Application of oil-free screw air compressor in Changbei CPF

Application of Oil-free Screw Air Compressor of Inner Mongolia Petrochemical in Changbei CPF Zhang Zhanping, Yu Zhi, Wang Hudan (1. Changqing Oilfield Company Gas Production Plant 2; 2. Changqing Oilfield Company Changbei Natural Gas Development Project Manager, Shaanxi Yulin Problems and Improvements, Common Faults and Treatments 1 Changbei CPF Air Compressor System Introduction Changbei Natural Gas Treatment Plant (CPF) sets 2 sets of CompAir D150 -08A air compressors, 1 with 1 preparation, and the processing capacity is: 25m3/min, exhaust pressure 0l8MPa, ambient temperature requirement 0-oil capacity: 40L, can be used to purify air non-purified air and compressed air for nitrogen production. Also set up a 58m3 non-purified air storage tank and 1 The air compressed by the purified air storage tank with 58m3 is dried by the non-heating regenerative dryer and then enters the purified air storage tank. When the emergency power is cut off, the non-purified air storage tank can be changed to the instrument purifying air storage tank to purify the air. The non-purified air storage tank capacity can be It can meet the air supply volume of the instrument 48 minutes after the power failure of the first phase of the plant and the air supply of the instrument 16 minutes after the second power failure.

1. 1 Air compressor principle and unit configuration The principle of screw compressor is to use the male and female rotors to mesh with each other and rotate at high speed to produce volume change, so as to obtain compressed air of rated pressure.

The air compression process is: air enters from the suction port, through the suction filter, the suction muffler and the suction regulator to the first level of air. For those occasions that can continue to operate after the instantaneous power failure, in addition to selecting the inverter of the appropriate price, the speed reduction ratio of the load motor should be considered in advance. 3.2 The fault caused by the inverter 3. The fault caused by the parameter setting should pay more attention to the motor. Parameters, inverter control mode and startup mode settings, etc. If a parameter setting fault occurs, the parameters can be modified according to the fault code or product manual. If necessary, the factory value can be restored and reset.

3.2.2 Overcurrent and overload If the inverter is powered on, it will report overcurrent fault. It may be that the rectifier bridge or inverter tube is damaged and needs to be replaced. If the motor is removed and no alarm is issued, there may be an open circuit between the inverter and the motor. If it is in operation, mechanical jamming and heavy load, acceleration time setting is too short or sudden load may cause overcurrent, it should be checked one by one from the above possibilities.

3.2.3 Overvoltage and Undervoltage Overvoltage are mainly caused by the motor dragging large inertia load or multi-motor dragging the same load due to uneven load distribution; undervoltage end compression, compressed air enters intercooler and moisture The condensed water formed by the separator in the intercooler is periodically discharged through the electromagnetic valve, and the cooled compressed air is compressed into the air having the final pressure through the second-stage air end, and the compressed air from the second-stage air end passes through the muffler, and the non-return The valve, aftercooler, and water vapor separator are output to the off-machine drying system. The check valve is used to prevent the compressor from being unloaded. The entire unit is controlled by the SureScan control and management system. The system has a simple operation interface. It has the functions of operating parameter storage password protection, instant alarm protection and emergency stop. It does not accept the artificial parameter setting beyond the control range. When the compressed air pressure of the pipe network rises to the unloading pressure of the unit, the automatic controller unloads the components such as the solenoid valve according to the instruction. , the compressor is unloaded during the unloading of the compressor, the air between the check valve and the second stage air end After the noise is reduced by the muffler, the air is discharged into the atmosphere. At this time, the displacement of the unit is 0%. When the pressure of the pipe network drops to the loading pressure of the unit, the automatic controller commands the loading of the solenoid valve and other components to restore the original gas flow. The unit is loaded and operated, and the displacement is quickly reached 100%. The unit does not need to manually adjust the air volume. The power supply voltage is too low or the voltage on the DC bus is too low or the undervoltage detection component is faulty. Check whether the power supply voltage is normal and replace the fault. Component or repair the corresponding detection circuit.

3.24 Overheat faults should pay attention to the ambient temperature of the inverter, try to ventilate, check the inverter fan and so on.

4 Conclusion Different manufacturers have slightly different operating methods for the inverter, but the working mode mainly includes the panel operation mode and the external operation mode. Due to the limited space, it is not detailed here to use the inverter reasonably. The manual provided by the manufacturer has accumulated more experience in practical applications.

Wang Tingcai. Principle and application of the inverter. Beijing: Mechanical Industry Press.

He Chao. AC frequency control technology. Beijing: Beijing University of Aeronautics and Astronautics Press.

The application of 15 sheets of the oil-free screw air compressor in the Changbei CPF compressed air system is protected by two safety valves. One safety valve is installed on the water gas separator between the intercooler and the second stage air end, and the other is installed between the second stage water gas separator and the air compressor exhaust port if the two points A pressure becomes too high and the safety valve opens to vent the compressed air to the atmosphere. The temperature of the compressed air is monitored by a temperature Sensor, which is installed at the first stage air end exhaust port, the second stage air end suction port and the exhaust port, and the exhaust pipe. 1. Air filter; 2 intake air adjustment 3. Stage air end; 4. Silencer; 5. Intercooler; 6. Water gas separator; 7. Secondary air end; 8. Exhaust muffler; 9. Check valve; Cooler; 11. Cooling fan; 19. Stop valve; 20. Drain solenoid valve; 21. Manual drain valve compressed air flow 1.2 Oil-free screw air compressor Features 1 Compact structure, small footprint, energy saving, automation High degree, low noise, etc. 2 Oil-free screw air compressor has less wearing parts, simple maintenance, high reliability and stability. 3 The cooling system adopts air cooling to eliminate various troubles caused by water cooling. 4 It can provide the best cooling effect. The reliability of the compressor is guaranteed, the compressed air temperature is low, and the load on the dryer is reduced. 5 The motor also has a cooling system to extend the life of the motor itself. 6 It is easy to operate and maintain. The operator does not have to go through long-term professional training to achieve unattended operation. 7The motor-driven oil pump is used to provide full lubrication before starting and during the shutdown phase, prolonging the service life of the compression assembly and bearing. 8 Two-stage air inlet filter prevents airborne particles from entering the compression unit, and the outer casing filter can extend the filter element. Lifetime, while ensuring maximum cooling for the motor and cooler 2 Maintenance and maintenance of the screw air compressor Since the commissioning in November 2006, the unit has performed well. Two units can meet the gas requirements of our factory. The gas pressure and flow rate are very stable. Because of the low temperature of the compressed gas, the drying effect is better. After several years of practice, it is found that to ensure the good operation of the unit, air cleanliness, cooling effect of the cooler, and cleanliness of the lubricating oil are the three main problems affecting the normal operation of the air compressor. The maintenance should pay attention to several aspects: 21 Purification and replacement of the air filter Because the Changbei natural gas processing plant is located in the northern part of Shaanxi Province, on the edge of the Maowusu Desert, the annual wind and sand is relatively large, the air filter is easy to block, and needs to be periodically purged and replaced, according to several years. Experience, the air filter needs to be inspected every two weeks and replaced every 8000h.

2. 2 Lubricating oil and oil filter cartridge replacement D150-08 air compressor uses ShellTurbo68 or FuchsRenolin AC68 lubricant, replace it every 8000h. Replace the oil filter cartridge every time you change the lubricating oil.

2. 3 Cooling fins cleaning D150-08 screw air compressor adopts air cooling. Due to the large wind and sand in the area where the Changbei natural gas processing plant is located, the cooling fins of the cooler are easy to cover the dust, affecting the cooling effect and finally causing the exhaust. The temperature or the temperature of the lubricating oil rises, the unit alarms, and then the shutdown is based on years of experience. The cooling fins need to be blown once a month. 3 Problems in the operation and improvement 3.1 Improvement of the cooling air passage The machine is in There were two problems at the beginning of the operation. First, there was a phenomenon that the secondary exhaust gas temperature was high and the machine was shut down. Second, when the equipment was switched in winter, the spare air compressor was cooled to the ambient temperature due to the long parking time. The press can not be started normally. After analysis, the reason for the high exhaust gas temperature is that the cooling effect is not prolonged. The cooling method of the first stage compressed air, the secondary compressed air and the lubricating oil are all air-cooled by the motor-driven fan, so it is guaranteed to be good. The cooling effect requires sufficient air-cooled heat exchange area, and sufficient air-cooled air flow rate sufficient air-cooled air flow rate requires the fan to have sufficient power. The cooling air has a sufficiently large passage. The cooling air passage of the air compressor is not air-loaded, and the passage area is small. Therefore, increasing the cooling air passage is the fundamental solution to the problem. The second problem is that to increase the temperature of the lubricating oil, it is required to have a higher room temperature. Therefore, it is considered to introduce a part of the high-temperature cooling air after heat exchange into the air compressor room to increase the room temperature in consideration of the winter and summer in the Yulin area. The temperature difference is large. In the summer, the ambient temperature is higher, and the cooling air after heat exchange enters the room, which will greatly increase the room temperature. The air is cooled by the high temperature air, and the cooling effect is not good, which is easy to cause the unit. High exhaust gas temperature shutdown Comprehensive analysis of the above problems, the cooling air duct has been completely improved, while increasing the cooling air passage, an opening is added to the passage wall, so that the cooling air after heat exchange can be discharged into the room, or It is discharged to the outside; at the same time, a regulating valve is installed at the opening of the passage wall to control the amount of cooling air entering the room and discharging outdoors. In the winter, open the valve, let some of the cooling air after heat exchange enter the room, increase the room temperature to increase the oil temperature of the standby machine, easy to start, part of it is directly discharged to the outside, and the valve opening degree can be adjusted according to the height of the room temperature. Meet the requirements of room temperature In the summer, close the regulating valve, and let the cooling air after heat exchange be discharged to the outside. After two years of operation, it is proved that the modified system works normally, there is no phenomenon that the exhaust gas temperature is high and the oil temperature is low and cannot be started. 3. 2 The muffler plug material is improved. The cleanliness of the air filter is affected by the surrounding environment. Larger, air compressor running! After more than a year later, I found that the air compressor 2 Inner Mongolia Petrochemical machine could not be loaded normally. The alarm was low in the middle pressure. It was suspected that the suction regulator was faulty. After careful inspection, it was found that the plug at the end of the silencer was missing. In the case of the air compressor, it was found that the plug has been trapped in a certain size, so it is judged that the plug at the end of the faulty compressor silencer is sucked into the silencer, and finally the plug in the downstream section of the silencer is found 5 After analysis, it is found that the material of the plug is aluminum, and the material of the silencer is steel. After the air compressor is running for a period of time, the plug of the silencer and its end becomes hot, because the expansion coefficient of steel is larger than that of aluminum, causing the silencer The plug hole at the end is relatively large, the aluminum plug is trapped in the silencer, the system is no longer sealed, and the intermediate pressure is not established. This requires the material with a larger expansion coefficient than steel. Finally, the coefficient of expansion is determined. Larger copper is a common material. The copper plug has been used for more than a year, and there is no situation where the plug is stuck. This also reminds the manufacturer that when designing, the thermal expansion coefficient of the material can be fully considered. 3.3 The pressure tube is increased at the secondary compression outlet of the compressor. At the beginning of the operation of the air compressor system, it was found that the air compressor was frequently loaded and unloaded, but at this time the pressure of the two storage tanks and the pipe network was still very high, and there was no set point pressure as low as the air compressor was loaded. The system flow of the compressor is that the compressed air after the second stage is dried by the dryer before entering the storage tank, and the pressure point of the screw compressor is automatically loaded and unloaded at the secondary compression outlet. When the pressure of the storage tank system is still high At the time, due to the sudden pressure relief during the regeneration of the dryer, the secondary compression outlet pressure is reduced (the single-flow valve at the outlet of the drying gas, the pressure of the tank system cannot be balanced here), when the secondary outlet pressure is low to the loading pressure At the time, the air compressor starts to load, but because the pressure of the secondary outlet and the dryer is low, the air compressor is just loaded, the secondary outlet pressure reaches the set value of the unloading, and the air compressor starts to be unloaded again. When the next time the dryer is regenerated, the loading situation occurs again. The frequent loading and unloading damages the unit greatly, which easily causes the suction regulator to malfunction. Because the compressor and the dryer are armored, it is not convenient to change the system flow to compression. After the air passes through the storage tank in the drier, it is decided to introduce the system pressure, that is, the pressure after the dryer, through the pressure pipe to the secondary compression outlet, so that the pressure at this point is always with the system.

3.4 Reasonable setting of water separator separator drainage time This screw air compressor is automatically loaded and unloaded. It is automatically loaded when the outlet pressure is less than the set value. When the outlet pressure is greater than a certain set value, the air compressor is found at the initial stage of automatic unloading operation. The loading time is longer, but compared with the air compressor processing capacity and the downstream air consumption, there is a big deviation between the two, indicating that some of the compressed air may leak. After careful investigation, it was found that the two gas-water separation gas of the air compressor has a long draining time, so that a part of the compressed air is discharged after the condensed water is discharged, so it is required to properly set the draining time according to the air in the Yulin area. In the actual situation where the humidity is relatively small, we have explored the drainage time to adapt to the local air characteristics, which not only reduces the waste of compressed air, but also does not cause the liquid to be dirty. 4 Common faults and treatment 4.1 The compressor cannot be loaded with air intake adjustment The faulty pressure sensor fails the solenoid valve and the computer board is faulty.

4.2 Oil temperature warning / tripping machine high ambient temperature, oil cooler heat transfer effect is poor oil level too high / low 4.3 oil pressure low oil level low, oil pump failure, pressure sensor failure, oil cooler internal blockage, oil filter blockage 4.4 Intermediate pressure alarm / tripping intermediate pressure sensor failure, secondary air end fault line or silencer leakage 4. 5 exhaust temperature alarm tripping high ambient temperature, insufficient cooling air, intermediate stage high pressure internal air flow resistance The temperature sensor is connected to the fault of the primary or secondary air terminal.

5 Summary Screw air compressors have been widely used in modern industry for their advancement and energy saving. The machine itself is also relatively stable, but since many of its accessories are not armored, it is necessary to have more stringent requirements in design. It also requires proper maintenance to ensure the normal operation of the equipment, improve the replacement cycle of parts, and reduce operating costs.

Wang Hao. Maintenance and troubleshooting of the GA22P2-10 screw compressor. Compressor Technology, 2007, (4).

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