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Reasons and Judgment of Overhaul of Head Bearing of Air Compressor

Reasons and Judgment of Overhaul of Head Bearing of Air Compressor

  • Categories:Industry News
  • Author:
  • Origin:
  • Time of issue:2020-07-31
  • Views:0

(Summary description)
With the running time of the air compressor, each bearing of the main engine will inevitably wear, which will cause the screw to produce axial movement and increase the radial displacement. The gap between the end faces changes. These clearance changes are normal and permissible during the bearing life period, and the resulting air compressor air production decline and main motor load increase are also normal and permissible.

As the operating time of the unit approaches the overhaul period of the main engine, the life of the main engine bearing gradually tends to the maximum allowable time limit. At this time, the axial and radial movement of the screw gradually tends to the maximum design allowable value, and this change will greatly change the clearance between the screw and the screw, between the screw and the host shell and the front and rear surfaces. At this point the mainframe operation is still safe, but it is time to consider planning for a major overhaul of the mainframe. Because once the running time of the unit exceeds the overhaul period, the bearing wear and the matching clearance of the main engine will reach the limit value allowed by the technical conditions of the main engine. At this time, the main engine is in an unsafe operation state, and the following serious consequences may occur at any time:

1. The operating load of the main engine increases, causing harm to the main motor and electrical system

The possible strong friction between the screw of the host, between the screw and the front and rear faces, and between the screw and the shell of the host will cause the running load of the host to increase sharply, and the running load of the severely worn bearings is also very large. As a result, the motor will be in an overloaded working state, which will seriously endanger the safe operation of the motor. In severe cases, if the electrical protection device of the air compressor unit is insensitive or fails, it may also cause the motor to burn out.

2. The exhaust volume of the air compressor will be attenuated to a large extent.

The increase in the matching clearance of the main engine will lead to a serious reduction in the efficiency of the main engine, that is, the air compressor exhaust volume will have a large attenuation, which will have a certain impact on the normal production of the air unit. Especially for those users whose air compressor displacement configuration is relatively small, due to the attenuation of air compressor displacement, when the air consumption of the air system is relatively stable, the compressed air pressure of the pipe network will be greatly reduced, so It may occur that the gas system equipment cannot work normally or cannot work at all, thus affecting the normal production of the unit or causing a temporary shutdown, causing losses to the enterprise.

3. The most serious consequence is the sudden "locking" of the host.

Once such a situation occurs, if the electrical protection system does not respond in time or the protection fails, it may also cause serious damage to the main motor and electrical system.

For the handling of the "locking" of the host, on the one hand, the maintenance cost of the overhaul will be much more expensive than that of the normal overhaul. . And if the damage of the host has reached the point where it has no repair value or cannot be repaired at all, it can only be scrapped and replaced with a new host, and the direct loss is the greatest. Because the cost of newly purchased main engine is usually about one-third of the cost of purchasing the entire air compressor unit, which is much higher than the cost of overhauling the main engine under normal circumstances. But it's very close!

From the above analysis, it can be seen that the normal main engine overhaul work is not only the basic requirement for equipment maintenance, but also the basic requirement for enterprises to control normal equipment maintenance costs, avoid unnecessary capital losses and ensure the normal production of enterprises!

Therefore, it is not only necessary but also necessary to overhaul the air compressor main engine on time and according to the standard! Judgment that the main engine of the screw air compressor needs to be overhauled:

To be precise, the time for the main engine to be overhauled should be based on the expiration of the service life of the bearing, but in fact it is difficult to have an accurate indicator to judge whether the service life of the bearing is about to expire or has expired. The standard set by compressor manufacturers based on their practical experience of nearly a hundred years is to overhaul the main engine after 20,000 hours of compressor operation or 4 years.

In addition to the above general standards, based on experience, a more accurate judgment of the host status can be made from the following aspects:

1) The sound of the main engine running, especially whether there is any abnormal sound in the beari

Reasons and Judgment of Overhaul of Head Bearing of Air Compressor

(Summary description)
With the running time of the air compressor, each bearing of the main engine will inevitably wear, which will cause the screw to produce axial movement and increase the radial displacement. The gap between the end faces changes. These clearance changes are normal and permissible during the bearing life period, and the resulting air compressor air production decline and main motor load increase are also normal and permissible.

As the operating time of the unit approaches the overhaul period of the main engine, the life of the main engine bearing gradually tends to the maximum allowable time limit. At this time, the axial and radial movement of the screw gradually tends to the maximum design allowable value, and this change will greatly change the clearance between the screw and the screw, between the screw and the host shell and the front and rear surfaces. At this point the mainframe operation is still safe, but it is time to consider planning for a major overhaul of the mainframe. Because once the running time of the unit exceeds the overhaul period, the bearing wear and the matching clearance of the main engine will reach the limit value allowed by the technical conditions of the main engine. At this time, the main engine is in an unsafe operation state, and the following serious consequences may occur at any time:

1. The operating load of the main engine increases, causing harm to the main motor and electrical system

The possible strong friction between the screw of the host, between the screw and the front and rear faces, and between the screw and the shell of the host will cause the running load of the host to increase sharply, and the running load of the severely worn bearings is also very large. As a result, the motor will be in an overloaded working state, which will seriously endanger the safe operation of the motor. In severe cases, if the electrical protection device of the air compressor unit is insensitive or fails, it may also cause the motor to burn out.

2. The exhaust volume of the air compressor will be attenuated to a large extent.

The increase in the matching clearance of the main engine will lead to a serious reduction in the efficiency of the main engine, that is, the air compressor exhaust volume will have a large attenuation, which will have a certain impact on the normal production of the air unit. Especially for those users whose air compressor displacement configuration is relatively small, due to the attenuation of air compressor displacement, when the air consumption of the air system is relatively stable, the compressed air pressure of the pipe network will be greatly reduced, so It may occur that the gas system equipment cannot work normally or cannot work at all, thus affecting the normal production of the unit or causing a temporary shutdown, causing losses to the enterprise.

3. The most serious consequence is the sudden "locking" of the host.

Once such a situation occurs, if the electrical protection system does not respond in time or the protection fails, it may also cause serious damage to the main motor and electrical system.

For the handling of the "locking" of the host, on the one hand, the maintenance cost of the overhaul will be much more expensive than that of the normal overhaul. . And if the damage of the host has reached the point where it has no repair value or cannot be repaired at all, it can only be scrapped and replaced with a new host, and the direct loss is the greatest. Because the cost of newly purchased main engine is usually about one-third of the cost of purchasing the entire air compressor unit, which is much higher than the cost of overhauling the main engine under normal circumstances. But it's very close!

From the above analysis, it can be seen that the normal main engine overhaul work is not only the basic requirement for equipment maintenance, but also the basic requirement for enterprises to control normal equipment maintenance costs, avoid unnecessary capital losses and ensure the normal production of enterprises!

Therefore, it is not only necessary but also necessary to overhaul the air compressor main engine on time and according to the standard! Judgment that the main engine of the screw air compressor needs to be overhauled:

To be precise, the time for the main engine to be overhauled should be based on the expiration of the service life of the bearing, but in fact it is difficult to have an accurate indicator to judge whether the service life of the bearing is about to expire or has expired. The standard set by compressor manufacturers based on their practical experience of nearly a hundred years is to overhaul the main engine after 20,000 hours of compressor operation or 4 years.

In addition to the above general standards, based on experience, a more accurate judgment of the host status can be made from the following aspects:

1) The sound of the main engine running, especially whether there is any abnormal sound in the beari

  • Categories:Industry News
  • Author:
  • Origin:
  • Time of issue:2020-07-31
  • Views:0
Information

With the running time of the air compressor, each bearing of the main engine will inevitably wear, which will cause the screw to produce axial movement and increase the radial displacement. The gap between the end faces changes. These clearance changes are normal and permissible during the bearing life period, and the resulting air compressor air production decline and main motor load increase are also normal and permissible.

As the operating time of the unit approaches the overhaul period of the main engine, the life of the main engine bearing gradually tends to the maximum allowable time limit. At this time, the axial and radial movement of the screw gradually tends to the maximum design allowable value, and this change will greatly change the clearance between the screw and the screw, between the screw and the host shell and the front and rear surfaces. At this point the mainframe operation is still safe, but it is time to consider planning for a major overhaul of the mainframe. Because once the running time of the unit exceeds the overhaul period, the bearing wear and the matching clearance of the main engine will reach the limit value allowed by the technical conditions of the main engine. At this time, the main engine is in an unsafe operation state, and the following serious consequences may occur at any time:

1. The operating load of the main engine increases, causing harm to the main motor and electrical system

The possible strong friction between the screw of the host, between the screw and the front and rear faces, and between the screw and the shell of the host will cause the running load of the host to increase sharply, and the running load of the severely worn bearings is also very large. As a result, the motor will be in an overloaded working state, which will seriously endanger the safe operation of the motor. In severe cases, if the electrical protection device of the air compressor unit is insensitive or fails, it may also cause the motor to burn out.

2. The exhaust volume of the air compressor will be attenuated to a large extent.

The increase in the matching clearance of the main engine will lead to a serious reduction in the efficiency of the main engine, that is, the air compressor exhaust volume will have a large attenuation, which will have a certain impact on the normal production of the air unit. Especially for those users whose air compressor displacement configuration is relatively small, due to the attenuation of air compressor displacement, when the air consumption of the air system is relatively stable, the compressed air pressure of the pipe network will be greatly reduced, so It may occur that the gas system equipment cannot work normally or cannot work at all, thus affecting the normal production of the unit or causing a temporary shutdown, causing losses to the enterprise.

3. The most serious consequence is the sudden "locking" of the host.

Once such a situation occurs, if the electrical protection system does not respond in time or the protection fails, it may also cause serious damage to the main motor and electrical system.

For the handling of the "locking" of the host, on the one hand, the maintenance cost of the overhaul will be much more expensive than that of the normal overhaul. . And if the damage of the host has reached the point where it has no repair value or cannot be repaired at all, it can only be scrapped and replaced with a new host, and the direct loss is the greatest. Because the cost of newly purchased main engine is usually about one-third of the cost of purchasing the entire air compressor unit, which is much higher than the cost of overhauling the main engine under normal circumstances. But it's very close!

From the above analysis, it can be seen that the normal main engine overhaul work is not only the basic requirement for equipment maintenance, but also the basic requirement for enterprises to control normal equipment maintenance costs, avoid unnecessary capital losses and ensure the normal production of enterprises!

Therefore, it is not only necessary but also necessary to overhaul the air compressor main engine on time and according to the standard! Judgment that the main engine of the screw air compressor needs to be overhauled:

To be precise, the time for the main engine to be overhauled should be based on the expiration of the service life of the bearing, but in fact it is difficult to have an accurate indicator to judge whether the service life of the bearing is about to expire or has expired. The standard set by compressor manufacturers based on their practical experience of nearly a hundred years is to overhaul the main engine after 20,000 hours of compressor operation or 4 years.

In addition to the above general standards, based on experience, a more accurate judgment of the host status can be made from the following aspects:

1) The sound of the main engine running, especially whether there is any abnormal sound in the bearing;
2) The motor running current, especially the difference between the no-load running current and the standard value;
3) The vibration of each bearing of the machine head.

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(1) The air compressor has abnormal noise 1. There is a sound in the cylinder ① If foreign objects or broken valve plates fall into the cylinder, clean up the foreign objects or broken valve plates; ② The top of the piston collides with the cylinder head, and the clearance should be adjusted; ③ The large end tile, small end bushing and piston transverse hole of the connecting rod are excessively worn and should be replaced; ④ Excessive wear of the piston ring, impact occurs in the ring groove during operation, replace the piston ring; ⑤ There is water in the cylinder.  2. There is a sound in the valve ① If the inlet and exhaust valve groups are not pressed tightly, the tightening nut of the square cover of the valve chamber should be tightened:; ② If the valve spring is damaged, replace it in time; ③ Loosen the bolts and nuts of the air valve, and tighten the nuts; ④ The gap between the valve plate and the bonnet is too large, adjust the gap, and replace the valve plate if necessary 3. There is a sound in the crankcase ① The connecting rod bush is worn out excessively, replace it with a new one, ② Connecting rod bolts are not tightened, tighten them; ③ If the flywheel is not installed tightly or the key is too loose, it should be installed tightly. ④ The main bearing is damaged, replace the bearing; ⑤ The oil retaining ring on the crankshaft is loose, replace it with a new oil retaining ring. (2) Failure of the lubrication system 1. The oil strike needle is broken and should be replaced; 2. If the oil level is too high or too low, adjust the oil level to the specified range 3. If the oil grade is wrong, the oil should be changed according to the instructions: 4. The lubricating oil is too dirty and should be replaced with clean lubricating oil. (3) The pressure at all levels is abnormal (low or high) 1. The valve plates or springs of the intake and exhaust valves are damaged and leak, and should be replaced; 2. There is dirt on the valve seat of the intake and exhaust valves, air leakage, clean up the dirt; 3. The air filter is seriously blocked and should be cleaned; 4. If there is air leakage in the gas pipeline or air leakage in the cooler, repair it; 5. Piston rings and cylinders are severely worn and leak air and should be replaced. (4) Exhaust temperature or cooling water drainage temperature is too high (referring to water-cooled type) 1. Cylinder brushing makes the cylinder overheat, repair the cylinder and piston; 2. The exhaust valve is leaking or the valve spring is damaged, the valve plate is damaged, and the damaged parts are replaced; 3. Insufficient cooling water, increase the cooling water flow; 4. The cooling water circuit is blocked, the scale in the cylinder, cylinder head, and cooler is too thick or blocked, clean the scale or blockage; 5. The inlet and exhaust valves are charcoal, so that the gas passage is not smooth, and the charcoal is cleaned up. (5) Exhaust pressure gauge jumps 1. The intake and exhaust valve sheets or springs are stuck, overhaul; 2. The pressure gauge is damaged, replace it; 3. There is a foreign body in the instrument pipeline. Clean and blow out. (6) The exhaust volume is reduced 1. The air valve is leaking, repair it by grinding or replace it with a new one; 2. Excessive wear of piston ring, oil scraping ring and cylinder, replace the worn parts; 3. The air filter is blocked, the air pipeline is leaking, clean the dust under the filter screen, and repair the pipeline; 4. The clearance at the top dead center of the piston is too large, reduce the cylinder gasket and the clearance volume, 5. If the speed of the air compressor is lower than the rated speed, check the line voltage, frequency, overhaul or replace the motor. (7) Mechanical failure The piston ring is stuck, the cylinder is dry-grinded, the crankshaft connecting rod is seized, the rolling bearing is damaged, the assembly clearance is too small or the lubrication If the lubricating oil is too dirty and the oil level is too low, the assembly clearance should be adjusted or the lubricating oil should be replaced.
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