There are many reasons for the low efficiency of air compressors, the common ones are: increase in suction temperature at any level, cooler leakage, decrease in grid frequency or voltage, blockage or increase in resistance of the compressor intercooler, gas leakage due to poor sealing, blockage or increase in resistance of the air filter, blockage or increase in resistance of the pipeline of the small air separation unit.
Clogged air filter, reduced suction pressure affecting exhaust volume
The design inhalation pressure of the compressor is -0.199kpa and the actual inhalation pressure at the time of the fault is -4kpa. This phenomenon indicates that there is a slightly greater resistance to the inlet filter of the compressor, but the inhalation pressure is not sufficient to cause such a significant drop in the exhaust volume of the compressor.
Compressor intercooler blockage or increased resistance
As this type of compressor is not equipped with a special resistance meter, the technician uses a precision transmitter to detect the inlet and exhaust pressure of each stage of the compressor and then calculates the resistance of each intercooler, and the calculated resistance of each intercooler is within the design range.
Poor sealing, causing gas leakage
Gas leaks include internal and external leaks. Typical manifestations when internal leakage occurs are a change in compression ratio at all levels, an increase in pressure ratio at the low pressure level and a decrease in pressure ratio at the high pressure machine. External leakage can be divided into: leakage from the venting valve; leakage from the pipeline connection; leakage from the air seal of the compressor shaft. The 3 parts that may cause external leakage were checked and there were no leakage points. The pressure ratio of each compression stage was calculated to be normal according to the air compressor operation records.
For the first time, Dear Air Separation has reduced the discharge pressure of an air compressor from the traditional 0.52 MPaG to 0.412 MPaG. The ultra-low pressure and energy efficient air separation can save 15% of energy consumption.
