Analysis of Common Faults and Maintenance Strategies of Centrifugal Air Compressor

The reliability of centrifugal air compressor depends on the quality of brand and the quick response of after-sales service. Centrifugal air compressor has become the core power equipment in many industries with its characteristics of large flow and high pressure. However, long-term high-load operation will inevitably lead to various failures, which will affect production efficiency. It is the key to ensure the stable operation of the equipment to deeply understand the common faults of centrifugal air compressors and the corresponding maintenance strategies.
Analysis of Common Faults and Maintenance Strategies of Centrifugal Air Compressor
1、The output gas volume cannot meet the production demand.
(1) Equipment failure
During the operation of centrifugal air compressor, the actual output gas volume can not meet the production demand, resulting in the downstream equipment can not work normally due to insufficient air pressure.
(2) Causes of equipment failure
Air intake filter is blocked: dust and impurities in the air are constantly accumulating on the surface of the filter, which increases the intake resistance and reduces the intake air volume.
Impeller wear: During the long-term operation, the impeller is subjected to the effects of airflow erosion, corrosion and mechanical friction, which leads to the change of blade shape, the decrease of gas compression efficiency and the decrease of gas output.
Failure of sealing device: The aging and damage of the seal inside the air compressor make the gas leak during compression, resulting in gas loss.
(3) Equipment maintenance strategy
Regularly clean and replace the air intake filter: according to the use environment and frequency, make a reasonable maintenance plan, clean the impurities on the filter surface in time, and replace it when it reaches the service life.
Maintenance or replacement of impeller: For the impeller with light wear, surfacing welding, grinding and other processes can be used for maintenance; If the wear is serious, a new impeller is needed, and the model and specification of the new impeller should be matched with the original equipment.
Check and replace the sealing device: Check the seals inside the air compressor, and replace the aged and damaged seals in time. At the same time, ensure the installation quality and sealing effect of the seals during installation.
2、Abnormal vibration fault
(1) Equipment failure
When the centrifugal air compressor is running, the fuselage vibrates violently, and the vibration amplitude is beyond the normal range, which not only produces loud noise, but also may damage the structure of the equipment.
(2) Causes of equipment failure
Rotor unbalance: there are errors in the manufacturing and installation of rotor parts such as impeller and shaft, or wear and deformation occur during operation, which leads to uneven mass distribution of rotor, unbalanced force and vibration.
Bearing damage: Bearing is subjected to high load operation for a long time, and poor lubrication, serious wear or abnormal impact will lead to bearing damage, which will reduce the running stability of the rotor and cause vibration.
Loose foundation of air compressor: During the long-term operation of the foundation of air compressor, due to reasons such as foundation settlement and loose bolts, the stability of the foundation becomes worse, and the equipment cannot be effectively supported, resulting in abnormal vibration.
(3) Equipment maintenance strategy
Carry out rotor dynamic balance correction: disassemble rotor parts, check and correct them with dynamic balance equipment, and make the rotor reach dynamic balance by adding or removing counterweight at appropriate positions.
Replace damaged bearings: select reliable bearings for replacement, and ensure the installation accuracy and lubrication of bearings. In the installation process, it should be carried out in strict accordance with the regulations to avoid bearing damage.
Strengthening the foundation: check the foundation of the air compressor, tighten the loose bolts, reinforce the settlement part of the foundation, and re-pour the foundation if necessary to ensure the stability of the foundation.
3, The oil temperature is too high fault
(1) Equipment failure
When the air compressor is running, the temperature of lubricating oil continues to rise, exceeding the specified normal range, affecting the performance of lubricating oil and accelerating the wear of equipment parts.
(2) Causes of equipment failure
Failure of cooler: blockage of internal pipeline of cooler, damage of cooling fins or insufficient cooling water will all lead to the decrease of cooling condition, which can not effectively take away the heat of lubricating oil and increase the oil temperature.
Deterioration of lubricating oil: after long-term use, lubricating oil will deteriorate due to oxidation, pollution and other reasons, and its lubricating performance and heat dissipation performance will decrease, resulting in an increase in oil temperature.
Oil pump failure: the working efficiency of the oil pump decreases, and it can’t provide enough lubricating oil for the equipment, or the oil pump leaks, resulting in poor circulation of lubricating oil and high oil temperature.
(3) Equipment maintenance strategy
Cleaning and maintenance of cooler: regularly clean the cooler, clean up the dirt and impurities inside, check the damage of radiator and pipeline, and repair or replace it in time. At the same time, it is necessary to ensure sufficient cooling water and normal water flow.
Replacement of lubricating oil: according to the requirements of the equipment operation manual, the lubricating oil should be replaced regularly, and the lubricating oil with qualified quality and suitable for the equipment operation conditions should be selected. When replacing the lubricating oil, thoroughly clean the oil tank and oil system to avoid the pollution of the residual old oil to the new oil.
Check and repair the oil pump: check the oil pump, repair or replace the damaged parts to ensure the working efficiency and sealing of the oil pump. At the same time, the oil pump should be maintained regularly to extend its service time.
4、The exhaust pressure instability fault
(1) Equipment failure
The exhaust pressure of centrifugal air compressor fluctuates in the process of operation, sometimes too high and sometimes too low, which can not keep stable and affects the normal operation of production technology.
(2) Causes of equipment failure
Pressure regulator failure: the control element of the pressure regulator is damaged and the adjustment fails, and the exhaust pressure cannot be automatically adjusted according to the actual demand, resulting in pressure instability.
Leakage of pipe network system: there are leakage points in the exhaust pipeline and valve of air compressor, which makes the gas leak during transportation and affects the stability of exhaust pressure.
Change of intake flow: the resistance of intake system changes, or the opening of intake valve is unstable, which leads to fluctuation of intake flow and instability of exhaust pressure.
(3) Equipment maintenance strategy
Overhaul and debug the pressure regulator: inspect and repair the pressure regulator, replace the damaged control elements, and debug again to ensure that it can adjust the exhaust pressure accurately and sensitively.
Find and repair the leakage point of pipe network: use inspection equipment to inspect the whole pipe network system, find out the leakage point and repair it in time. In the process of maintenance, the welding quality and sealing should be ensured to prevent leakage again.
Air intake flow: check the air intake system, clean the impurities in the air intake pipeline, and adjust the opening of the air intake valve to ensure the stable air intake flow. At the same time, the air intake system should be maintained regularly to ensure its normal operation.
The timely diagnosis and effective maintenance of common faults of centrifugal air compressor require the staff to have rich experience and knowledge. Understanding and mastering the above-mentioned common faults and maintenance strategies can help enterprises to better maintain centrifugal air compressors, reduce equipment downtime, improve production efficiency, reduce production costs and ensure the smooth progress of industrial production. If you still want to know more detailed analysis of specific faults, or other related contents, please feel free to contact Turbo-Tech4008861856.