds and heating conditions of parts, whether the main components have abnormal operation, and to find problems and solve them in time through various detection equipment and combined with practical experience to ensure the normal operation of the air compressor. Operators must operate the equipment strictly in accordance with the operating procedures, keep records of the operating conditions of the equipment, and inspect the main components of the air compressor.
(II) Regular maintenance and maintenance of air compressors
Doing a good job of daily maintenance and maintenance of air compressors is only the basis for the maintenance of air compressors. On the basis of daily maintenance and inspection, regular maintenance and long-term maintenance plans should be made. According to the equipment manual of the air compressor and combined with the use of the equipment, specific maintenance rules should be formulated, which mainly include cleaning and maintenance of air filters, replacement and repair of various air valves of air compressors, regular inspection and maintenance of cylinders, and inspection and calibration of various instruments and meters. In order to make the air compressor operate normally and stably and extend the service life of the equipment, a detailed and complete equipment maintenance plan should be formulated to determine the monthly, three-month, and half-year inspection and maintenance content, so as to meet the working requirements of efficient and safe operation of air compressors. Monthly maintenance content: Determine whether it needs to be cleaned according to the contamination of the surface of the oil cooler, check whether the lubricating oil has deteriorated and whether the connecting hose is aging or damaged, and check the connection of the oil circuit and the circuit. Maintenance content at three-month intervals: add lubricating grease to the bearings of the clean main motor and fan motor, clean the cooler, condenser, oil filter and air filter, and check whether various air valves and sensors have been replaced. Maintenance content for half a year: check the use of cooling fans, cylinders, safety valves and oil and gas filter elements, focus on the analysis of the overall operation of the air compressor, ｒｅｐｌａｃｅ related parts, and eliminate safety hazards.
(III) Maintenance and maintenance of the main parts of the air compressor
The air compressor is mainly composed of the fuselage, cylinder, piston, oil filter, gas cooler, air filter and other related parts. Some of these parts are prone to wear and aging, causing the air compressor to fail to operate normally. Therefore, it is necessary to strengthen the maintenance and maintenance of key parts related to the air compressor to ensure the continuous and stable operation of the air compressor, reduce the failure rate, and reduce downtime and maintenance times. The air filter is mainly used to filter dust and impurities in the air. The quality of its working effect will affect the life of the air compressor cylinder to some extent. The life of the piston ring is related to the gas temperature inside the cylinder, the quality of the air filter and the humidity content in the air. The lubricating grease of each component can greatly improve the wear of the parts and thus extend the service life of the device, so it is necessary to ensure that the amount of lubricating oil is sufficient. In order to ensure the stable operating temperature of the air compressor, it is necessary to ensure that the heat dissipation effect of the cooler is good. As a key component that determines the quality of compressed gas in the air compressor, the oil-gas separator must ensure its good filtration efficiency.
Fault analysis and treatment suggestions for the safety valve tripping caused by long-term shutdown of air compressors
1. Case description
A company producing graphite-related products has used air compressors for only more than 1,200 hours in total. The unit has been shut down for about 3 months since the last startup. This restart caused the unit's safety valve to trip.
1.1 On-site inspection
There is serious rust on the surface of the filter material inside the built-in oil separator core, which is seriously blocked on the surface of the filter material, resulting in poor exhaust of the compressor and ultimately causing the safety valve to trip.
1.2 Fault analysis
The filter material of the built-in oil separator core is composed of glass fiber and plant fiber, which will not rust. From the disassembly of the built-in oil separator core, it is mainly the blockage of the outside of the filter material.
The cause of the blockage is that the air compressor runs occasionally and is shut down for a long time. The surface of the oil separator core absorbs lubricating oil and water vapor and contacts with air for a long time. After air drying, it adheres to the surface of the oil separator core, causing the oil separator core to be blocked.
1.3 Troubleshooting
The unit was maintained (three filters, lubricating oil, and oil and gas barrels were replaced), and the safety valve was replaced. The unit is operating normally.
2. Suggestions
2.1 If the compressor is only used occasionally, the maintenance time should be shortened;
2.2 If the customer wants to stop using the compressor for a long time, the compressor needs to be sealed and the filter element should be checked before starting the machine. The machine can only be started after the inspection.
Special note: For the situation where the compressor needs to be placed for a long time, it is recommended to run it for 1-2 hours per week.
