The following are the precautions for using piston compressors:
Before startup
Check equipment integrity: Check whether the main components of the machine are complete, whether there are cracks, rust, etc., to ensure that the equipment is intact and undamaged
Confirm lubrication system: Check the lubricating oil level, which should be kept within the red circle in the middle of the oil mirror. The oil quality should be clean, without deterioration, foaming, or other phenomena. Generally, it needs to be replaced every 500 hours of use; At the same time, check if the oil level in the oil injector tank is above 1/2 to ensure that the lubrication system is working properly
Check the cooling system: Confirm that the cooling water pipeline is firmly connected, there is no leakage, the water level in the cooling water tank is normal, and the valve opening is correct to ensure that the compressor can receive effective cooling during operation
Check the electrical system: Check whether the wires and electrical switches comply with regulations, whether the wiring is correct, whether the boundaries are clear, whether the supporting points of each wheel foot are fixed and stable, whether the compressor pulley can be easily rotated by hand, ensure that the electrical equipment is well grounded, and prevent leakage accidents
Check the pipeline system: Check if the inlet ball valve, outlet ball valve, instrument air valve, etc. are open, if the discharge valve of the recovery tank is closed, if the pipeline connection is tight and there is no leakage
Confirm safety devices: Check whether the emergency stop button is working properly, whether the pressure gauge, safety valve and other safety devices are sensitive and effective, regularly verify the safety valve to ensure that it can open normally under the set pressure
Cleaning and preparation: Clean up the operation site, remove debris and flammable materials, keep the surrounding environment clean, dry, and well ventilated; Operators are required to wear personal protective equipment that meets the requirements, such as acid and alkali resistant gloves, protective clothing, protective goggles, and safety shoes
At startup
No load start: Before the compressor starts working, it should be started with no load first, idle for 2 to 3 minutes or more, observe the operating status of the compressor, check for any abnormal noise, vibration or leakage, and if there are any problems, stop the machine for inspection in a timely manner
Check the steering: After starting, check if the direction of operation is the same as the indicated arrow. If not, for a three-phase motor, swap any two of the three power sources
Running
Monitoring of operating parameters: Pay close attention to the operating parameters of the compressor, such as the lubricating oil pressure should be maintained at 0.350.45MPa, whether the temperature is normal, whether the oil filter pressure difference exceeds 10 psi (70 KPa), whether the crankcase liquid level is between 1/22/3, whether the suction pressure, exhaust pressure, exhaust temperature, and exhaust pressure of each stage of the compressor unit are within the specified range, etc. If there are any abnormalities, stop the machine in time for processing
Prevent overload: It is strictly prohibited to operate beyond the rated working range and load of the compressor to avoid faults and safety accidents caused by overheating
Pay attention to lubrication and maintenance: Regularly check the oil level and quality of the lubricating oil, add lubricating oil in a timely manner, and ensure that the oil level is within the normal range; Regularly clean and replace the oil filter to ensure the normal operation of the lubrication system and reduce equipment wear
Cooling system maintenance: Pay attention to the discharge and temperature of cooling water at all levels to ensure good cooling effect and prevent the compressor from overheating due to insufficient cooling
Check for leaks: Regularly inspect the internal and external pipelines or body of the compressor sled for oil and gas leaks. If any leaks are found, the machine should be shut down for rectification in a timely manner
Abnormal situation handling: If the readings of the pressure gauge, oil pressure gauge, temperature gauge, and ammeter suddenly exceed the specified values or indicate abnormally, causing water leakage, air leakage, electric leakage, or sudden interruption of the coolant, or if the safety valve continues to release air or the air compressor makes abnormal sounds, and cannot be adjusted, the vehicle should be stopped immediately for maintenance
After shutdown
Normal shutdown: Turn the "RUN/OFF" key switch on the on-site operation panel to the "OFF" position, and the compressor will automatically unload. Wait for the "compressor running" indicator light on the control cabinet and on-site operation panel in the control room to turn off before shutting down, and hang a "shutdown" sign on the on-site operation panel
Emergency stop: The emergency stop button can only be used in emergency situations and cannot be used during normal shutdown; After an emergency stop, the compressor must not be started until the problem causing the emergency stop has been resolved
Cut off power supply: If the compressor encounters a power outage or use during operation, it is necessary to cut off the power supply to ensure safety; After shutdown, all power switches should also be turned off to prevent accidental start-up
Discharge and maintenance: During daily shift handover, the discharge valve should be opened to remove any accumulated moisture and oil stains from the bucket; Regularly perform comprehensive maintenance on the compressor, including changing lubricating oil, cleaning or replacing air filters, inspecting and tightening screws in various parts, etc
1. Daily maintenance (after each shift)
Appearance cleaning: Use a clean cloth to wipe the outer surface of the compressor, removing dust, oil stains, and other impurities. Keeping the body clean not only prevents impurities from entering the interior of the machine, but also facilitates observation of any abnormal situations such as leaks.
Check for leaks: Carefully inspect the various connection parts, pipeline interfaces, valves, and seals of the compressor to see if there are any natural gas or lubricating oil leaks. Leak detectors (such as soapy water) can be used to detect small leaks. If a leak is found, the connecting components should be tightened or the seals replaced in a timely manner.
Record operating parameters: Record the operating time, exhaust pressure, exhaust temperature, lubricating oil pressure and temperature, and other parameters of the compressor. These records can help analyze the operating status of the compressor and promptly identify potential issues. For example, if the exhaust temperature gradually increases, it may indicate a malfunction in the cooling system or wear on internal components of the compressor.
Drainage: Open the drainage valve to discharge the condensed water from the gas tanks and coolers at all levels of the compressor. If too much condensed water accumulates, it may enter the compression chamber, affect the quality of compressed gas, and may cause rusting and corrosion of components.
2. First level maintenance (after 500 to 1000 hours of operation)
Lubrication system maintenance
Replace lubricating oil: Drain the old lubricating oil and collect it in a clean container to check the oil quality and whether there are impurities such as metal shavings. Then add new lubricating oil that meets the requirements of the compressor, and the model and specifications of the lubricating oil should be strictly selected according to the equipment manual. After adding new oil, check if the oil level is within the specified range.
Cleaning oil filter: Disassemble the oil filter and use a specialized cleaning agent to clean the filter element, removing oil stains and impurities from the filter element. If the filter element is damaged or severely clogged, a new filter element should be replaced. After cleaning or replacing the oil filter, ensure proper installation and no leakage.
Air intake system maintenance
Clean air filter: Remove the filter element of the air filter, blow compressed air from the inside of the filter element outward to remove dust and debris. If the filter element is very dirty or damaged, a new filter element should be replaced. When installing the cleaned filter element, ensure good sealing to prevent unfiltered air from entering the compressor.
Check the intake duct: Check for any deformation, blockage, or looseness in the intake duct. If any leakage is found in the pipeline, it should be repaired in a timely manner; If there are foreign objects inside the pipeline, they should be cleaned thoroughly.
Cooling system maintenance
Check the cooling water pipeline: Check whether the cooling water pipeline leaks and whether the connection parts are loose. If a leakage point is found, sealant should be used or the sealing gasket should be replaced for repair; If the pipeline is blocked, high-pressure water guns or chemical cleaning agents can be used for cleaning.
Check the cooling water pump and cooling tower (if any): Check the operation of the cooling water pump, including the operation of the motor, lubrication of the bearings, and wear of the impeller. For the cooling tower, check whether the nozzle is blocked, whether the packing is damaged, and clean the debris inside the tower.
3. Second level maintenance (after 2000 to 3000 hours of operation)
Check and adjust the main components of the compressor
Check the piston and cylinder: Remove the cylinder head, check the wear of the piston ring and the clearance between the piston and the cylinder wall. If the piston ring is severely worn, it should be replaced; If the clearance exceeds the specified range, it may be necessary to replace the piston or perform cylinder boring treatment on the cylinder.
Check the connecting rod and crankshaft: Check the wear of the bearings on the big and small ends of the connecting rod, and inspect the journal wear and surface roughness of the crankshaft. For bearings with severe wear, they should be replaced in a timely manner; For minor wear of the crankshaft journal, it can be repaired by grinding, but for severe wear, the crankshaft needs to be replaced.
Check the air valve: Disassemble the air valve and inspect the wear of the valve disc, spring, and seat. If there are cracks, deformations or severe wear on the valve disc, it should be replaced; The spring elasticity is insufficient and needs to be replaced; If there is damage to the sealing surface of the valve seat, it should be repaired by grinding or the valve seat should be replaced.
Electrical system inspection
Check the motor: Check the insulation resistance, winding temperature, and wiring condition of the motor. The insulation resistance should meet the requirements, otherwise leakage may occur; Check if the wiring of the motor is secure and if there are any loose or burnt marks.
Check the control cabinet and sensors: Clean the dust inside the control cabinet and check if all electrical components (such as contactors, relays, fuses, etc.) are working properly. At the same time, check whether the temperature sensor, pressure sensor, etc. are accurate, and replace them in a timely manner if there is a malfunction.
Inspection of other components
Check the safety valve: Check if the safety valve can be opened and closed normally. The popping pressure and reseating pressure of the safety valve can be checked for compliance with regulations through manual testing or professional calibration equipment. If the safety valve fails, it should be replaced or repaired in a timely manner.
Check the foundation bolts and connecting bolts: Check whether the foundation bolts of the compressor and the connecting bolts between various components are loose. If there is looseness, appropriate tools should be used to tighten it to ensure the stability of the compressor.
4. Third level maintenance (after 8000 to 10000 hours of operation)
Comprehensive disassembly and maintenance: completely disassemble the compressor, conduct detailed inspection and repair of all components. This includes conducting non-destructive testing on the body, cylinder block, crankcase, etc. to check for defects such as cracks; Precision measurement and repair of all bearing shells and shaft necks; Replace all seals and gaskets.
Update vulnerable parts: In addition to the vulnerable parts replaced in daily maintenance and first and second level maintenance, for some parts with a longer service life but may experience wear, such as piston pins, crosshead slides, etc., they should be replaced according to the inspection results.
Reinstall and debug: After all components have been inspected and repaired, reassemble according to the requirements of the equipment manual. During the assembly process, attention should be paid to the installation sequence of each component, gap adjustment, and tightening torque of bolts. After assembly, perform no-load debugging and load debugging to check whether the performance of the compressor has been restored to normal levels and whether the operating parameters comply with regulations.
