How many hours is the first guarantee for the screw machine

Technical Guidelines for the First Maintenance of Screw Air Compressors

as the key air supply equipment in the industrial field, the reliability of screw air compressor directly affects the stability of the production system. According to the operating characteristics of the equipment and industry practice, the following specifications are made for the first maintenance cycle and related technical requirements:

1. first maintenance core cycle
it is suggested that after the new equipment is put into use, the first special maintenance shall be carried out at the node that has been running for 500 hours. The cycle setting is based on the following technical considerations:

1. characteristics of running-in period at the initial operation stage of the equipment, there are processing lines on the microscopic surface of the metal parts, which need to be continuously operated for 500 hours to complete natural grinding. The metal particles generated during this process will be mixed into the lubrication system.
2. Lubrication system purification: The first maintenance focuses on replacing lubricating oil and oil filter, which can completely remove impurities generated during the running-in period and avoid scratches on the surface of screw rotor caused by impurities participating in circulation.
3. Air intake system cleaning: Synchronously replace the air filter element to prevent environmental dust from entering the compression cavity during installation and commissioning, and ensure the initial cleanliness of the oil and gas separation system

basis for Adjusting 2. Cycle
when the equipment is under the following special working conditions, the first maintenance period shall be adjusted accordingly:

1. environmental factors:
   • dust concentration exceeds 0.5 mg/m & sup3; Workplace, cycle time is shortened to 400 hours
   • hot and humid environment with relative humidity continuously higher than 80%, and the cycle time is shortened to 450 hours
   • containing corrosive gas environment, the cycle is shortened to 400 hours and the gas water separation device is added.
2. Operating characteristics:
   • under frequent start-stop conditions, it is recommended to convert the maintenance period according to the actual compression duration.
   • Frequency conversion operation mode, 20% maintenance frequency shall be increased on the basis period
   • when the continuous exhaust temperature exceeds 85 ℃, the cooling system shall be maintained and tested in advance.

Code of practice for 3. maintenance
the following standard procedures shall be included in the first maintenance work:

1. lubrication system maintenance:
   • simultaneous cleaning of sediment at the bottom of the sump when draining the old oil
   • the filling amount of new oil shall conform to the calibration capacity of the equipment, and the error shall not exceed 2%.
   • Check opening pressure of bypass valve when changing oil filter
2. intake system treatment:
   • the air filter element shall be cleaned by low-pressure pulse back-blowing, and high-pressure water gun shall not be used for flushing.
   • The inner wall of the intake hose shall be inspected with a special endoscope, and the residual area exceeding 10% shall be replaced.
   • Check the permeability of the respirator screen to ensure that the pressure difference does not exceed 0.02MPa.
3. Operation status check:
   • record the vibration intensity value before and after maintenance, and compare the running state of the bearing
   • check the exhaust temperature curve and confirm the matching of the cooling system
   • check the tripping pressure of safety valve, and the error range shall be controlled within ± 3%

economic Analysis of 4. Technology
strict observance of the first service specification results in:

• extend the main engine overhaul cycle by more than 30%
• reduce sudden failure rate by 65%
• increase volumetric efficiency by 8%-12%
• reduce unplanned downtime losses

it is recommended that enterprises establish equipment electronic files, record operating parameters and maintenance records in real time, and dynamically optimize maintenance strategies through data analysis. For continuous operation equipment, an online monitoring system can be configured to realize real-time early warning of key parameters such as lubricating oil quality and filter element pressure difference.