Don’t know how to deal with air compressor failure?

 

1. The outlet temperature of the compressor head or the exhaust temperature is high

Excessive temperature rise is a common fault during the operation of the screw air compressor. The screw air compressor is often operated at high temperature, which will seriously affect the exhaust volume and service life of the machine. When the temperature rise is too high, a high temperature shutdown failure will occur. The reasons are:

(1) The temperature sensor is faulty. If the temperature sensor fails, it will cause the PLC to falsely report that the temperature is too high, causing the machine to shut down.

(2) Ambient temperature factor. The outlet temperature of the screw air compressor head is generally set at about 110°C, and the outlet temperature of the head is equal to the ambient temperature plus 60°C. The ventilation environment under the pit is poor, and most of the overheating is caused by this.

(3) The temperature control valve is faulty. When the compressor starts cold, the temperature control valve can make the oil bypass the cooler and spray directly into the head of the main engine, so as to accelerate the rise of oil temperature and prevent condensation in the compressor. The ratio of oil volume between the injector and bypass, and control the injection temperature. If the temperature control valve is damaged or the action is insensitive, a large amount of high-temperature oil will directly circulate into the head of the main engine without going through the cooler, resulting in high temperature of the main engine.

(4) The oil filter is faulty. The oil filter is used to filter the dust and impurities in the oil circuit. After a period of use, it is easy to block. After the blockage, the oil return is not smooth and the temperature of the main engine is high. (often appearing at the moment of loading).

(5) The fuel cut-off valve is faulty. The oil cut-off valve controls its reciprocating motion to spray oil through the air pressure of the air storage tank. If a fault occurs, the oil circuit will be blocked and the oil temperature will be high; It will cause the head of the main engine to have a high temperature due to lack of oil or poor heat dissipation due to lack of oil.

(6) The amount of lubricating oil is insufficient, the oil cooler is dirty and blocked, all of which will cause the temperature to be too high.

(7) The cooling fan fails, the air cooler is blocked, and the air exhaust resistance is too large, resulting in poor heat dissipation and high temperature. The external dust and internal oil of the cooler should be cleaned.

2. The output exhaust pressure is too low

(1) The actual gas consumption is greater than the gas production of the unit, the connected equipment and pipe network should be checked, and any leaks should be repaired in time. If the air consumption of the system is greater than the air output of the compressor unit under normal operating conditions, the compressor unit with a larger size should be replaced or the compressor unit should be added.

(2) The set value of unloading pressure is too low. Correctly set the unloading pressure value to give full play to the efficiency.

(3) The air filter element is dirty and clogged, resulting in insufficient air intake and low exhaust pressure of the compressor unit. The air filter condition should be checked and replaced if necessary.

(4) Solenoid valve failure. The main bleed solenoid valve and the cold start bleed solenoid valve on the exhaust line are leaking and need to be replaced.

(5) Control the leakage of the air hose. Replace the control air hose.

(6) The intake valve is insensitive and not fully opened. Need to overhaul and check the condition of the control system.

(7) The oil separator is blocked, and the filter element of the oil separator needs to be replaced.

(8) The safety valve leaks. The valve needs to be recalibrated or replaced.

(9) The drain valve of the gas-water separator is stuck after opening and causes leakage, and it should be repaired.

(10) The vent valve is faulty and cannot be closed when the compressor unit is loaded. Repair or replacement is required.

3. The output exhaust pressure is too high

(1) The intake valve is faulty. In need of repair or replacement.

(2) The setting of loading and unloading pressure value is unreasonable. The loading and unloading pressure value should be set according to the actual air consumption.

(3) The pressure sensor is faulty. replace.

(4) The unloading valve is not closed, the unloading valve is stuck or not closed tightly, and the solenoid valve is malfunctioning. Overhaul the unloading valve and solenoid valve and replace if necessary.

4. Frequent load unloading

(1) The loading and unloading pressure difference of the pressure controller is too small, reset the loading and unloading pressure value.

(2) The pressure sampling tube is blocked or leaking, and the pressure decays too fast. The sampling line needs to be repaired.

(3) The actual air consumption in production is unstable, sometimes large and sometimes small or discontinuous. An air storage tank can be added after the compressor unit.

(4) When the compressor unit is unloaded, the minimum pressure valve is not closed in time or is not closed tightly. Overhaul the minimum pressure valve and replace if necessary.

(5) The loading control solenoid valve is faulty. The solenoid valve should be checked, it may be caused by the influence of oil and water gas, which may cause insensitivity or burn out of the coil. Check and replace if necessary.

(6) The pressure sensor that controls the start and stop of the unit is faulty or damaged. Should be repaired and replaced.

5. The compressor unit has not been unloaded after loading

(1) The actual air consumption of the production is greater than the air production of the compressor unit, and the compressor unit is always in a loaded operation state.

(2) Check whether there is air leakage in the connecting pipe network.

(3) Check whether the loading and unloading solenoid valve operates or is damaged.

(4) Check whether the intake valve of the compressor unit is closed tightly.

(5) Check whether the drain valve of the gas-water separator is leaking.

(6) Check whether there is internal leakage in the safety valve and oil separator.

6. The oil consumption of the compressor unit is too large or the discharged compressed air contains oil

(1) Too much fuel. If the oil level is too high, the air flow will entrain the oil in the oil separator into the compressed air. Cause the oil content in the discharged compressed air to exceed the standard. Therefore, the amount of refueling should be controlled below the red line and yellow line.

(2) The failure of the minimum pressure spring causes the opening pressure to be too low, the pressure difference between the front and rear of the oil separator is too large, the flow rate of the oil-air mixture in the tank is high, and the oil condensed on the cylinder wall and the oil separator filter element will be taken away by the high-speed airflow , thereby affecting the oil-gas separation effect.

(3) The filter element of the oil separator is blocked or damaged, check and clean it and replace it if necessary.

(4) The oil return pipe of the oil separator is blocked, check and clean it.

(5) There is a leak in the air cooler system, check and repair and make up for the leak.

(6) The oil has been used for an extended period of time and the oil quality has deteriorated. Clean the compressor unit and replace the qualified marked oil.

6. The compressor unit is noisy

(1) The compressor unit is faulty, the bearing is damaged or the rotor of the main engine head is faulty. Shut down immediately and contact the dealer or after-sales service center.

(2) The cover panel is not installed properly, and the sound insulation cotton is damaged.

(3) If the parts are loose, it is necessary to carefully check and strengthen the connecting parts.

 

Sollant Group-Professional Compressed Gas Solutions Provider