Guarantee Measures for Reducing Water Content of Screw Air Compressor

As a kind of mechanical equipment, compressors will have many failures in the whole life cycle, some common, some rare. The high water content of compressed air is a problem we often encounter. Users often require dry and clean air when using compressed air. Although most air compressors are equipped with post-treatment equipment for compressed air, post-treatment does not always solve the problem of water content in all compressed air.

What are the causes of water in the air compressor? ① There is water in the air, that is, the "humidity" of the air. After being compressed, the air will become supersaturated, and the water in the air will separate out and become liquid. The water content in the compressed air is related to the humidity of the air. If the environment in the machine room is too humid or seasonal, the water content in the air will exceed. ② The compression process produces liquid water. When the air compressor is working, the temperature of the head is very high. The moisture in the natural air inhaled will form water vapor during the operation of the air compressor, which will be discharged with the compressed air. As the compressed air flows downstream, the temperature will gradually decrease and the water vapor will condense into liquid water.

In the era of piston compressor, the main problem often encountered is the large oil content in the compressed air. The pressurized air will press oil stains into the surface of aluminum products, resulting in a high waste rate. Due to the post-treatment equipment and good sealing effect of the screw compressor, almost no excess oil enters the compressed air produced downstream, which has certain guarantee for improving the product quality. However, during the operation of the screw compressor, the water content will exceed the standard. If the compressed air contains excessive moisture, if it is involved in the downstream process, it will adhere to the surface of the product during the processing of aluminum products and produce stains, which will cause waste products in serious cases. Although this kind of harm is lighter than the high oil content, it will also affect the product quality after all, so it has also attracted the attention of the Production Guarantee Center. In view of this problem, several specific countermeasures are proposed.

1. Timely drainage

The post-treatment equipment of the compressor shall be drained every two hours, and the outdoor air storage tank shall be normally open or drained.

The peak period usually occurs at the time of seasonal alternation. At this time, the exchange of hot and cold air will cause the equipment to be maladjusted, just like the maladjustment of the human body during the season change, which is easy to cause diseases. The same is true of the compressor. The water content in the air is affected by the cold and hot air after the season change, so the water content in the compressed air changes. For example, at the beginning of September every year, the temperature drops, and the temperature difference between morning and night in Northeast China is large, so the water content of compressed air begins to increase. At this time, we should discharge water frequently for post-treatment, and increase the drainage frequency of the air tank, so as to ensure the dryness of the compressed air to a certain extent.

Why should we strengthen the drainage frequency of the air tank? This is because the air receiver can not only provide a buffer and gas storage space for the compressed air, but also play a role in cooling the compressed air. When the compressed air passes through the air tank, the high-speed airflow hits the air tank wall to cause confluence, which makes the temperature drop rapidly in the air tank, and a large amount of water vapor is liquefied to form condensed water. In case of wet weather or winter, more condensate will form. Therefore, when the water content of compressed air is high, attention must be paid to the drainage of the air tank.

In addition, qualified users can add insulation layer or steam tracing on the gas transmission pipeline. A drain valve is added at the low point for regular inspection and drainage. This measure can also prevent freezing of the pipe in winter, remove part of the moisture in the compressed air, and reduce the impact of water in the compressed air on users

2. Timely maintenance of treatment equipment

When the water content of compressed air is high, the post-treatment equipment focuses on the replacement of aluminum oxide. This white ball, which is similar to a small soybean particle, can absorb and dry the water in the compressed air. Compressed air is generally converted into liquid and gaseous forms alternately in the compression process, and finally delivered to users as dry gas.

Users who use adsorption dryers should pay special attention to that activated alumina is not tightly filled, which will rub and collide with each other under the impact of compressed air, resulting in pulverization. The pulverization will make the adsorbent gap larger and larger, and a large amount of compressed air passes through the gap without effective treatment, eventually leading to the failure of the dryer. This problem is reflected in the fact that there is a large amount of liquid water and slurry in the dedusting filter on site. Therefore, we should fill the activated alumina as closely as possible, and check and supplement it after a period of use.

At the maintenance stage, we also replace the oil filter rod and muffler, so as to ensure that the equipment can work effectively in a new state.

3. Start up with the best

To start the compressor, the post-processing equipment must be started at the same time. At the same time, the air compressor with the best post-processing equipment status is the main operating equipment.

There are two models of the five compressors in our station building, and the post-processing equipment is different, so the state is good or bad during operation. In this case, we should have a choice when starting the compressor, and the compressor with good post-processing operation status is the first choice when starting; Those with poor post-processing effect are candidates.

If there are some problems, corresponding maintenance shall be carried out according to the situation. If the alumina needs to be replaced, it shall be replaced in time, and the causes of electrical or mechanical failures shall be found out and handled in a timely manner, so as to ensure the integrity of post-processing equipment and enable it to be opened in a timely manner.

4. Special plane

Each compressor shall be responsible by a specially assigned person, including drainage frequency, equipment operation status, daily operation and maintenance, etc.

The compressor and post-treatment are associated equipment. We used to use the package mechanism, and we have package captains in all positions of the company. With the change of the deepening reform of the enterprise, the package mechanism has changed into the work area system. Our air compressor station is in the power control work area, but now the package mechanism has evolved into a special mechanism. Five compressors are allocated to each team member, and the equipment is labeled with the name of the responsible person. In addition to the operation of the compressor in charge, the operation of the post-treatment equipment is also within the scope of responsibility. At the same time, the sanitation around the equipment is also included, and the corresponding minor repair tasks are also required.

5. Intelligent transformation

Communicate and discuss the possibility of installing online water content monitoring with the manufacturer, and plan to install online water content monitoring on the main pipe of each station building instrument to monitor the water content of compressed air in real time.

There is no water content monitoring equipment in the initial installation of the air compressor station, but the company's benefits will be affected for a long time if this problem is not solved. And install automatic monitoring equipment to monitor the water content of the air compressor, which can not only know the operation of the equipment, but also be timely and effective the control of water content can also reduce the pressure of compressor operators and contribute to the improvement of the company's product quality.

6. Establish a sense of service

The work of our power plant is to provide qualified and timely power services for downstream production branches. Compressed air discharged from air compressor station it should be used by the downstream production line eventually. Whether the compressed air products meet the demand, the downstream users have the most say. Therefore, a service group should be established team, often go deep into the production branch for on-site service.

In the past, in the era of piston engine, due to the large oil content in the compressed air, we were often informed by the downstream production branch that the gas quality was not up to the requirements.

We are required to check the oil and water conditions at the production branch factory from time to time.

Now in the actual operation process, the production system constantly reflects the problem of large water content in compressed air, which is not the problem of users in several production branches has been raised by many branches. This product quality is related to the development and survival of the company.

Small defects affect the economic benefits of enterprises. Serving users is our tenet, and meeting users' needs is our responsibility. in line with the guiding principle of serving users is to visit users regularly, solve problems in a timely manner, and set up a team with technicians to diagnose users pulse, timely cooperate to solve the problem of large water content.

Summary

The water content of compressor is an important standard to check the operating state of compressor. If it is not solved properly, the quality of the company's products will be affected effective measures must be taken to control and eliminate certain impacts.