4 Treatment Measures for Insufficient Exhaust Pressure of Screw Air Compressors

Introduction

In industrial production, screw air compressors are widely used across various manufacturing enterprises due to their high efficiency, reliability, and broad application range. However, insufficient exhaust pressure is a common and significant issue that can severely affect compressor performance. When the exhaust pressure is insufficient, the equipment cannot provide an adequate supply of compressed air, which negatively impacts production efficiency and may even lead to production shutdowns.

Therefore, timely and accurate diagnosis and resolution of this issue are crucial to ensuring continuous production and the normal operation of equipment. This article will analyze the causes of insufficient exhaust pressure, introduce diagnostic methods, and propose practical solutions to help enterprises optimize the operation of their screw air compressors.

1. Risks of Insufficient Exhaust Pressure

Insufficient exhaust pressure can lead to various negative consequences:

1. Production Disruptions:

   • Pneumatic tools and equipment may not function properly.
   • Manufacturing processes that require a specific air pressure may be disrupted.

2. Equipment Damage:

   • Long-term operation under low pressure increases wear on internal components.
   • Poor lubrication circulation due to insufficient pressure can reduce the lifespan of the equipment.

3. Increased Energy Consumption:

   • The compressor takes longer to reach the required pressure level.
   • Frequent start-stop cycles lead to higher energy consumption.

4. Safety Hazards:

   • Pneumatic control systems, such as pressure valves, may fail to operate correctly.
   • This could create potential safety risks in the production environment.

2. Causes of Insufficient Exhaust Pressure

Insufficient exhaust pressure is typically caused by issues in the intake system, compression system, exhaust system, or control system.

2.1 Problems in the Intake System

1. Clogged Air Filter

   • Cause: Dust and impurities accumulate in the filter, increasing intake resistance.
   • Impact: Reduced intake volume leads to lower compressed air output.

2. Air Intake Pipe Leaks

   • Cause: Poor sealing at pipe joints or damaged pipes.
   • Impact: Reduced intake volume affects the production of compressed air.

3. Malfunctioning Intake Valve

   • Cause: The intake valve is stuck or damaged.
   • Impact: Insufficient air intake reduces compression efficiency.

2.2 Problems in the Compression System

1. Worn Rotors

   • Cause: Long-term operation leads to increased rotor clearance.
   • Impact: Reduced compression efficiency results in insufficient exhaust pressure.

2. Bearing Failure

   • Cause: Worn or damaged bearings cause unstable rotor operation.
   • Impact: Unstable rotor movement affects compression performance.

3. Seal Leakage

   • Cause: Aging or damaged seals lead to air leakage.
   • Impact: Leaking compressed air causes a drop in exhaust pressure.

2.3 Problems in the Exhaust System

1. Blocked Exhaust Pipe

   • Cause: Oil, impurities, or scale buildup restricts airflow.
   • Impact: Increased exhaust resistance leads to lower exhaust pressure.

2. Faulty Exhaust Valve

   • Cause: The exhaust valve is stuck or damaged.
   • Impact: Poor air discharge leads to pressure reduction.

3. Insufficient Air Tank Pressure

   • Cause: Inadequate air tank capacity or incorrect pressure settings.
   • Impact: The air tank cannot provide sufficient buffering, causing pressure fluctuations.

2.4 Problems in the Control System

1. Malfunctioning Pressure Sensor

   • Cause: A faulty pressure sensor provides inaccurate pressure readings.
   • Impact: The control system fails to regulate exhaust pressure properly.

2. Defective Pressure Control Valve

   • Cause: A stuck or damaged valve prevents accurate pressure regulation.
   • Impact: Ineffective pressure control reduces operational efficiency.

3. PLC System Malfunction

   • Cause: Errors in the PLC program or damaged modules.
   • Impact: The equipment fails to function correctly, leading to insufficient exhaust pressure.

3. Diagnostic Methods for Insufficient Exhaust Pressure

1. Observe the Pressure Gauge

   • Check if the displayed pressure is below the required setpoint.
   • Monitor pressure fluctuations for abnormal behavior.

2. Inspect the Intake System

   • Clean or replace the air filter to remove dust and debris.
   • Check for leaks in the intake pipe and ensure proper sealing.
   • Verify that the intake valve operates correctly and is not stuck or damaged.

3. Examine the Compression System

   • Measure rotor clearance and adjust it if necessary.
   • Inspect bearings for wear and replace them if needed.
   • Check seals for leaks and replace them if they are damaged.

4. Inspect the Exhaust System

   • Check for blockages in the exhaust pipe and clean if necessary.
   • Ensure the exhaust valve is functioning correctly and not stuck or faulty.
   • Verify that the air tank pressure setting is appropriate and its capacity is sufficient.

5. Test the Control System

   • Calibrate or replace the pressure sensor for accurate measurement.
   • Check the pressure control valve for malfunctions and replace if needed.
   • Inspect the PLC system for software or hardware faults.

4. Treatment Measures for Insufficient Exhaust Pressure

4.1 Intake System Solutions

• Replace the air filter regularly to ensure proper airflow.
• Repair or replace damaged intake pipes to prevent leaks.
• Fix or replace a faulty intake valve to restore proper functionality.

4.2 Compression System Solutions

• Adjust rotor clearance according to manufacturer specifications.
• Replace worn bearings to maintain stable rotor movement.
• Replace aging seals to prevent compressed air leaks.

4.3 Exhaust System Solutions

• Clean the exhaust pipe regularly to remove oil, impurities, and scaling.
• Repair or replace a faulty exhaust valve to ensure smooth airflow.
• Adjust the air tank pressure settings to meet production requirements.

4.4 Control System Solutions

• Calibrate or replace the pressure sensor to ensure accurate readings.
• Repair or replace a defective pressure control valve for proper pressure regulation.
• Check and troubleshoot the PLC system to fix errors in programming or faulty modules.

Conclusion

Insufficient exhaust pressure in screw air compressors is a complex issue that can stem from multiple factors, including the intake, compression, exhaust, and control systems. By implementing timely and accurate diagnostic measures, as well as effective treatment solutions, companies can successfully resolve this issue and ensure the stable and efficient operation of their equipment.

It is hoped that this article provides valuable insights and guidance for enterprises, enabling them to effectively manage exhaust pressure issues, improve equipment reliability, and reduce operational costs.

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