Just now, the Ministry of Ecology and Environment issued the "Guiding Opinions on Further Deepening the Reform of" Decentralization, Management, and Service "in the Field of Ecology and Environment to Promote High Quality Economic Development" (hereinafter referred to as the "Opinions"), in which Article 8 explicitly requires: strictly prohibit "one size fits all" and protect the rights and interests of legitimate and compliant enterprises. And strictly regulate the relevant content of "one size fits all" throughout the paragraph.
Introduction to the Functions and Fault Diagnosis of Components of Screw Air Compressors: The functions of each component of the oil-injected screw air compressor are described, and the working principles of the components are analyzed. In the maintenance process, precautions and the analysis and elimination of individual faults are also provided. Now, let's take a look at the relevant analysis of the
Zhigao Screw Air Compressor by the staff of Hunan Ruiseng Mechanical and Electrical Equipment:
Functions and troubleshooting of each component of the screw air compressor:
Lubricating oil has the functions of lubrication, cooling and sealing.
1) Pay attention to the oil level of the lubricant. Insufficient oil can cause the unit to overheat, lead to carbon deposits, and accelerate the wear of the operating components, thereby shortening the service life of the unit.
2) Prevent the formation of condensate in the lubricating oil. The operating oil temperature should be around 90℃. It is strictly prohibited for the oil temperature during operation to be lower than 65℃.
The composition of lubricating oil: base oil + additives.
The additives have the following functions: anti-foaming, anti-oxidation, anti-corrosion, anti-coagulation, wear resistance, descaling (rust removal), more stable viscosity (especially at high temperatures), etc. The lubricating oil can be used for up to one year, and if used for too long, it will deteriorate.
Functions of the components of the screw air compressor:
The main function of the air filter is to prevent dust and other impurities in the air from entering the air compressor system. Filtration accuracy: 98% of particles larger than 0.001mm are filtered out, 99.5% of particles larger than 0.002mm are filtered out, and 99.9% of particles larger than 0.003mm are filtered out.
Oil filter function: Removes all the impurities and dust that cause wear from the lubricating oil, but does not separate the special additives that have been added.
Filter paper precision: 50% of particles larger than 0.008mm are filtered out, and 99% of particles larger than 0.010mm are filtered out. The counterfeit filter paper has not undergone the heating lubricating oil test. It has only a few wrinkles, significantly reducing the filtration area. Moreover, the spacing of the wrinkles is not uniform. If the air entering the intake port contains a lot of dust, after using the lubricating oil for a period of time, the filter paper becomes severely clogged, and the filter will hinder the flow of the lubricating oil. If the pressure difference of the lubricating oil in the oil filter is too large (during cold start or filter blockage), there will be a lack of lubricating oil in the oil passage, and the temperature of the lubricating oil will rise, which will damage the rotor.
Working principle of the oil-gas separator:
The main function of the oil-gas separator is to separate the compressor lubricating oil from the oil-gas mixture, and further remove the lubricating oil particles from the compressed air. The oil-gas mixture that enters the oil-gas tank (consisting of the oil-gas separator, the minimum pressure valve, the safety valve and the container shell) undergoes three types of separation: centrifugal separation, gravity separation (oil is heavier than gas) and fiber separation.
Separation process: The oil-gas mixture enters the oil-gas tank along the tangential direction of the outer wall of the oil-gas separator. 80% to 90% of the oil is separated from the oil-gas mixture (through centrifugal separation), while the remaining (10% to 20%) of the oil adheres to the outer wall surface of the oil-gas separator for separation (through gravity separation), and a small amount of oil enters the interior of the oil-gas separator (through fiber separation), and is then pressurized back into the screw main chamber through the return oil pipe.
Functions and troubleshooting of each component of the screw air compressor:
The gasket of the oil and gas separator is conductive. As air and oil pass through the glass fibers, static electricity will be generated between the two separation layers. If the two metal layers carry static electricity, there will be a risk of static discharge accompanied by electric sparks, which may cause the oil and gas separator to explode. Good oil and gas separator components ensure the conductivity between the separator core and the oil and gas barrel shell. The metal components of the air compressor have good conductivity, which can ensure that all static electricity can be promptly discharged and prevent the generation of electric sparks.
The adaptability of the oil-gas separator to pressure difference. The pressure difference that the oil-gas separator is designed to handle is limited. If the filter element of the separator exceeds the maximum allowable value, the oil-gas separator may rupture, and the oil in the compressed air cannot be separated. This will affect the air compressor or cause the separator core to be completely damaged. Additionally, excessive pressure drop of the oil-gas separator may also cause the separator to catch fire. The possible causes of excessive pressure difference include: blockage of the oil separator due to dirt, reverse flow of air, large fluctuations in internal pressure, and using counterfeit oil-gas separator cores.
The metal of the oil-gas separator is usually electroplated and is not prone to corrosion. Depending on the surrounding environmental conditions (temperature and humidity) and the operating conditions of the compressor, condensate water may form inside the oil-gas separator. If the oil-gas separator is not electroplated, a corrosion layer will form. This corrosion layer will cause damage to the antioxidant of the compressor oil, significantly reducing its service life and flash point of the oil.
Measures to ensure the service life of the oil-gas separator include preventing the accumulation of dust, residual oil, air pollutants or wear, as all these factors can shorten the service life of the oil-gas separator.
The air filter and oil filter can be replaced in a timely manner, and the oil change time can be monitored to limit the amount of dust entering the compressor oil.
② Use the correct anti-aging and water-resistant lubricants.
Some precautions for screw air compressors:
The rotor of a screw air compressor must never be reversed. The rotor is the core component of the screw air compressor. The surfaces of the male and female screws do not touch each other. There is a gap of 0.02 to 0.04 mm between the male and female screws. The oil film serves as protection and sealing. If the rotor is reversed, pressure cannot be established in the pump head, the screws in the pump head have no lubricating oil, and the lubricating oil cannot circulate. Heat accumulates instantly in the pump head, causing high temperature, which causes deformation of the screws and the housing inside the pump head. The male and female screws bite and lock together, and the end face of the rotor sticks to the end cover due to high temperature, resulting in severe wear of the end face of the rotor and even component damage and failure, causing damage and scrapping of the gearbox and the rotor.
Method for checking the rotation direction: Sometimes the phase sequence of the incoming power in the factory may change, or the power supply of the screw air compressor may be altered for some reason, which can cause the phase sequence of the motor of the screw air compressor to change. Most air compressors have phase sequence protection, but to be on the safe side, the following test should be conducted before starting the air compressor:
Press the cooling fan contactor with your hand to check if the fan is rotating in the correct direction.
② If the power line of the fan has been moved, manually briefly start the main motor and observe whether the rotation direction of the coupling of the motor is correct.
The rotor of the screw air compressor does not accumulate carbon:
(1) Causes of carbon deposits
Using inferior, non-original factory quality lubricants.
② Using fake or damaged air filters.
③ Long-term operation under high temperature conditions.
④ Insufficient lubricating oil quantity.
⑤ When changing the lubricating oil, the old oil was not completely drained or the old and new oils were mixed together.
Different types of lubricants can be used together.
(2) Method for inspecting carbon deposits on the rotor
① Remove the intake valve and check if there is any carbon deposit on the inner wall of the pump head.
② Observe and analyze the presence of carbon deposits in the oil filter surface and the inner wall of the lubricating oil pipeline.
(3) Requirements for inspecting the pump head: The outer shell of the screw compressor pump head is not allowed to be disassembled by non-professionals. If there is carbon deposits inside the pump head, only the professional technicians of the manufacturer can perform the repair. The gap between the inner and outer screws of the screw compressor pump head is very small. During the repair process, it is essential to ensure that no impurities enter the pump head.
Regularly add lubricating grease to the motor bearings. Use a dedicated grease gun for the addition. The specific steps are as follows:
On the opposite side of the fuel filler cap, open the vent hole.
② The fuel nozzle and the fuel nozzle hole must be properly matched with the motor.
③ The lubricating oil is divided into high-speed motor oil and low-speed motor oil. These two types of oils cannot be mixed; otherwise, they will undergo a chemical reaction.
④ Each time you press the fuel nozzle, 0.9 grams of fuel is dispensed. Add 20 grams each time. It will take multiple presses to complete the process.
⑤ If the amount of lubricating grease added is insufficient, the grease will remain in the oil pipeline and fail to provide lubrication; if too much is added, the bearing will overheat and the grease will turn into a liquid, thereby affecting the lubrication quality of the bearing.
The air compressor should be replenished once every 2,000 hours of operation.
Replacement of the main motor coupling: The coupling must be replaced if any of the following conditions occur:
There are cracks on the surface of the coupling.
② The surface of the coupling has been charred.
③ The coupling grease has broken.
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