螺杆压缩机螺杆压缩机2021/6/162021/6/161 11、绪论就压缩原理而言，螺杆压缩机与活塞式压缩机同属容积式压缩机。就运动形式而言，与透平压缩机相似。2021/6/162021/6/162 22、螺杆压缩机的基本结构和工作原理阴转子圆柱滚子轴承2021/6/162021/6/163 32、螺杆压缩机的基本结构和工作原理一对相互啮合的螺旋形转子节圆外具有凸齿的转子，称为阳转子或阳螺杆主动转子把节圆内具有凹齿的转子，称为阴转子或阴螺杆从动转子吸气孔口、排气孔口分别开设在压缩机机体的两端。2021/6/162021/6/164 42、螺杆压缩机的基本结构和工作原理螺旋转子的一对相互啮合齿随着转子旋转，完成吸气、压缩、排气三个过程。每一对相互啮合齿相继完成相同的工作循环。螺旋转子旋转工作容积作回转运动，气体的压缩依靠容积的变化来实现。无脉动，不喘振。螺杆式压缩机工作过程2021/6/162021/6/165 53、螺杆压缩机特点螺杆压缩机与活塞压缩机比较，具有下列决定性的优点，使其得到迅速发展。1、无不平衡的质量力这点使得机器能平稳地、无振动地运转，实现高的工作转速，通常，螺杆压缩机不需要特别的基础，所以对于这种机型，即使功率大的机器；也可用于移动式装置中。2、转速高高转速可使同样生产能力的机器结构容积小和重量轻。一台螺杆压缩机的重量，约为一台可比功率的活塞式压好机重量的17至113这使得制造这大功率而尺寸紧凑的机器成为可能由于工作转速高，可以它按选用价格便宜的原动机而不需装设减速设备3、无磨损干式压缩机的转子是以非接触方式运转的，从而保证了无磨损，长寿命，以及在整个使用期间功率保持恒定不变，机器寿命受轴承的耐久性所限制4、结构简单，运轮可靠螺杆压缩机零部件少，没有易出故障的气闷或密封件。故运转可靠，维护工作少，对侵蚀性气体和污垢不敏感。5、调节性能良好螺杆压缩机可在多方面顺应工况的要求，作为调节措施有：变转速调节、吸气节流调节、用电力驱动时的停机-运转控制、旁通调节以及特别用于制冷压缩机的滑阀调节。6、绝对的无油压缩与大多数其它压缩机型比较，干式螺杆压缩机具有绝对无油压缩的优点，因此可用于输送不能受油侵蚀的气体。螺杆压缩机具有基本上连续的输送量和功耗小等优点，与透平压缩机比较，则螺杆压缩机具有硬特性曲线和没有喘振界限的优点。2021/6/162021/6/166 63、螺杆压缩机特点缺点：1、效率较低螺杆压缩机发展到今天，虽有许多改进，但由于其内部密封性不好和高的气流速度，螺杆压缩机的等温效率，比同等功率的活塞式压缩机低。只有高转速螺杆压缩机，才具有良好的相对密封性。2、转子制造复杂支承要求高基于高的转速和很小的间隙，螺杆压缩机转子必须高精度加工，为此所需的工具和机床加工十分昂贵。由于齿廓形状复杂，故配对的每个转子均需用独用的铣刀加工。转子配对也不能随便组合，所以损坏的压缩机转子常常是成对的调换。无论是喷油式机器所用的滚动轴承或大型杆式机器所用的滑动轴承，都必须精心加工制作。3、噪声较高干式压缩机噪声高，须附带有特殊的吸气及排气消音器，以便将放射的声能保持在允许限度内。由于频谱的特性（高频成分占优势），可采用隔声罩壳，螺杆压缩机的噪声问题一般比活塞式压缩机的好处理些。2021/6/162021/6/167 7喷油式压缩机的优缺点喷油式压缩机的优缺点喷油冷却的螺杆压缩机有下列优点结构大为简化它省去同步齿轮，又省去高压端的轴封。应用滚动轴承，省去大多数干式压缩机常用的滑动轴承所需的复杂的润滑系统。接近等温压缩通过喷入相当大量的冷却油到压缩腔（油与空气的质量约5：1至10：1），气体受压缩所产生的热量被油液带走，故不会有显著的温升。因此单级压缩比可达到1：15，而压缩温度不会超过100度。这种机器的转子和壳体可造成很小的公差配合，因为转子和壳体的热膨胀是近乎均匀的且比干式机器的小。噪声低基于较小的圆周速度和喷油的缓冲作用，喷油冷却的压缩机产生的噪声远低于干式螺杆压缩机产生的噪声。喷油式螺杆压缩机的缺点由于喷油螺杆压缩机转速一般比干式压缩机低，故机器的重量和尺寸都较大。把喷入的油从被输送的介质中分离出来，也是比较麻烦的，目前，经粗分和细分装置虽能使气体含油量达到510mg/m3以下，但对大型机器而言，油耗量也是相当可观的。另外，喷油系统油路复杂，设备投资增加，因气体带油，食品工业不能应用等，都是其不足之处。由于气体密封和转子刚度等方面的限制，螺杆压缩机还不能达到较高的终了压力，目前只能用于中压4.5MPa以下。2021/6/162021/6/168 84、螺杆压缩机的分类按运行方式的不同，分为无油压缩机（LGW-）和喷油压缩机（LG-）两类；无油螺杆工艺压缩机又可分为干式和喷液两类喷液：喷水、喷轻质柴油按被压缩气体种类和用途的不同，分为空气压缩机、制冷压缩机和工艺压缩机三种；按结构形式的不同，分为移动式和固定式、开启式和封闭式等。 2021/6/162021/6/169 95、无油螺杆压缩机的主机结构及和主要零部件2021/6/162021/6/1610105、无油螺杆压缩机的主机结构及和主要零部件无油机器的转子并不直接接触，相互间存在一定的间隙。阳转子通过同步齿轮带动阴转子高速旋转，同步齿轮在传输动力的同时，还确保了转子间的间隙 所谓“无油”，指的是气体在被压缩过程中，完全不与润滑油接触，即压缩机的压缩腔或转子之间没有油润滑。但压缩机中的轴承、齿轮等零部件，仍是用普通润滑方式进行润滑的，只是在这些润滑部位和压缩腔之间，采取了有效的隔离轴封 2021/6/162021/6/1611115、无油螺杆压缩机的主机结构及和主要零部件在喷油螺杆压缩机中，大量的润滑油被喷入所压缩的气体介质中，起着润滑、密封、冷却和降低噪声的作用。喷油机器中不设同步齿轮，一对转子就象一对齿轮一样，由阳转子直接带动阴转子旋转。所以，喷油机器的结构更为简单无油螺杆压缩机和有油螺杆压缩机的主要结构区别? 2021/6/162021/6/1612125、无油螺杆压缩机的主机结构及和主要零部件无油螺杆压缩机的主机结构及和主要零部件1 1一径向止推轴承一径向止推轴承22一轴封装置一轴封装置33一转子一转子44一气缸体一气缸体55一吸气端盖一吸气端盖66一径向轴承一径向轴承77一同步齿轮一同步齿轮88一喷油管一喷油管99一排气端盖一排气端盖图5-2无油螺杆工艺压缩机2021/6/162021/6/1613135、无油螺杆压缩机的主机结构及和主要零部件轴封装置；采用石墨环式、迷宫式或机械式密封等，并拥有平衡气口、放空口和充气口。向轴封内充气，可使压机的气体泄漏量减小为零。l一内侧静环2一内侧动环35一弹簧4-弹簧座6一外侧动环7一外侧静环8-压盖9一密封室2021/6/162021/6/1614145、无油螺杆压缩机的主机结构及和主要零部件同步齿轮：转子的间隙和驱动靠同步齿轮来实现。同步齿轮有可调式及不可调式两种结构，通常都采用图示的可调式结构2021/6/162021/6/1615155、无油螺杆压缩机的主机结构及和主要零部件2021/6/162021/6/1616165、无油螺杆压缩机的主机结构及和主要零部件2021/6/162021/6/1617176、注油式空压机的主要系统注油式空压机的主要系统气路系统气路系统注油式空气压缩机撬上主要有压缩机气路系统，压缩机油路系统和空气干燥系统。气路系统主要由分离/滤器、油罐、后冷器（压缩空气冷却器）、除水（雾）分离器、单向阀及最小压力阀、进气阀（带调节器）组成，如图5所示。在分离器的顶部装有最小压力阀。该阀作用是：（1）使分离器内的气体保持一定压力，在该压力下，分离器罐内的油能够连续地注入到压缩机内；（2）限制分离器内气体的流速，防止过多的油被带走。进气阀的开度大小是由压缩机油压系统及要求负荷大小自动控制的。2021/6/162021/6/161818气路系统2021/6/162021/6/1619197、油路系统油路系统图6 油路系统2021/6/162021/6/162020空气干燥系统空气干燥系统图7 空气干燥系统2021/6/162021/6/162121空压机的仪表与控制空压机的仪表与控制空气压缩机橇上的2台压缩机各有该机的主控制盘，控制该机的起动与停车，在主控制盘上又可显示压缩机的工作状态。在公用的橇上又设有1个现场指示控制盘，该盘显示2台压缩机的报警参数，同时，当1台压缩机故障时，该盘控制自动起动的备用压缩机工作。为保证空气压缩机安全运行，同时也为了使平台上的其它设备不受压缩机的影响，整个系统主要采用了以下仪表与安全保护措施。2021/6/162021/6/162222报警与关断压缩机排气高温报警关断压缩机排气高高压关断进气滤器高压差报警与关断冷却器出口空气高温报警与关断前、后滤器高压差报警与关断低压启动控制开关2021/6/162021/6/162323PSDPSD安全阀安全阀保护装置的设定值见表1序号项目描述设 定值备注1PDSH-A进气滤器压差开关(A)4.8kPag2PDSH-B进气滤器压差开关(B)4.8kPag3PDSH前滤器压差开关60kPag4PDSH后滤器压差开关60kPag5ITAS-A报警关断(A机)106.66ITAS-B报警关断(B机)106.67TSH-A关断(A机)558TSH-B关断(B机)559PSHH-A关断1 137 KPag10PSHH-B关断1 137 Kpag11PSL压力开关980/800 kPag备用机停/起12PSV-A压缩机(A机)1 140 Kpag13PSV-B压缩机(B机)1 140 Kpag14PSV-A橇块上1 140 Kpag15PSV-B橇块上1 140 Kpag16PSV-干燥器(左)1 140 KPag17PSV-干燥器(右)1 140 KPag2021/6/162021/6/162424压缩机主控制盘压缩机主控制盘每台压缩机上的主控制盘面主要有以下仪表及控制开关（图8）：1.急停车按钮2.启动按钮3.自动再启动4.油滤器高压差指示灯(需清洗)5进气滤高压差指示灯(需清洗)6.通电指示灯7.计时表8.负荷/无负荷选择开关9.排气压力表10.管线/油罐压力选择开关11.ON-OFF/调节选择开关12.排气温度表13.风扇电机故障指示灯14.主电机故障指示灯15.排气温度(高温)指示灯16.复位按钮17.排气高压指示灯18.运转指示灯(绿)19加载指示灯(红)2021/6/162021/6/162525控制板图8 主控制盘面2021/6/162021/6/162626橇上现场盘橇上现场盘（图9）橇上现场控制盘开关与指示灯有：压缩机A关断报警指示灯空气高温报警指示灯(A机)高压差报警指示灯(前滤器)高压差报警指示灯(后滤器)压缩机B关断报警指示灯空气高温报警指示灯(B机)仪表空气低压报警指示灯仪表空气低低压关断指示灯干燥器启动故障指示灯压缩机A程控指示灯压缩机B程控指示灯压缩机A,B机同时运转指示灯复位按钮消除报警按钮就地/程控选择位置开关(A机)1-2位置开关(主、备机选择开关)就地/程控选择位置开关(B机)2021/6/162021/6/162727橇上现场盘橇上现场盘（图9）2021/6/162021/6/1628282021/6/162021/6/162929SSR50-100HP介绍2021/6/162021/6/1630302021/6/162021/6/1631312021/6/162021/6/1632322021/6/162021/6/163333目的机器概述主要的区别元件概述控制系统调节系统安装保养零部件2021/6/162021/6/163434与SSR50-100的区别SE控制器进气阀运动冷却器类型温控阀筒体尺寸启动装置制造商油分离芯机器的外形尺寸与安装尺寸风扇电机超载时手动设置2021/6/162021/6/163535类似处相同的驱动系统相同的主机尺寸空气流动途径冷却剂流动途径2021/6/162021/6/163636空气滤清器新3微米系统分离元件使用寿命的提高每隔4000小时更换一次多级高除尘过滤器可选项延长的寿命预过滤器初级过滤二级过滤2021/6/162021/6/1637372021/6/162021/6/163838进气阀4”进气阀自润滑的球轴承汽缸控制的2021/6/162021/6/1639392021/6/162021/6/1640402021/6/162021/6/164141主机50和60HP127.5mm75和100HP178.5mm与SSR50-100相同防震安装3-点系统悬臂电机支撑2021/6/162021/6/1642422021/6/162021/6/1643432021/6/162021/6/164444驱动电机标准开式可选择的闭式整体的齿轮驱动与SSR500-100相同2021/6/162021/6/1645452021/6/162021/6/164646止逆阀阀片与弹簧与SSR50-100相同2021/6/162021/6/1647472021/6/162021/6/164848排气管连接主机与油分离筒体使主机与油分离筒体分离正确安装非常重要保养项目每隔二年更换一次2021/6/162021/6/1649492021/6/162021/6/165050油分离筒体直径12?和14?锥形挡板新型的导向板牢固安装由冷却器支撑架支撑提供震动隔离2021/6/162021/6/1651512021/6/162021/6/1652522021/6/162021/6/165353分离元件扩大的表面面积缩小的尺寸2021/6/162021/6/1654542021/6/162021/6/165555最小压力阀设定在60PSIG与SSR50-100相同2021/6/162021/6/1656562021/6/162021/6/165757后冷却器油冷却器和后冷却器组合后冷却器15CTD40%RH压降1PSI油冷却器100FETD压降5PSI靠铰链移动方便清洗2021/6/162021/6/1658582021/6/162021/6/1659592021/6/162021/6/166060水分离器离心式铝质构造2021/6/162021/6/1661612021/6/162021/6/166262温控阀IR阀体Caltherm阀芯，设定在160F冷启动时，内置式旁通装置（约50PSIG）2021/6/162021/6/1663632021/6/162021/6/166464控制系统标准SE智能控制SE星三角控制系统电磁阀,1SV,2SV,3SV,6SV,10SV调节是一个可选项使用特殊的调节阀，在小孔与灵敏度方面与SE调节阀不同。2021/6/162021/6/1665653-通阀，线圈失电直接操作1SV 控制电磁阀 和 6SV2021/6/162021/6/1666663通阀，线圈通电直接操作1SV 控制电磁阀 和 6SV2021/6/162021/6/1667672通正常关闭阀，线圈失电，阀关闭直接操作2SV 调节电磁阀2021/6/162021/6/1668682通正常关闭阀，线圈得电，阀打开直接操作2SV 调节电磁阀2021/6/162021/6/1669692通正常开启阀，线圈失电，阀打开导向操作3SV 放气阀2021/6/162021/6/1670702通正常开启阀线圈得电，阀关闭导向操作3SV 放气阀2021/6/162021/6/1671712通正常关闭阀，线圈失电，阀关闭PILOT OPERATED5SV 断油阀2021/6/162021/6/1672722通正常关闭阀，线圈得电，阀打开导向操作5SV 断油阀2021/6/162021/6/1673732021/6/162021/6/167474使用仪器主机排气温度2ATT主机排气温度1ATS机组排气压力3APT分离前压力3APT(10SV)2021/6/162021/6/1675751ATS散热器油过滤器后冷却器状态：机器停机，无电源状态：机器停机，无电源TCVCBA水分离器与疏水器主机主机SE2ATT安全阀SO最小压力阀5SV止逆阀油分离筒体进气阀1SVN.C.6SV N.O.2SVN.C.3SVN.O.10SV3APT调节阀1ATS空滤器液压缸2021/6/162021/6/1676761ATS散热器油过滤器后冷却器状态：机器无加载状态：机器无加载TCVCBA水分离器与疏水阀主机主机SE2ATT安全阀回油过滤器最小压力阀5SV止逆阀油分离筒体进气阀1SVN.C.6SV N.O.2SVN.C.3SVN.O.10SV3APT调节阀1ATS空滤器液压缸2021/6/162021/6/1677771ATS散热器油过滤器后冷却器状态：机器加载状态：机器加载TCVCBA水分离器与疏水阀A/EA/ESE2ATT安全阀回油过滤器最小压力阀5SV止逆阀油分离筒体进气阀1SVN.C.6SV N.O.2SVN.C.3SVN.O.10SV3APT调节阀1ATS空滤器液压缸2021/6/162021/6/1678781ATS散热器油过滤器后冷却器机器处于加载状态并可调节机器处于加载状态并可调节TCVCBA水分离器与疏水阀A/EA/ESE2ATT安全阀回油过滤器最小压力阀5SV止逆阀油分离筒体进气阀1SVN.C.6SV N.O.2SVN.C.3SVN.O.10SV3APT调节阀1ATS空滤器液压缸2021/6/162021/6/1679791ATS散热器油过滤器后冷却器STATUS:UNITLOADED,STATUS:UNITLOADED,MODULATING&10SVSHIFTEDMODULATING&10SVSHIFTEDTCVCBA水分离器与疏水器主机主机SE2ATT安全阀回油过滤器最小压力阀5SV止逆阀油分离筒体进气阀1SVN.C.6SV N.O.2SVN.C.3SVN.O.10SV3APT调节阀1ATS空滤器液压缸2021/6/162021/6/168080调节系统筒体压力由移动液压缸的尾端来调节回跳压力/起跳压力,ETC.在SE控制器上调节调节使用调节阀调节2021/6/162021/6/168181安装注意事项环境温度35F-115F空气充分流通远离化学物品和灰尘避免雨淋、日晒容易维修(最小42?不能缩小管道尺寸2021/6/162021/6/168282用户连接时注意事项空气排气端位置-后左角冷凝器位置-后左角电源位置-左边，在启动器附件的顶部2021/6/162021/6/168383日常保养空气滤清器每4000小时更换油过滤器最初150小时更换以后每2000小时更换一次或当更换油时同时更换冷却剂每隔8000小时或2年更换一次2021/6/162021/6/168484日常保养油分离元件每隔8000小时更换一次或当压差大于或等于12PSID时更换清洁冷却器润滑电机闭式1000小时润滑开式2000小时润滑一次清洁回油管小孔每次油过滤器更换时2021/6/162021/6/168585日常保养n n轴封每每2 2年一次年一次n n更换软管每每2 2年一次年一次2021/6/162021/6/168686常用备件空气滤清器油过滤器冷却剂最小压力阀组件放气阀组件温控元件分离元件2021/6/162021/6/168787常用备件3APT压力传感器热敏电阻HATS高温温度开关进气汽缸调节器轴封与轴套熔断器辅助触点2021/6/162021/6/1688882021/6/162021/6/168989机组排气温度高机组排气温度高 故障排除指南故障排除指南 机组排气温度高机组排气温度高(超过超过100C)机组在起动后机组在起动后10秒钟之内停机秒钟之内停机冷却剂添置到正确位置并试机冷却剂添置到正确位置并试机YES怀疑断油电磁阀故障怀疑断油电磁阀故障环境温度高环境温度高 冷却剂的液位正确冷却剂的液位正确油冷却器脏油冷却器脏 检查喷油温度检查喷油温度 环境灰尘大环境灰尘大冷却水脏冷却水脏进风量小进风量小排气阻力大排气阻力大冷却空气循环冷却空气循环 堵塞的过滤网减少了堵塞的过滤网减少了冷却空气的流量冷却空气的流量 改善环境使冷却器干净改善环境使冷却器干净 温控阀故障温控阀故障 测量进测量进 / 出口的温度出口的温度 检查电机电流检查电机电流检查油标检查油标检查主机的声音检查主机的声音检查振动检查振动检查油过滤器内是否有大量运行中磨损的金属颗粒检查油过滤器内是否有大量运行中磨损的金属颗粒NO机组在空载运行时发生报警机组在空载运行时发生报警YES冷却剂流量小冷却剂流量小油过滤器堵塞油过滤器堵塞喷油软管破裂喷油软管破裂温度表有问题温度表有问题 更换温度表更换温度表主机故障主机故障 YESYESNONOYES2021/6/162021/6/169090故障排除指南故障排除指南 主电机过载主电机过载主电机过载主电机过载MOL动作动作MOL 设定是否正确设定是否正确热敏继电器动作热敏继电器动作 MOL 设置在自动设置在自动电压在规定范围内电压在规定范围内检查接线是否正确检查接线是否正确检查压力是否正确检查压力是否正确正确设定正确设定用户调整到用户调整到规定的范围内规定的范围内必要时重新接线必要时重新接线INTELLISYS要重新设置要重新设置如果是设置到手动如果是设置到手动检查发热的来源检查发热的来源检查直流电接线故障检查直流电接线故障检查检查INTELLISYS输入输入INTELLISYS重新设置重新设置检查压力传感器检查压力传感器YESNONONONONONONONO2021/6/162021/6/169191故障排除指南故障排除指南 风扇电机过载风扇电机过载风扇电机过载风扇电机过载MOL动作动作MOL 设定正确设定正确风扇继电器动作风扇继电器动作MOL 设置在自动设置在自动电压在规定范围内电压在规定范围内检查接线是否正确检查接线是否正确检查检查风扇叶片是否坏风扇叶片是否坏正确设定正确设定用户调整到用户调整到规定的范围内规定的范围内必要时重新接线必要时重新接线INTELLISYS重新设置重新设置如果是设置到手动如果是设置到手动查找原因查找原因检查直流电接线故障检查直流电接线故障检查检查轴承是否有故障轴承是否有故障合适的新风扇合适的新风扇更换轴承或更换轴承或合适的新电机合适的新电机YESNONONONONONONONONO检查检查INTELLISYS输入输入2021/6/162021/6/169292YESNO水冷却器漏水冷却器漏故障排除指南故障排除指南 油分离芯寿命短油分离芯寿命短油分离芯寿命短油分离芯寿命短压差大压差大压差小或压差小或 冷却剂排出冷却剂排出 经过过滤器的流量小经过过滤器的流量小冷却剂变质冷却剂变质/碳化碳化筒体内回油管太短筒体内回油管太短冷却剂内有水冷却剂内有水回油堵塞回油堵塞过滤器旁通过滤器旁通机组在寒冷的地方运行机组在寒冷的地方运行分离筒体内挡板破裂分离筒体内挡板破裂筒体内回油管短筒体内回油管短 回油管堵塞回油管堵塞元件击穿元件击穿机组加载机组加载/卸载频繁卸载频繁MPV(最小压力阀最小压力阀)坏坏CHECKINSTRUMATION2021/6/162021/6/169393空压机的操作空压机的操作启动前准备启动前准备启动空压机前的准备：-检查冷却液液位,不低于玻璃窗的中间位置,必要时添加.-排放系统中的冷凝物（用分离/滤器罐下方的手动球阀）-确认压缩机及橇上无妨碍物，并确认所有的防护盖已盖好.-确认所有电线的绝缘良好-确认所有阀门处于正确位置-关闭干燥器前预滤器的进口阀-确认电源已供电(压缩机主控制盘”Poweron指示灯应亮)2021/6/162021/6/169494空压机的启动空压机的启动1完成上述准备后，将橇上现场控制盘上机（或机）对应的选择开关LOCALSEQUENCE置于LOCAL位置2在压缩机（或压缩机）主控制盘上于UNLOAD/NORMAL开关置UNLOAD位置3在主控制盘上按下START按钮，启动压缩机，运行指示灯亮（绿）4几分钟后，将开关置于位置，压缩加载，加载指示灯亮（红）5根据需要设在或控制方式2021/6/162021/6/169595启动后检查启动后检查检查是否有异常振动与噪音。检查管线连接处有无漏气。用手动操作分离滤器罐底部球阀来检查排放阀的自动动作。检查公用气出口及公用气瓶的压力上升情况。压缩机排气温度检查（应小于）。检查油罐及管线空气压力（在主控制盘上）。手动停车手动停车：将无负荷负荷开关置于无负荷位置，按停车按钮，关掉主电源。2021/6/162021/6/169696干燥器投入工作干燥器投入工作当公用管瓶达到工作压力时，干燥器方可投入工作，操作步骤如下：打开预滤器进口阀，使公用气瓶的空气进入干燥系统。缓慢打开干燥器进气阀，同时保持旁通阀开启。当塔压力达工作压力时，为干燥器供电。缓慢打开出气阀。关闭旁通阀。至此，干燥器已合适地投入工作，并进入完全自动，连续功能注意：干燥器初次投入工作天到天后，应全面检查供气管线，因为，由于空气湿度减小可能会有地方漏气，应及时处理2021/6/162021/6/169797压缩机排气量控制压缩机排气量控制压缩机排气量控制压缩机排气量控制压缩机排气量控制有种方式：，在主控制盘上有选择开关“”来改变选择： 控制控制这种控制方式是，压缩机在全负荷排量或零排量下工作，以适应供气变化范围大的要求。这一工作方式是靠压力变送器（1PS）来传送气压力的变化，传送器激开负荷电磁阀（1SV），从而通气阀关闭，进气阀全开，因负荷电磁阀在工作时使放空阀动作接着，压缩机的全负荷排量工作，如果系统中空气压力升到压力设定的上限，则负荷电磁阀断电，使进气阀关闭，同时通气阀打开，使气罐压力下降。上下限之间的压力设定范围是，上限设定点为压缩机额定排出压力以上如图10所示。：控制：控制上限范围调节控制方式可用于供气要求比较高和连续的情况下这种控制方式保留控制的特点，而且在管线压力升到压力开关（1PS）设定的上限值时，保证进气节流调节图10排气量控制调节调节阀放掉少量气后，便激开调节电磁阀，个空气减少信号传到进气阀上的气动气缸，使气缸“移”向进气阀侧，由管线压力变化决定，当压缩机排出压力达到额定压力的左右时开始调节，压缩机排气等于用气时，调节稳定，并且出厂设定调节限量约为额定排量的如果供气要求减少到低于调节排气时，管线压力将逐渐升高到压力设定的上限，当压缩机转变到控制位置后，接收器就放空动作见下图2021/6/162021/6/169898压缩机排气量控制调节压缩机排气量控制调节压缩机排气量控制调节压缩机排气量控制调节图10排气量控制调图10 排气量控制调节2021/6/162021/6/169999压缩机联动控制压缩机联动控制压缩机自动起停控制当系统用气量小于压缩机供气量时，系统压力逐渐升高，当达“”的设定值时，压缩机将自动卸载，主电机和风扇电机延时停止，运行绿灯亮，加载红灯灭，自动启动灯亮。延迟停机时间可通过定时器设定，厂家标准设定为分钟若在延时停机期间，用气量增大，系统压力降至“”的下限设定点（）时，压缩机将自动加载，加载（红）灯亮，运转绿灯也亮。当在延时停机期间压力未下降到，电机到延时结束后将停止运转，（运行红绿灯灭），自动启动灯亮当系统压力低到时，压缩机再自动启动。即压缩机的自动起/停是随系统压力变化由“1PS”（850kPag/1000kPag）控制的。注意：根据用气量情况与压缩机供气运转情况，由设定延时器来保证压缩机在小时内自动启动不应超过次（避免频繁启动）2台压缩机自动备用当A机（或B机）启动后，将现场盘上Lead“1-2”位置开关置于“1”（或“2”）位置。表示机（或机）为主工作机，机（或机）为备用机。将现场盘上、机对应的两选择开关LOCALSEQUENCE均置于SEQUENCE位置，进入程序控制模式。正常的情况下，作为主工作机的（或）随系统压力变化，由该机的1PS控制自动启动，当系统压力降至850kPag）时，主工作机未自动启动加载，则表示主工作机故障，接着由“PSL”（设定850kPag）控制备用机会自动启动投入工作。当系统压力升高到980kPag时，备用机自动停止加载，延时停机同前。若原主工作机未被排除故障，被用机仍在“PSL”控制下自动起停（850kPag/950kPag）2021/6/162021/6/16100100运转中巡回检查运转中巡回检查空压机橇巡回检查时，主要检查部位有：橇块现场控制盘、压缩机主控制盘、压缩机罩壳、分离/滤器、干燥器、前后滤器、管线/仪表。按照表2所列检查内容及其正常状态进行检查，判别压缩机的工作情况2021/6/162021/6/16101101空压机橇巡回检查空压机橇巡回检查空压机橇巡回检查空压机橇巡回检查检查部位检查部位检查内容检查内容正常状态正常状态橇块现场控制盘1选择开关位置1位置正常2所有故障报警灯2灯不亮3两机同时运转指示灯3灯不亮4手动启动2台机时4灯亮5程序控制指示灯5灯亮压缩机主控制盘1电源灯1灯亮2无负荷/负荷开关2负荷位置3计时器3正常4运转状态指示灯4运转绿灯亮，加载红灯亮5自动启动灯5卸载后灯亮6 ON-OFFLINE/MODULATION6按需要设置正常7排气压力表7=10008排气温度表8106.69所有故障指示灯9灯不亮压缩机罩壳1运转时振动和噪声1无异常2打开活侧板，检查冷却液液位2可视孔中间3油路系统有无泄漏3无4空气系统有无泄漏4无干燥器1控制盒上电源1灯亮2干燥塔压力表读数2正常3塔的操作和切换3正常4干燥气指示4粉红色分离/滤器1观察压差表10.5 psig/1 psig2检查自动排泄阀动作正常2手动打开球阀无凝聚物3管接头处有无漏气3无前后滤器1压差指示160 kPag（绿色区）2自动排放情况2正常管线/仪表1各压力表读数正常 800kPag1000 kPag2压缩机出口空气温度表552021/6/162021/6/16102102空压机故障分析与处理空压机故障分析与处理空压机故障分析与处理空压机故障分析与处理故障类型可能原因处理方法“电源接通”L。E。D。不亮控制电压没有检查控制保险丝检查变压器副边线圈（控制电压的）压缩机达不到额定压力要求太高检查泄露，阀开启情况或压力要求OFF-LINE压力设定太低检查其设定值压缩机加不上载进气阀打不开检查进气阀开启是否省油检查负荷电磁阀“ISV”的工作情况压缩机达不到额定排量检查负荷电磁阀的动作情况检查负荷电磁阀“ISV”的动作情况检查进气滤器堵塞情况，如有堵塞L。E。D。应指示冷却液（滑油）消耗量过大净化管路堵塞清除堵塞物分离器元件破裂或堵塞更换该元件循环速度快或接受器不放空到无负荷工作压力负荷/无负荷循环太快负荷周期太快增加系统排量最小压力阀（MPA）卡住开着拆下MPV并校验，必要时修理安全阀在压缩机加载时开启MPV卡住关死拆下MPV并校验，必要时修理安全阀故障检查安全阀的设定及标定压力2021/6/162021/6/16103103干燥器故障分析与处理干燥器故障分析与处理故障类型可能原因处理方法高压差1进/出口气体分配器堵塞1清洗或更换2流量过大2校正流量3压力太低3检查压缩机往复阀对开关失效1流量过大1减小流量2压力太低（0.4Mpa）2增加压力3出口阀故障3检查和或更换电磁阀4（控制器）PCB失灵4更换PCB再生塔压力建立，但吸收过程中损失过高1往复阀故障1清洗阀座或更换2出口阀堵塞2检查和/或更换电磁阀露点过高1再生空气量太低1清洗或更换针阀2工作压力太低2检查压缩机3流量太大3检查压缩机排量4进口有水4检查预滤器的冷凝排放5进气温度过高5检查压缩机空气后冷器6更换干燥剂2021/6/162021/6/16104104活塞式压缩机油田上，主要用于天然气的压缩以及制冷使用。基本工作原理：活塞式压缩机种类繁多，结构复杂，但基本结构大致相同。图2所示为有十字头的活塞式压缩机简图。压缩机主要由机身、曲轴、连杆、活塞、气缸和吸、排气阀、十字头、滑道、活塞杆和填料函等组成。压缩机运转时，电动机带动曲轴作旋转运动，通过连杆使活塞作往复运动。曲轴旋转一周，活塞往复运动一次，气缸内相继实现吸气、压缩、排气的过程，即完成一个工作循环。(1)吸气过程当活塞向左运动时，气缸内的工作容积逐渐增大而压力逐渐降低。当压力降至稍低于进气管中压力时，进气管中气体便顶开吸气阀进入气缸，直到活塞达到最左位置（又称内止点）时，工作容积为最大，吸气阀开始关闭。(2)压缩过程当活塞向右运动时，气缸内工作容积缩小，而气体压力逐渐增大。由于吸气阀有止逆作用，故气缸内的气体不能倒流到进气管中。同时，因排气管中的气体压力又高于气缸内部的压力，气缸内的气体无法从排气阀流出，而排气管中的气体因排气阀的止逆作用，也不能进入气缸内。此时，气缸内的气体量保持一定，随着活塞的右移，气体压力不断升高。(3)排气过程当活塞右移到一定的位置时，气缸内气体压力升高到稍高于排气管中气体压力，气体便顶开排气阀进入排气管中，直至活塞运动到最右位置（又称外止点）为止。排气阀关闭，活塞再次左移，上述过程重复出现。2021/6/162021/6/16105105活塞压缩机工作原理图2021/6/162021/6/16106106多级压缩多级压缩2021/6/162021/6/16107107活塞式压缩机的总体结构活塞式压缩机的总体结构气缸轴线在空间的位置是压缩机型式的基本特征。根据气缸轴线在空间的位置，压缩机可分为立式、卧式、角式三大类。2021/6/162021/6/16108108立式压缩机立式压缩机图62021/6/162021/6/16109109卧式压缩机卧式压缩机卧式图7 卧式2021/6/162021/6/16110110对称平衡型压缩机2021/6/162021/6/16111111对置式压缩机2021/6/162021/6/16112112角式压缩机角式压缩机2021/6/162021/6/16113113卧式压缩机的典型结构卧式压缩机的典型结构2021/6/162021/6/16114114Crankcase 压缩机曲轴箱压缩机曲轴箱2021/6/162021/6/16115115Connecting Rod Assembly连杆组件连杆组件2021/6/162021/6/16116116Crosshead Assembly十字头组件十字头组件2021/6/162021/6/161171172021/6/162021/6/161181182021/6/162021/6/16119119Cross Section of Multi-Compartment Crosshead Guide2021/6/162021/6/16120120Packing Case Drawing填料盒组图填料盒组图2021/6/162021/6/16121121Cross Section of Packing Used with Multi-Compartment Crosshead Guides2021/6/162021/6/161221222021/6/162021/6/16123123Piston and Rod Assembly2021/6/162021/6/16124124Double Acting Cylinder2021/6/162021/6/16125125Parts Drawing2021/6/162021/6/161261262021/6/162021/6/16127127PulsationCauses and Methods of Eliminating or Reducing its Effects2021/6/162021/6/161281282021/6/162021/6/161291292021/6/162021/6/161301302021/6/162021/6/16131131VibrationComponent Imbalance is the Most Component Imbalance is the Most Common Cause of Mechanical Common Cause of Mechanical Vibration in a Gas CompressorVibration in a Gas Compressor2021/6/162021/6/161321322021/6/162021/6/161331332021/6/162021/6/1613413475lb105lb132lb153lb193lb6lb10lb14lb18lb22lb26lb30lbAllowedreciprocatingweightdifferencebetweenthrows:1Pound2.5Pounds5PoundsJG/A/M/P/N/Q/R/W/JJGH/E/K/T/C/DJGB/V2021/6/162021/6/161351352021/6/162021/6/16136136CompressionRodLoadPdisPsuc2021/6/162021/6/16137137TensionRodLoadPdisPsuc2021/6/162021/6/161381382021/6/162021/6/16139139ArielPerformanceDataSheet2021/6/162021/6/16140140PerformanceDataContd2021/6/162021/6/161411412021/6/162021/6/16142142Compressor Rod ReversalWhatiscompressorrodreversal?Whatcaneffectrodreversal?2021/6/162021/6/16143143Minimum Allowable Rod(Pin Load) Reversal ThecurrentversionofArielsReciprocatingCompressorPerformanceProgramcalculatescombinedloadsatthecrossheadpin.CombinedRodLoadisthesumofinternalgasloadandinertiaload.Allframesareratedintermsofinternalgasrodload.Inertialoadbecomesimportantforsmallbore/highpressuredoubleactingcylinders,singleactingcylinders,andcylinderblowthroughconditionsduetocrossheadpinloadreversal.Combinedrodloadwilldeterminetheloadonthecrossheadpinbearingsandwilldefinereversalatthecrossheadpinforproperlubrication.Reversalisthechangefromacompressionloadtoatensionloadatthecrossheadpin,thusallowingoiltoflowintotheloadedsideofthebearings.Arielrecommendsreversalforatleast30degreesofcrankrotation.2021/6/162021/6/16144144SuctionDischargeCrosshead PinCrosshead to Bushing Clearance(Exaggerated)Direction of Force onConnecting Rod and Crosshead PinDirection of net force onPiston, Piston Rod and CrossheadPs Suction PressurePd Discharge PressureTo provide lubrication of the crosshead pin and bushing the clearance between the pin and bushing must change sides during each stroke. The pin to bushing contact is osculating and not rotating like the crankshaft pins and journals. The rotating crankshaft pins and journals pull oil around for a full 360 degree lubrication film. Sometime during the compression cycle the crosshead pin must pull away from the crosshead bushing to allow the lubricating oil to flow into the clearance. If rod load reversal does not occur, no oil will get between the crosshead pin and bushing and galling of the metals subjected to dry contact will occur.PsPsPdPdAriel Copyright Material 20032021/6/162021/6/16145145SuctionDischargeSuctionDischargeDouble ActingThe net force on the piston is pushing the crosshead towards the crankshaft, the crosshead pin is being pushed away from the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the crankshaft side of the pin.The net force on the piston is pulling the crosshead away from the crankshaft, the crosshead pin is being pulled towards the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the piston side of the pin.Crosshead Pin Load Reversal has OccurredPdPdPdPdPsPsPsPs2021/6/162021/6/16146146SuctionDischargeSuctionDischargeSingle Acting - Crank EndH.E. suction valve removedThe net force on the piston is pushing the crosshead towards the crankshaft, the crosshead pin is being pushed away from the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the crankshaft side of the pin.The net force on the piston is pulling the crosshead away from the crankshaft, the crosshead pin is being pulled towards the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the piston side of the pin.Crosshead Pin Load Reversal has OccurredPdPdPdPsPsPsPsPs2021/6/162021/6/16147147SuctionDischargeSuctionDischargeSingle Acting - Head EndC.E. suction valve removedThe net force on the piston is pushing the crosshead towards the crankshaft, the crosshead pin is being pushed away from the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the crankshaft side of the pin.The net force on the piston is pushing the crosshead towards the crankshaft, the crosshead pin is being pulled towards the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the piston side of the pin.Crosshead Pin Load Reversal has NOT OccurredPdPdPdPsPsPsPsPs2021/6/162021/6/16148148SuctionDischargeSuctionDischargeFailed H.E. Disch. ValveThe net force on the piston is pushing the crosshead towards the crankshaft, the crosshead pin is being pushed away from the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the crankshaft side of the pin.The net force on the piston is pushing the crosshead towards the crankshaft, the crosshead pin is being pulled towards the crankshaft, thus the crosshead pin to crosshead bushing clearance is on the piston side of the pin.Crosshead Pin Load Reversal has NOT OccurredPdPdPdPdPdPsPsPs2021/6/162021/6/16149149Capacity Control Devicesand Systems2021/6/162021/6/16150150Capacity ControlWhy do we need Capacity Control Devices?Reduce flow / horsepowerChanging ConditionsRod Loads / TemperaturesTherearemanyreasonswhywemayneedtochangethecapacity/horsepowercapabilityofagivencompressorcylinder.Afewexamplesare,theupstreamsupplyand/ordownstreamrequirementsmaybereduced,anewwellhasbeenbroughtonlineandtheenginedoesnothavetheextrahorsepowertopulltheextraloadcausedbythehighersuctionpressure,ortoadjustinterstagepressurestoavoidexceedingrodloadand/ordischargetemperaturelimits.Therearemanymorereasonsthatthecapabilityofagivencylindermayneedtobereduced.2021/6/162021/6/16151151Methods of Compressor/Capacity ControlSpeed controlRecycle discharge to suctionVariable volume pocket adjustmentEnd De-activation2021/6/162021/6/16152152Factors Affecting CapacityGAS CONDITIONSPressuresSuction TemperatureSpecific GravityCLEARANCE VOLUME Increasingclearancevolumereducesvolumetricefficiencyandreducesthroughput.Thisisaveryefficientwaytoreducecapacity.DISPLACEMENTSpeed ReducingthroughputbyreducingspeedcanbeanefficientwaytocontrolcapacityEnd Deactivation2021/6/162021/6/16153153Clearance Volume What Is It and How Does It Affect Capacity?Clearance volume is the space within the cylinder where gas can be trapped during a stroke of the piston. This space is filled with gas which contributes to the re-expansion part of the stroke and affects compressor capacity. Clearance Is Cylinder Volume Not Swept by the Piston.Normal Clearance is the Minimum Fixed Clearance of a CylinderAdded Clearance is any Clearance above Normal2021/6/162021/6/16154154TheportsofthesuctionvalveguardsandthedischargevalveseatsThespacebetweenthefaceofthepistonandtheheadThespacebetweentheinsidediameterofthecylinderandtheoutsidediameterofthepistonfromthefacesofthepistonendsbacktothepistonringsNormal Head End Clearance2021/6/162021/6/16155155Normal Head End ClearanceHead End Clearance 2021/6/162021/6/16156156Crankendclearanceissimilartoheadendclearanceexceptingthefollowingfactors:ThespacethatthepistonrodoccupiesreducesthesweptvolumeinthecrankendofthecylinderAdditionalspaceexistsaroundthepistonrodbacktothepackingringsNormal Crank End Clearance2021/6/162021/6/16157157Normal Crank End ClearanceCrank End Clearance2021/6/162021/6/16158158Capacity Control DevicesVVCP-variablevolumeclearancepocketPFCVP-pneumaticfixedvolumeclearancepocketHCA-highclearanceassembliesDDFVCP-doubledeckfixedvolumeclearancepktSVUL-suctionvalveunloaderH.E. BypassAllofthesedevicesaddclearancevolumetothecompressorcylinder/s2021/6/162021/6/16159159Cylinder with Variable Volume Clearance PocketCross-Section Variable Volume Clearance PocketCapacity Control Devices2021/6/162021/6/16160160Spring Loaded “V” PackingShrunk On PistonGas VentGrease FittingStep-Cut Joint Piston Ring Variable Volume Clearance PocketCapacity Control Devices2021/6/162021/6/16161161Pneumatically Actuated FVCPCapacity Control Devices2021/6/162021/6/16162162Pneumatically Actuated FVCPCapacity Control Devices2021/6/162021/6/16163163High Clearance AssemblyCapacity Control Devices2021/6/162021/6/16164164High Clearance AssemblySpacer InstalledSpacer not InstalledCapacity Control Devices2021/6/162021/6/16165165High Clearance AssembliesHigh Clearance Valve Assembly SpacerCapacity Control Devices2021/6/162021/6/16166166Capacity Control DevicesDouble Deck Fixed Volume Clearance PocketsPipeline cylinders only!Adds approx. 15% fixed clearancewatch side by side interference2021/6/162021/6/16167167 Suction Valve UnloadersFingers Keep Suction Valve Plates OpenOne on each Head End suction ValveCapacity Control Devices2021/6/162021/6/16168168 Suction Valve UnloadersCapacity Control DevicesUnloader Assembly Attached to Suction Valve2021/6/162021/6/16169169Head End BypassCapacity Control Devices2021/6/162021/6/16170170H.E. BypassBy-pass closedBy-pass openCapacity Control Devices2021/6/162021/6/16171171Capacity Control Devices Variable Volume Clearance Pocket2021/6/162021/6/16172172 Variable Volume Clearance PocketNormal ClearanceClearance added to “fixed” clearance with installation of VVCPCapacity Control Devices2021/6/162021/6/16173173Capacity Control66% VE36% VEPocket closedPocket 50% open2021/6/162021/6/16174174Capacity Control DevicesVariableVolumeClearancePockets(VVCPs)aremanuallyoperatedandmaybeadjustedwhilethecompressorisrunning.ToadjusttheVVCPforoptimumcompressoroperation:LoosenthelockinghandleTurntheadjustingscrewclockwise(CW)forlessclearanceandcounterclockwise(CCW)formoreclearanceRe-tightenthelockinghandleVariable Volume Clearance Pocket2021/6/162021/6/16175175Methods of End DeactivationFinger Type Suction Valve UnloadersValve Removal2021/6/162021/6/16176176Suction Valve RemovalStandard Double-Acting Cylinder with All Valves Installed2021/6/162021/6/16177177Suction Valve RemovalDouble-Acting Cylinder with Head End Suction Valves RemovedNote: Cap is flush to cylinder body2021/6/162021/6/161781782021/6/162021/6/161791792021/6/162021/6/16180180SeatfacescapGasketonguardPlatemovesawayfromstudSuctionValveWhenproperlyinstalled,thevalveseatfacesthevalvecap.Thevalvegasketslidesontotheguard.2021/6/162021/6/16181181DischargeValveGuardfacescapGasketonSeatPlatemovestowardstudWhenproperlyinstalled,thevalveguardfacesthevalvecap.Thevalvegasketslidesontothevalveseat.2021/6/162021/6/16182182PEEK-manila-475OFMT-green-340OFNylon-milk-250OFAlternative Valve MaterialsNylonplatesinthesuctionvalvesandMTplatesinthedischargevalvesarethetypicalmaterialsusedinastandarddoubleactingcylinder.2021/6/162021/6/16183183VALVETHEORY2021/6/162021/6/161841842021/6/162021/6/16185185Valve Detail2021/6/162021/6/16186186SealingLands2021/6/162021/6/16187187Valve Problems2021/6/162021/6/16188188Valve ProblemsSpringing2021/6/162021/6/16189189Function of SpringsClose the Valve at the Proper TimeStabilize Valve Opening ActionProvide Some Damping EffectSPRINGS ARE THE FIRST THING TO REVIEW IF YOU ARE HAVING VALVE DURABILITY PROBLEMS2021/6/162021/6/16190190LiftEnd of StrokeTimeIDEALLIGHTHEAVYProper Valve Closure at End of StrokeValve Closes After End of StrokeValve Closes Before End of Stroke, Reopens with Late Closure2021/6/162021/6/16191191Thisillustrationshowsatypicalfailureofaportedvalveplate.Duetounevengasflowacrosstheentireplate,theplatewasnotclosingflatcausingcontactwiththevalveseatononesidefirst.Thestressesfromthistypeofclosurewerehighestattheoutsidediameteroftheplateresultinginthefailureshownhere.2021/6/162021/6/161921922021/6/162021/6/16193193Valve ProblemsSpringingLiquids2021/6/162021/6/161941942021/6/162021/6/16195195Eachstageofcompressionmusthaveaseparatorbetweenthegascoolerandthesuctionflangeofthecylinder(s).2021/6/162021/6/16196196Coolerlouversmayneedtobeclosedduringcoldambientweatherconditionstopreventexcessiveliquefaction.Anighttimetemperaturedropcancauseheavyhydrocarbondrop-outthatexceedstheabilityoftheseparatortoremoveit.2021/6/162021/6/161971972021/6/162021/6/16198198Valve ProblemsSpringingLiquidsDirt 2021/6/162021/6/16199199Dirtorweldslagleftinthepipingcanquicklyaffecttheabilityofthevalvestocheckthegasflow.Thisplateisnotrepairableandwillneedtobereplaced.2021/6/162021/6/16200200Valve ReplacementALWAYS follow the Ariel TECHNICAL MANUAL for the recommended valve removal and re-assembly procedures. ALWAYS properly identify suction anddischarge valves, and install in the correctvalve pocket.2021/6/162021/6/16201201Valve ReplacementCAUTION BEFORE ATTEMPTING TO REMOVE ANY VALVE CAP, BE CERTAIN THAT ALL PRESSURE HAS BEEN VENTED FROM THE COMPRESSOR CYLINDER. THE PRESSURE MUST BE COMPLETELY VENTED FROM BOTH THE SUCTION AND DISCHARGE PASSAGES OF THE CYLINDER. 2021/6/162021/6/16202202Valve Removal1 Loosenalloftheboltsslightly,oneachvalvecap.Withalltheboltsloose,thecapshouldstayinitsoriginalposition.Ifitpushesoutonitsownaccord-stop!Takestepstocompletelyventthecylinder.Afteralltheabovesafetychecks,removethevalvecapbolts.Apairofprybars(orscrewdrivers),oneoneachsideofthecap,willhelppryitloose.Withtheretainerstillinplace,screwavalvetooloverthevalvecentrebolt.Nowthevalveandretainercanbepulledouttogether.2 Inmostcasestheflatmetalgasketwillremaininthepocket.Itisdifficulttosee.Aflashlightandasmallmirroronanadjustablerodarethebesttoolstoseethegasketclearly.Oncylinderswithhorizontalvalves,thegasketmayfallintothegaspassage.Asmallmagnetonaflexibleextensionrodwillhelpfishitout.Thisgasketshouldbereplacedaftereveryotheruse.2021/6/162021/6/16203203Valve Installation1.The1/32inches(0.8mm)thicksoftmetallicflatgasketshouldbecoatedwithananti-seizelubricant.Itcanthenbeeitherinsertedintothevalvepocketorstuckonthevalve.Ineithercase,caremustbetakentokeepthisgasketfromfallingintothegaspassage.2.Theretainerkeeperisathermo-plasticthumbscrewinathreadedholeinthebottomvalveretainers.Thisshouldbescrewedthroughjustfarenoughtoprovidefrictionsothatbottomretainerswillnotfalloutwhilethecapisbeinginstalled.3.UsingtheValveToolthevalveandtheretainermaybeinsertedintothepockettogether.Wheninstalledcorrectly,thedistancefromtheouterretainerfacetothesurfaceofthevalvebossonthecylinderwillbeapproximately1/8inches(3mm)shorterthanthelengthofthenoseonthevalvecap.2021/6/162021/6/16204204Valve Installation4Inspectthevalvecapo-ringforcutsorgashesandreplaceitifnecessary.Lubricatetheo-ringandthenoseofthevalvecap.Somehighpressurecylindersuseasoftmetallicwiregasketinlieuoftheo-ringdesign.Insertthecapandtightentheboltsevenlytotherecommendedtorque.See“BoltTighteningforValveCaps”.Iftheassemblyiscorrect,thedistancefromtheundersideofthecaptothevalvebosssurfaceonthecylinderwillbeapproximately1/8inches(3mm)whenvalveandgasketsarenew.Thisdimensionwillvaryasaresultofvalvemaintenanceandgasketthickness.NOTE: BE CERTAIN ALL PARTS, GASKET FACES, AND MATING SURFACES ARE ABSOLUTELY CLEAN AND ALWAYS USE CLEAN, FRESH OIL ON THE THREADS BEFORE REINSTALLING BOLTS.2021/6/162021/6/16205205Valve Cap Tightening ProceduresCAUTIONSEVERE PERSONAL INJURY AND PROPERTY DAMAGE CAN RESULT IF VALVE CAP BOLTING IS NOT INSTALLED TO PROPER TORQUE. REFER TO TECHNICAL MANUAL FOR PROPER TORQUING PROCEDURE. 2021/6/162021/6/16206206Valve Cap Tightening ProceduresProperfastenertighteningtechniqueisessentialforsealingofvalvecapswithsoftmetallicwiregasketsusedinsomehighpressurecylinders.Itisimportanttodrawupboltingtofulltorqueinevenandgradualsteps.Donotallowthevalvecaptobetightenedwithbiasononeboltortobecomecockedinthebore.Suchbiasorcockingcancauseunevencrushofthegasket,whichcouldcausealeakandcouldalsocauseboltfailure.Thissteptighteningprocedureisalsorecommendedforallvalvecaps.Lubricatethreadsandboltseatingsurfaceswithpetroleumtypelubricant,andinstallbolts.Donotuseanti-seizecompoundsonvalvecapbolting.Tighteneachboltuntilsnugusingacriss-crosspattern.Next,tighteneachboltto25%offulltorque,movingacrossfrombolttobolt,inacriss-crosspattern.Repeatthisstepfor50%,75%and100%offulltorque.2021/6/162021/6/16207207THELUBRICATIONSYSTEM2021/6/162021/6/162082082021/6/162021/6/162092092021/6/162021/6/162102102021/6/162021/6/162112112021/6/162021/6/162122122021/6/162021/6/162132132021/6/162021/6/162142142021/6/162021/6/162152152021/6/162021/6/162162162021/6/162021/6/162172172021/6/162021/6/16218218FRAME LUBRICATIONArielsLubricationPhilosophy“Ifitmoves,oilit.”2021/6/162021/6/162192192021/6/162021/6/16220220879105346212021/6/162021/6/162212212021/6/162021/6/16222222812356742021/6/162021/6/16223223PressureGaugesOilFilterOilinOiloutThedifferentialpressure,asmeasuredbythetwopressuregauges,isanindicationoftheconditionofthefilter.Whendifferentialpressureexceedsallowablelevels,theoilandfiltermustbechanged.RefertothecompressorTechnicalManualforyourmodelforallowabledifferentialpressure.2021/6/162021/6/16224224One,twoorthreecanisterspin-onfiltersareusedfor1-1/8”,1-1/2”and2”diameterpistonrodunits.2021/6/162021/6/16225225BAC2021/6/162021/6/16226226CYLINDER LUBRICATION2021/6/162021/6/16227227CompressorForceFeedLubricationSystemsCompressorCylindersCompressorRodPacking2021/6/162021/6/16228228Cylinder and Packing Lube Tubing2021/6/162021/6/16229229CompressorForceFeedLubricationSystems:OmniTraps2021/6/162021/6/162302302021/6/162021/6/162312312021/6/162021/6/16232232Fill PointOver Flow LineSight GlassDrainFilterRupture Disc2021/6/162021/6/16233233Check Valve2021/6/162021/6/1623423440 In. Lbs.Purge ConnectionsNo AirNo LeaksNo Dirt2021/6/162021/6/162352352021/6/162021/6/16236236Cross Section of a Lubricator PumpArielusesthePremierhighpressurepump,thispumphasaremovablepistonandcylinder(unscrewsfromthehousing)foreaseofrebuilding.Otherpumpsdonothavearemovablecylinderandcanstillbypasslubricationevenifthepistonisreplaced.Ifthepumpisrebuiltthecylinderandpistonmustbereplacedasamatchedset.2021/6/162021/6/16237237 Lube Oil Distribution Block System2021/6/162021/6/16238238 Divider Blocks2021/6/162021/6/1623923975 In. Lbs.Pressure Gauge, Divider Block and Slow-flow/No-flow ShutdownThepressuregagesuppliedoneverydividerblockisagreattroubleshootingtool.Theneedlemovementshouldbesmoothandthepressureswillreflectthelubricationpointthatisbeingfedbyeachvalve.Erraticmovementofthepointeronthepressuregaugeindicatesimpropercyclingofthedividerblock.Thiscouldbetheresultofair,dirtorovertighteningtheboltsofthedividerblockitself.2021/6/162021/6/162402402021/6/162021/6/16241241SparkPlugs2021/6/162021/6/16242242SparkPlugs2021/6/162021/6/162432432021/6/162021/6/162442442021/6/162021/6/162452452021/6/162021/6/162462462021/6/162021/6/162472472021/6/162021/6/162482482021/6/162021/6/162492492021/6/162021/6/162502502021/6/162021/6/162512512021/6/162021/6/162522522021/6/162021/6/162532532021/6/162021/6/162542542021/6/162021/6/162552552021/6/162021/6/16256256Unit Purge Warning2021/6/162021/6/162572572021/6/162021/6/162582582021/6/162021/6/162592592021/6/162021/6/162602602021/6/162021/6/162612611.空压机气阀空压机气阀环状阀（单环、双环）环状阀（单环、双环）网状阀网状阀蝶状阀蝶状阀2021/6/162021/6/162622621.空压机气阀空压机气阀环环状状阀阀2021/6/162021/6/16263263环环状状网网2021/6/162021/6/16264264环环状状网网2021/6/162021/6/16265265空空压压机机低低压压级级气气阀阀1 12021/6/162021/6/16266266空压机空压机低压低压级气阀级气阀2 22021/6/162021/6/16267267空压机空压机高压高压级气阀级气阀2021/6/162021/6/16268268空压机气阀阀盘空压机气阀阀盘2021/6/162021/6/16269269环环状状碟碟2021/6/162021/6/162702703.3.空压机的冷却空压机的冷却空压机的冷却空压机的冷却1）级间冷却）级间冷却2）气缸冷却）气缸冷却3）后冷却）后冷却4）滑油冷却）滑油冷却2.2.空压机的润滑空压机的润滑空压机的润滑空压机的润滑1）飞溅润滑）飞溅润滑2）压力循环润滑）压力循环润滑一级气缸一级气缸油杯滴油油杯滴油二级气缸二级气缸油勺击溅油勺击溅冷却器冷却器上部为中冷、下部为后冷；上部为中冷、下部为后冷；2021/6/162021/6/162712713.3.气液分离气液分离气液分离气液分离气液分类的形式：气液分类的形式： 惯性式惯性式 过滤式过滤式 吸附式吸附式2021/6/162021/6/162722724.4.余隙容积调节余隙容积调节余隙容积调节余隙容积调节气缸垫气缸垫 垫加厚垫加厚 Vc增加，反之相反；增加，反之相反；曲拐箱曲拐箱 垫加厚垫加厚Vc1增加，增加，Vc2减小，减小，反之相反。反之相反。2021/6/162021/6/16273273二二二二. .空压机的自动控制空压机的自动控制空压机的自动控制空压机的自动控制 排气量调节排气量调节 调节方法（控制方法）：停车法调节方法（控制方法）：停车法空气瓶到空气瓶到3.0MPa 停机，停机，2.2MPa启动。启动。采用采用电触点式压力表电触点式压力表或或压力继电器压力继电器。空车法空车法 压缩机不停，停止供气。压缩机不停，停止供气。1）停止吸入法）停止吸入法增大余隙容积增大余隙容积Vc2）旁通法）旁通法将排气管与大气相同将排气管与大气相同3）压开吸入阀法）压开吸入阀法使吸气阀常开使吸气阀常开2021/6/162021/6/16274274第三节第三节 活塞式空压机的管理活塞式空压机的管理一、操作一、操作1.启动启动2.运转运转3.停用停用滑油温度滑油温度70排气温度排气温度 200 冷却水进出口温差冷却水进出口温差 13 滴油润滑量滴油润滑量46滴滴/分钟分钟气液分离器泄放气液分离器泄放二、检修二、检修1.气阀的研磨气阀的研磨 8字形字形2.活塞环倒角应向上活塞环倒角应向上 防止串油防止串油3.运转方向运转方向 油勺的方向油勺的方向2021/6/162021/6/16275275 结束语结束语若有不当之处，请指正，谢谢！若有不当之处，请指正，谢谢！