Large air compressor units are widely used in biological fermentation, petrochemical, air separation and other industries. The above industries have one thing in common, which is usually continuous production. Therefore, the safe and stable operation of air compressor units is very important. Especially for large-scale air compressor units, once an abnormal shutdown occurs, it is difficult to resume operation of the unit in a short period of time. If there are insufficient spare units, it will inevitably cause immeasurable losses to the company's production. This article combines the reality of the production line to discuss with colleagues the safe and stable operation of large air compressors.
1. The key role of large air compressor units in production
Large air compressor units have the advantages of large flow, high energy efficiency, and high degree of automation compared with ordinary small and medium-sized units. They are usually managed as key devices in enterprises. In view of the fact that abnormal shutdown of large equipment will have a serious impact on the safe production and economic operation of the enterprise, its continuous operation cycle is often listed as an important assessment indicator for equipment managers and equipment operation departments. For example, a biological fermentation enterprise has more than ten air compressors. Through technological upgrades in the past two years, two new large and efficient centrifugal air compressors have been added to replace the previous small and medium-sized air compressors. Judging from actual operation, large-scale air compressors save nearly 10 million yuan in electricity annually. Ensuring the long-term and stable operation of high-efficiency air compressor units is conducive to reducing the company's operating costs. Excluding the annual preventive maintenance time of the air compressor, it is necessary to ensure the safe and stable operation of the air compressor throughout the year. Once an abnormal shutdown occurs, the equipment management department and equipment usage department will be assessed.
In addition, large air compressor units play an important role in the safe supply of air systems. Once a large air compressor shuts down abnormally, it will directly cause the air supply indicators to be unable to meet production needs, which will bring greater safety and quality risks. . Therefore, the safe and stable operation of large air compressor units directly affects the company's production and operation results.
2. Factors affecting the safe operation of large air compressor units
Analyze the factors affecting the safe operation of large air compressors from five aspects: people, machines, materials, methods and environment.
Human aspects: First, the safety training of job personnel (operators and maintenance and repair personnel) is not in place, resulting in misoperation or the unit maintains and repairs online instruments without authorization in the running state without removing the chain protection, causing unit abnormalities. Shutdown; second, non-resident personnel mistakenly control the air source of the unit’s on-site electrical facilities or instruments, causing the unit to shut down abnormally.
Materials used: As a rotating machinery, large air compressor units have very critical lubrication. The use of inferior lubricating oil during unit maintenance will cause poor
lubrication of the unit and burnt bearings and rotors; in addition, the quality of spare parts such as bearings, rotor components, filters, etc. will also seriously affect the safe
operation cycle of the air compressor.
System guarantee: Inadequate operation, maintenance and inspection procedures for air compressors, and lack of safety management systems for large equipment will
have a direct impact on the safe operation of air compressor units.
External environment: The cooling water temperature of the unit is too high, the flow is insufficient or interrupted, which will cause the efficiency of the air compressor to
decrease or abnormal shutdown; the air pipe network pressure is too high, causing the unit to surge, vent or shut down; in addition, the fluctuation of the power grid also
affects the air conditioner. Common reasons for safe press operation.
3. Measures to ensure safe and stable operation of air compressor units
1. Strengthen safe operation training for employees on the job, improve employees’ safe operation skills and emergency response capabilities, and reduce operating
errors; strengthen maintenance management of maintenance personnel, and correct and adjust parameters involving unit chain protection after completing the chain
protection removal procedures. operations to reduce downtime during unit maintenance. After the unit maintenance is completed, the chain protection function is restored
in a timely manner; in order to reduce the safety risks brought by outsiders to the unit, the air compressor position is listed as a key part of the company for control, and
access control is set up at the entrance and exit of the factory. and other measures to prevent and control outsiders from entering the air compressor plant at will.
2. The installation plan of the air compressor unit should be designed by a formal design institute, and a construction team with similar installation experience of large air
compressor units should be selected for construction. Standardized design and installation are prerequisites for the safe and stable operation of air compressors. Key
operating indicators are a direct reflection of the operating status of the air compressor unit. The first is to ensure that the indicators are monitored in real time, the second
is to ensure accurate data transmission, and the third is to prevent artificial lifting of the inherent chain protection of the unit.
3. During the maintenance process of the unit, when purchasing key components such as lubricating oil, bearings, rotor parts, and oil filters, try to purchase them directly
from the air compressor manufacturer to reduce the impact of the influx of counterfeit and shoddy products on the safe operation of the unit.
4. In order to ensure the long-term stable operation of the unit, as the equipment operation department, rules and regulations should be formulated to ensure the safe
operation of the air compressor. The first is to establish and improve air compressor safety operating procedures, air compressor maintenance procedures, large equipment
inspection systems, etc., so that there are laws to follow; the second is to strengthen the inspection system management, and it is recommended to establish three-level
inspections of departments, workshops, and teams. Establish an inspection system to clarify the frequency of inspections, content and standards of inspections, rewards
and punishments, etc., so that problems can be discovered and dealt with early.
5. Optimize the external conditions for stable operation of the unit. The first is to ensure the stable operation of the cooling water system and meet the water quality,
flow rate and temperature of the cooling water required by the air compressor; the second is to strengthen production scheduling and coordination, stabilize the air
balance of the air pipe network, and avoid sudden high and low air pressures. On-site; third, do a good job in the management of power transformation and distribution
facilities to avoid abnormal power outages or voltage fluctuations.
It can be seen that there are many factors that affect the safe and stable operation of air compressor units, which requires equipment managers and equipment operators
to conduct comprehensive management and control of large air compressor units from design, installation to operation, maintenance, and repairs. . After all, only with
ideological attention and the implementation of various guarantee measures can the safe and reliable operation of large air compressor units be ensured.