Regarding compressor fault inspection and troubleshooting
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There is currently a compressor capable of handling 1000 M3 of gas per hour under normal pressure and temperature conditions; after three stages of compression, the pressure reaches 2 MPa. The temperature at the exit of the first compression stage consistently reaches 96 degrees, and the load has been reduced by almost half. It has been confirmed that the inlet valves of the compressor are in good condition. The first compression cylinder is of the single-rod double-acting type, and all three compression stages are functioning properly. Are there any issues with the first cylinder based on these parameters?
A primary outlet temperature of 96 degrees shouldn’t be high. When the load is reduced by half, does the flow rate also decrease by half or is it the current that drops? If it’s the flow rate, there might be a problem with the gas valve or the return valve
Is there a return line? Like three in and one out? If it exists, the opening degree of the control valve in the return pipeline should be checked; additionally, the exhaust valve can also be inspected
The current remains unchanged, and the compression pressures at all stages are normal
Has the flow rate decreased? If so, check whether there are any leaks in the return valve, safety valve, etc
I don’t know what the default temperature setting of the compressor is at factory If it is on the high side, check the exhaust valves first; use a temperature gun to measure the temperature of each exhaust valve to see if any of them have a higher temperature compared to the others. If so, it’s possible that the exhaust valve is leaking. It could also be a problem with the support rings or piston rings, such as a broken support ring or air leakage from the piston rings. It’s best to compare the intake temperature of cylinders of the same level to check for cross-ventilation. Finally, if nothing else works, disassemble it to check the piston and cylinder block.
If nothing changes, it might be a piston leak
What’s the compression ratio? How is the load reduced?
96℃ is not high. 1. Check the heat exchanger； 2. Check the clearance of the support ring and piston ring ； 3. Check the air valve ； 4. Check the circuit ； 5. Check the heat exchange efficiency of the jacket.
It is recommended to check the piston rings, as well as the clearance between the piston and the cylinder block. Check if there is a problem with the air valve.