Huguangsheng Hubei Huangshi Daye Nonferrous Metals Co., Ltd. smelting plant, Huangshi 435005, Hubei Province, proposed design improvement measures based on over-temperature fault analysis of main engine head of water-cooled air compressor.
1 Introduction The structure of screw air compressor is simple, easy to install and overhaul, automatic protection function, strong operation, safe and reliable maintenance, and it is widely used in industries and other fields. The unit is mainly composed of compressor main air filter gas storage tank oil separator oil cooler and aftercooler main motor control system safety device. In recent years, our factory has 4 oil-injected screw water-cooled air compressors put into operation, the main technical parameters such as F maximum working pressure 0.75MPa normal working pressure 0.70 river, motor power 25, 14 sectors, four machines in operation There is a phenomenon of over-temperature protection and jumping of the host head. We have taken effective measures to eliminate the faults through the practice analysis in recent years, and proposed a thinking plan for the manufacturers to optimize and set up the ten.
2 failure phenomenon and, on the analysis of the external conditions of the normal operation of the squirting screw air compressor, the operating environment of the shack should be between 540, the surrounding environment is clean and the passage is good, the oil level is in the normal state, the shutdown mountain 1 Check the oil level once in the mouth. Cooling water flow water temperature maximum inlet water temperature does not exceed 40, meet the requirements and the water pressure is maintained between 0.150.3 river center.
The main factors affecting the overheating of the head of the water-cooled compressor of the oil-injected screw are the fuel injection quantity and the injection temperature.
The fuel injection quantity and the injection temperature are also important parameters for improving the performance of the compressor by improving the working conditions of the main engine. The main purpose of lubricating oil injection into the machine head is to cool and lubricate. The oil injected into the head of the main engine is in direct contact with the compressed gas, absorbs the heat of compression of the gas, greatly reduces the discharge temperature of the gas, and the injected oil adheres to the oil. On the screw meshing surface, the relative moving auxiliary surface is lubricated, and the frictional power consumption of the moving pair is reduced. The injection temperature also directly affects the normal operation of the compressor. When the injection temperature is too high, the viscosity of the lubricating oil is reduced, which is easy to oxidize and affect the lubrication performance and the life of the lubricating oil. Although the injection temperature is too low, the exhaust temperature can be lowered, but it can also The moisture in the inhaled gas is precipitated during the compression process, causing the oil to be emulsified; the low temperature of the injection is mainly affected by the heat exchange effect of the oil cooler, so the injection quantity and the injection temperature should have the best range and the best value.
After satisfying the basic conditions of the normal operation hall of the machine, first confirm whether the temperature measuring component of the machine is faulty, and can check it; if it is confirmed that the temperature measuring component is not in question, check the temperature difference between the inlet and outlet of the oil cooler, normally between 515 and satisfy at the same time. If the temperature difference between the inlet and outlet of the oil cooler is large, the flow rate of the oil entering the main engine is insufficient. The cause of the oil is blocked by the throttle or the temperature control valve of the thermostatic bypass valve is faulty. In this case, check the oil filter plugging condition and check whether the temperature control valve is working properly. By removing the valve core or controlling the valve core, force the lubricating oil to pass through the cooler to confirm that the lubricating oil flow rate is maximized. For example, the above method could not be solved. It is necessary to consider that the lubrication system may be blocked by throttling or foreign matter.
If the temperature difference between the inlet and outlet of the oil cooler is small, the heat transfer effect of the oil cooler is poor. Under normal circumstances, the water-cooled compressor checks whether the cooling water inlet flow is insufficient. The inlet water temperature is too high. The temperature is higher than 40 迸 7 ft. 7 The illusion card is too low. The inspection is the cooler scaling. The air-cooled compressor checks if the radiator is too dirty and the heat sink is received. 2, 1.31 is also a fan, often lack of scenery. If the above check is in the normal range and the main head is still hot, then the heat generated by the main unit is out of the normal range. Should check whether the host is abnormal, such as whether the machine is over-pressure running or lubricating oil asks or judges whether there is a mechanical problem. If there is a fault in the oil valve, the oil valve will jump and the temperature will rise linearly.
3 failure analysis 3.1 oil temperature too high analysis oil-injected water-cooled screw air compressor main head over-temperature typical failure 1! 1 head take-off and cooling cooling lubrication oil; too high, causing the dirt head cooling does not Over temperature. In terms of machine protection, the action of the jumper affects the normal operation; on the other hand, the oxidation rate of the lubricating oil is accelerated and the production of the sputum is poor, and the nails and even the machine are smashed and damaged. The four machines that our factory put into operation, the manufacturer first A clamshell chiller rear cooler is provided. The plate cooler aftercooler is in good operation at the beginning of operation. The heart 1 machine was put into operation in February 2002. After half a year of operation, the host head overheated, causing frequent jumps and sometimes fleas and then kinetic energy, right time. After checking the oil temperature of the oil cooler, the oil cooler shell-and-oil oil cooler disintegrated the structure and found that the temperature of the oil entering the main head was too high. Similarly, the scale of the cooler water channel was severely normal after the chemical cleaning of the oil cooler. However, the same failure occurred again after about a month of operation. The heart 2 machine was put into operation in January 2003. The manufacturer configured the plate heat exchanger as the oil cooler. After the operation, the small machine overheating phenomenon appeared. The main reason for the 12 machine is that the cooling water uses urban tap water. , without softening, 7-foot quality is very high. 1. There are more impurities. One of the ions in the cooler is easy to form water, so the heat-reducing effect of the adult is reduced to the host head. The temperature is too high and sometimes reaches 750. The manufacturer's configuration of the shell-and-tube or plate heat exchanger is a product with high heat exchange efficiency. When the scale is covered with a small amount of scale, the heat exchange efficiency is greatly reduced. Therefore, in the factory where the conditions permit, soft water is used as the cooling medium as much as possible. At the same time, after the four machine oil coolers of our factory are replaced with externally, the heat exchange area is appropriately enlarged, and the resistance loss is calculated. The domestic plate heat exchanger is calculated and runs well.
3.2 Analysis of Lubricating Oil Flow Rate and Oil-Gas Separator Structure, 2 After the machine was put into operation for a month, the host over-temperature phenomenon occurred. The machine was originally equipped with a plate heat exchanger as the oil cooler, and was replaced with the latest design of the shell-and-tube type. Oil cooler, but failed to solve.
After observation, if the working pressure of 2 machines is running at 0.250.3 PCT for a long time, about 3, the injection pressure of the main head is 0.141. After the test, the working card force reaches 0.6 inch, and the squeezing force is 0.1813. By disintegrating the lubrication system Inspection found that the lubrication system to the main head between the local position due to the manufacturing of the original 1 is also throttled, there are also foreign bodies blocked by the cold caused by the main head oil volume is greatly reduced, after replacement parts and normal operation within a period of time. Later, the heart 2 machine still showed an over temperature fault of the main engine head. At the same time, it was found that the lubricating oil of the machine was large and the oil separator core had been replaced, and the oil level was within the normal range. Through the analysis of the structure of the oil and gas separator of the four machines, the main dimensions and structure are as follows: 1. 600, 2, the diameter of the parent, the lower part of the intake position, the upper part of the exhaust position; the upper part of the gas position 1 . The upper part of the exhaust position, such as the 2 machine main head overheating, is mainly due to the long time the machine is operating at a lower working pressure. Oil and gas separation efficiency is relatively poor, 1 machine has also been running under low working pressure for a long time, no! Now ask, 34 machines have higher operating pressures. In this way, we have modified the 2 machine helium separator unit. Increase the operating pressure of the machine to solve the problem.
3.3 Lubrication flow control device and temperature control valve structure analysis was put into operation in September, and the main head over-temperature system configuration also appeared in the operation soon. The chest 1 such as 2 machine adopts the thermostatic bypass valve temperature control valve to control the main head. The oil temperature is constant, and his 3 such as 4 machine adopts the pneumatic control flow test throttling according to the working card force feedback to adjust the escape main engine oil test. The constant temperature bypass valve works when the oil temperature is lower than 40, when the bypass valve is closed, the oil is closed. The cooler is bypassed, and the oil is circulated by the air pressure from the oil separator directly through the oil filter and the oil shutoff valve to the main engine and the lubrication points; when the oil temperature exceeds 40, the bypass valve starts to open, and some of the compressor oil passes. The cooler is cooled, and when the oil temperature rises to about 55, the oil is completely cooled by the cooler. That is, the high-temperature lubrication 汕 is heated at a constant rate under the action of the constant temperature bypass, at! It can be seen directly on the screen that the feed rate can be adjusted at any time during the addition of 1 without manual operation or parking to change the feed rate. In addition to the upper and lower workpieces, the machining process is fully automatic and the production efficiency is high. Due to the use of wet chips, it is more environmentally friendly.
At present, Feihe Group has been fully prepared for the processing of high-precision worm star wheel blades from the special tools of the knives to the testing instruments, etc. This is the solid foundation of the manufacturing technology, which provides a guarantee for the spring life of the Stars. From the aspect of actual production and sales, Feihe Group has already become the leading company of single screw compressors in China. Moreover, the number of sub-productions and sales has accumulated a lot of experience. In summary, the single screw technology of Feihe is already in a mature state.
In the middle and late stages of this phase, there was a breakthrough in the single-screw manufacturing technology. The wheel material was also improved for the third time. A better lining is used. Design techniques are also more mature. Zhongyi single screw compressor can be better and faster. Up to now, the specifications of the existing single-screw air compressors in China have been quite complete, and the product specifications have even exceeded the foreign products, and its comprehensive performance indicators have reached the international advanced level. As long as we are determined to reform and innovate, we will work hard to explore the mechanism of single-screw compressors, deepen our design techniques, and continuously improve and improve manufacturing technology. Under the current conditions in China, we can create high-level international-level single-screw compression. machine. In this respect, China has become a world manufacturing center, and it has also benefited from 30 years of hard work on single-screw compressor technology. We believe that China's screw compressors will be fully accepted and recognized by the Chinese and the world in the long-term future.
Comprehensive 1 mentioned. In the past three years, the development of the single-screw contraction machine has experienced a tortuous and uneven process. The first ten years have been difficult to explore, and the progress has been slow. The manufacturing technology and product performance are at an initial low level. In the last ten years, especially in the last ten years or so, single-screw compressors have developed rapidly. Make the technology more mature. The testing methods are basically complete, the varieties and specifications are complete, and the manufacturing technology processing method has achieved a major breakthrough in the cutting machine. It has reached the international advanced level, and some products have advanced international level, and have a single-screw air compressor. In these 30 years of experience, single-screw compressors have grown from scratch in China, from low levels to high levels. This is the result of the perseverance and exploration of the developers of all factories and colleges.
However, we should also be aware that the current single-screw compressor is only a single-stage compression air compressor. There are still many applicable fields waiting for R&D. There is a long way to go and a broad development space. Enterprise research institutes and scientific and technical personnel engaged in single-screw need to continue their efforts to explore and innovate, and create new glories for the development of China's single-screw compressors.
He has been engaged in the manufacture and operation of oil-free oil-free piston and single-screw compressors. The company he led has launched a series of single-screw air compressors since 1997 and has taken the lead in opening up the market, becoming the pioneer in the development of the single-screw market. Eat and inherit and develop the single-screw technology at home and abroad. After three technical reforms, especially the talents, the precision CNC worm is successfully designed. Star wheel processing machine. The single-screw technology has matured and is at the leading position at home and abroad, and has made great contributions to the development of China's single-screw compressor manufacturing industry. Its single-screw air compressor product has won the title of Shanghai Famous Brand Product. In 2004, he was awarded the title of China's outstanding private technology entrepreneur.
Xia Zhenpeng. Male, chief engineer of Shanghai Feihe Industrial Group Co., Ltd. Professor-level senior engineer.
In 1952, he entered Tsinghua University to study aviation engine. He has been working on compressor design and research since 1957. He served as Beitong. Chief Engineer, Design Chief, Beijing Jinhuan Compressor Factory. Since 1984, he has served as a member of the Compressor Technical Committee of the former Ministry of Machinery and a member of the Compressor Professional Standards Review Committee of the former Ministry of Machinery. The former member of the Beijing Fluid Engineering Society is in charge of compressor engineering. It is the pioneer of China's metal diaphragm diaphragm compressor high pressure and ultra high pressure and its series of products. In 1975, he first developed the single-screw compressor as the development team leader in China, and in 1976 developed the first single-screw compressor 097. From 1975 to 2005, he has been engaged in the design test improvement of single-screw compressor for 30 years. jobs. I personally experienced the whole process of the gradual improvement of the domestic single-screw compressor. It has contributed to the development of China's single screw air compressor.
The purpose of the above two methods is to ensure that the main head is fully cooled and lubricated during operation, so that the main engine head exhaust temperature is 55 100, and the right safe and stable operation.
Then why, in the exclusion of other factors, there is still a superseding cylinder air source part of the main engine head is provided with a sintered air filter, and the filtering precision is high. It is found that the filter part accumulates a large amount of impurities and causes the air to enter the cylinder. The flow makes the amount of oil entering the main head less, causing the main head to overheat.
4 Conclusion Through the inspection and analysis of the over-temperature fault of the main machine head of 4 machines in our factory, the agriculture, measures, and perfect system local configuration meet the requirements of long-term operation of the machine.
1 Huang Yuanming. Experimental study on fuel injection single screw compressor. The temperature phenomenon of the compressor technology, after disintegration inspection, found that he 34 machine control plunger
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