Maintenance guide of centrifugal air compressor: from fault early warning to maintenance points

The maintenance of centrifugal air compressor needs to establish the core principle of “prevention first, combination of prevention and control”. Compared with passively waiting for failure before maintenance, preventive maintenance in advance can effectively reduce equipment wear and prolong service. This requires the operation and maintenance personnel to master the structural characteristics of the equipment, including the working principle and loss law of key components such as impeller, spindle, bearing, seal, cooling system, etc. Through regular inspection and accurate inspection, potential hazards can be found in time and properly handled.
Maintenance guide of centrifugal air compressor: from fault early warning to maintenance points
First, repair it if it is broken.
The traditional “after-fault maintenance” mode has been difficult to meet the strict requirements of continuity in modern production lines. At present, the mainstream trend is to implement the full-cycle management strategy combining predictive and preventive maintenance;
-Predictive maintenance: capturing abnormal signals in real time by means of vibration monitoring, temperature sensing and current analysis;
-Preventive maintenance: make planned maintenance according to operating hours and working condition intensity to prevent problems before they happen.
Second, the centrifugal air compressor early warning
1. Abnormal vibration and noise
It may be caused by factors such as unbalanced rotor (eccentric mass caused by fouling and wear of impeller), excessive or worn bearing clearance, misalignment of coupling, collision of foreign bodies in casing, etc. The vibration value of each bearing seat can be measured by vibration detector, and the reference data of normal operation of the equipment can be compared; At the same time, the source of noise is judged by stethoscope, and whether it is mechanical component failure or airflow disturbance is preliminarily distinguished.
2. Bearing overheating
Excessive bearing temperature will directly threaten the safety of equipment. The core reasons are mostly poor lubrication (insufficient lubricating oil, deteriorated oil quality, mixed impurities), too small bearing installation clearance, cooling system failure (such as oil cooler blockage, insufficient cooling water flow) and so on. During maintenance, it is necessary to monitor the bearing temperature with the help of infrared thermometer, and at the same time detect the oil level and oil quality of lubricating oil (whether there is emulsification or impurities) and the circulating state of cooling system.
3. Decrease of exhaust volume and pressure fluctuation
Directly affect the quality of production gas supply. Such problems may be caused by the blockage of air inlet filter, gas leakage caused by abrasion of impeller or seal, unreasonable system pressure setting and change of pipe network resistance. It is necessary to detect intake pressure, exhaust pressure and flow data, and combine with the detection of filter cleanliness to determine whether the equipment itself is faulty or the system working condition is abnormal.
4. Electrical system failure
Such as motor failure to start, overload trip, overheating in operation, etc. The root causes are power supply problems (voltage instability, lack of phase), motor winding insulation decline, control circuit components (contactors, relays) damage, etc. It is necessary to use a multimeter to detect the power supply voltage, phase sequence and circuit on and off, and at the same time measure the insulation resistance of the motor winding to determine the fault location.
5. Surge phenomenon
It shows that the pressure and flow fluctuate periodically and violently, accompanied by strong vibration and noise, which may damage the equipment in serious cases. The essence is that the operating conditions deviate from the design point and enter the surge zone, or the anti-surge devices (such as anti-surge valves and control systems) fail. It is necessary to detect the position of the current operating point of the equipment on the performance curve, and check the switching sensitivity of the anti-surge valve and the response speed of the control system.
Three, the key parts maintenance points
1. Impeller and diffuser
Long-term operation is easy to accumulate dust or process medium residue, which leads to the decline of aerodynamic performance.
2. Bearing system
Rolling bearings need to be regularly inspected for clearance and lubrication;
3. Seal assembly
Wear of labyrinth seal or carbon ring seal will directly lead to increase of internal leakage and decrease of efficiency. Spare parts with original specifications should be used during maintenance to ensure that the fit clearance meets the design requirements.
4. Control system
Including PLC, frequency converter, sensor, etc., it is recommended to check the software version and back up the parameters once a year to prevent misoperation caused by program drift.
Fourth, how to choose reliable maintenance services?
-Technical qualification: Do you have successful maintenance cases of the original equipment factory or similar models?
-ce inspection ability: whether it is equipped with vibration spectrum analyzer, laser centering instrument, dynamic balancing machine and other tools.
-Spare parts guarantee: Can you provide core components (such as brand-specific parts such as Turbo-Tech)?
-Service response: Do you support 7×24 hours remote diagnosis and on-site arrival within 48 hours?
The above is an introduction to “Maintenance Guide for Centrifugal Air Compressor: From Fault Warning to Maintenance Points”. The maintenance of centrifugal air compressor is essentially awe and care for precision high-speed rotating system. Only by changing “passive emergency repair” into “active health management” can we truly release its potential of long-term, energy-saving and longevity, and lay a solid foundation for green industry.