Analysis of the large cracked end of a multi-return gas air compressor

According to the circuit, the circuit was tested one by one, and it was found that: a "HAT-1" high temperature switch is open, that is, the unit exhaust temperature is high and the switch is operated, and the normal state should be closed; b "IPS" pressure switch is open, the pressure The switch is the first-stage outlet pressure high-jump switch of the unit. The pressure is higher than the 2bar switch. The pressure-conducting tube of the removed switch is found to be blocked. After the treatment, the switch is automatically closed, which is normal. The disconnection of the above two switches is the cause of the failure of the emergency stop button.

"SENSERFAILURE2CTT" alarm, meaning "2CTT" sensor failure. In the online test data, the exhaust temperature and the injection temperature are abnormal, which are indicated as D34°C and 123°C respectively. The two sensors are measured without millivolt voltage. It is obvious that the two sensors “2CTT” and “2ATT” have problems. .

The action of the pressure switch and the safety valve take-off are consistent, proving that the safety valve is a normal take-off. The following three points can explain the problem of the intelligent controller: (1) Under normal circumstances, the "HAT-1" and "IPS" switch actions, the unit should automatically stop the chain, and the intelligent controller has not issued a shutdown signal; (2) " 2CTT” and “2ATT” indicate that the temperature should be the same; (3) Why the parking softkey on the controller does not work. The oil at the inlet of the unit should be caused by the lag of the action of the shut-off valve of the direct pull-off and power-off.

The inspection can be seen from the four bolts of the gland, which have been twisted in one direction, as evidenced by the further removal of the gear. First, the secondary screw is seriously damaged, the screw and the end cap are bonded together, the secondary screw has peeling and pulling phenomenon, the screw near the end cover is blue-black, and the secondary shell surface has different degrees of black sintered plaque. The first-stage screw is blue-black at the screw near the end cap, and there is iron residue at the first-stage inlet.

There are different levels of carbon deposits found inside the unit, which appear in the first and second high-pressure end shells, bearing lubrication and screw oil inlets, especially in the oil-filled holes of the high-pressure end bearing of the first-screw, which are about 10 cm long. The carbon deposit, the center of the carbon deposit is just the lubrication hole of the high-pressure bearing of the first grade. Carbon deposits were found at the inlet. The oil cooler heat exchanger tube is seriously fouled.

Renovation and Suggestions (1) Ingersoll Rand provides an air compressor control system that enables real-time operational data monitoring and remote start-stop (air compressors can only detect operational signals on the DCS operator interface). (2) According to the oil sample analysis, the acidity of the oil is too high, which is caused by the incomplete separation of oil and water during normal operation. It is recommended to raise the exhaust temperature of the unit from about 83 °C to 95 to 97 °C, so that the circulating water must be closed. It is bound to cause rapid fouling of the oil cooler, which can be achieved by modifying the temperature-controlled three-way valve.

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