The common problems during hydrogen compression mainly include the following aspects:
1. Compressor malfunction
Lubricating oil system malfunction:
Low lubricating oil pressure: It may be due to leakage in the lubricating oil system or poor quality of the lubricating oil (such as high water content, metal ion content, etc.) leading to deterioration.
Lubricating oil condensation: Due to the solubility of lubricating oil in the external air of the compressor pipeline, it is difficult to avoid a small amount of air from dissolving into it; At the same time, the return oil of the secondary oil pressure limiter device mixes with a small amount of undissolved air to form an air foam, which may cause the gap to become larger when it gathers.
Air valve and valve malfunction:
The valve disc of the air valve is prone to carbon deposition, accumulation of oil sludge or dust, which can cause the air valve to malfunction.
The spring of the air valve is prone to breakage, which affects the opening and closing of the air valve.
Cross head and connecting rod malfunction:
The crosshead, crosshead pin, skateboard, and guide rail are collectively referred to as crosshead components, which are prone to cracking due to high pressure.
Connecting rods convert the reciprocating motion of pistons into the rotational motion of crankshafts, and are prone to wear and fracture even under long-term stress.
2. Compressor performance issues
Exhaust temperature too high:
It may be due to the failure or improper adjustment of the exhaust pump, resulting in excessive pressure of hydrogen and an increase in exhaust temperature.
Excessive oil temperature may also cause high exhaust temperature, which is usually due to poor heat dissipation in the oil circuit.
Leakage problem:
Hydrogen Compressor leakage is usually caused by poor sealing or aging or damage of sealing materials.
Insufficient displacement:
Blockage caused by scale buildup, long or small suction pipes can all increase suction resistance and affect exhaust volume.
Severe wear of cylinders, pistons, and piston rings can also lead to increased leakage and affect exhaust volume.
3. Process medium issues
Damage caused by foreign objects in gas:
Gas pollutants such as rust, fine sand particles, or corrosive powder particles can significantly exacerbate the wear of valve components, while increasing the wear of cylinders, piston rings, and packing rings.
Medium with liquid:
The presence of liquid in the medium may affect the lubrication of the cylinder and even cause damage to the air valve or liquid hammer accidents.
4. Other operational issues
Compressor inlet pressure fluctuation:
Fluctuations in the inlet pressure of the compressor may cause the compression ratio to exceed the set value, leading to overheating of the compressor exhaust temperature and burning out of the compressor air valve.
Improper operation:
The lack of professional training or improper operation by operators may also lead to compressor failure or performance degradation.
In summary, common problems during hydrogen compression involve compressor failures, hydrogen compressor performance issues, process medium issues, and other operational issues. To ensure the safety and efficiency of hydrogen compression, it is necessary to regularly inspect and maintain the compressor, promptly identify and address potential issues. At the same time, operators also need to receive professional training and strictly follow the operating procedures.
Some possible solutions based on general fault handling principles and common types of faults in hydrogen compressors.
For equipment such as hydrogen compressors, common faults and troubleshooting methods include:
1. Valve malfunction
Fault manifestation: Valve failure is the main cause of unit shutdown, which may manifest as valve leakage, valve plate damage, spring failure, etc.
Handling method:
Check and replace damaged valve components such as valve plates, springs, etc.
Clean the carbon deposits and oil sludge inside the air valve to maintain its cleanliness and smoothness.
Adjust the opening and closing time of the air valve to ensure its normal operation.
2. Piston ring and support ring malfunction
Fault manifestation: The piston ring and support ring are severely worn, which may lead to increased leakage and affect the displacement and efficiency of the compressor.
Handling method:
Regularly inspect and replace worn piston rings and support rings.
Adjust the gap between the piston ring and the cylinder to ensure proper sealing.
Strengthen the lubrication and cooling of the cylinder to reduce wear on the piston rings and cylinder.
3. Lubricating oil system issues
Fault manifestations: low lubricating oil pressure, deteriorated oil quality, insufficient oil quantity, etc.
Handling method:
Check the pipelines and valves of the lubricating oil system to ensure there are no leaks or blockages.
Regularly replace and clean the lubricating oil filter to maintain the cleanliness of the oil quality.
Adjust the pressure and flow rate of the lubricating oil to ensure proper lubrication effect.
Use appropriate lubricating oil and avoid using expired or unqualified lubricating oil.
4. Process issues
Fault manifestations: gas carrying solid particles, medium carrying liquid, compressor inlet pressure fluctuations, etc.
Handling method:
Filter and purify the gas before entering the compressor to remove solid particles and impurities.
Control the moisture and liquid content of the medium to avoid damage to the compressor.
Stabilize the inlet pressure of the compressor to prevent excessive pressure fluctuations from causing compressor failure.
5. High exhaust temperature
Fault manifestation: The discharge temperature of the compressor is higher than the design value.
Handling method:
Check the operation status of the cooling system to ensure good cooling effect.
Adjust the operating parameters of the compressor, such as reducing the compression ratio, decreasing the start-up load, etc.
Strengthen the heat dissipation and ventilation of the compressor, and reduce the impact of ambient temperature on the compressor.
6. Other faults
Fault manifestations: such as collision sound on the body, compressor not starting, motor not synchronizing, etc.
Handling method:
Diagnose and troubleshoot based on specific fault symptoms.
Tighten loose components and replace damaged parts.
Check the electrical and control systems to ensure normal operation.
In summary, the fault handling methods for hydrogen compressors need to be targeted according to specific fault types and causes. When dealing with faults, it is necessary to ensure safe operation, follow the equipment's usage and maintenance manual, and avoid further damage to the equipment.
