4 Air compressor post-processing equipment
For factory compressor systems, a micro-heat regenerative dryer is used for post-processing; for bag dust removal, pneumatic ash removal and desulfurization systems Generally speaking, a cold dryer is used for post-processing.
4.1 Cold
4 Air compressor post-processing equipment
For factory compressor systems, the post-processing equipment Micro-heat regenerative dryer for treatment; for bag dust removal, pneumatic ash removal and desulfurization systems, cold dryer for post-treatment.
4.1 Use of refrigerated dryer
4.1.1 Inspection before starting the cold dryer
(1) All maintenance work is completed and the work ticket is canceled;
(2) Check that the motor wiring is intact and the voltage is normal;
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(3) Check that the oil level of the refrigeration compressor is around 2/3, and the oil quality is good;
(4) Check that all meters are complete and intact, and the high and low pressure values ??of the refrigerant are within 1.3MPa -1.5MPa;
(5) Check that the air pipeline is normal, the inlet pressure is not less than 0.6MPa, and the inlet air temperature is not greater than 40°C;
(6) Check the cooling water The pressure is 0.2-0.4MPa, and the water temperature is ≤32°C;
(7) The compressed air pipeline system must be purged before startup to prevent debris from entering the dryer and filter and affecting use.
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4.1.2 Operations before starting the cold dryer
(1) Open the cooling water inlet door of the cold dryer;
(2) Open the cooling water of the cold dryer Exit door;
(3) Open the automatic drain valve of the cold dryer;
(4) Open the automatic drain valve of the pre-filter of the cold dryer;
(5) Open the cold dryer drain valve and close it after draining the water;
(6) Open the cold dryer inlet butterfly valve;
(7) Open the cold dryer outlet butterfly valve;
(8) Turn on the control power supply of the cold dryer.
4.1.3 Start-up operation of the cold dryer
(1) Close the air switch and connect the Turn on the power and check that the power indicator light is on;
(2) Press the start button, check that the operation indicator light is on and the compressor starts to run;
(3) Check that the compressor is operating normally and the refrigerant The high and low pressure gauges indicate normal;
(4) After checking that everything is normal, start the air compressor to supply air to the cold dryer;
(5) After observing for 5-10 minutes, cool down the The air treated by the dryer can meet the usage requirements. At this time, the refrigerant low-pressure gauge indicates between 0.3-0.5 MPa, and the refrigerant high-pressure gauge indicates between 1.3-1.5 MPa.
4.1.4 Cold dryer Shutdown operation
(1) Check if the corresponding air compressor is shut down;
(2) Press the stop button to stop the cold dryer;
(3) Disconnect the control power of the cold dryer;
(4) Close the cooling water inlet and outlet door of the cold dryer;
(5) Open the drain valve of the cold dryer and drain it Close after water;
(6) Close the inlet butterfly valve of the refrigerated dryer;
(7) Close the outlet butterfly valve of the refrigerated dryer.
4.1.5 Cold drying Operation and maintenance of the machine
(1) Check that the condensation pressure is within the range of 1.3~1.5MPa;
(2) Check that the evaporation pressure is between 0.36~0.4MPa;
(3) Open the sewage valve of the cold dryer every 2 hours to drain the sewage;
(4) Check that the air source pressure is not less than 0.6MPa;
(5) Frequent operation is strictly prohibited Start and stop the refrigerator, and keep an interval of at least 3 minutes each time;
(6) Check that the refrigerator runs smoothly and without noise;
(7) Check the oil filter, When the pressure drop exceeds 0.05MPa, the filter element should be replaced;
(8) The automatic drainer operates normally.
4.1.6 Causes and solutions of refrigerated dryer failures
Troubleshooting the cause of the serial number phenomenon
1 The condensation pressure is too high and there is a large amount of non-condensable gas venting in the system
The cooling water valve or water volume regulating valve is not open. Open the valve that is not open.
The water volume is too small or the water temperature is too high. Take measures to increase water and cool down the water.
The quality of the cooling water is poor and the condenser tube is seriously knotted. Clean the cooler
If there is too much Freon, let it go properly
A certain valve on the compressor outlet pipe has a small opening and fully open the valve
Thermal expansion valve hot air Improper adjustment of the bypass valve and readjust it
2 The condensing pressure is too low The cooling water temperature is too low and the water volume is too large Adjust the water volume
Insufficient Freon Add more
3 Evaporation pressure The opening of the hot gas bypass valve is too high. Adjust the opening correctly.
Excessive Freon should be properly discharged
Treat excessive air volume and take measures to reduce it
Thermal expansion There is something wrong with the valve. For example, the temperature sensor bulb is not tight. Check the expansion valve temperature bulb.
The expansion valve opening is too large. Adjust the appropriate opening.
4. The evaporation pressure is too low. The bypass valve opening is too low. Adjust the bypass valve if it is too small
There is something wrong with the expansion valve, such as the opening is too small or blocked, etc. Check and adjust the expansion valve
The opening of a certain valve in the compressor inlet pipeline is too small and fully open. Valve
If the suction filter is clogged, clean or replace the filter element
If the load is small, contact the relevant unit
5 The compressor cannot start or stops immediately after starting and the power supply is not connected. Or the fuse is broken. Check the circuit.
Low voltage. Check the voltage and notify relevant personnel
Improper adjustment of high and low voltage controllers
A certain valve on the compressor outlet pipeline Not open. Open the valve that is not open.
The solenoid valve is faulty and does not open. Check, repair or replace
6. The compressor makes noise and sucks in liquid Freon. Find out the cause, such as whether to add fluoride
Improper
Inhalation of oil and Freon foam may be due to insufficient heating time of the crankcase oil
Disassembly and inspection of compressor mechanical failure
7 Air inlet and outlet pressure
If the difference is large and the inlet pressure is low, increase the pressure
If the pipeline resistance is large, improve the pipeline, such as increasing the pipe diameter
The air volume exceeds, the flow rate is large, and the resistance is large Reduce gas volume
Select a smaller equipment and change the model
Drain water from the equipment
The evaporator temperature is too low and the water freezes. Adjust the bypass valve to increase the evaporation pressure.
The air system is too dirty and there is too much dirt to clean
The pre-filter is clogged and the filter element is replaced
The air pipeline is blocked, such as the valve is not open
< p>Or the opening is not enough, check the pipeline8 The outlet of the dryer is empty
The gas dew point temperature is high, lack of Freon replenishment
The condensation pressure is too high, see 1.
There is air discharge in the system
If the load is too large, ask the relevant personnel to adjust the load
The displacement of the refrigeration compressor has decreased and the compressor must be inspected
< p>The air outlet temperature is too high, try to lower the temperatureThe evaporation pressure is too high, see 3 items
The air pressure is very low, increase the pressure
Condensate water is not discharged, check the apricot Automatic drainage device and Y
type filter
4.2 Use of micro-thermal regeneration adsorption compressed air dryer
4.2.1 Equipment specifications Technical parameters Name Technology Parameter value
Rated gas processing capacity Nm/min 1-250
Inlet pressure MPa 0.8
Pressure drop MPa ≤0.02
Inlet temperature ℃ ≤50
Imported oil content mg/m3 <0.5
Finished gas dew point ℃ - 40 (at normal temperature)
Regeneration gas consumption % ≤6 < /p>
Desiccant fine-porous spherical activated alumina (Φ4-Φ8) molecular sieve
Regeneration method: micro-heat regeneration temperature 120-150℃
Working method: two adsorption tubes alternate Continuous work,
Period: 120-360min
Operation mode ADH computer controller fully automatic control
Power supply 380V/5
0Hz
4.2.2 Use
(1) Start the air compressor first, and when the dryer air inlet pressure is >0.5MPa, send power to the ADH controller (first close the control The control power supply in the box, and then turn on the heater power supply), the equipment will start running. When shutting down, just turn off the ADH controller power supply (first turn off the heater power supply, and then turn off the controller power supply).
(2) If the heatless operation mode is used, the heater power can be disconnected, the switch in the controller is placed in the heatless position, and the power can be turned back on again.
(3) The compressed air without opening the dryer can also be sent to the point of use through the dryer (the two towers are drying and adsorbing at the same time), but the time should not be too long.
(4) It will automatically exchange after each power outage and restart. Working tower can avoid repeated use of one tower.
(5) When the heating part fails, it will automatically switch to non-heat operation mode and wait for repair.
4.2.4 Failure Treatment
(1) When the operating parameters of the drying system remain unchanged but the dew point of the dry air does not reach -40°C, it indicates that the desiccant has failed and needs to be replaced.
(2) When the regenerated adsorption tube discharges exhaust gas, its pressure is <0.05Mpa. If the pressure exceeds this value, remove the muffler to clean the dust, replace the filter element or muffler if necessary, and connect the exhaust pipe and muffler to the outdoors.
< p>(3) Since the working pressure of the pneumatic membrane cut-off valve is 0.2-0.3MPa, always check whether the pressure of the filter pressure reducing valve exceeds the limit.(4) Check that the regeneration balloon valve is in the open state. < /p>
Common troubleshooting table
Serial number fault troubleshooting method
1 The dew point does not meet the requirements, the adsorbent is insufficient, broken, or failed. Add adsorbent or replace it
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Regeneration gas volume or abnormal switching between towers A and B. Adjust to a reasonable gas volume, check valves and controllers
If the inlet air temperature is high, adjust the process configuration and improve the cooling effect of the cooler
< p>The oil content in the inlet air is high, which causes the adsorbent to fail. Improve the oil filtering effect and replace the adsorbentThe working pressure is low, resulting in low adsorption capacity. Increase the inlet air pressure appropriately
The switching cycle has expired Adjust the switching cycle reasonably and long
The muffler outlet is too high or rainwater pours back. Lower the height of the muffler outlet to prevent rainwater from entering the muffler
2 The pressure drop is too large (0.02MPa) The adsorbent is seriously damaged Remove the damaged adsorbent and replenish it
If the filter is clogged, check and clean the clogged filter
The adsorbent has expired or has been prematurely broken into dust. Sieve or replace the adsorbent
3 The flow loss is large and the diameter of the outlet pipe does not meet the requirements. Replace it
The outlet pipe is not smooth. Clean and discharge sewage
The regeneration gas volume is too large and the regeneration gas volume should be reduced appropriately
There are too many pipe elbows. Reduce the pipe elbows appropriately
4 The regeneration pressure is no longer zero. The muffler or the muffler pipe is clogged. Clean the muffler (replace the filter element) or clean the muffler pipe
Membrane switching valve ( or plunger switching valve) fails or seriously leaks, check and replace damaged parts (diaphragms, seals, etc.)
The regeneration gas volume is too large and appropriately reduce the regeneration gas volume
The regeneration gas outlet pipe If the road is not smooth, check the air outlet pipe, muffler, etc.
Check valve leakage, check the valve head
5 B tower switching is abnormal, the intelligent controller program is incorrect, check and eliminate
The output terminal of the computer controller is incorrectly wired
or the controller is faulty. Re-adjust the solenoid valve terminal as required, repair or replace the controller
Replace the solenoid valve if it is damaged
Membrane switching valve (or plunger shut-off valve)
Failure or serious leakage, check and replace damaged parts (such as diaphragm rupture)
Pilot solenoid valve external circuit failure Check and eliminate
The check valve is leaking or stuck. Check whether the valve head is normal
4.3 Use of heatless regeneration adsorption compressed air dryer
4.3 .1 Inspection before starting the dryer
(1) All maintenance work is completed and the work ticket is canceled;
(2) Check that the power supply voltage is normal;
>(3) Check that all the meters on the control instrument panel and adsorption tower are complete and intact;
(4) Check that the air pipeline is normal and the pneumatic pipe connection of the pneumatic membrane isolation valve is intact;
(5) Check that the pneumatic membrane isolation valve at the inlet of the adsorption tower is open and the pneumatic membrane isolation regeneration valve is closed.
4.3.2 Operations before starting the suction dryer
(1) Turn on the suction dryer Dryer inlet butterfly valve;
(2) Open the suction dryer oil removal filter drain valve;
(3) Open the suction dryer dust removal filter drain valve;
(4) Open the butterfly valve at the outlet of the suction dryer;
(5) Close the pressure relief valve in the outlet pipeline of the suction dryer;
(6) Open the regeneration gas regulating valve;
(7) Send in the control power supply of the suction dryer.
4.3.3 Start-up operation of the suction dryer
(1) Put the corresponding air compressor into operation ;
(2) Turn on the switch, turn on the power, and check that the power indicator light on the panel is on;
(3) After the A and B adsorption towers increase to the set pressure, Press the run button and check that the adsorption indicator light of tower A is on, the pneumatic film cut-off valve at the entrance of tower B is closed, the pneumatic film partition regeneration valve of tower B is opened, and the dryer starts to work in cycles.
4.3.4 Blotting dry Shutdown operation of the dryer:
(1) Turn the switch on the panel to the stop position to stop the dryer;
(2) Disconnect the control power of the dryer;
(3) Close the butterfly valve at the inlet of the dryer;
(4) Close the butterfly valve at the outlet of the dryer;
(5) Slowly open the outlet of the dryer Pressure relief valve in the pipeline until the pressure gauge indication of adsorption tower A and B reaches zero.
4.3.5 Operation and maintenance of the suction dryer
(1) Check the indications of each instrument every hour Normal;
(2) Calibrate the pressure gauge regularly;
(3) When the suction dryer is regenerated, the pressure in the regenerated adsorption tower shall not exceed 0.02MPa;
< p>(4) Each pneumatic membrane cut-off valve operates flexibly and switches correctly;(5) Each automatic drainer operates normally;
(6) The system has no leakage.
4.3.6 Causes and solutions for dryer failures
Troubleshooting
1 Press the switch and the dryer does not work. There is no current input. Check the voltage on the wiring board< /p>
The power switch fails. Replace the power switch
The air switch is not closed. Close the air switch
Poor electrical contact. Check whether the wires are loose or replace the electrical appliance
2 The dew point is high and the air processing capacity exceeds the maximum value. Replace the machine with a larger processing capacity.
The adsorbent has expired. Replace the adsorbent.
The adsorbent is contaminated. Repair the filter and replace the adsorbent.
The intake air pressure is too low or the intake temperature is too high. Increase the intake pressure or reduce the intake air temperature
3 The working pressure is not reached during charging. The regeneration valve is not closed and the regeneration valve is not strictly inspected.
Close the regeneration gas control valve completely and open the regeneration gas control valve
Detect and repair air leaks at the joints of pipes and valves
4 Pressure in the regeneration tower during operation Clean or replace the muffler if the large muffler is blocked
The regeneration valve is not fully opened. Repair the regeneration valve
The check valve has a bad seal. Repair the check valve