Troubleshooting of diaphragm compressor

Summary: Common faults problems and troubleshooting methods.

When diaphragm compressor can’t work normally, it is available to trouble shoot fault reasons according to kinds of common faults of diaphragm compressor, and trouble shoot faults to make sure the machine can work normally.

Kinds, reasons and troubleshootings of common faults of compressor

The pressure of lubricating oil is reduced suddenly, lower than 0.2MPa

1. Lack of lubricating oil in crankcase.

2. Blocking of filter and filter components.

3. Malfunction of oil pressure gauge.

4. Blocking or rupture of oil tube.

5. Out of action of oil supply system.

6. Viscosity of oil is reduced.

7. Imprecision of each joint part of oil tube.

8.Severe wear of bearing bush and copper bush of movement mechanism.

9. Damage of gear pump.

10. Aging of sealing component

 

1. Add oil immediatelly

2. Cleaning.

3. Replace the oil pressure gauge.

4. Check and repair oil tube.

5. Check oil supply system.

6. Replace lubricating oil according to requirements.

7. Screw down nuts or add gaskets.

8. Check and repair bearing bush and copper bush.

9. Replace gear shaft.

10. Replace sealing components.

 

No oil supply of compensating oil pump

1. Untight of oil inlet and outlet valve port.

2. Untight close of inlet and out oil valve.

3. Pressure of gear oil pump is lower than 0.3MPa.

4. Wrong location and direction of inlet and out oil valve.

 

1. Replace.

2. Unpick and wash inlet and outlet oil valve.

3. Check the reason of oil pressure.

4. Check carefully and install again.

 

Overtemperature of lubricating oil

1. Short supply of lubricating oil.

2. Inferior quality of lubricating oil, poor heat dissipation.

3. Lubricating oil is too dirty and increase mechanical wear.

4. Mechanical failures of moving machines.

5. Poor cooling.

 

1. Check oil leakage and loss, add lubricating oil.

2. Replace eligible lubricating oil.

3. Clean oil sump, replace lubricating oil.

4. Check and repair trouble components.

5. Increase cooling water.

 

Water leaking or other faults of cooling water system

1. Water tube leaking.

2. Too much water scale and overtemperature of gas discharge.

 

1. Repair and replace.

2. Clean water scale.

 

Fault of safety valve

1. Fail to open it in time.

2. Fail to open it.

3. Untight close.

 

1. Update the calibration.

2. Update the calibration.

3. Clean dirt and regrind.

 

Overheat of main bearing bush

1. Poor contact surface of cross-section diameter and bearing bush.

2. Radial clearance is too small.

3. Poor oil supply.

 

1. Check and repair.

2. Check and repair.

3. Check and repair lubrication system.

 

Pressure regulating valve not works normally

1. Untight valve seat and valve port.

2. Spring loses elasticity.

3. Failure of the gasket under pressure regulating valve.

 

1. Replace.

2. Replace.

3. Replace gasket or increase the thickness of gasket.

 

Slave valve not works normally

1. Diaphragm rupture and untight sealing.

2. Oil tube blocking.

3. Broken valve seat and valve port.

 

1. Replace.

2. Clean.

3. Repair or replace.

 

Abnormal sounds

1. Pat of cylinder.

2. Strikes of connecting rod and crankshaft counterweight.

3. Bad cooperation of big pulley and crankshaft taper or pulley is loose.

4. Gas valve is loose.

5. Improper size or wearing of rolling grains of bearing.

6. Bolt of connecting rod is loose.

7. Crosshead and piston rod is loose.

8. Big ellipticity, tolerance clearance of crankshaft main journal, crank neck or cross head pin.

9. Stabbed crosshead slide.

 

1. Short of oil of oil cylinder, check oil pressure of oil cylinder.

2. Regulate clearance and get rid of redundance part.

3. Replace big pulley to make the conical contact surface over 70%, and tighten big pulley.

4. Tighten the gland nut of valve.

5. Replace.

6. Tighten and lock.

7. Tighten hat back and lock.

8. Check the clearance and ellipticity of accessories, repair or replace.

9. Repair and replace.

 

Insufficient gas displacement

1. Untight valve port of suction and discharge valve, and clamping stagnation of suction and discharge valve.

2. Big clearance of suction and discharge valve.

3. Abnormal oil pressure.

4. Locally abnormal gas leakage.

5. Uneven tension force of diaphragm and diaphragm gas entrapment.

 

1. Repair and replace.

2. Reduce clearance.

3. Repair.

4. Take sealing measures according to leak locations.

5. Evenly tighten bolt of gas cylinder.

 

No oil pressure after starting

1. Insufficient oil amount in oil cylinder.

2. Abnormal compensating oil pump.

3. Abnormal regulating valve (slave valve).

4. Unclosed unloading valve of pressure gauge.

 

1. Check oil amount of crankcase, and replenish oil.

2. Troubleshooting.

3. Troubleshooting.

4. Close.

 

Abnormal pressure of oil cylinder

1. Abnormal regulating valve.

2. Abnormal compensating oil pump.

3. Diaphragm rupture.

4. Untight sealing surface of cylinder block.

5. The one-way valve and damper under oil pressure gauge not work normally, and the pointer fiercely swings back and forth.

 

1. Troubleshooting and replace.

2. Troubleshooting and replace.

3. Replace.

4. Troubleshooting.

5. Replace and clean.

 

Oil and gas leakage of sealing surface of cylinder block

1. The tightening force of bolt of cylinder cover is too small or uneven.

2. Sealing surface is defective.

3. O-rings is broken.

4. Untight sealing of tube joints.

 

1. Tighten bolt.

2. Repair sealing surface.

3. Replace O-rings.

4. Repair or replace.