Henan Chemical 5-40/8 Air Compressor Technical Transformation Zhuang Xinsheng (Henan Shenma Nylon Chemical Co., Ltd., Pingdingshan 467000, Henan) The frequent occurrence of 5-40/8 air compressors was analyzed, combined with the actual situation, this Carrying out economic and practical principles and proposing a transformation plan.
After changing the material, thickening the spring, adding the tension ring, and protecting the nitrogen, the satisfactory results are obtained.
1 Fault phenomenon -40/8 type oil-free lubricating air compressor. It was used in 2001 and overhauled every two years in 2009. The following faults still occur frequently: 1 second-class exhaust temperature is high; 2 de-oiler is frequently blocked; 3 The gas valve fails quickly; 4 oil pump shaft oil seal leaks oil.
2 Cause analysis 2.1 The secondary exhaust gas temperature is high 2.1.1 * The intake air temperature The high intake air temperature is the atmospheric temperature of the suction port outside the plant. It varies with the change of the atmospheric temperature and is within the design requirements. Judging the high intake air temperature is not the main cause of the high secondary exhaust temperature.
2.1.2 * Level 1 inlet and outlet one-way air valve leakage level inlet and outlet check valve leakage often occurs at the same time as the stage exhaust pressure low fault, the defect does not exist often, and occasionally it can quickly find the cause and eliminate it, so It can be judged that the leakage of the primary inlet and outlet one-way valve is not the main cause of the high temperature of the secondary exhaust.
2.1.3 *The piston ring of the grade is damaged or worn. The first-stage piston is installed vertically, not easy to be eccentric, and the piston ring is overhauled or replaced once every two years. Therefore, it can be judged that the damage or wear of the piston ring is not caused by the high temperature of the secondary exhaust. The main reason.
2.1.4 Secondary air intake cooler cooling effect is not good In normal operation, the secondary air intake cooler cooling water back to the water observation mirror has bubbles, and the bubble gradually increases with the extension of the driving time. Therefore, it can be judged that the leakage of the secondary air intake cooler is the main cause of the high temperature of the secondary exhaust gas.
2.1.5 The leakage of the secondary inlet and outlet check valves can be determined according to the maintenance of the equipment. There are two main reasons for the leakage of the secondary inlet and outlet check valves, which are often found in the daily minor repair and repair process. There is rust on the valve plate.
In particular, the compressor that has just been repaired is ready for normal use. When the vehicle is used for one or two months, the phenomenon of rust jam on the valve is more obvious. Second, the spring of the check valve wears quickly and is easy to break. The weak spring force also causes the valve to not close and open quickly, resulting in high secondary exhaust temperature. Therefore, it can be judged that the one-way valve leakage caused by rust and the one-way valve spring wear fast and the low elasticity is the main cause of the high secondary exhaust temperature.
2.1.6 Two-stage piston ring is stuck, worn, broken, and the secondary cylinder is worn. The spare equipment often fails after being put into use: disassembling the piston ring and the cylinder often finds that the piston ring is seriously worn, and the piston ring sometimes gets stuck in the piston ring. In the tank, there is even a phenomenon of fracture, wear of the lower part of the cylinder, and rust on the inner wall of the cylinder. Each overhaul and intermediate repair piston ring and piston, piston ring and cylinder clearance are also installed according to technical requirements.
It can be judged that the large moisture in the secondary cylinder of the standby compressor is the main cause of the seizure, wear, breakage and wear of the secondary piston of the secondary piston ring. In addition, the outer tension of the piston ring is insufficient. If the small foreign matter is caught in the piston ring groove after the thermal expansion, the piston ring does not work, and the gas is repeatedly compressed in the cylinder, and a small part is discharged, which also causes the second row. The main reason for the high gas temperature.
2.1.7 The secondary exhaust outlet line is equipped with a degreaser filter plug to block the degreaser filter, the secondary exhaust can not be smoothly discharged to the user, the gas in the secondary cylinder is repeatedly compressed by the piston -), male , mechanical engineer, has long been engaged in mechanical equipment management and research work, telephone. Henan chemical exhaust temperature rises, so it can be judged that the plug of the degreaser filter is the main cause of high secondary exhaust temperature.
2.2 De-oiler clogging frequently After repeated inspections of the degreaser, it is found that the causes of frequent blockage are: 1 The secondary vent gas cooler and the degreaser are not timely drained, causing water, oil and dust in the degreaser After mixing, it is adsorbed on the filter element; 2 the lower filter layer of the degreaser is glass wool felt, which is easily blocked by oil and dust pollution; 3 The main material of the degreaser filter is sintered polytetrafluoroethylene, poor gas permeability; 4 degreaser The lower head is made of 20 steel, and a large amount of rust and corrosion is eroded to block the lower head filter and filter element.
2.3 The main cause of gas valve failure due to valve failure is spring, valve damage, foreign matter and so on. The spring failure is caused by the small diameter of the spring wire, which is too sensitive to wear and injury, resulting in easy breakage and reduced spring force. The failure of the valve plate and seat sealing surface is mainly due to damage to the sealing surface due to foreign matter such as rust. After repeated inspections of the secondary air intake cooler, it was found that there was a large amount of rust and moisture at the bottom of the cooler casing.
2.4 Oil pump shaft head seal oil leakage oil seal, replace the operation for 1 month or so, start dripping oil. The reason for the analysis is the design defect, and there is no design oil return hole before the oil seal.
3 transformation method 1 secondary air intake cooler leakage problem: cooler head bolt, from the design of the use of 25 steel to high temperature resistant material 35CrMn.2 secondary air intake, outlet cooler has a large number of rust problems in the housing: Change the material of the cooler casing from 20 steel to 1Cr18Ni9Ti stainless steel. 3 gas valve is easy to damage failure problem: take the steel wire with good elasticity and toughness, and increase the diameter and elasticity of the wire after communicating with the manufacturer. 4 piston ring easy to jam and insufficient tension problem: improve the piston ring structure after communication with the manufacturer, add a tension ring inside the piston ring. 5 Degreaser filter plugging problem: The material of the degreaser head shell is changed from 20 steel to 1Cr18Ni9Ti stainless steel. The glass wool felt in the lower part of the degreaser was changed to stainless steel mesh filter layer; the filter material was changed from sintered polytetrafluoroethylene to new high-efficiency precision folding filter, and the number was changed from 25 to 7. 6 Oil pump shaft seal leakage oil leakage problem: Four M6 threaded holes are machined around the shaft seal gland and one oil plug cap is made. After the gasket is installed, it can be completely sealed without oil leakage. 7 secondary exhaust gas temperature, degreaser blockage, valve failure, piston ring stuck, wear, breakage, secondary cylinder wear and other defects are related to rust, in order to reduce rust, at the compressor inlet to the degreaser The outlet is equipped with a nitrogen line, and the machine is filled with nitrogen for protection.
4 After the transformation, the effect is improved by the equipment and the operation process is optimized (the sewage in the cooler and the degreaser is discharged in time, the spare air compressor cooling water valve is closed in time, and the air compressor, the cooler, the degreaser, the pipeline are flushed with nitrogen) Protection and other measures), the secondary exhaust temperature is significantly reduced, the de-oiler blockage frequency is reduced, the valve life is prolonged, and the oil pump shaft seal leakage is eliminated.
Table 1 Comparison of the operating parameters of the secondary exhaust temperature before and after the transformation. The second-stage exhaust temperature after the transformation of the project before the renovation. * Table 2 Comparison of the repair frequency before and after the transformation. The project is repaired and the gas valve is overhauled for 30 days. The secondary air intake cooler is repaired and degreased. Filter filter replacement 90 days Piston ring replacement 90 days overhaul 2 years 3 years 5 Conclusions This article creatively proposed the corresponding modification method for the actual problems encountered in production. After production practice, the transformation is successful and solves the production problem. .
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