During the operation of Biogas Compressors, various faults may occur. The following is a detailed introduction for you:
Mechanical failure
Wear and tear
Wear of piston ring: The piston ring is a key component that plays a sealing role in the compressor cylinder. Due to long-term operation in high-pressure, high-temperature, and high-speed environments, friction will occur between the piston ring and the cylinder wall, leading to wear. When the piston ring is severely worn, air leakage may occur, causing a decrease in the displacement and compression efficiency of the compressor, and may also lead to an increase in cylinder temperature.
Bearing wear: The bearings of the compressor are used to support rotating components and ensure their smooth operation. If there is insufficient lubrication, excessive load, or impurities entering the bearing, it will accelerate the wear of the bearing. After bearing wear, abnormal vibration and noise will be generated, which may lead to journal wear and even prevent the compressor from operating normally in severe cases.
Loose
Loose bolts: The compressor will generate vibration during operation. If the bolts are not tightened properly during installation or if they become loose due to long-term vibration, it may affect the stability of the compressor. For example, loose cylinder head bolts can cause air leakage in the cylinder, affecting the compression effect; Loose anchor bolts can intensify the overall vibration of the compressor and damage other components.
Loose connection of components: Loose connections between various components inside the compressor, such as couplings, pulleys, etc., can lead to unstable power transmission, decreased transmission efficiency, increased vibration, and even component damage.
crack
Crankshaft fracture: The crankshaft is a component in the compressor that bears a large load, and it converts the rotational motion of the electric motor into the reciprocating motion of the piston. If there are defects in the material of the crankshaft, insufficient machining accuracy, or long-term exposure to excessive loads, it may lead to crankshaft fracture. Crankshaft fracture is a serious malfunction that can cause the compressor to immediately stop running and may damage other related components.
Connecting rod fracture: The connecting rod, which connects the crankshaft and piston, is subjected to alternating tensile and compressive loads during operation. When the strength of the connecting rod is insufficient, fatigue damage accumulates, or abnormal impact occurs, fracture may occur. A broken connecting rod can damage the internal structure of the cylinder and cause serious equipment damage.
Gas delivery malfunction
Insufficient displacement
Air intake filter blockage: Biogas contains certain impurities, and the air intake filter is prone to blockage after a period of use. A clogged filter will increase the intake resistance, leading to a decrease in the amount of biogas entering the compressor and resulting in insufficient exhaust volume.
Valve malfunction: The valve is a critical component that controls the flow of gas into and out of the cylinder, including the intake and exhaust valves. If the air valve seal is not tight, the spring is damaged, or the valve plate is worn, it will cause gas leakage and reduce the displacement of the compressor.
Piston wear or cylinder leakage: The sealing performance between the piston and cylinder directly affects the displacement of the compressor. When the piston is severely worn or there are wear and scratches on the inner wall of the cylinder, it can cause cylinder leakage, causing some gas to flow back during compression, thereby reducing the displacement.
Abnormal exhaust pressure
Excessive pressure: If the exhaust pipe is blocked, the safety valve fails, or the adjustment is improper, it will increase the exhaust pressure of the compressor. Excessive exhaust pressure can increase the load on the compressor, which may cause component damage and even lead to safety accidents.
Low pressure: In addition to the reasons for insufficient exhaust volume mentioned above, pipeline leaks, internal compressor leaks, etc. can also cause low exhaust pressure. Low exhaust pressure can affect the transportation and utilization efficiency of biogas.
Lubrication malfunction
Insufficient lubricating oil
Low oil tank level: If the operator fails to check and replenish the lubricating oil in a timely manner, or if the lubricating oil leaks, it will cause the oil tank level to be too low. Insufficient lubricating oil can increase friction between moving parts, raise temperature, accelerate component wear, and even lead to equipment jamming.
Oil pump failure: The oil pump is a critical equipment that delivers lubricating oil to various lubrication parts. If the oil pump malfunctions, such as damage or blockage of the inlet and outlet of the oil pump, it will cause the lubricating oil to be unable to supply normally, resulting in insufficient lubrication of the compressor.
Lubricating oil deterioration
Oxidation: Lubricating oil is prone to oxidation reactions under high temperature, high pressure, and contact with air. Oxidized lubricating oil will produce acidic substances and precipitates, increasing the viscosity of the lubricating oil, reducing its lubrication performance, and also corroding equipment components.
Pollution: Impurities, moisture, and other substances in biogas may enter the lubricating oil, causing contamination of the lubricating oil. Contaminated lubricating oil will lose its original lubricating properties and exacerbate component wear.
Electrical malfunction
Motor malfunction
Overload: If the load on the compressor is too high, the voltage is unstable, or there is a fault in the motor itself, it can cause the motor to overload. Motor overload can cause the temperature of the motor to rise, and long-term overload operation can damage the insulation layer of the motor winding, even leading to motor burnout.
Short circuit: Damage to the insulation layer of the motor winding, moisture damage, or external force damage can all cause a short circuit in the motor. A short circuit in a motor can generate a large short-circuit current, causing the motor to quickly heat up and even trigger a fire.
Control circuit malfunction
Relay malfunction: Relays are important components in control circuits used to control the start, stop, and regulation of compressors. If the contacts of the relay are poorly connected, the coil is damaged, or the action is not flexible, it will cause control circuit faults, making the compressor unable to operate normally.
Sensor malfunction: Various sensors, such as temperature sensors, pressure sensors, etc., are usually installed in the control circuit of the compressor to monitor the operating status of the equipment. If the sensor malfunctions, it will result in inaccurate control signals, making it impossible to effectively control the operating parameters of the compressor.
The following are corresponding handling methods for different types of biogas compressor failures:
Mechanical fault handling
Wear and tear issues
Wear of piston rings: When problems such as air leakage and decreased displacement are found due to wear of piston rings, the piston rings should be replaced in a timely manner. Before replacement, it is necessary to inspect and measure the inner wall of the cylinder to ensure that its dimensional accuracy and surface roughness meet the requirements. If the inner wall of the cylinder is severely worn, it may be necessary to perform cylinder boring or replace the cylinder liner.
Bearing wear: If abnormal vibration and noise are generated due to bearing wear, the machine should be stopped immediately for inspection. For bearings with light wear, methods such as adjusting the lubrication method and increasing the amount of lubricating oil can be used to alleviate wear; But if the wear is severe, the bearings must be replaced in a timely manner. When installing new bearings, attention should be paid to the installation method and accuracy to ensure the normal operation of the bearings.
Loose issue
Loose bolts: Regularly check the tightening of bolts in various parts of the compressor, and tighten them in a timely manner if any looseness is found. For bolts in important parts, such as cylinder head bolts, foundation bolts, etc., they should be tightened according to the specified torque. At the same time, anti loosening measures can be taken, such as using spring washers, stop washers, etc., to prevent the bolts from loosening again.
Loose connection of components: For loose connections of components such as couplings and pulleys, the connection parts should be readjusted to ensure a secure connection. If the coupling is loose, it is necessary to check the alignment of the coupling and make accurate alignment adjustment; If the pulley connection is loose, adjust the tension of the belt to achieve the appropriate state.
Fracture issue
Crankshaft fracture: Crankshaft fracture is a serious fault, and once it occurs, the crankshaft must be replaced. When replacing the crankshaft, it is necessary to strictly follow the installation process to ensure the installation accuracy and assembly quality of the crankshaft. At the same time, relevant components such as connecting rods and pistons need to be inspected and repaired to ensure the normal operation of the entire transmission system.
Broken connecting rod: After the connecting rod breaks, the compressor should be stopped immediately and the broken connecting rod should be replaced. When replacing the connecting rod, attention should be paid to the material, size, and assembly requirements of the connecting rod to ensure that the new connecting rod fits well with the crankshaft, piston, and other components. At the same time, a comprehensive inspection of the interior of the cylinder should be carried out to remove debris and impurities caused by broken connecting rods, in order to prevent damage to other components.
Gas transportation fault handling
Insufficient displacement
Air intake filter blockage: Regularly clean or replace the air intake filter. If the filter is not severely clogged, it can be cleaned by using compressed air blowback or cleaning methods; If the blockage is severe, a new filter needs to be replaced. At the same time, it is necessary to check whether there is any air leakage in the intake pipe, and if there is any air leakage, it should be repaired in a timely manner.
Valve malfunction: Inspect and repair the valve. If the air valve seal is not tight, the valve disc and seat can be ground to restore good sealing performance; If the spring is damaged or the valve plate is severely worn, the corresponding components should be replaced in a timely manner. When installing the air valve, pay attention to the installation direction and sequence of the air valve to ensure its normal operation.
Piston wear or cylinder leakage: When the piston wears or the cylinder leaks, repair or replacement should be carried out according to the wear condition. If the piston wear is light, it can be repaired by methods such as chrome plating; If the wear is severe, the piston needs to be replaced. For cylinder leakage problems, if the wear on the inner wall of the cylinder is not severe, honing repair can be carried out; If the wear is severe, the cylinder liner needs to be replaced.
Abnormal exhaust pressure
Excessive pressure: First, check if the exhaust pipe is blocked. If there is any blockage, it should be cleaned in a timely manner. At the same time, check the working status of the safety valve to ensure that it can be opened and closed normally. If the safety valve fails, it should be promptly debugged or replaced. In addition, it is necessary to check the operating parameters of the compressor, such as intake pressure, speed, etc., to ensure that they are within the normal range.
Low pressure: Check if there is any leakage in the pipeline, and repair it promptly if there is any leakage. At the same time, conduct a comprehensive inspection of the compressor, identify the reasons for insufficient displacement, and handle it according to the above methods. In addition, it is necessary to check the pressure sensor and control system to ensure accurate pressure display and control.
Lubrication fault handling
Insufficient lubricating oil
Low oil tank level: Check the oil tank level in a timely manner and replenish lubricating oil to the appropriate level. At the same time, identify the cause of the lubricant leakage and carry out repairs. Common leakage locations include seals, oil pipe joints, etc. In case of seal damage, it is necessary to replace the seal in a timely manner; For loose oil pipe joints, tighten the joints or replace the sealing gasket.
Oil pump malfunction: Check and repair the oil pump. If the oil pump is damaged, it should be replaced in a timely manner; If the inlet and outlet of the oil pump are blocked, the blockage should be cleaned to ensure the normal flow of lubricating oil. When installing the oil pump, pay attention to the installation direction and connection method of the oil pump to ensure its normal operation.
Lubricating oil deterioration
Oxidation: Regularly replace lubricating oil, and determine the oil change cycle reasonably based on the usage of the compressor and the quality requirements of the lubricating oil. At the same time, antioxidants and other additives can be added to the lubricating oil to slow down the oxidation rate of the lubricating oil. In addition, it is necessary to control the operating temperature of the compressor to avoid lubricating oil working for a long time at high temperatures.
Pollution: If the lubricating oil is contaminated, it should be replaced in a timely manner and the lubrication system should be cleaned. When cleaning, specialized cleaning agents can be used to clean components such as oil tanks, oil pipes, and filters to ensure that there are no impurities left in the lubrication system. At the same time, it is necessary to strengthen the purification treatment of biogas to reduce the possibility of impurities and moisture entering the lubricating oil.
Electrical fault handling
Motor malfunction
Overload: Check the load condition of the compressor, and if necessary, adjust the operating parameters of the compressor or reduce the load. At the same time, check whether the power supply voltage is stable. If there is a problem of excessive voltage fluctuation, corresponding voltage stabilization measures should be taken. If there is a fault in the motor itself, such as winding short circuit, grounding, etc., the motor should be repaired or replaced in a timely manner.
Short circuit: Immediately cut off the power and inspect the motor. Find the location of the short circuit, and for cases where the insulation layer is damaged, insulation repair methods can be used for handling; If the short circuit is severe and cannot be repaired, the motor winding or the entire motor needs to be replaced. When dealing with motor short-circuit faults, it is necessary to strictly follow electrical safety operating procedures to ensure the safety of operators.
Control circuit malfunction
Relay malfunction: Check the contact condition of the relay contacts. If there is a problem of poor contact, the contacts can be sanded with sandpaper to restore good contact performance. If the coil of the relay is damaged, the relay should be replaced in a timely manner. When replacing a relay, pay attention to the model and parameters of the relay to ensure that it matches the requirements of the control circuit.
Sensor malfunction: Check and calibrate the sensor. If the measurement value of the sensor is inaccurate, it can be calibrated by adjusting the zero point and range of the sensor; If the sensor is damaged, it should be replaced promptly. After replacing the sensor, it is necessary to re debug to ensure that the control circuit can accurately monitor and control the operating status of the compressor.
