Impact of high exhaust temperature in the three stages of a reciprocating compressor on the unit
Thread Content
Our factory has four 4M80 reciprocating compressors. Recently, due to insufficient amount of coke oven gas, the exhaust pressure at the third stage of these units is low, which results in high exhaust temperatures in the cylinders at that stage (above 160°C). I would like to ask our colleagues: 1. What impacts or damages can long-term high exhaust temperatures in the cylinders at the third stage have on the equipment itself? (Designed to trigger an alarm at 160°C exhaust temperature, and shut down the system at 170°C)
It has an impact on the spring of the air valve, and it also affects the valve disc to some extent. Increase the cooling water volume
It is our limited tolerance that causes the high temperature of the exhaust gas at three stages; otherwise, the intake air temperature, piston ring support rings, and valve are all normal. I just want to ask: what specific impacts or hazards does three-stage over-temperature have on the unit itself? Thank you.
High exhaust temperature raises the intake temperature in the rear section, which deteriorates the properties of the lubricant and makes it prone to degradation. Prolonged exposure to high temperatures reduces the lifespan of the components inside the compressor, increases energy consumption, and ultimately damages the compressor. The gas exiting the compressor can be sent back to the inlet, thereby preventing a range of hazards caused by insufficient gas flow!
Adjusting the pressure ratios at various levels will ensure normal operation. If it operates for an extended period at elevated temperatures, this will affect not only the lifespan of the valve plates but also the piston rings and support rings
If the capacity is low, operate at reduced load or use backflow; prolonged high temperatures can affect the lifespan of the piston rings, support rings, and valve seats made of grade 3 steel. Another possibility is that the design temperature of the compressor material may be reached. Compressors operate under excessive conditions, which shortens their lifespan and poses significant safety risks.
Excessive temperature can lead to liquid entrainment, damaging the machine and posing risks; it also reduces volumetric efficiency and increases energy consumption； The reduced viscosity of the lubricating oil leads to unnecessary wear on components such as the cylinder piston bearings ； Overheating causes the piston to expand, affecting performance ； High temperatures cause the circulating water to vaporize, thereby affecting its circulation. If the temperature exceeds the normal range, it indicates that there is a problem with the machine; it is necessary to investigate this promptly without taking any risks, to check whether the compression ratio is appropriate.
Please consider a variable air volume system, which is energy-efficient and helps avoid this problem. It’s just expensive: lol
There are 4 in total; how many are in use and how many are as backups? The gas capacity is low – should we consider shutting down one of them?