The wellhead gas compressor may encounter various common faults during use. The following is a detailed summary of these faults and their solutions:
The compressor does not start
Fault phenomenon: The compressor cannot start and has no response.
Possible reasons:
Power failure, such as voltage fluctuations, phase loss, contactor sintering and sticking, etc.
Internal mechanical failures of the compressor, such as motor burnout, screw jamming, etc.
Protector actions, such as overload protection, thermal protection, etc.
resolvent:
Check if the power supply voltage and current are stable, ensuring they are within the rated voltage and current range of the compressor.
Check if the internal mechanical components of the compressor are intact, and replace them promptly if damaged.
Check if the protector is activated. If it is activated, identify the cause and troubleshoot before resetting.
Low discharge pressure of compressor
Fault phenomenon: The discharge pressure of the compressor is lower than the set value.
Possible reasons:
The compressor sucks in liquid or gas containing a large amount of moisture.
Condenser malfunction, such as poor heat dissipation, blockage, etc.
The pipeline resistance is high, such as excessively long pipelines or too many bends.
resolvent:
Check if there is any liquid or moisture entering the suction port of the compressor, and clean it promptly if necessary.
Check if the condenser has good heat dissipation, and clean it promptly if there is any blockage.
Optimize pipeline layout to reduce pipeline resistance and the number of bends.
The compressor has a loud noise
Fault phenomenon: Excessive noise during compressor operation.
Possible reasons:
Internal wear of the compressor, such as bearing and gear wear.
The compressor installation is unbalanced or the fasteners are loose.
There is air or impurities mixed in the system.
resolvent:
Check the internal wear of the compressor, and replace the worn parts in a timely manner if there is any wear.
Check if the compressor installation is balanced and if the fasteners are loose. If necessary, adjust and tighten them in a timely manner.
Check if there is any air or impurities mixed into the system, and promptly eliminate them if necessary.
Compressor overheating
Fault phenomenon: The temperature of the compressor is too high during operation.
Possible reasons:
Cooling system malfunction, such as insufficient cooling water, blocked cooler, etc.
Poor lubrication or insufficient lubricating oil inside the compressor.
Compressor overload operation.
resolvent:
Check if the cooling system is functioning properly, ensuring sufficient cooling water and smooth operation of the cooler.
Check the internal lubrication of the compressor and replenish lubricating oil in a timely manner if there is any deficiency.
Avoid overloading the compressor and arrange the operating time and load reasonably.
High winding current
Fault phenomenon: The current of the compressor winding exceeds the rated value.
Possible reasons:
Internal short circuit or overload of the compressor.
The power supply voltage is too high or too low.
System blockage leads to high pressure being too high and low pressure being too low.
resolvent:
Check whether there is a short circuit or overload inside the compressor, and promptly eliminate it if necessary.
Check if the power supply voltage is stable, and adjust it promptly if there are any fluctuations.
Check if the system is blocked and clean it promptly if necessary.
In addition to the common faults mentioned earlier, the wellhead gas lift compressor may also encounter the following faults and their corresponding solutions:
Compressor stalling (stuck)
Fault phenomenon: The compressor cannot rotate and makes abnormal sounds.
Possible reasons:
Foreign objects enter the interior of the compressor, causing the moving parts to jam.
The compressor is running low on oil or overloaded, resulting in severe wear and tear of mechanical components.
Low voltage or motor burnout.
resolvent:
Clean the foreign objects inside the compressor to ensure that the moving parts are unobstructed.
Check the lubrication condition of the compressor and promptly replenish or replace the lubricating oil.
Check the power supply voltage and motor status, and replace or repair them promptly if there are any abnormalities.
Compressor reversal
Fault phenomenon: The direction of the compressor is incorrect during operation.
Possible reasons:
Wiring error caused the compressor to reverse.
The three-phase power supply is in reverse phase.
resolvent:
Check the wiring of the compressor to ensure correct and error free wiring.
Check the phase sequence of the three-phase power supply, and adjust it promptly if there is any reverse phase.
Excessive vibration of compressor
Fault phenomenon: The compressor vibrates significantly during operation.
Possible reasons:
The compressor installation is unbalanced or the foundation is not firm.
Loose or damaged internal components of the compressor.
Pipeline vibration is transmitted to the compressor.
resolvent:
Check the installation of the compressor to ensure that the installation is balanced and the foundation is firm.
Check whether the internal components of the compressor are loose or damaged, and tighten or replace them in a timely manner if necessary.
Optimize pipeline layout to reduce the impact of pipeline vibration on the compressor.
Compressor leakage
Fault phenomenon: The compressor has gas or liquid leakage.
Possible reasons:
The compressor seal is damaged or aged.
Loose or poorly sealed pipeline connections.
resolvent:
Replace damaged or aged seals.
Check if the pipeline connections are loose or poorly sealed, and if necessary, tighten or replace the seals in a timely manner.
Compressor capacity adjustment fault
Fault phenomenon: The compressor capacity adjustment function has failed.
Possible reasons:
The oil circuit is not smooth, such as clogged oil filters, clogged solenoid valve cores, etc.
The solenoid valve coil is faulty.
Capacity adjustment control system malfunction.
resolvent:
Clean up blockages in the oil circuit and replace damaged oil filters or solenoid valve cores.
Check if the solenoid valve coil is damaged or faulty, and replace it promptly if necessary.
Check the electrical components of the capacitance control system to ensure their proper functioning.
In summary, the wellhead gas lift compressor may encounter various malfunctions during use. To ensure the normal operation and prolong the service life of the compressor, operators should be proficient in common faults and their solutions, and strengthen maintenance and upkeep work in daily work. Meanwhile, regular inspection and maintenance are also important measures to prevent malfunctions from occurring.
