Common Faults Of Compressors

Insufficient exhaust volume
Insufficient exhaust capacity is one of the most common faults in compressors, which is mainly caused by the following reasons [8]:
1. Fault of the intake filter: Fouling blockage, resulting in a decrease in exhaust volume; The suction pipe is too long and the diameter is too small, which increases the suction resistance and affects the air flow. It is necessary to regularly clean the filter.
compressor
compressor
2. The decrease in compressor speed leads to a decrease in exhaust volume: Improper use of the air compressor, as the exhaust volume of the air compressor is designed based on a certain altitude, suction temperature, and humidity. When used on high plateaus that exceed the above standards, the suction pressure decreases, and the exhaust volume will inevitably decrease.
3. The cylinder, piston and piston ring are severely worn and out of tolerance, which increases the clearance and leakage, affecting the exhaust volume. In case of normal wear, vulnerable parts such as piston ring shall be replaced in time. When the installation is incorrect and the gap is left improperly, it should be corrected according to the drawings. If there are no drawings, empirical data can be obtained. For the gap between the piston and the cylinder along the circumference, if it is a cast iron piston, the gap value is 0.06/100~0.09/100 of the cylinder diameter; For aluminum alloy pistons, the gap is 0.12/100 to 0.18/100 of the gas diameter; Steel pistons can have a smaller value than aluminum alloy pistons.
4. The stuffing box is not tight, resulting in air leakage and a decrease in air volume. The first reason is that the stuffing box itself did not meet the requirements during manufacturing; Secondly, it may be due to poor alignment between the piston rod and the center of the stuffing box during installation, resulting in wear, strain, and other causes of air leakage; Generally, lubricating oil is added to the stuffing box, which can play a role in lubrication, sealing, and cooling.
5. The impact of compressor suction and exhaust valve failures on the exhaust volume. Metal fragments or other debris fall between the valve seat and the valve plate of the air valve, resulting in poor closure and air leakage. This not only affects the exhaust volume, but also affects the changes in interstage pressure and temperature; The occurrence of this problem may be due to one manufacturing quality issue, such as valve plate warping, and the other is due to severe wear and tear between the valve seat and valve plate, resulting in air leakage.
6. The spring force of the gas valve does not match well with the gas force. If the elasticity is too strong, the valve disc will open slowly, while if the elasticity is too weak, the valve disc will not close in a timely manner. These not only affect the air volume, but also affect the increase in power and the lifespan of the valve disc and spring. At the same time, it also affects changes in gas pressure and temperature.
7. Improper tightening force of the compressed air valve. If the compression force is small, air leakage is necessary. Of course, it cannot be too tight, which can cause deformation and damage to the valve cover. Generally, the compression force can be calculated using the following formula: p=k π/4 D2P2, D is the valve chamber diameter, P2 is the maximum gas pressure, K is a value greater than 1, generally taken as 1.5-2.5, K=1.5-2.0 at low pressure, and K=1.5-2.5 at high pressure. This method of taking K has been proven to be good in practice. If the air valve malfunctions, the valve cover will inevitably heat up, and the pressure will also be abnormal.