How to save the maintenance cost of air compressor

How to save the maintenance cost of air compressor

1.Introduction

The okmarts.com power plant has 8 screw air compressors, which are responsible for the supply of instrument air, dust removal air, power air, and gas for second desulfurization and nitrogen production for coal preparation, coking, purification and power plants. Although it belongs to the supply and auxiliary system, if there is a problem with the gas supply, it will affect the production system of the entire company, so the stable operation of the air compressor is very important. The maintenance cost of the air compressor is a must. How to reduce the maintenance cost of the air compressor has become the primary issue. Among the 8 screw air compressors, two air compressors 1# and 2# are produced by a company in Shanghai, and six air compressors 3#, 4#, 5#, 6#, 7# and 8# are from a Beijing company. They are produced by the company, but their working principles are basically the same, and the service life of vulnerable spare parts is slightly different. This article takes the air compressor of a Beijing company as an example to talk about reducing maintenance costs by establishing a planned maintenance mode for the air compressor and improving the filter element.

　　 2. Air compressor establishes a planned maintenance mode

In the daily troubleshooting of air compressors, the most common failures are high exhaust temperature and high fuel consumption. The most common cause of high exhaust temperature is the clogging of the oil filter element and the use of air compressor oil. Overtime and the surface of the cooler is too dirty or clogged, the most common cause of high oil consumption is the rupture of the filter element of the oil fine separator. Among them, the oil filter element and the oil fine separator element are all vulnerable spare parts of the air compressor, in addition to the air filter element, the air compressor oil needs to be replaced regularly.

　　 (1) The recommended operating time of the air filter element is 1500h, and it needs to be cleaned regularly. Generally, it is purged once every 2 to 4 weeks. The air source below 2kg should be used for purging.

　　 (2) It is recommended to replace the oil filter element after running for 3500 hours, or when the oil injection pressure is lower than 0.25 MPa, it is recommended to replace it.

　　 (3) The oil filter element is recommended to be replaced after running for 5000 hours, or the oil partial pressure difference exceeds 0.055 MPa.

　　 (4) It is recommended to run the air compressor oil for 2000h for sampling and analysis, and decide whether to replace it according to the test results.

　　3. Improvement of air compressor filter element

　　3.1 Improvement of the air filter element of the air compressor

Before the air enters the system, it passes through the air filter, so the quality, filtration accuracy, and convection area of the air filter directly affect the use of the unit oil system (including oil filter element, oil separation filter element), bearings, rotors and other head equipment life.

The filter of the air compressor filters out all fine dust and particles from the outside. It is the first protective filter element of the air compressor. In order to extend the service life of other vulnerable spare parts of the air compressor, after searching for information and consulting the manufacturer, we The original air filter with a filtration accuracy of 10μm used in the 6 air compressors was changed to an air filter with a filtration accuracy of 3μm. The accuracy is changed. In order not to affect the convection area and the gas production, the original air filter is lengthened by 20cm, and the corresponding installation parts are lengthened. After being put into use, the service life of the air compressor oil filter element is significantly extended.

　　3.2 Improvement of oil filter element

　　 oil filter can filter out the impurities in the internal oil system of the air compressor to protect the unit. It is the second filter element of the air compressor. The average service life of the built-in oil filter element is about 1000h. The service life of the air filter has been improved after the improvement, but there is still a phenomenon that the oil filter is blocked and the oil injection pressure drops, which causes the unit temperature to rise and the exhaust temperature to rise sharply.

　　In order to further extend the service life of the oil filter, we read a lot of information and learn from other types of oil filters, and finally changed the original one built-in oil filter to two external oil filters in parallel. The price of a built-in oil filter is about 1660 yuan, and the price of two external oil filters is about 1440 yuan. The cost of the improved oil filter has not increased, but the service life is greatly improved. Now the service life of the oil filter used in the operating units has exceeded 2000h, and the highest has reached 6000h, and there is still no drop in oil injection pressure, and the effect is very good.

　　3.3 The effect of the improved two filter elements of air compressor

　　 oil fine separator is a device that separates the residual oil in the compressed air. As the operating time of the unit increases, there will be viscous materials on the surface of the oil fine separator filter element, which will gradually increase the oil partial pressure difference. As the oil partial pressure difference increases, the power consumption of the unit also increases. Moreover, if the oil partial pressure difference is too large, the filter element of the oil fine separator will be damaged, and the compressed air will have high oil content, which will not only lose the oil in the unit, but also cause the aluminum oxide of the dryer and the carbon molecular sieve of the nitrogen generator of the subsequent equipment to contain oil due to the intake air. High amount and poisoning.

If the oil filter element of the air compressor is newly replaced, its oil partial pressure difference is 0.01～0.02mpa, and the oil filter element has been running for about 2000h, and its oil partial pressure difference is 0.03～0.04mpa. Low, long-running air compressor consumes high power. Therefore, the oil partial pressure difference of the oil fine separator filter element should not be too high, let alone damaged. It takes more than 8,000 yuan to replace an oil separation filter element. Properly extending its service life is very meaningful to reduce the maintenance cost of the air compressor.

　　 The use of air compressor coolant directly affects the quality of the entire unit, and is expensive. It is more meaningful to extend the service life of air compressor coolant.

After the air filter and oil filter of the air compressor are improved, not only the service life of the oil filter is prolonged, but also the service life of the oil fine separator filter element and the air compressor coolant. The average service life of the oil fine separator filter element and the air compressor coolant before the air compressor filter element transformation is about 4000h.

After the air compressor filter element is improved, the oil filter element of each unit has now exceeded 5000h, and there is no increase in the oil partial pressure difference or oil damage, which does not affect the air compressor power consumption and the quality of the subsequent air source; the air compressor coolant The use time also exceeds 5000h, the sampling analysis results all indicators are not exceeded, you can continue to use.

4 Conclusion

From the perspective of the annual cost before and after the improvement of the vulnerable spare parts of the air compressor, ensuring that the air filter element is not damaged can extend the service life of the oil, oil and oil filter, and protect the parts in the unit from damage, and the air filter is cheap. The replacement cycle is fixed to be replaced after 1500h operation, so the maintenance cost of the air filter is relatively fixed. By reviewing the maintenance records before the improvement, the average number of replacement parts and the cost of each equipment per year, it is found that after the improvement, the service life of the oil filter is calculated at 3500h, and the oil and coolant are calculated at the service life of 5000h. The frequency and cost, including one replacement The coolant needs half a bucket.

　　 The annual maintenance cost of the air compressor before the transformation was 318706.2 yuan, and the annual maintenance cost of the air compressor after the transformation was 208,143 yuan. After calculating the air compressor filter element improvement, the equipment is expected to save 110563.2 yuan in maintenance costs per year.