Screw type compressors play a vital role in industrial production, and their stable operation is directly related to production operating efficiency and equipment safety. To guarantee that the compressor operates efficiently and safely, strict adherence to operating procedures is indispensable from pre-startup preparation to in-operation monitoring and post-power-down upkeep. Below is a comprehensive guide to operating screw type compressors, helping you easily master their daily use and upkeep.
Key Takeaways
- Follow the documented startup and power-down sequence every time; shortcuts cause pressure shocks and wear.
- Keep the compressor room ventilated, clean, and free of combustible material.
- Train operators to recognize abnormal noise, vibration, and warning indicators before they escalate.
Pre-Startup Precautions
1. Power Supply Check: First, guarantee that the three-phase power supply is normal, with no voltage fluctuations or outages. Stable power supply is the foundation for smooth startup of the compressor.
2. Oil Level Check: Open the machine door lock and carefully check the oil level of the screw type compressor. The oil level must not be below the specified low-level line; otherwise, the compressor-specific lubricant needs to be added promptly to the normal position. Note that the mention of “coolant” here may be a misnomer; in fact, it should be compressor-specific lubricating oil.
3. Controller Check: Switch on the controller power and observe the LCD display for any abnormal indications. Displaying “Device Stopped” indicates a normal state, signifying that the controller is in standby mode.
4. Valve Opening: Confirm that the screw type compressor’s outlet valve is fully open to guarantee smooth gas flow.
1. Observe Initial Operation: After startup, let the screw type compressor run unloaded for 3-5 minutes. During this time, closely observe for any abnormal noises, vibrations, or leaks. If any abnormalities are detected, immediately power down the compressor and inspect it to troubleshoot the issue.
2. Pipeline Safety: During operation, never loosen pipes, plugs, or open unnecessary valves, as this could release pressure and cause accidents.
3. Oil Level Monitoring: Continuously observe the oil level during operation. Due to temperature increases during operation, the oil level may drop slightly, which is normal. Nevertheless, if the oil level is too low and the exhaust temperature reaches 100°C, immediately power down the compressor and add lubricant after the system pressure has been released.
4. Drain Condensate Water: Condensate water forms when gas is cooled by the cooler and must be drained regularly to avoid moisture from entering the system. In summer, when temperatures are higher, condensate water formation is more frequent, requiring more frequent draining.
5. Record Operating Parameters: Daily, record key parameters such as voltage, current, outlet gas pressure, outlet exhaust temperature, and oil level for future reference during upkeep.
1. Normal Power-down: Press the OFF button and wait for the intelligent controller to gradually power down the screw type compressor according to the pre-programmed sequence. This process takes approximately 10-15 seconds, avoiding direct power-down under heavy load that could damage the motor.
2. Emergency Power-down: In emergency situations, press the emergency stop switch (red button) to quickly cut off the power to the main controller and contactor, ensuring equipment safety.
3. Delayed Restart: After power-down, wait for 1-2 minutes for the system’s internal pressure to be automatically released before restarting the compressor to avoid heavy-load startup from damaging the motor.
4. Parameter Setting: After commissioning the screw type compressor, set the pressure and other operating parameters according to actual needs and configure it for fully automatic control mode. Typically, users do not need to adjust these parameters themselves.
By following this detailed operating guide, you now have a comprehensive understanding of the daily operation and upkeep of screw type compressors. Adhering to these steps not only ensures the stable operation of the compressor but also effectively extends its working life, bringing greater benefits to your production.
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Frequently Asked Questions
What should I check before starting a compressor?
Check oil level, condensate drains, inlet filters, belt tension, and that all safety guards are in place.
Why does the machine need to warm up or cool down?
Proper warm-up distributes lubricant, and a controlled shutdown lets the unit depressurize and cool evenly.
How much clearance does a compressor need around it?
Follow the manufacturer clearance for intake, exhaust, and service access, typically at least one meter around the unit.
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