The common faults of reciprocating Hydrogen Compressors are as follows:
1. Valve malfunction:
Valve plate damage: After long-term use, the valve plate may crack, deform, or break due to frequent opening and closing, gas impact, and wear. This will cause the gas valve to not close tightly, resulting in gas leakage, affecting the displacement and pressure of the compressor, reducing compression efficiency, and increasing energy consumption.
Spring failure: Weakened elasticity, fracture, or fatigue deformation of the spring can cause inaccurate valve opening and closing time and abnormal speed. The spring elasticity is insufficient, and the valve plate closes slowly, causing gas reflux; If the spring breaks, the air valve cannot function properly, causing pressure fluctuations and affecting the performance of the compressor.
Poor sealing: Foreign objects, wear, or damaged sealing gaskets between the valve seat and valve disc can cause gas leakage. This will cause unstable exhaust pressure, reduced suction volume, gas leakage during compression, reduced compressor efficiency, and may also cause an increase in valve temperature.
2. Piston and piston ring malfunction:
Wear: Long term friction between the piston and cylinder wall, as well as impurities in the gas, can cause wear on the piston and piston rings. Resulting in increased clearance between the piston and cylinder, increased gas leakage, decreased displacement and pressure, decreased compression efficiency, and possibly abnormal vibration and noise.
Piston ring jamming: The piston ring is stuck in the piston ring groove and cannot move freely, often due to insufficient lubricating oil, deterioration, or impurities in the gas entering the ring groove. This will damage the sealing function of the piston ring, causing gas leakage, affecting the performance of the compressor, and may also lead to excessive wear of the piston ring and cylinder wall.
Piston damage: The piston may crack, deform, or even rupture due to uneven force, material defects, or long-term high temperature and high pressure effects. This will seriously affect the normal operation of the compressor, leading to gas leakage, unstable pressure, and even causing the compressor to shut down.
3. Piston rod malfunction:
Wear and tear: The relative movement between the piston rod, packing box, guide sleeve and other components can easily lead to wear and tear. Wear will cause the diameter of the piston rod to decrease, affecting the sealing performance and motion accuracy; Pulling can damage the surface finish, leading to leakage, and may also cause vibration and noise.
Fracture: The piston rod is subjected to alternating loads during operation. If the design is unreasonable, the material quality is poor, the installation is improper, or the pre tightening force is too large, it is prone to fracture in stress concentration areas. This is a serious malfunction that can cause the compressor to shut down and even lead to safety accidents.
4. Fault in crankshaft and connecting rod:
Wear: Long term friction between the journal of the crankshaft and the bearings, as well as the large and small end pads of the connecting rod and their corresponding parts, can cause wear. Resulting in an increase in clearance, causing vibration and noise, affecting power transmission efficiency, and in severe cases, causing the compressor to malfunction.
Deformation and fracture: Long term exposure to complex loads may cause deformation of the crankshaft and connecting rod. This will affect the movement trajectory of the piston and the sealing performance of the cylinder, resulting in a decrease in compressor performance. In extreme cases, such as overload, material defects, or fatigue damage, the crankshaft and connecting rod may break, causing serious equipment damage.
5. Lubrication system malfunction:
Abnormal oil pressure: Oil pump failure, clogged oil filter, oil circuit leakage, or inappropriate oil viscosity can cause high or low oil pressure. Low oil pressure, unable to provide good lubrication for moving parts, increases the risk of wear and tear; Excessive oil pressure may damage the seals and cause oil leakage.
Deterioration of oil quality: After long-term use, lubricating oil will age, deteriorate, mix impurities, moisture, or be affected by high temperatures, leading to oxidation, carbonization, and other deterioration of oil quality. This will reduce lubrication performance, increase component wear, and may also block oil circuits, affecting heat dissipation and causing equipment temperature to rise.
6. Cooling system malfunction:
Poor cooling effect: Insufficient cooling water volume, high water temperature, scaling or blockage of the cooler, fan failure (air-cooled), etc., can prevent the cooling system from effectively removing the heat generated during the compression process. Causing high exhaust temperature, oil temperature, cylinder temperature, etc. of the compressor, affecting equipment performance and service life, and even triggering safety protection device action due to overheating, resulting in compressor shutdown.
Cooling system leakage: Damaged seals and corroded pipes in cooling water pipelines, coolers, and other areas can cause cooling water leakage. This not only results in insufficient cooling water, affecting the cooling effect, but may also allow water to enter the interior of the compressor and damage components.
7. Abnormal vibration and noise:
Mechanical imbalance: The rotor, piston, and other moving parts of the compressor are unbalanced, causing vibration during operation. This will accelerate component wear, affect equipment stability, and in severe cases, may lead to equipment damage.
Unstable foundation or improper installation: Unreasonable design of compressor foundation, poor construction quality, or failure to align and level during installation can cause vibration and noise during equipment operation. This will affect the normal operation of the equipment, shorten its lifespan, and may also have an impact on the surrounding environment.
Loose or worn components: Loose connecting components, worn bearings, faulty air valves, etc. can also cause vibration and noise. This not only affects the operational stability of the equipment, but may also be a precursor to other faults that need to be promptly investigated and dealt with.
Common troubleshooting solutions
1. Solution to valve malfunction
Valve plate damage:
Regularly inspect the air valve. If cracks, deformations, or breakage are found in the valve disc, the valve disc should be replaced in a timely manner. When replacing, it is necessary to ensure that the model, material, and size of the new valve plate are consistent with the original valve plate, and that the installation is correct to ensure that the valve plate fits tightly with the valve seat.
Conduct quality inspection on the new valve disc, including surface flatness, hardness and other indicators, to ensure that its quality meets the requirements and can withstand frequent opening and closing actions and gas impacts.
Spring malfunction:
Check whether the spring has weakened elasticity, broken or deformed due to fatigue. If any problems are found with the spring, it should be replaced immediately, and attention should be paid to the installation direction and preload force of the spring during installation.
Choose springs with reliable quality, whose elasticity coefficient should meet the design requirements of the air valve to ensure that the valve plate can open and close accurately and timely. At the same time, the reserve coefficient of the spring can be appropriately increased to improve its service life.
Poor sealing:
When it is found that the seal between the valve seat and the valve plate is not tight, first clean the foreign objects on the surface of the valve seat and valve plate, and check whether the sealing gasket is damaged. If there is damage, the sealing gasket should be replaced.
For worn valve seats and plates, grinding can be used to repair them and restore their contact surfaces to a good sealing state. After grinding, a sealing test should be conducted to ensure that the air valve can work properly.
2. Solution to piston and piston ring faults
Wear and tear:
For the wear of pistons and piston rings, the first step is to check the degree of wear. If the wear is light, it can be solved by adjusting the tension of the piston ring or replacing the piston ring. When replacing the piston ring, pay attention to the specifications and installation sequence of the piston ring to ensure that it can move freely in the piston ring groove.
When the piston is severely worn, it needs to be replaced. At the same time, it is necessary to check the wear of the cylinder wall. If the wear of the cylinder wall exceeds the allowable range, it may be necessary to perform cylinder boring repair or directly replace the cylinder. In daily operation, it is necessary to ensure the cleanliness of the intake and reduce the wear of impurities on the piston and piston ring.
Piston ring stuck:
When the piston ring is found to be stuck, first check the condition of the lubricating oil. If the lubricating oil is insufficient or deteriorated, it should be added or replaced in a timely manner. Clean the impurities in the piston ring groove to ensure that the piston ring can move freely in the groove.
For piston ring jamming caused by wear or deformation, it is necessary to replace the piston ring and check the fit between the piston and cylinder wall. If necessary, repair or replace it.
Piston damage:
Once cracks, deformations, or ruptures are found in the piston, it must be replaced immediately. Before replacing the piston, carefully check whether there are any other damaged parts inside the cylinder, such as piston pins, connecting rod small head bushings, etc., and replace or repair the damaged parts together. At the same time, it is necessary to analyze the causes of piston damage, such as whether it is due to overload, insufficient cooling, or material defects, and take corresponding preventive measures.
3. Solution to piston rod malfunction
Wear and tear:
For minor wear and tear of the piston rod, repair methods can be used. For example, chrome plating treatment can be applied to the worn parts to restore the size and surface smoothness of the piston rod. After repair, the precision of the piston rod should be checked to ensure that it meets the requirements.
If the wear or tear is severe and cannot be repaired, the piston rod needs to be replaced. At the same time, it is necessary to check the wear of the packing box, guide sleeve and other components that match it, and replace or repair them together to ensure good fitting accuracy.
crack:
When the piston rod breaks, the machine must be stopped immediately to replace the piston rod. During the replacement process, it is necessary to strictly follow the installation instructions of the equipment to ensure installation accuracy. Quality inspection should be carried out on the new piston rod, including material inspection, strength testing, etc.
Analyze the causes of piston rod fracture, such as whether it is due to unreasonable design, excessive load, or material quality issues. Take corresponding measures based on the reasons, such as optimizing the design, controlling the working load, or replacing high-quality materials, to prevent the recurrence of fracture accidents.
4. Solutions for crankshaft and connecting rod faults
Wear and tear:
For the wear of the crankshaft and connecting rod, the first thing to check is the location and degree of wear. If the wear is light, it can be solved by adjusting the fit clearance. For example, replacing the bearing or liner to restore the fit clearance to the normal range.
When the wear is severe, it may be necessary to repair or replace the crankshaft or connecting rod. During the repair process, appropriate processing techniques should be used to ensure the dimensional accuracy and surface quality after repair. At the same time, it is necessary to strengthen lubrication management, ensure good lubrication conditions, and reduce wear and tear.
Deformation and fracture:
When the crankshaft or connecting rod is found to be deformed, different measures should be taken according to the degree of deformation. For minor deformations, straightening can be used for repair, but accuracy checks and balance tests must be conducted after straightening. If the deformation is severe, the crankshaft or connecting rod needs to be replaced.
When the crankshaft or connecting rod breaks, it is a serious accident and must be stopped immediately for replacement. At the same time, a comprehensive inspection of the entire compressor system should be conducted to identify the causes of fracture, such as overload, fatigue, material defects, etc. Corresponding preventive measures should be taken, such as optimizing operating parameters, strengthening equipment maintenance, and replacing high-quality materials.
5. Solution to lubrication system faults
Abnormal oil pressure:
When the oil pressure is too low, first check if the oil pump is working properly. If the oil pump malfunctions, it should be repaired or replaced in a timely manner. Check if the oil filter is clogged. If it is clogged, clean or replace the oil filter in a timely manner.
Check if there is any leakage in the oil circuit, and if there is, repair the leaking area. For situations where the oil viscosity is not suitable, it is necessary to replace the lubricating oil with a suitable viscosity according to the equipment requirements and actual working conditions. When the oil pressure is too high, check whether the oil pressure regulating valve is working properly. If there is a problem, adjust or replace the regulating valve in a timely manner.
Deterioration of oil quality:
Regularly inspect the quality of lubricating oil and replace it promptly if the oil quality deteriorates. When replacing lubricating oil, thoroughly clean the oil tank and oil circuit to remove impurities and old oil residue. At the same time, it is necessary to strengthen the management of lubricating oil to prevent moisture, impurities, and other substances from mixing into the lubricating oil.
Choose lubricating oil with good quality and stable performance according to the working environment and requirements of the compressor. Some lubricating oil purification equipment, such as oil filters, oil purifiers, etc., can be used to circulate and purify lubricating oil, extending its service life.
6. Solution to Cooling System Malfunctions
Poor cooling effect:
For situations where the cooling water volume is insufficient, it is necessary to check the cooling water supply system, such as whether the water pump is working properly, whether the water pipes are blocked or leaking, etc. If it is a water pump malfunction, it should be repaired or replaced in a timely manner; If the water pipe is blocked, it needs to be cleaned; If there is a leak, repair the leaking area.
When the water temperature is too high, check the working condition of the cooling tower or cooling water tank and take measures to reduce the water temperature. For cases of scaling or blockage in the cooler, chemical or mechanical cleaning methods can be used to clean the cooler and restore its cooling function. If the fan of the air-cooled cooling system is faulty, it should be repaired or replaced in a timely manner.
Cooling system leakage:
When a cooling system leak is detected, immediately shut down and inspect the leak location. If the seal is damaged, it needs to be replaced; If it is pipeline corrosion, the corroded part of the pipeline should be replaced. After repair, a pressure test should be conducted to ensure that the cooling system no longer leaks.
To prevent leakage of the cooling system, high-quality sealing materials and corrosion-resistant pipeline materials can be used. Regularly inspect and maintain the cooling system to promptly identify and address potential leakage hazards.
7. Solutions for abnormal vibration and noise
Mechanical imbalance:
For vibrations and noise caused by unbalanced moving parts, balance tests should be conducted on components such as rotors and pistons. If it is unbalanced, it is necessary to use the method of balancing or removing weights for balancing treatment.
After equipment installation and maintenance, key components should be re balanced and tested to ensure that the equipment does not produce vibration and noise due to imbalance during operation.
Unstable foundation or improper installation:
Check if the foundation of the compressor is firm. If there is any looseness or sinking, the foundation should be reinforced. Recheck the installation levelness and verticality of the equipment, adjust according to the installation instructions of the equipment to ensure correct installation.
When designing and constructing equipment foundations, factors such as the weight and vibration characteristics of the equipment should be considered. Suitable foundation structures and materials should be used to ensure that the foundation can withstand the operating load of the equipment and reduce vibration transmission.
Loose or worn components:
Regularly check whether the connecting components are loose, and if they are loose, tighten them in a timely manner. For vibration and noise caused by bearing wear, valve failure, etc., corresponding fault handling methods should be used for maintenance or component replacement.
Establish a vibration and noise monitoring system for equipment, monitor the operating status of the equipment in real time, promptly detect and handle abnormal situations, and avoid further expansion of faults.
