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    Screw compressor oil system workflow and common faults

    Screw compressor oil system workflow and common faults 1. Working process of screw refrigeration unit The working process of screw refrigeration unit can be divided into refrigerant process and oil system process. Friends who are familiar with screw unit all know that screw refrigeration unit failure often occurs in the oil system. Today we will focus on the screw unit oil system and oil circuit Common system faults. The refrigerant flow of the screw unit is: evaporator ~ intake pipe ~ intake stop valve ~ suction filter ~ compressor ~ exhaust pipe ~ oil separator ~ exhaust stop valve ~ condenser ~ drying filter ~ throttle valve ~ Evaporator. 　　Screw unit oil circuit flow is: oil separator ~ oil cooler ~ oil coarse filter ~ oil pump ~ essential oil filter ~ compressor ~ oil separator. 2. Brief introduction of the main oil system components: 　　 Oil separator: Because the high-pressure steam discharged from the screw compressor contains a large amount of freezing oil, it is necessary to have an efficient oil separator to prevent the heat transfer efficiency from decreasing and reduce the consumption of freezing oil. Due to the injection of a large amount of lubricating oil in the screw refrigeration compressor, the mixture of refrigerant vapor and oil is discharged from the compressor exhaust port. If the gas and oil mixture enters the heat exchanger such as condenser and evaporator, an oil film will be formed on the wall surface of the heat exchanger because the oil does not evaporate, which greatly reduces the heat transfer effect and the cooling efficiency. For this reason, the oil in the refrigerant must be separated in the oil separator before entering the system. Precautions: 　　 Oil level control: between two sight glasses; 　　 The function of the oil return operation oil heater in the front and rear parts of the oil separation filter; 　　 If the oil filter element is seriously polluted, it will increase the exhaust resistance, increase the power consumption, and reduce the efficiency. It should be replaced; 　　Oil cooler: The lubricating oil separated by the oil component increases the temperature (close to the exhaust temperature) due to the absorption of frictional heat and the heat of the gas. The normal use temperature of lubricating oil is 30～60℃. If the oil temperature is too high, the viscosity will decrease, which will weaken the sealing effect, increase the internal leakage, and reduce the efficiency of the compressor. Therefore, the lubricating oil must be cooled before it can be recycled. The oil cooler is used to cool the oil. 　　General oil cooler adopts water cooling method. It is easy to clean the waterway by taking oil to the shell side and water to the tube side. 　　 Advantages: The system is simple, the oil temperature can be reduced to a relatively low temperature (depending on the water temperature); 　　 Disadvantages: Water-side piping is easy to corrode. Working fluid cooling. 　　Crude oil filter: To protect the normal operation of the oil pump, impurities are filtered through the crude oil filter before the lubricating oil enters the oil pump. The filter is composed of a shell and a metal filter screen. After the initial operation, the cleanliness of the crude oil filter should be checked, and the filter screen should be regularly dismantled according to the system cleanliness. You can use gasoline or kerosene to clean the filter, and blow it with dry air to continue using it. Essential oil filter: The essential oil filter is also composed of a housing and a filter net. It is installed after the oil pump and before the oil distributor to filter the fine particles in the oil to protect the compressor rotor and shaft seal. In order to filter out fine metal abrasive debris, permanent magnets are installed in the filter screen. The filter screen of the essential oil filter is relatively fine, which is easy to be polluted and increase the resistance. When the pressure drop of oil flowing through the essential oil filter exceeds 0.05～0.1Mpa, the fine filter should be cleaned or replaced. The unit is equipped with differential pressure protection before and after the fine filter, and the set value is 0.1Mpa. Oil flow switch: The oil flow switch is a flow switch installed in the pipeline of the oil system. It is used to monitor the flow state of the refrigeration oil in real time. Once the cooling oil stops flowing, or if it is too low for a long time, the oil flow switch will send an alarm signal to Central control room, so that the central control room can deal with it in time to avoid accidents. In order to ensure that the working temperature of the unit is within a reasonable range. When the cooling oil system fails, if the oil circulation stops, it will cause the temperature of the unit to rise, affecting the normal operation of the unit, and seriously causing the unit to burn out. 　　 Differential pressure switch: The differential pressure switch is a control switch, which is a type of switch that controls the switch to close or open based on the pressure difference between the components and the electrical signal for information transmission. In general, the pressure difference between the two pipelines is used to send out electrical signals. When the pressure difference at the two ends of the oil circuit system increases (or decreases) and exceeds the setting value of the controller, a signal is sent to control the directional valve or Monitor the lubrication system. 　　Oil viewing mirror: The role of oil viewing mirror and sight glass is similar, but it can help to judge the condition of refrigeration oil in the system, so that you can know whether there is a problem with the oil circuit system in advance. The main body of the oil sight glass is made of brass, and the two ends are connected with welded copper pipes and pipelines, or with threads and pipes, and they are also directly installed on the pipelines or on the filter drier. 　　 Refrigerating oil replacement cycle: 　　 Generally check or replace the lubricating oil every 10,000 hours of operation. After the first operation, it is recommended to replace the lubricating oil and clean the oil filter after 2500 hours Note: The operation period is calculated based on 16 hours of operation per day. 　　 Third, the screw unit operation failure handling: 　　 Oil circuit problem: The oil circuit is mainly reflected in the quality, cleanliness, oil return temperature and other lubricating oils in the screw compressor refrigeration system. The main functions are lubrication, cooling, and sealing. 　　 The temperature of the oil return affects the service life of the screw compressor to a great extent. The recommended operating temperature is generally between 40 and 60 ℃, and some manufacturers have also marked 70 ℃ or 80 ℃. Excessively high oil temperature will cause oil coking and destroy the formation of oil film. The oil temperature also affects the exhaust temperature and thus the compression ratio, so please pay attention to adjust when selecting the oil temperature. Cleanliness of oil: The cleanliness of oil is also the cleanliness of the system. Maintaining cleanliness is the main feature of the screw machine. Screw compressors are not equivalent to piston compressors. Due to structural reasons, the cleanliness of the system requires more than the piston machine. high. Many failure types of screw compressors are entangled in several aspects, such as: lubrication failure caused by oil shortage, the bearing is stuck, the rotor is stuck, and the compressor motor is blocked, the compressor meets abnormally high, and the motor burns out . And why is there a lack of oil or lubrication failure? In fact, it is mostly caused by the exhaust gas temperature being too high and liquid blow. 　　Oil boiling during start-up or operation: This fault belongs to compressor liquid intake, or there is too much refrigerant in the lubricating oil. Please adjust the throttle mechanism to check whether the refrigerant is overcharged. 　　 Insufficient or too high oil level: Insufficient should consider whether it is an oil failure, insufficient fuel supply, and difficulty in returning oil to the evaporator. Pay attention to whether there is no liquid level in the reservoir during maintenance, and consider the failure of the throttle mechanism or the unreasonable installation. If it is too high, it should be considered that the oil filter is blocked and the refrigerant is mixed into the oil. 　　 Exhaust gas temperature is too high: There are many factors of high exhaust gas temperature, mainly to consider too much or too little refrigerant, too high intake heat, unstable operating conditions, etc. 　　 Inspiratory pressure is low or fluctuating: the low intake pressure is mainly manifested as the lack of refrigerant, the adjustment of the throttle mechanism, the condensation temperature is high, the liquid blow, etc.

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