Leak in the air pipe of the Ingersoll Rand air compressor’s 3-stage cooler
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Dear all, three of our Ingersoll Rand air compressors have developed leaks in the air pipelines of their level 3 coolers. Previously, these compressors gave warnings related to vibration and high temperatures; we thought it was due to a clogged air intake filter, so we didn’t replace it. The filter has been replaced, and the impeller, diffuser, and cooler have been cleaned. Leaking occurred after operation, and this happened with all 3 units after cleaning; there were no problems during previous operations. Have you all encountered the same situation before?
1. Leaks in the air pipeline are caused by poor sealing of the seals on the cooler. 2. If the O-ring is fine, then it’s the flare at the pipe end that isn’t sealing properly (it seems to be flared, but I didn’t pay close attention). 3. Another possibility is that the corrosion in the tubes caused leaks, and these leaks were fixed through your cleaning process. Also, during cleaning, it is necessary to check whether the O-ring has been cleaned thoroughly. 4. Also, during installation, make sure the cooler is installed level; if it is tilted, it can lead to poor sealing and water leaking into the air passage. It’s generally best to replace all the O-rings at once when removing them. Imported O-rings are of better quality, while domestic ones usually maintain their sealing properties after being compressed just once. This problem is easy to solve; this machine has been used many times before, and I’ve never encountered a situation like yours. The assembly is also simple. I’m not sure if my answer can help you.
Agree with what was said above; the main thing is to check whether there is corrosion or leaks in the piping
Thank you for the reply. We have better sealing rings after taking it apart. The pipe joints are expanded. I asked the manufacturer, and they also said it might be caused by corrosion, due to sulfur dioxide in the air. It has not been disassembled yet; the bundled pipes are inside the cooler, so they are not visible. If it needs to be taken apart, how should it be done?
It doesn’t seem easy to remove this pipe, but there is a method; I saw this method back when I was in school. It’s used to seal off the leaking pipes after corrosion occurs in the heat exchanger tube bundles. If conditions permit, pressure testing can be carried out one by one. You’ll have to figure out the specific steps on your own; I’ve never taken it apart either. I suggest replacing them with new ones outright. Since corrosion is suspected, it’s likely that the other pipes won’t last long either; it’s better to replace them all.