Specification for operation and maintenance of air compressor system
1. air compressor system operation specification
preparations before starting up
- check the shift change record book to understand the operation of the equipment in the previous shift.
- Check the cooling water system: the circulating water pipeline valve should be in the closed state; the air compressor cooling water inlet and outlet valves should be in the open state; the filter inlet and outlet valves should be in the closed state.
- Check the outlet valve of air compressor: it should be closed.
- Check the gearbox oil level: the oil level should be between 1/3 and 2/3 of the oil level gauge.
- Check the dryer and auxiliary equipment: the inlet and outlet air valves shall be closed, and the bypass valve shall be closed.
- Check the automatic drainer of the air reservoir to ensure that there is no dirty blockage.
Boot steps
- start the circulating water pump to ensure that the water inlet pressure is not lower than the equipment requirements.
- Start the cooling tower or other cooling equipment.
- Switch on the main power switch of the air compressor, press the "start" button, the air compressor should run automatically.
- When the system pressure reaches the set value, start the dryer or other post-treatment equipment.
- Record the operating parameters of the air compressor and observe the operation of the equipment.
Monitoring in operation
- the operator should always pay attention to the meter readings, especially the readings of the barometer, thermometer and ammeter.
- Listen to the sound of each part of the equipment. If there is any abnormal sound, stop the machine immediately for inspection.
- Make an inspection every two hours, record the operating parameters of the equipment, and check whether the system has air leakage, water leakage and oil leakage.
Shutdown steps
- deactivate the dryer or other post-treatment equipment.
- In the no-load state, press the "stop" button of the air compressor to stop the air compressor.
- Wait for a period of time (according to equipment requirements) and deactivate the circulating pump and cooling tower.
- Cut off the total power supply (no need to turn off the total power supply when it is not shut down or repaired for a long time).
Precautions for safe operation
- the operator should be specially trained to understand the structure, performance and function of the air compressor, and be familiar with the operation and maintenance procedures.
- Before operating the air compressor system, make sure that the door of the operating room is closed, and then start the power supply switch.
- Use personal protective equipment, such as helmets, protective glasses, protective gloves, etc.
- It is strictly forbidden to operate after drinking, to engage in things unrelated to operation, and to leave the job without authorization.
- It is strictly forbidden to open the chassis of the air compressor system without authorization or make any unauthorized changes.
Exception handling
- in the event of equipment failure, it should be stopped immediately to avoid further damage.
- When steam, water vapor and air leakage are found, the air compressor system equipment should be shut down immediately and the cause should be found out in time.
- In case of emergency, press the "emergency stop" button immediately to ensure the safety of personnel and equipment.
2. air compressor system maintenance specification
daily maintenance
- keep the air compressor and auxiliary equipment clean, and regularly clean up dust and oil.
- Check and tighten the bolts of all connecting parts to prevent loosening.
- Check whether the quality and quantity of lubricating oil and coolant are qualified, and supplement them in time when they are insufficient.
- Drain the oil and water from the gas tank and the oil-water separator to keep the system dry.
Regular maintenance
monthly maintenance:
- check whether the cooler fins are clean, and purge with compressed air if necessary.
- Check whether the inlet temperature of the dryer is normal and whether the high and low pressure of the refrigerant is normal.
Quarterly maintenance:
- replace the air filter element (according to the use, it is generally replaced every 1000 hours of operation).
- Check and clean the filter element of oil and gas separator.
- Check the insulation resistance of the motor and whether the terminal is loose.
Annual maintenance:
- hydraulic pressure test shall be carried out on the gas tank, and the test pressure shall be 1.5 times of the working pressure.
- Clean and check safety valves, pressure gauges and other safety accessories to ensure their sensitivity and reliability.
- Replace the oil and oil filter (depending on the use, it is generally replaced every 2000 to 3000 hours of operation).
- Check and adjust the tightness of the drive belt and replace if necessary.
Long-term out of service
- if the air compressor is stopped for a long time, the power supply should be cut off and the compressed air and cooling water in the system should be discharged.
- The equipment shall be thoroughly cleaned and coated with anti-rust oil to prevent rust.
- Start the air compressor regularly (such as monthly) and run for a period of time to maintain the flexibility and tightness of the equipment.
3. Other Considerations
- the air compressor should be parked in a well-ventilated place away from steam, gas and dust.
- The air inlet pipe shall be equipped with a filter device to prevent dust and impurities from entering the air compressor.
- When cleaning the heat sink, the oil in the pipeline shall not be cleaned by combustion method, and the maintenance work such as cleaning and fastening must be carried out after shutdown.
- When blowing parts with compressed air, it is forbidden to aim the air outlet at the human body or other equipment to prevent injury and destruction.
- Regularly conduct safety education and skill training for operators to improve their safety awareness and operational skills.
By following the above operation and maintenance specifications, the safe, efficient and stable operation of the air compressor system can be ensured, the service life of the equipment can be extended, and the operating cost can be reduced.
