Common Faults Of Compressors

Insufficient exhaust volume
One of the most frequent issues in compressors is the inadequate exhaust capacity, which can be attributed to several reasons [8]:.

 

The decreased exhaust volume can be attributed to fouling blockage in the intake filter. This blockage is caused by accumulated impurities that need regular cleaning. Additionally, the suction pipe's long length and small diameter increase the resistance, thereby negatively impacting the air flow. It is advisable to periodically clean the filter to maintain optimal performance.

 

compressor
compressor
Improper use of the air compressor can result in a decrease in exhaust volume due to a decrease in compressor speed. The exhaust volume of the air compressor is designed based on specific factors such as altitude, suction temperature, and humidity. However, when the compressor is used at high plateaus that exceed these standards, the suction pressure reduces, leading to an inevitable decrease in the exhaust volume.

 

The exhaust volume is greatly affected due to the worn and out-of-tolerance condition of the cylinder, piston, and piston ring, resulting in increased clearance and leakage. It is necessary to promptly replace vulnerable parts like the piston ring when normal wear occurs. In cases where incorrect installation and improper gap are identified, corrections should be made based on the provided drawings. However, if drawings are unavailable, empirical data can be relied upon. When considering the circumferential gap between the piston and cylinder, if the piston is made of cast iron, the appropriate gap value would be 0.06/100 to 0.09/100 of the cylinder diameter. On the other hand, for aluminum alloy pistons, the recommended gap ranges from 0.12/100 to 0.18/100 of the gas diameter. It is important to note that steel pistons may have a smaller gap value compared to aluminum alloy pistons.

 

The decrease in air volume and air leakage are caused by the stuffing box not being tight. This can be attributed to two reasons. Firstly, the stuffing box did not meet the required specifications during manufacturing. Secondly, poor alignment between the piston rod and the center of the stuffing box during installation leads to wear, strain, and subsequent air leakage. Generally, the addition of lubricating oil to the stuffing box serves the purpose of lubrication, sealing, and cooling.

 

The exhaust volume is significantly affected by failures in both the compressor suction and exhaust valves. When metal fragments or debris fall between the valve seat and the valve plate, it hampers the proper closure of the air valve, leading to air leakage. As a result, not only the exhaust volume is affected, but also the interstage pressure and temperature experience variations. The occurrence of this issue can be attributed to manufacturing flaws like valve plate warping or severe wear and tear between the valve seat and valve plate, causing air leakage.

 

The gas force and spring force of the gas valve do not align effectively. When the elasticity of the spring is too strong, the opening of the valve disc is slow, while if the elasticity is too weak, the closing of the valve disc is delayed. These issues not only impact the air volume but also have consequences for the valve disc and spring's longevity and the increase in power. Furthermore, they also have ramifications on changes in gas pressure and temperature. It is crucial to find a balance between these forces to ensure optimal performance and durability of the valve disc and spring.

 

One of the potential causes of air leakage in compressed air valves is improper tightening force. It is important to strike a balance between tightening the valve cover enough to prevent leaks and not over-tightening it, which can lead to deformation and damage. Formulae can be used to calculate the compression force required, taking into account factors such as the valve chamber diameter, maximum gas pressure and a value greater than one. Typically, a value of 1.5-2.5 is used for K. If the valve malfunctions, the valve cover may become hot and pressure may become abnormal. It is essential to ensure the valve is tightened correctly to avoid any potential issues.