How to Do the Air Compressor Maintenance?

Air compressors are used for a variety of tasks in working plants, including pressurizing air to power your working shop or operating heavy machinery. You can find many different types of compressors available for sale, and these work similarly to make sure that air is being pressurized appropriately. Air compressors don’t last forever and will eventually start to show signs of wear and tear. It’s important to do the air compressor maintenance regularly so it continues to run efficiently. We’ll take a look at maintaining your air compressor.

The two parts of a screw compressor are the main engine and the auxiliary engine. The main engine includes a screw air end and a main motor, while the auxiliary engine includes an air intake system, fuel injection and oil and gas separation system, a cooling system, a control system, and an air intake system.

Motors, heads, air oil separators, coolers, dryers, filters, etc. make up the main components. The reciprocating and vent valves, temperature control valves, minimum pressure valves, oil sight glasses, oil return pipe sight glasses, air filters, etc. are all components of the auxiliary components.

How to maintain the compressor?

how to maintain the air compressor-compmax

The exhaust air temperature is too high

(1) Lower the suction temperature and strengthen the ventilation of the air compressor room. Install an exhaust hood on the roof of the computer room to remove hot air. Make sure the computer room temperature does not increase above 40 degrees Celsius in hot summer. The indoor temperature should be kept below 40 degrees Celsius.

(2) The cooling water temperature should be lowered to 18°C ​​in winter and 24°C in summer. The active water can be increased to increase the heat exchange area and active water. In summer, the flow rate of cooling water is 3.7 liters/second, while in winter the flow rate is 3.9 liters/second.

(3) The flow of cooling water should be increased. The difference between the input temperature and the output temperature of cooling water is 15℃, and the cooling water flow rate is 3.7 liters/second. The cooling process may be poor if the thermal conductivity of the cooling water is low. In this case, detergent may be added to the cooling water to dredge the cooling water system for poor thermal conductivity.

(4) To ensure good thermal conductivity, clean the scale and sediment in the cooling water before adding detergent.

compressor maintenance-compmax

High oil temperature

Due to the presence of oil temperature protection settings on air compressors, the machine will trip whenever the oil temperature rises to 70°C. The oil cooler is frequently malfunctioning because the lengthy lubricating oil pipeline is prone to being oily, blocked.

Air filter is blocked

If screw compressors quality and installation problems can be solved out, most of them are caused by poor ambient air quality. A special compressor station is built, and the shutters can filter out most of the dust particles, cotton wool, and other sundries. Adding a mesh cover (pre-filter) above the compressor air filter can effectively prolong the service time of the air filter. Compmax compressor has a mesh cover.

Screw compressors tripping treatment

The tripping of a screw compressor occurs during operation. First, check the power source and the motor part, then check the rotary compressor temperature control system, pressure automatic adjustment system, and temperature control portion. A failure in the pressure regulating system valve may cause a tripping. The rubber seals, plastic diaphragms, springs, and other parts of the valve are prone to failure, which are often difficult to detect and cause difficulties.

Finding out early-opening unloading valve problems is difficult because the valve is closed before starting and opened slowly during the starting process, however, the opening time is longer than the unit setting. The valve opens a few seconds later, but it raises the compressor’s starting current, resulting in a compressor fault. When the spring elasticity on the piston rod and guide rod decreases, vacuum pressure is applied to the intake baffle as a result of the control system’s loading signal not being sent to the unloading valve. As a result, the valve is opened, resulting in the compressor being loaded in advance and the unit not being fully started, resulting in the motor being constantly turned up and the star-delta conversion being unsuccessful.

Others:

There are two factors that the compressor monitors: the maximum working pressure and the general working pressure. When choosing a compressor, make sure to select one with the general working pressure as the reference data. Excessive pressure can be exerted on the compressor for a long period of time and cause damage to the motor if it is selected with the maximum working pressure.

(2) Water-cooled compressors require high-quality water to ensure they operate properly. The cooling water of compressors in many companies is often contaminated with impurities due to inadequate water treatment. If a water softening device is installed when necessary, it can greatly reduce the chance of compressor failure.

preventative maintance for compressor

How to service air compressors? There are several maintenance tips. You can also refer to the user manual.

Maintenance of screw compressor

1.Air inlet filter Maintenance

Air dust and dirt are removed by an air filter. Clean air enters the screw machine’s compression chamber after passing through the air filter. Since the internal clearance of the screw machine only allows particles up to 15u in size to pass through, particles larger than 15u will enter the screw machine if the air filter element is blocked or damaged. To abbreviate the life of the oil filter element and oil fine separation core, as well as accelerate bearing wear, particles that enter the bearing cavity are numerous. To degrade the quality of compressed air and decrease compression efficiency, as well as to injure the rotor.

Note: when cleaning or replacing the air filter element, the components must be checked to prevent air remains particles from falling into the air inlet valve. At ordinary times, check whether the air inlet pipe is damaged or flattened.If found, it must be repaired and replaced in time according to the maintenance schedule

2 Replace oil filter

The oil filter element must be changed after operating the new machine for 500 hours. Screw oil should be added before installing the new filter element. To replace the oil filter element, both hands should be used to screw the seal back to the oil filter seat and tighten it with force. Add screw lubricate oil before setting up the new oil filter cartridge to ensure a good seal. It is forbidden to use the oil filter element beyond the expiration date. Otherwise, due to the serious obstruction of the filter element and the bypass valve pressure difference exceeding the bearing limit, the bypass valve will open automatically, leading to serious damage to the screw host.

3 maintenance of air oil separator

A fine separator separates oil and removes moisture from compressed air. The air oil separator requires 4000 hours of service life under normal conditions but can be maintained and replaced with reduced frequency in harsh environments. Even a mesh for front air should be installed.The air-oil separator must be replaced when it expires or the pressure difference exceeds 0.12mpa.

Replacement method: Remove the fastening bolts of the upper cover of the oil and gas barrel, remove the oil return pipe extending into the oil and gas barrel on the cover of the oil and gas barrel, and remove the asbestos pads, replacing them with new ones. The asbestos pads must be nailed and stapled when pressing them. When pressing, the asbestos pads ought to be placed neatly, otherwise leakage might occur. The upper cover plate, oil return pipe, and control pipes must be installed in the same manner as they were before, and leakage must be checked.

COMPMAX-your excellent partner for industrial air compressors system solutions!

4.Air Compressor Maintenance: Lubricated Oil

The performance of an oil lubricated screw machine is greatly impacted by the quality of the oil. An antioxidant-stable, rapid-separation, efficient foam, high viscosity and anti-corrosive quality good oil is critical. Pure special screw oil must be used. Oil replacements are typically carried out every 2000-4000 hours once the machine has been running for 500 hours.

5 air compressor maintenance :cooler

The heat dissipation effect of the cooler directly affects the service temperature of the compressor. If the cooler is standing upright, it is necessary to use dry compressed air above 0.4MPa to blow from the outside to the inside during maintenance. After blowing, clean the dust and particles in the air guide hood to prevent it from being blown into the cooler by the fan again, resulting in blockage and high temperature of the machine.

Summary

In short, the causes of air compressor failure are various, and there are many inducing reasons. Air compressor repair is costly. Only when we have a more comprehensive understanding of the compressors, timely replace the air filter,oil filter,air oil separators and oil, and do preventive maintenance in daily, monthly, quarterly and annual maintenance, although this is a time consuming work, it can prevent the compressor failure in advance.

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