Excessive moisture in the air compressor will affect the quality of compressed air, resulting in equipment failure or production problems. The following are the reasons for excessive moisture and systematic solutions:
1. core reason analysis
- air humidity too high
- when the ambient humidity is more than 70%, the moisture in the compressed air is easy to be saturated and precipitated.
- Drainage system failure
- the automatic drain is blocked or malfunctions, and the condensed water of the gas tank cannot be discharged.
- Drying equipment problems
- the dryer (cold dryer/suction dryer) is not installed or malfunctions, and cannot effectively remove gaseous moisture.
- Cooler contamination
- the cooler is blocked by dust/catkins, resulting in insufficient cooling of the compressed air and increased pressure dew point.
- Gas-water separator fault
- the efficiency of the cyclone is reduced and the liquid water is not completely separated.
- oil emulsification
- the anti-emulsification performance of lubricating oil is poor, and moisture accumulates in the oil circuit.
2. six-step solution
- upgrade the drying system
- cold dryer the pressure dew point is set to 10 ℃ lower than the ambient temperature, and the best working point is 4 ℃ (the largest proportion of water and the highest separation efficiency).
- suction dryer: Use activated alumina adsorbent, fill tightly to prevent pulverization, with timing regeneration function.
- Combination scheme cold dryer (coarse water removal) + suction dryer (fine water removal), suitable for dew point requirements below -40 ℃.
- Optimize drainage management
- gas tank: Install electronic automatic drain valve, and the drain frequency is adjusted according to the humidity (drain every 15 minutes in wet weather).
- Duct Low Point: Add manual drain valve, check and drain water every week.
- Cooler maintenance
- clean: Purge the cooler fins with compressed air daily to prevent catkin/dust clogging.
- Transformation: Add a sponge filter at the air inlet of the air compression station to reduce the entry of catkins.
- Maintenance of gas-water separator
- inspection cycle check the cyclone separator every month to clean up the oil and impurities inside.
- Efficiency improvement: Add a spiral baffle inside the separator to enhance the centrifugal separation effect.
- Lubricant management
- oil selection: Use special lubricating oil with strong anti-emulsification performance.
- Replacement cycle: Replace the lubricating oil and oil filter every 2000 hours to prevent the emulsified oil from polluting the compressed air.
- intelligent monitoring system
- dew point monitoring: Install dew point sensor at the outlet of the dryer to give real-time warning of excessive moisture.
- Energy consumption optimization: Adjust the power of the air compressor through the frequency converter to reduce the operating energy consumption in high temperature and humidity weather.
3. Maintenance Standards
| Project | maintenance cycle | operation content |
|---|
| cooler cleaning | daily | purge the fins with compressed air to ensure heat dissipation efficiency |
| drain valve inspection | weekly | manually drain the water and observe the water discharge. Disassemble and clean it in case of abnormality. |
| Lubricating oil replacement | every 2000 hours | replace lubricating oil, oil filter and air filter |
| dryer detection | quarterly | detect dew point and oil content, and calibrate drain valve parameters |
| maintenance of gas-water separator | every half year | disassemble and clean the inside of the separator, and replace the worn parts |
through the above measures, the dew point of compressed air can be stably controlled below -40 ℃, and the oil content is less than 0.01 mg/m & sup3;, which meets the requirements of precision processing and high-demand scenes. It is recommended to establish a gas source quality ledger and conduct all inspections every quarter to ensure long-term stable operation of the system.
