Key points of air compressor management

The management of air compressors needs to be combined with daily maintenance, troubleshooting, energy efficiency optimization and safety regulations. The following are carried out from 12 core dimensions:

1. Daily maintenance and cleaning

1. environmental management
   • Keep the machine room dry and ventilated, control the temperature at 0~40℃, and the humidity ≤70%, to avoid the entry of dust and corrosive gases.
   • Clean up dust on the equipment surface and heat outlet every day to prevent overheating caused by poor heat dissipation.
2. filter replacement
   • air cleaner: Check every 500 hours, shorten it to 200 hours for replacement if the pollution is serious, to prevent dust from entering the compression chamber.
   • oil filter: Replace it 300 hours for the first time after operation, and replace it every 2000 hours thereafter to prevent lubricating oil pollution.
3. Lubricating oil management
   • Select special compressor oil, change the oil for the first 500 hours, and then every 4000 hours or every year (annual operation is less than 4000 hours).
   • Keep the oil level at 1/2 to 2/3 of the oil mark to avoid lubrication failure due to insufficient oil amount or excessive emulsification.
4. Belt and hose inspection
   • Check the tension of the drive belt every month and adjust or replace the worn belt every 2000 hours.
   • Regularly check the hose for aging and cracking to avoid pressure drop caused by leakage.

2. Regular maintenance and maintenance

1. Three-level maintenance system
   • Level 1 maintenance (daily): Check the oil level and leak points, and clean the equipment surface.
   • Level 2 maintenance (every 800 hours): Clean the air valve and lubricating oil filter, and check the clearance of the moving mechanism.
   • Level 3 maintenance (annual): Test safety valves and pressure gauges, verify pressure switches, and comprehensively inspect seals.
2. overhaul period
   • Screw machines are overhauled every 20,000 to 26,000 hours, and piston machines are overhauled every 1400 hours, including the maintenance of core components such as crankshafts, connecting rods, and piston rings.

3. Troubleshooting and handling

1. common fault diagnosis
   • Low exhaust pressure: Check leakage points (pipelines, safety valves), clean filter elements, and adjust loading pressure.
   • Overheating shutdown: Clean the cooler, check the amount of lubricating oil, and check fan faults.
   • Excessive fuel consumption: Check whether the return pipe is blocked and adjust the oil separator pressure.
2. emergency treatment
   • Sudden abnormal sound or vibration: Immediately stop the car and check the crankshaft, connecting rod, piston and other moving parts.
   • Air leakage or abnormal pressure: Close the intake valve and check for faults in safety valves and pressure gauges.

4. Energy efficiency management

1. frequency conversion transformation
   • Upgrade the power frequency machine to a variable frequency air compressor, adjust the speed as needed, and save electricity by 30% to 50%.
2. waste heat recovery
   • Compression heat or waste heat is used to produce hot water for bathhouses, heating, etc., and the energy utilization rate is increased by 15% to 20%.
3. Leak control
   • Using an ultrasonic detector to locate the leak point can reduce energy consumption by 10% to 20% after repair.

V. Safety specifications

1. pressure control
   • The safety valve is calibrated every year, and the pressure setting does not exceed 10% of the rated value; the pressure gauge is calibrated every six months, and the error exceeds ±1%, and it will be replaced immediately.
2. operation specifications
   • Overpressure operation is prohibited. The air storage tank is hydraulically tested every 3 years, and the test pressure is 1.5 times the rated value.
   • Check cooling water and lubricating oil before starting, and maintenance under pressure is strictly prohibited.
3. protection facilities
   • Install protective covers on rotating parts, wear earplugs in areas exceeding noise levels, and are equipped with emergency stop buttons.

6. Long-term idle management

• Add anti-rust oil before sealing up, and start idling for 1 hour every month; replace lubricating oil and check seals when re-using.

VII. Compliance management

• Follow GB/T 3811-2008 “Crane Design Code” and other standards, and regularly submit special equipment test reports.

By systematically implementing the above management points, the operating efficiency of the air compressor can be improved by more than 30%, the equipment life can be extended to 8 to 10 years, and the failure rate can be reduced by 40%. Digital tools (such as vibration monitoring and energy consumption analysis software) are recommended to achieve predictive maintenance to further optimize management effects.