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Compressor Failure Analysis and Troubleshooting
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Displacement less than: Displacement compressor design is the lack of gas and comparison. Mainly from the following aspects to consider: A failure of the intake filter: plug fouling, so that displacement reduced; the suction pipe is too long, diameter is too small, resulting in increased inspiratory resistance of the gas, to clean the filter regularly. 2 reduces the compressor speed to reduce the displacement: improper use of air compressors, air compressor displacement is due at a certain altitude, suction temperature, humidity, design, and when it exceeds the standards used in Plateau, the suction pressure is reduced and so, inevitably reduce the displacement. 3 cylinder, piston, piston ring wear serious, ultra poor, so that the gap increases, the leakage increases, affecting the displacement. Is a normal wear, the need for timely replacement of wearing parts, such as piston rings and so on. Are not properly installed Indeed, the gap was not suitable to stay, they should be drawing to correct, without the drawings, the preferred empirical data, between the piston and the cylinder along the circumference of the gap, such as a cast iron piston, the gap is the cylinder diameter 0.06/100 ~ 0.09/100; for the aluminum alloy pistons, the gap diameter to the diameter of gas ~ 0.18/100 0.12/100; steel, aluminum alloy pistons piston desirable smaller value. 4 loose stuffing to produce gas leakage reduction. The reason is stuffing itself created the first time that non-conforming; followed may be due to the installation, the piston rod and stuffing in the center well, resulting in wear and tear, strain Etc., causing leakage; generally stuffing at the filling oil, which of lubrication, sealing, cooling effect. 5 compressor suction, exhaust valve on the displacement of the fault. Between the valve seat and fall into the metal fragments or other debris, closed lax, the formation of leakage. This not only affects the displacement, but also between the level of pressure and temperature Degree of change; loose contact with the valve seat and form a leak affecting the displacement, one is manufacturing quality problems, such as valves warp, and the second is due to wear of the valve seat and the formation of a serious leak. 6, and gas power valve spring force is not good matches. Stretch is too strong to open the valve slowly, the tension is too weak then the valve does not close in time, these not only affect the gas, but will affect the power increases, and Valves Valve spring life. It would also affect the gas pressure and temperature changes. 7, the pressing force pressing the wrong valve. Clamping force is small, will have to leak, of course, not too tight line, will make the valve cover deformation, damage, usually pressing force can be calculated: p = kπ / 4 D2P2, D is diameter of the valve chamber, P2 is the most Large gas pressure, K a value greater than 1, generally of 1.5 to 2.5, while low K = 1.5 ~ 2.0, high pressure K = 1.5 ~ 2.5. So take K, practice proved to be good. With valve failure, valve cover must fever, while the pressure Is not normal. Exhaust temperature is not normal Exhaust temperature is not normal is it higher than the design value. Theory into the impact of increased exhaust gas temperature factors are: intake air temperature, pressure ratio, and compression index (for air compression index K = 1.4). The actual situation Suction temperature is high impact factors such as: the middle of the cooling efficiency is low, or in the cold for more than node within the scale affects the heat transfer, the inspiration behind the class is bound to high temperature, exhaust temperature will be high. Valve leakage, piston rings leak, Affects not only the exhaust temperature, but also make the inter-stage pressure changes, as long as the pressure ratio higher than normal will cause the exhaust temperature. In addition, water-cooled machine, water or both water shortage will exhaust temperature. Pressure is not normal and reduced exhaust pressure Gas compressor discharge pressure at rated flow can not meet the requirements of users, the exhaust pressure is bound to reduce the exhaust pressure to reduce the phenomenon, its essence is the displacement can not meet the requirements of users. At this point, he had to replace it the same discharge pressure, while the larger displacement machines. Of inter-stage pressure is not normal is mainly due to valve leakage or piston ring wear and tear gas leakage, so these areas should take measures to find the causes and . Abnormal noise If certain pieces of compressor failure, an abnormal noise will, in general, the operator can distinguish the sound of the abnormal. Piston and cylinder gap is too small, direct impact; piston rod and piston screw Cap loose or release, the piston end wire blocking cypress, the piston moving up the string of the collision cylinder head, cylinder and the cylinder in the fall in the accumulation of metal fragments, water and so can be issued within the cylinder percussion. W crankshaft crankcase bolts, nuts , Connecting rod bolts, crosshead bolts loose, release, break, etc., shaft wear serious gap increases, the crosshead pin and bushing wear the gap is too large or severe, and so can be issued in the crankcase of a crash. Chip off the exhaust valve Broken, loose or damaged valve spring, the load regulator, etc. can be adjusted improperly issued a knocking sound in the valve chamber. Thus to find fault and to take measures. Overheat The crankshaft and bearings, crosshead and slide, the friction at the packing and the piston rod, etc., the temperature exceeds the value referred to overheating. The consequences of overheating: one is to speed up the wear between the friction pair, the second is off the heat Heat continue to accumulate until the friction caused by burning and the burning surface caused by the machine holds a major accident. Bearing overheating caused by main reasons: uneven fit with the journal bearing or contact area is too small; bearing crankshaft deflection bending, twisting; Run Oil viscosity is too small, oil plug, oil pump failure caused by a broken oil; installed without leveling, not to find a good space, not the spindle and motor shaft alignment, the two axis tilt.