Tangshan Jiahua Coal Chemical Co., Ltd. Power Plant has 8 screw air compressors, which are responsible for instrument wind, dust removal wind, power wind and sulfur dioxide gas, and nitrogen production for four coal preparation, coking, purification and power plants. The supply of gas, although it belongs to the auxiliary system, but the problem of gas supply will affect the production system of the entire company, so the stable operation of the air compressor is very important. The maintenance cost of the air compressor is a must-cost, and how to reduce the maintenance cost of the air compressor becomes the primary problem. Among the 8 screw air compressors, 1 and 2 air compressors were produced by Shanghai Bolet, and 3, 4, 5, 6, 7, and 8 air compressors were produced by Beijing Fusheng, but their work The principle is basically the same, and the service life of the vulnerable Spare Parts is slightly different. This article takes Beijing Fusheng air compressor as an example to discuss how to reduce the maintenance cost by establishing a planned maintenance mode for the air compressor and improving the filter element.
2 Air compressor to establish planned maintenance mode In the common fault handling of air compressors, the most common faults are high exhaust gas temperature and high fuel consumption, and the most common cause of high exhaust gas temperature is oil filtration. The filter element is clogged, the air compressor oil is used overtime and the cooler surface is too dirty or clogged. The most common cause of fuel consumption is the rupture of the fine oil separator filter. Among them, the oil filter element and the oil separator element are all vulnerable parts of the air compressor, in addition to the air filter element, the air compressor oil needs to be replaced regularly.
500h, and need to be cleaned regularly, usually once every 24 weeks, should be purged with a gas source below 2kg.
It is recommended to replace it when it is replaced for 500h or when the oil pressure is lower than 0.25MPa.
Replacement with 000h, or replacement of oil pressure difference over 0.055MPa is recommended.
Sampling analysis is performed for 000h, and it is decided whether to replace it according to the test result.
3 Air compressor filter improvement 3.1 Air compressor air filter element improvement air before entering the system, first through the air filter, so air filter element quality, filtration accuracy, convection area directly affect the unit oil system (including The service life of the oil head filter, oil filter, bearing, rotor and other head equipment.
The filter of the air compressor filters out all the dust and particles from the outside. It is the first protection filter of the air compressor. In order to prolong the service life of other vulnerable parts of the air compressor, after searching for information and consulting manufacturers, we The air filter with the filtration precision of lOjjim originally used for 6 Fusheng air compressors was changed to the air filter with a filtration accuracy of 3|JLm. The accuracy is changed. In order not to affect the convection area, the gas production is not affected, and the original air filter is lengthened by 20 cm, and the corresponding mounting parts are lengthened. After being put into use, the service life of the air compressor oil filter element is significantly prolonged.
3.2 Oil filter element The improved oil filter can filter the impurities in the internal oil system of the air compressor to protect the unit. It is the second filter element of the air compressor. The built-in oil filter has an average service life of around 1000h. After the air filter is improved, the service life is improved, but there is still oil filter blockage, and the oil injection pressure is lowered, which causes the unit temperature to rise and the exhaust gas temperature to rise sharply.
In order to further extend the service life of the oil filter, we read a lot of information, learn from other types of oil filters, and finally changed the original one built-in oil filter to two external oil filters in parallel. The price of a built-in oil filter is about 1,660 yuan, and the price of two external oil filters is about 1,440 yuan. The improved oil filter cost is not increased, and the service life is greatly improved. Now the service life of the operating unit using oil filter has exceeded 2000h, the highest has reached 6000h, and there is still no oil pressure drop phenomenon, the effect is very good.
3.3 Air compressor two filter elements after the improvement of the oil separator is a device that separates the residual oil in the compressed air. As the running time of the unit increases, there will be sticky material on the surface of the oil separator, which will gradually increase the oil pressure difference. As the oil pressure difference increases, the power consumption of the unit will also increase. Moreover, if the oil pressure difference is too large, the oil separator filter element is damaged, so that the compressed air has high oil content, which not only loses the oil in the unit, but also causes the carbon molecular sieve of the alumina and nitrogen generator of the subsequent equipment dryer to be oily due to the intake. High volume and poisoning.
If the oil filter of the air compressor is newly replaced, the oil pressure difference is 0.01 0.02 MPa, and the oil filter is operated for about 2000 h, the oil pressure difference is 0.03- 0.04 MPa, and the air compressor with new oil replacement has low power consumption. The long-running air compressor consumes a lot of power. Therefore, the oil pressure difference of the oil separator filter element is not too high, and it cannot be damaged. It takes more than 8,000 yuan to replace one oil filter element. Prolonging its service life is very meaningful to reduce the maintenance cost of the air compressor.
The use of air compressor coolant directly affects the quality of the entire unit. And the price is expensive, it is more meaningful to extend the service life of the air compressor coolant.
The air filter and oil filter of the air compressor not only prolong the service life of the oil filter, but also prolong the service life of the oil separator filter and the air compressor coolant. The average life of the oil fine separator filter and the air compressor coolant before the air compressor filter transformation is about 4000h.
After the air compressor filter element is improved, the oil filter elements of each unit have exceeded 5 oil pressure difference and oil breakage, which have not affected the air compressor power consumption and the quality of the subsequent air source; the air compressor coolant usage time Also exceeds 5 analysis results, all indicators are not exceeded, can continue to use.
4 Conclusions From the perspective of annual cost generation before and after the improvement of the vulnerable parts of the air compressor, ensuring that the air filter element is not damaged can prolong the service life of the oil, oil and oil filter, protect the parts inside the unit from damage, and the price of the air filter is cheap. The replacement period of the air filter is fixed to be replaced after 1500 hours of operation, so the maintenance cost of the air filter is relatively fixed. By reviewing the inspection records, the average number of replacement parts and cost per equipment per year is improved. After the improvement, the oil filter life is calculated according to 3500h, the oil and coolant are calculated according to the service life of 5 000h, the number and cost, and each time the coolant is replaced Need a half bucket.
Before the renovation, the annual maintenance cost of Jiahua Phase II air compressor was 318 706.2 yuan. After the renovation, the annual maintenance cost of Jiahua Phase II air compressor was 208143 yuan. After the improvement of the air compressor filter, the equipment is expected to save maintenance costs of 110563.2 per year. yuan.
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General |
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Model |
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FD20 |
FD25 |
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Power Type |
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Diesel |
Diesel |
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Load Capacity |
kg |
2000 |
2500 |
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Load centre |
mm |
500 |
500 |
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Tyre |
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Tyre |
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Pneumatic Tyre |
Pneumatic Tyre |
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Front Tyre |
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7.00-12-12PR |
7.00-12-12PR |
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Rear Tyre |
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6.00-9-10PR |
6.00-9-10PR |
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Overall Dimension |
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Lift Height |
mm |
3000 |
3000 |
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Fork Size |
L×W×T |
mm |
1070*120*40 |
1070*120*40 |
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Mast Tilt Angle |
F/R |
. |
6/12 |
6/12 |
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Mast Lowered Height |
mm |
2070 |
2070 |
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Mast Extended Height(with backrest) |
mm |
4070 |
4070 |
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Length to face of fork(Without fork) |
mm |
2590 |
2590 |
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Overall Width |
mm |
1150 |
1150 |
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Overhead Guard Height |
mm |
2070 |
2070 |
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