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A complete list of technical solutions for maintenance of screw refrigeration compressors

A complete list of technical solutions for maintenance of screw refrigeration compressors Screw refrigeration compressor is the core component of the refrigeration system. Whether the unit is running well is directly related to safety and energy consumption. If the mechanical cooperation gap is too large, the cooling effect is reduced, the oil consumption is increased, and the power consumption is also increased. As a result of the huge hidden dangers, it is necessary to repair the compressor on time. 　　 1. Current status of compressor 　　 1. The unit is running seriously, the two units 10# and 11# make up oil once a month, and the operator is forced to reduce the frequency of their startup; 　　 2. A large amount of metal dust was found when cleaning the oil filter, indicating that the internal wear and tear of the machine body was added; 　　 3. The starting current is too large, and the voice is sharp; 　　 4. The host has been in operation for more than 5 years since it was put into operation in 2008, and the operation time is far beyond its normal maintenance limit; 　　 2. Precautions for maintenance 　　 1. Preparation for inspection 　　A. Coordinate the maintenance sequence of the machine with the production department to ensure the orderly production and the quality of the stock products; 　　 B. The site hoisting equipment is intact, protective facilities are in place, and guardians are in place; 　　C. Discharge the frozen oil in the body to the empty oil drum, close all the inlet and outlet valves, and let the pressure in the body fall to the negative pressure before venting to the atmosphere; 　　D. Support the suspended pipeline to prevent collision; 　　E、Unload the slide valve to 0 position; 　　F. Confirm that all lifting equipment (including steel cables, lifting lugs, lifting rings, etc.) are safe and available. 　　G. Prepare a clean site for maintenance work; 　　H, cut off the power supply of the host; 　　 2. Matters needing attention during compressor overhaul 　　A. The slide valve is unloaded to 0 position; 　　B. Some of the parts on the rotor components are similar in shape, but they cannot be mixed. Marking should be made during the disassembly process to distinguish between the positive and negative rotors, and the suction and exhaust ends; 　　C. When reassembling, replace the damaged O-ring, stop washer and round nut; 　　D. Parts between different bearings cannot be interchanged; 　　E. When replacing a new O-ring, be sure to apply oil; 　　 3. Disassembly 　　A. After removing the coupling guard, suction filter, suction check valve, tubing, coupling, compressor anchor bolts from the compressor unit, hoist the compression unit to the maintenance work site; 　　B. Remove the energy level indicator cover and electrical components, and place the oil groove under the oil cylinder; 　　C. After removing the positioning pin, remove the suction end cap in parallel and remove the oil piston; 　　D. After removing the positioning pin, remove the suction end seat; 　　E. Remove the shaft seal cover, take out the shaft seal static ring and moving ring group; 　　F. After removing the positioning pin, remove the exhaust end cover; 　　G. Loosen the round nut, remove the thrust bearing, pay special attention to make the assembly mark; 　　H. Take out the active rotor, and use a special eye screw to gently take out the active rotor in a balanced manner. At this time, the driven rotor is attached to rotate, and the main rotor needs to be turned; 　　I. Take out the driven rotor with the eye screw; 　　J. After removing the positioning pin, remove the exhaust end seat. 　　K、Remove the spool 　　 4. Check 　　A. The rotor shaft stiffness surface and the surface of the shaft seal components must not have any defects such as rust and cracks, and whether the body and other parts are worn or frayed; 　　B. Renew the main bearing and thrust bearing; 　　C, gasket and O-ring replacement new parts; 　　D. Clean the original sealant on both ends of the machine body and the plane of the suction and exhaust ends; 　　 5. Assembly 　　A. Assemble should inspect each part, and repair and replace damaged parts. Be sure to pay attention to the assembly position mark when disassembling when assembling. Don’t confuse the position; 　　B. Clean all parts and blow dry with compressed air; 　　C. Install each main bearing into the bearing hole of the suction and exhaust end seat in situ, and measure the inner diameter of the bearing to make the inner diameter meet the clearance requirements of the rotor journal; 　　D. Place the suction end on the suction side of the machine body, and press the positioning pin. Pay attention to apply evenly when applying sealant; 　　E. Place the suction end seat on the suction side of the machine body, press in the positioning pin, and fix it with bolts. 　　F. The main bearing holes on the suction side and the holes in the machine body are coated with the same brand of refrigerant oil as in normal driving, and then installed in the male and female rotors. The end faces of the two rotors should be close to the suction end seat. At this time, the dimension value between the exhaust end face of the rotor and the exhaust end seat is measured; 　　G. Apply sealant to the flat surface where the exhaust end seat is attached to the machine body, pay attention to even application; 　　H. Put the exhaust end seat on the discharge end of the machine body, fix it with the positioning pin, and fix it with bolts. Pay attention to the inner hole of the main bearing when installing the exhaust end seat, and do not scratch the main bearing; 　　I. Put the adjusting washer and thrust bearing, and fix the inner race of the thrust bearing on the rotor journal with a round nut. Pay attention to the direction of the thrust bearing. 　　J. Install the bearing pressure ring. After installation, the active rotor should be gently turned according to the actual running direction, and the rotation should be flexible. If the gap at the exhaust end is unreasonable, the thickness of the gasket should be adjusted; 　　K. After positioning the exhaust end cover with positioning pins, fix it with bolts. 　　L. Install the shaft seal moving ring and other parts, and apply freezing oil on the friction surface of the moving ring; 　　M, install shaft cover and static ring N, install oil piston, suction end cover; 　　O. Install energy indicator, pay attention to the pointer corresponding to the position of the slide valve; 　　P. Hang the installed compressor into the unit, and align it with the motor, proofread the coaxial and install the coupling; 　　 6. Trial operation after maintenance The overhauled compressor needs to go through trial operation, and it can be put into official operation only after the trial operation is normal. No-load trial operation, adjust the installation status of each component during the trial operation. The trial operation includes: 　　A. Unit leakage test; 　　B. Oil pump oil pressure test; 　　C, sliding valve action test; 　　 D. Check the motor steering before installing the coupling. After connecting the coupling, the crank should be easy and free of jams. f Adjust the slide valve to the O position, start the compressor, pay attention to check the vibration, oil temperature, oil pressure, noise, etc.; 　　G, the spool valve is adjusted to the O position, and the compressor should be easily turned after the shutdown; 　　H. Vacuum test should be able to achieve absolute pressure below 5.332KPA 　　I、Replace lubricant after compressor overhaul 　　J. After the compressor is put into trial operation and before the formal operation, the lubricant in the unit should be replaced completely; 　　K, refueling: refueling by vacuum; 　　 3. Preliminary trial operation 　　 1. The start-up procedure is the normal operation, the first run, the time should not be too long, 30 minutes. 　　 2. Observe the parameters according to the above 1 operation, and there is no abnormality before it can run according to the normal operation; 　　 4. Operation and shutdown observation matters 　　 1. Observe and record data such as suction pressure, suction temperature, discharge pressure, discharge temperature, oil pressure, oil temperature, etc.; 　　 2. If it is automatically shut down due to a certain safety protection action, it must be turned on after the cause of the fault is identified, and it will never be restarted again by changing the fixed value at will; 　　 3. When the main engine is shut down due to a sudden power failure, due to the failure of the bypass energy solenoid valve to open, the compressor may reverse due to the difference between the exhaust gas and the suction pressure, and the suction cut-off valve should be closed quickly 　　 4. Normal oil level-The normal oil level in the oil separator is between the upper side oil sight glass and the lower side oil sight glass, and this should be ensured before starting each time. After starting, the oil level may drop, but when it reaches a certain level, the liquid level switch can give a signal to automatically stop. The operator should always pay attention to whether the oil level is safe and replenish oil if necessary. 　　 5. Refueling during operation-generally not recommended to refuel during operation, it is recommended to stop the vacuum refueling or external refueling; 　　 6. If the machine is shut down for a long time, the oil pump should be started for 10 minutes every week to let the lubricant spread all over the compressor; 　　 7. Disc coupling once a week, this will help to avoid bearing erosion; 　　 8. If the machine is shut down for more than 3 months, in addition to the above measures, the engine group must be started every 3 months, and the transportation time is about 30 minutes. 　　 V. Maintenance items and deadline 　　The compressor's annual inspection period is 1 year, and the overhaul period is 3 years.

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