Specific items and details of daily maintenance of air compressor

Specific items and details of daily maintenance of air compressor

Class A maintenance every 24HR/day (performed by customers)

1. Check the oil level;

2. Record the exhaust pressure;

3. Record the oil temperature;

4. Check whether there is a fault alarm;

5. Check whether the loading and unloading are normal;

6. Drain condensate or check the function of the automatic drainer.

Class B maintenance every 100HR/week (performed by customers)

1. Check whether the cooling fan is operating normally;

2. Check the main motor current;

3. Check whether there is abnormal noise when the unit head motor is running;

4. Check the operation of the aftercooler;

5. Clean the air filter;

6. Check whether the transmission belt is tight;

7. Clean the dust on the body and check for leakage;

8. Check the oil cooler and aftercooler, and clean the cooler if necessary.

C-type maintenance every 2000HR

1. replace  the air filter element;

2. Clean the return oil filter and throttle valve;

3. replace  the oil filter;

4. replace  the engine oil;

5. replace  the oil-gas separator core and seal ring;

6. Clean the oil cooler;

7. Check the operation of the protection device;

8. Check whether the control device is working well;

9. Disassemble and clean the rear cooler automatic drainage system;

D-type maintenance every 4000HR (additional to C-type maintenance)

1. Clean the seal ring and gasket of the minimum pressure valve;

2. Clean the seal ring of the vacuum release valve;

3. Clean the unloading Loading valve;

4. Clean the check valve;

5. Clean the constant temperature valve;

6. replace  the pipe filter element;

E-type maintenance every 8000HR (additional to D-type maintenance)

1. replace  the minimum pressure valve maintenance kit;

2. replace  the unloading valve maintenance kit;

3. replace  the check valve maintenance kit

4. replace  the constant temperature valve maintenance kit;

5. replace  the intake valve maintenance kit;

6. Clean the oil cooler and aftercooler;

7. Check each pipeline and contact plug and connector;

8. Check the electrical control cabinet and internal electrical components: insulation and tightness;

9. Clean the electrical control cabinet and tighten the screws of each contactor.

Inspection items:

1. Clean the air filter to ensure that the air compressor is in the best suction state.

2. Clean the radiator. When the exhaust temperature of the air compressor is higher than 95℃, the radiator needs to be disassembled and the dirt on the radiator needs to be thoroughly cleaned with dust to prevent high exhaust temperature.

3. Check whether the lubricating oil is sufficient and add or ｒｅｐｌａｃｅ it as appropriate.

4. Check whether the operating temperature and air supply temperature are between 70℃-95℃, and ensure that the exhaust temperature is above the dew point to prevent condensed water from precipitating in the oil circulation system, damaging the oil quality and affecting the service life of the main engine rotor. If the temperature is not in this range, try to make it reach normal temperature.

5. Check whether the transmission components are normal and whether the tightness of the transmission belt is normal. If not, adjust and correct it to avoid belt wear.

6. Regularly check the safety valve and pressure gauge, check whether the function of the capacity regulating valve and the pressure maintaining valve is normal, eliminate hidden faults and ensure the safety of the machine.

7. Check whether the unloading solenoid valve functions normally, whether the suction controller is sensitive, and whether the intake valve is closed tightly, to ensure the lowest load is started, effectively protect the motor, and maintain the lowest no-load current, save energy, and prevent reverse oil spitting, so that the various parts of the air compressor are kept clean for a long time.

8. Clean the cooling motor fan to keep the air compressor in good heat dissipation state.

9. Check whether the temperature control valve functions normally. The vibration during the operation of the air compressor may cause some parts to loosen and malfunction, and need to be re-tightened.

10. Clean the dryer body and radiator, check whether the high and low pressures of the refrigerant are normal, and whether the machine is operating normally.

11. The replacement cycle of consumable parts is absolutely related to the use environment of the air compressor. An unfavorable environment may shorten the service life of consumables or cause carbon accumulation in components to cause failures.

Guide for Air Compressor Maintenance

 Since air compressors have important uses, the stability and continuity of their working state directly affect the production efficiency of enterprises. Therefore, in order to ensure the normal operation of air compressors, common faults should be judged and handled in time, and the maintenance and management of air compressors should be strengthened to avoid abnormal operation of air compressors or even major safety accidents.

Air compressors are the most basic industrial equipment, which are widely used in various industries such as mining, petrochemicals, metallurgy, textiles, machinery manufacturing and electricity, especially in mining work. It is an extremely important auxiliary design. Since air compressors have important uses, the stability and continuity of their working state directly affect the production efficiency of enterprises. Therefore, in order to ensure the normal operation of air compressors, common faults should be judged and handled in time, and the maintenance and management of air compressors should be strengthened to avoid abnormal operation of air compressors or even major safety accidents.

1. Overview of air compressors

Air compressors (Air Compressor) are a main gas source device that converts the mechanical energy of the prime mover into gas pressure energy, and increases the gas pressure or transports the gas by highly compressing the gas. It belongs to power machinery equipment. Air compressors are widely used in different industries such as mining, textiles and metallurgy. They are widely used as general basic equipment. They can provide sufficient pressurized gas at the work site to ensure the continuous production. Air compressors have very obvious performance characteristics such as convenient delivery of pressurized air, abundant air medium resources for transmitting pressure, good compressibility and elasticity, safe and fast energy delivery and no fire hazards.

The following mainly introduces the performance advantages of several common air compressors. Screw air compressors have the advantages of high speed, good dynamic balance performance, high degree of automation and high gas transmission efficiency; piston compressors are easy to cause gas pressure loss, low mechanical efficiency of the compressor itself, low safety performance and short life, and the application range in most areas is getting smaller and smaller; screw air compressors have the characteristics of high reliability, increased compression efficiency, simple mechanical structure and convenient and safe maintenance; vortex air compressors are new air compressors developed in the past two decades or so, with excellent performance, especially small size, low noise and high efficiency. With the rapid development of my country's economy, the demand for air compressors in the domestic and foreign markets will surely increase, and its future development prospects are very optimistic. However, due to improper installation, improper operation and imperfect daily maintenance, air compressors are prone to some failures, delaying the production of enterprises. Therefore, it is necessary to do a good job in the maintenance and maintenance of air compressors.

2. Maintenance and maintenance content of air compressors

Since the working environment of air compressors is very harsh and they operate under high temperature and high pressure conditions for a long time, their maintenance and maintenance work is particularly important. In order to prevent the aging or wear of parts and adverse effects on the stable performance of air compressors, relevant staff are required to do a good job in the daily maintenance of air compressors, so as to reduce the failure rate of air compressors and prevent major safety accidents. Air compressor operators should strictly follow the relevant documents on air compressor maintenance and maintenance to maintain and maintain air compressors, find problems in time and solve them, so as to ensure the normal work of relevant departments of the enterprise and ensure the economic benefits of the enterprise.

(I) Daily maintenance and care of air compressors

Daily maintenance and care of air compressors is crucial to ensure the normal operation of air compressors, mainly including the following contents: First, the relevant operators should conduct a comprehensive inspection and test before the equipment is put into operation. This is the basic step to ensure that the air compressor can work normally and stably. We should strive to do a good job in daily maintenance and inspection, and make comprehensive inspections without omissions. We should formulate detailed and comprehensive daily maintenance rules and regulations, establish and improve the supervision mechanism, and strive to improve the skills and comprehensive quality of operators.

Before starting the air compressor, the operator should conduct a comprehensive inspection of the equipment, including checking whether the amount of lubricating oil in the oil pool and the oiler is sufficient; checking whether the protective device is reliable and safe; checking whether the oil and gas pipelines are unobstructed; checking whether the operating parts are flexible, etc. The focus of daily maintenance work should be to observe whether the readings of various instruments of the air compressor are normal when it is running, whether there are abnormal sounds and heating conditions of parts, whether the main components have abnormal operation, and to find problems and solve them in time through various detection equipment and combined with practical experience to ensure the normal operation of the air compressor. Operators must operate the equipment strictly in accordance with the operating procedures, keep records of the operating conditions of the equipment, and inspect the main components of the air compressor.

(II) Regular maintenance and maintenance of air compressors

Doing a good job of daily maintenance and maintenance of air compressors is only the basis for the maintenance of air compressors. On the basis of daily maintenance and inspection, regular maintenance and long-term maintenance plans should be made. According to the equipment manual of the air compressor and combined with the use of the equipment, specific maintenance rules should be formulated, which mainly include cleaning and maintenance of air filters, replacement and repair of various air valves of air compressors, regular inspection and maintenance of cylinders, and inspection and calibration of various instruments and meters. In order to make the air compressor operate normally and stably and extend the service life of the equipment, a detailed and complete equipment maintenance plan should be formulated to determine the monthly, three-month, and half-year inspection and maintenance content, so as to meet the working requirements of efficient and safe operation of air compressors. Monthly maintenance content: Determine whether it needs to be cleaned according to the contamination of the surface of the oil cooler, check whether the lubricating oil has deteriorated and whether the connecting hose is aging or damaged, and check the connection of the oil circuit and the circuit. Maintenance content at three-month intervals: add lubricating grease to the bearings of the clean main motor and fan motor, clean the cooler, condenser, oil filter and air filter, and check whether various air valves and sensors have been replaced. Maintenance content for half a year: check the use of cooling fans, cylinders, safety valves and oil and gas filter elements, focus on the analysis of the overall operation of the air compressor, ｒｅｐｌａｃｅ related parts, and eliminate safety hazards.

(III) Maintenance and maintenance of the main parts of the air compressor

The air compressor is mainly composed of the fuselage, cylinder, piston, oil filter, gas cooler, air filter and other related parts. Some of these parts are prone to wear and aging, causing the air compressor to fail to operate normally. Therefore, it is necessary to strengthen the maintenance and maintenance of key parts related to the air compressor to ensure the continuous and stable operation of the air compressor, reduce the failure rate, and reduce downtime and maintenance times. The air filter is mainly used to filter dust and impurities in the air. The quality of its working effect will affect the life of the air compressor cylinder to some extent. The life of the piston ring is related to the gas temperature inside the cylinder, the quality of the air filter and the humidity content in the air. The lubricating grease of each component can greatly improve the wear of the parts and thus extend the service life of the device, so it is necessary to ensure that the amount of lubricating oil is sufficient. In order to ensure the stable operating temperature of the air compressor, it is necessary to ensure that the heat dissipation effect of the cooler is good. As a key component that determines the quality of compressed gas in the air compressor, the oil-gas separator must ensure its good filtration efficiency.

Fault analysis and treatment suggestions for the safety valve tripping caused by long-term shutdown of air compressors

1. Case description

A company producing graphite-related products has used air compressors for only more than 1,200 hours in total. The unit has been shut down for about 3 months since the last startup. This restart caused the unit's safety valve to trip.

1.1 On-site inspection

There is serious rust on the surface of the filter material inside the built-in oil separator core, which is seriously blocked on the surface of the filter material, resulting in poor exhaust of the compressor and ultimately causing the safety valve to trip.

1.2 Fault analysis

The filter material of the built-in oil separator core is composed of glass fiber and plant fiber, which will not rust. From the disassembly of the built-in oil separator core, it is mainly the blockage of the outside of the filter material.

The cause of the blockage is that the air compressor runs occasionally and is shut down for a long time. The surface of the oil separator core absorbs lubricating oil and water vapor and contacts with air for a long time. After air drying, it adheres to the surface of the oil separator core, causing the oil separator core to be blocked.

1.3 Troubleshooting

The unit was maintained (three filters, lubricating oil, and oil and gas barrels were replaced), and the safety valve was replaced. The unit is operating normally.

2. Suggestions

2.1 If the compressor is only used occasionally, the maintenance time should be shortened;

2.2 If the customer wants to stop using the compressor for a long time, the compressor needs to be sealed and the filter element should be checked before starting the machine. The machine can only be started after the inspection.

Special note: For the situation where the compressor needs to be placed for a long time, it is recommended to run it for 1-2 hours per week.

Choosing an air compressor model

 Air compressors are common power equipment in enterprises. They are devices that convert mechanical energy into gas pressure energy. Air compressors can be used in different occasions such as providing air power, controlling automation devices, and ventilation of underground passages. They are widely used in various industries such as mining, textiles, metallurgy, machinery manufacturing, civil engineering, and petrochemicals. They are indispensable key equipment for the production and operation of many enterprises. Therefore, the selection of air compressors is very important.

When choosing an air compressor model, I think the following aspects should be considered:

1. Consider the exhaust pressure and exhaust volume of the air compressor

1) Exhaust pressure of air compressor

The exhaust pressure of air compressors for general use is 0.7Mpa, 0.8Mpa, and 1MPa. If the exhaust pressure you use reaches 0.8Mpa~1.2Mpa, please choose NANXINAIR screw air compressor.

2) Exhaust volume of air compressor

The exhaust volume is one of the main parameters of the air compressor. The exhaust volume of the air compressor should match the required air volume, and a ten percent margin should be left.

2. Consider the air quality of the air compressor

Generally, the compressed air generated by the air compressor contains a certain amount of lubricating oil and a certain amount of water vapor. When the use occasion is oil-free and water-free, you should not only pay attention to the air compressor model, but also the air compressor post-processor.

3. Consider the danger of air compressor operation

The air compressor is a machine that works under pressure. When working, it is accompanied by temperature rise and pressure. The risk factor of its operation needs to be reduced to 0. The state implements a pressure vessel production license (gas tank) for air compressors ≥0.03m³. Therefore, when purchasing air compressor products, for those with ≥0.03m³ gas tanks, it is necessary to strictly examine whether there is a "pressure vessel production license (gas tank)" and whether there is a pressure vessel supervision and inspection certificate issued by the regulatory department. Only with a certificate can you purchase.

4. Consider the specific power of the air compressor

Is the air compressor energy-saving? It is not about how large the exhaust volume of the unit is, nor how much the motor power is, but the specific power of the unit. The lower the specific power of the unit, the more energy-saving it is.

Nanxinair Screw Air Compressor

NANXINAIR NANXIN MECH specializes in comprehensive solutions for compressed air systems, focusing on energy-efficient, effective, and reliable aerodynamic solutions. The company excels in the independent research, design, and production of compressor units, offering a wide range of complete air compressor systems and related equipment. As a leading manufacturer, they are recognized for their expertise in positive displacement air compressors and are among the few domestic firms mastering the core technology of screw air compressors. Throughout the year, NANXINAIR consistently produces high-quality permanent magnet screw air compressors.

Renowned in the industry for its exceptional R&D and innovation, particularly in Screw Air Compressors, Two-Stage Air Compressors, Laser Air Compressors, and Integrated Screw Air Compressors, NANXINAIR has received numerous awards, including the "National High-Tech Enterprise" recognition. With strong research and development capabilities, a skilled professional team, advanced testing equipment, and a scientific management system, the company provides outstanding comprehensive compressed air system solutions to users in nearly 50 countries worldwide.