Maintenance of double stage double acting reciprocating air compressor (with english subtitles)

Introduction

This tutorial provides a comprehensive guide on the maintenance of a double stage double acting reciprocating air compressor. By following these steps, you will learn when to perform maintenance, how to conduct checks, dismantle the compressor, inspect its components, and reassemble it effectively. Proper maintenance ensures the longevity and efficiency of your compressor.

Step 1: Recognizing Maintenance Needs

• Frequency of Maintenance: Regular maintenance is required based on operating hours and environmental conditions.
• Indicators for Maintenance:
  • Unusual noises or vibrations
  • Decreased performance or pressure
  • Oil leaks or discoloration
  • Increased energy consumption

Step 2: Performing Maintenance Checks

• Visual Inspection:

  • Check for oil levels and leaks.
  • Inspect hoses and fittings for wear.
  • Ensure that all bolts and screws are tight.

• Operational Checks:

  • Test the pressure gauges for accuracy.
  • Monitor the temperature of the compressor during operation.
  • Listen for abnormal sounds during startup and operation.

Step 3: Dismantling the Compressor

• Preparation:

  • Disconnect power supply and ensure safety measures are in place.
  • Gather necessary tools (wrenches, screwdrivers, etc.).

• Dismantling Process:

  1. Remove the outer casing or housing.
  2. Disconnect the suction and discharge valves.
  3. Remove the intercooler tube bundle, if applicable.
  4. Take out the piston assembly from both the high-pressure (HP) and low-pressure (LP) cylinders.

Step 4: Inspection and Corrective Actions

• Inspect Key Components:

  • Pistons: Check for wear or damage.
  • Cylinder Walls: Look for scoring or excessive wear.
  • Valves: Ensure suction and discharge valves are functioning properly.

• Corrective Actions:

  • Replace worn or damaged components (e.g., piston rings, valves).
  • Clean any carbon deposits or debris from components.
  • Lubricate moving parts as necessary.

Step 5: Assembling the Compressor

• Reassembly Steps:

  1. Start with the piston assembly, ensuring proper alignment.
  2. Reinstall the intercooler tube bundle and secure the suction and discharge valves.
  3. Replace the outer casing and ensure all bolts are tightened.

• Final Checks:

  • Confirm that all components are correctly assembled.
  • Refill oil and perform a final inspection for any loose parts.

Conclusion

Proper maintenance of a double stage double acting reciprocating air compressor is crucial for optimal performance and longevity. By recognizing maintenance needs, performing regular checks, carefully dismantling and inspecting components, and reassembling correctly, you can ensure your compressor operates efficiently. Regular maintenance not only extends the life of the equipment but also enhances its performance. Consider establishing a maintenance schedule based on your operating conditions for consistent upkeep.