Screw Compressor with high efficiency, stability and other advantages, widely used in the industrial field. However, in the process of long-term operation, it is inevitable that all kinds of faults. Understanding the causes of common failures, and mastering effective solutions, to ensure the normal operation of the equipment, improve production efficiency is essential.
First, abnormal vibration and noise
Failure causes
Wear of mechanical parts: rotor, bearings and other key components wear after long-term operation, resulting in increased clearance, resulting in vibration and noise during operation; poor alignment of the coupling, so that the power transfer between the compressor and the motor is not balanced.
Problems with foundation installation: the foundation of the compressor is not solid, and the ground bolts are loose; the equipment is tilted to run without horizontal adjustment during installation.
Pipeline resonance: unreasonable pipeline arrangement, insufficient support points or improper location, resonance during compressor operation.
Solutions
Check mechanical parts: Regularly test the rotor, bearings and other parts, and replace them in time if they are badly worn; readjust the alignment of the coupling to ensure smooth power transmission.
Reinforce the foundation and adjust the level: tighten the ground bolts to reinforce the foundation; use a level meter to adjust the level of the compressor to ensure the precision of equipment installation.
Optimize the pipeline arrangement: reasonably increase the pipeline support point, adjust the support position, change the pipeline intrinsic frequency to avoid resonance.
Second, the exhaust temperature is too high
Failure causes
Cooling system failure: serious internal scaling of the cooler, hindering heat exchange; cooling fan damage or insufficient speed, resulting in poor heat dissipation; insufficient cooling water flow or high water temperature, unable to effectively take away the heat generated by the compression process.
Lubricant problem: insufficient quantity of lubricant can not fully lubricate and cool the rotor and bearings; the quality of lubricant decreases, anti-oxidation, anti-wear performance deteriorates, increasing the friction heat; oil filter clogging, resulting in poor circulation of lubricant.
Compressor overload: long time in full load or overload running state; inlet valve failure, can not normally adjust the inlet volume, so that the compressor continues to work at high loads. Solution
Check the cooling system: regular cleaning and descaling of the cooler; check the cooling fan motor and fan blade, repair or replace the damaged parts in time; adjust the cooling water flow to ensure that the water temperature is in the normal range, and increase the cooling equipment if necessary.
Deal with lubricating oil problems: check the oil level and replenish the lubricating oil in time; replace the lubricating oil regularly and choose high-quality lubricating oil that meets the requirements of the equipment; clean or replace the oil filter to ensure the smooth flow of lubricating oil.
Adjust the compressor load: Reasonable arrangement of production tasks, to avoid the compressor overloaded for a long time; overhaul the air inlet valve, to ensure that it can be adjusted according to the actual demand for normal air inlet.
Third, the exhaust pressure is not stable
Failure causes
air intake system failure: air intake filter clogging, increasing air intake resistance, resulting in unstable air intake; intake pipeline leakage, so that part of the air is not into the compressor on the loss, affecting the exhaust pressure.
Pressure sensor failure: pressure sensor damage or deviation, can not accurately monitor the exhaust pressure, resulting in control system malfunction.
Unloading valve failure: the unloading valve cannot open and close normally, when the system pressure reaches the set value, the unloading valve is not opened in time to unload, or it is not closed in time after the pressure drops, resulting in fluctuation of exhaust pressure.
Solution
Maintain the air intake system: clean or replace the air intake filter regularly; check the air intake piping and seal the leaks.
Calibrate or replace the pressure sensor: use professional instruments to calibrate the pressure sensor; if it is still inaccurate after calibration, replace it with a new one in time.
Overhaul the unloading valve: check the mechanical parts and control lines of the unloading valve, repair the damaged parts to ensure that the unloading valve operates sensitively and accurately.
Four, motor overload
Failure causes
Electrical system failure: motor winding short circuit or grounding, resulting in excessive current; voltage instability, too high or too low will increase the motor load.
Excessive mechanical load: compressor internal components jammed or excessive friction resistance, such as abnormal friction between the rotor, rotor and shell; belt is too tight, increasing the motor drive load.
Solutions
Examine the electrical system: use an insulation resistance meter to test the insulation of the motor windings and repair short-circuit or grounding faults; install a voltage regulator to ensure that the voltage is stabilized within the rated operating range of the motor.
Deal with the mechanical load problem: disassemble the
compressor, check the internal parts, repair or replace the jammed or worn parts; adjust the belt tightness to make it meet the equipment requirements.
Through the in-depth analysis of the common causes of
screw compressor failure, and take appropriate measures to solve the problem, can effectively reduce the equipment failure rate, prolong service life. Enterprises in the daily use, should also strengthen the maintenance of equipment, regular inspections and testing, timely detection of potential problems, will nip the failure in the bud, to provide a strong guarantee for the stable operation of production.
