How to prevent and prevent fire and explosion from oil lubricated air compressors?

Fire and explosion prevention of oil-lubricated air compressors require a full-cycle prevention and control system, covering the three core aspects of equipment selection, operation management, and emergency response. The following are the specific implementation specifications:

1. Equipment intrinsically safe design

1. Protection level matching: During the type selection stage, it is necessary to confirm that the protection level of electrical components such as motors and control cabinets is not less than IP54. The cable introduction device must use explosion-proof flexible connecting pipes to prevent electric sparks from igniting lubricating oil vapor.
2. Oil and gas separation optimization: Equipped with a two-stage oil and gas separation system to ensure that the residual oil content is ≤3ppm and reduce the risk of accumulation of combustibles. The separator body should be equipped with a temperature sensor, and the temperature should be exceeded by 115℃ automatically.
3. Explosion relief device configuration: Install bursting discs in closed cavities such as crankcase and oil and gas cylinders, and set the bursting pressure to 1.7 times the working pressure to ensure directional pressure relief in case of abnormal pressure increase.

2. Operating environment management and control

1. ventilation system design: Install independent exhaust system, ventilation frequency ≥12 times/hour, ensure that the oil and gas concentration is lower than 25% of the lower explosive limit. Explosion-proof fan shall be set at exhaust outlet and interlocked with compressor for start and stop.
2. Electrostatic elimination measures: All metal pipe flange jumper resistance <0.03Ω, compressed air pipe end installed ion wind rod, real-time neutralization of electrostatic charge.
3. Fire ban area management: A 10-meter range around the equipment is designated as a no-fire zone, a combustible gas detector is equipped, the alarm threshold is set to 30% of the lower explosion limit, and accident exhaust is triggered in conjunction.

3. Lubricating system maintenance

1. Oil selection specifications: Use synthetic compressor oil with flash point ≥215℃, regularly test kinematic viscosity (85-95mm²/s at 40℃) and oxidation stability (TOST>3000h), and the oil replacement cycle shall not exceed 2500 hours.
2. Oil path cleaning and maintenance: Replace the oil filter synchronously every time the oil is changed, and use a special cleaning agent to cycle the oil system to ensure that the cleanliness reaches the NAS 7 standard.
3. Intelligent oil level monitoring: Equipped with an electronic oil level gauge and set a double limit alarm. When the oil level is less than 1/3, the load will be automatically reduced and the operation will be forced to stop when the oil level is less than 1/5.

4. Handling of abnormal working conditions

1. Over-temperature interlock protection: Set three-level temperature protection:
   • Level 1 alarm (105℃): Start backup cooling fan
   • Level 2 alarm (110℃): Automatic switch to bypass cooling
   • Level 3 alarm (115℃): Emergency shutdown and power cut off
2. Leak Incident Response Service: When a lubricating oil leak is found, start it immediately:
   • Area isolation (radius of 5 meters)
   • Positive pressure ventilation (air changes ≥15 times/hour)
   • Adsorption treatment (use a special oil-absorbing felt to cover the leak point)
3. Fire fighting procedures：
   • Initial fire: Use a Class D dry powder fire extinguisher to fight
   • Spread stage: Start the rain extinguishing system (design water spray intensity ≥6L/min·m²)
   • System isolation: Emergency shut-off valve closes the air supply pipe within 30 seconds

5. Preventive maintenance system

1. Carbon deposit cleaning cycle：
   • The valve block and pipes are soaked and cleaned with special cleaning agent every 500 hours
   • The cooler is chemically cleaned every 2000 hours
   • The compression chamber is disassembled every 8000 hours
2. vibration monitoring and analysis: Install a vibration sensor and establish a spectrum database. When the frequency 1 vibration speed is greater than 4.5mm/s, focus on checking the meshing status of bearings and gears.
3. Pressure pulsation detection: Use a pressure sensor to monitor exhaust pulse. When the amplitude exceeds 15% of the average pressure, check the resonance frequency of the pipeline and add an expansion joint.

6. Personnel qualification management

1. Operation certification system：
   • Basic operation certificate (theoretical + practical operation assessment)
   • Emergency response certificate (simulated fault handling)
   • Safety administrator certificate (risk assessment capability certification)
2. Special training content：
   • Physical and chemical properties and combustion mechanism of oil
   • Fire protection spacing requirements (equipment and buildings ≥3 meters)
   • Principle of selection for explosion-proof electrical (applicability of Ex dⅡB T4 level)

Through the coordinated implementation of the above technologies and management measures, the risk of fire and explosion of oil-lubricated air compressors can be reduced by more than 90%. It is recommended to establish equipment health records, use thermal imaging instruments to regularly detect high temperature points, and combine predictive maintenance with oil analysis technology to build an intrinsically safe compressed air supply system.