• 2025/2/25 9:22:15

Why does the safety valve of air compressor frequently jump?

Air compressor safety valve as an important protection equipment, its main function is to automatically open when the internal pressure of the system exceeds the set value, and release excessive gas to protect the system from high pressure damage. However, in practical applications, it is not uncommon for air compressor safety valves to jump frequently, which not only affects the normal operation of air compressors, but also may cause damage to equipment. This paper will conduct an in-depth analysis of the reasons for the frequent jump of air compressor safety valves from multiple angles, in order to provide a professional reference for relevant practitioners.

First, the oil partial pressure difference causes the safety valve to jump

The large differential oil pressure is a common reason for the frequent jump of air compressor safety valve. When the pressure difference is large after the oil is used for a short time, it is mainly due to the pollution or deterioration of the oil. Although the oil separating filter oil separates the oil from the compressed air, oil contaminants also remain on the filter material, resulting in increased resistance and increased pressure differential. When this pressure difference exceeds the take-off pressure set by the safety valve, the safety valve will protect the take-off.

Pollutant source analysis:

1. Air intake system: poor air dust environment at the user site, or the air intake system seal gap is not tight, will lead to a large amount of dust and impurities into the air compressor system, and then pollute the oil.

2. Oil system: Unreasonable oil selection or residue of oil circuit system can also lead to oil pollution. Improper oil selection may lead to oil deterioration at high temperature or high pressure, resulting in sediment; The residue of the oil circuit system may be left in the system due to incomplete cleaning.

3. Machine operating conditions: Long-term high temperature operation of the machine will produce caking and scaling, while long-term low temperature operation or low start-up rate may lead to large water content of the barrel. All these will aggravate the pollution and deterioration of oil products.

Handling suggestion:

• Accurately locate the source of contaminants and replace the contaminated oil.

· After parking and decompression, use a clean mineral water bottle to connect a certain amount of lubricating oil to the outlet of the oil distribution barrel, and let it stand for observation to check whether there are any abnormalities in the lubricating oil, such as granular impurities, viscous substances, and black blocks at the bottom. Carbon deposits, water quantity, whether there is an odor, etc

• According to the abnormal condition of lubricating oil, take corresponding treatment measures, such as replacing the air filter, cleaning the oil circuit system, replacing the oil, etc.

Second, the safety valve failure or improper setting

The problem of the safety valve itself is also an important reason for its frequent jump. Safety valve failure may be manifested as failure to open or close properly, or improper opening pressure setting.

Cause analysis of safety valve failure:

1. Weak seal: the sealing surface of the safety valve is worn or polluted seriously, resulting in weak seal and gas leakage.

2. Spring failure: the spring of the safety valve is tired or damaged due to long-term use, resulting in unstable opening pressure.

3. Loose adjustment screws: The adjustment screws on the safety valve are loose or damaged, resulting in the opening pressure can not be accurately set.

Improper safety valve setting analysis:

• The opening pressure is set too low: If the opening pressure of the safety valve is set too low, a slight increase in the internal pressure of the system may trigger the safety valve to jump.

• High start pressure: Although the high start pressure can prevent frequent take-off, it may also cause high internal pressure in the system, which damages the device.

Handling suggestion:

• Check the tightness and opening pressure of the safety valve regularly, and replace or maintain it in time if any abnormality is found.

• For safety valves with spring failure, replace them with new springs.

• For safety valves with loose or damaged adjustment screws, tighten or replace the adjustment screws and reset the opening pressure.

• Set the opening pressure of the safety valve reasonably according to the system requirements to ensure that the system is protected and frequent trips are avoided.

Third, the machine does not uninstall or load abnormal

The air compressor will be unloaded when it is loaded to a certain pressure, and the pressure will not keep rising. If the unloading is displayed on the machine panel, but the machine continues to load, the pressure will continue to rise and exceed the starting pressure of the safety valve. Cause the safety valve to jump.

The machine does not uninstall or load abnormal cause analysis:

1. Loading and unloading control valve failure: loading and unloading control valve is a key component to control the loading and unloading of air compressor. If it fails, the air compressor cannot be unloaded normally.

2. Solenoid valve failure: The solenoid valve is another important part of the control of air compressor loading and unloading, if it fails, it may also lead to the air compressor can not be unloaded normally.

3. Control system failure: The control system of the air compressor is responsible for monitoring and regulating the operating state of the air compressor. If the control system fails, the air compressor may not respond correctly to the unloading instruction.

Handling suggestion:

• Check the working status of loading and unloading control valve and solenoid valve, and replace or maintain the fault in time.

• Check the operating status and parameter Settings of the control system to ensure that the control system can correctly monitor and adjust the operating status of the air compressor.

• For control system failures, professional maintenance personnel should be contacted for overhaul and commissioning.

Fourth, the air outlet is not smooth

The air outlet is blocked by foreign matter or the minimum pressure valve is not sensitive and other factors may lead to the machine's air is not smooth, and the safety valve will intermittently jump when this phenomenon occurs.

Cause analysis of unsmooth air outlet:

1. Foreign body blockage: there may be dust, impurities and other foreign bodies in the air outlet pipeline, resulting in pipeline blockage or poor airflow.

2. Minimum pressure valve failure: The minimum pressure valve is used to control the minimum pressure at the outlet of the air compressor. If it fails or acts insensitively, it may cause abnormal air flow fluctuations.

Handling suggestion:

• Check the cleanliness and working status of the outlet pipe and minimum pressure valve regularly, and clean or replace the blocked or faulty foreign matter in time.

• For minimum pressure valve failure, professional maintenance personnel should be contacted for repair and commissioning.

5. System design and operation problems

In addition to the above specific reasons, air compressor system design and operation problems may also lead to frequent safety valve jumping.

System design and operation problem analysis:

1. The system pressure setting is unreasonable: If the system pressure setting is too high or too low, it may cause the safety valve to jump frequently.

2. Large system load fluctuation: Large system load fluctuation may lead to frequent loading and unloading of the air compressor, which triggers the safety valve to take off.

3. Poor system heat dissipation: Poor system heat dissipation may cause the air compressor temperature to be too high, which affects the oil performance and system pressure stability.

Handling suggestion:

• Set the system pressure according to the system requirements to ensure that the production needs can be met and the safety valve can avoid frequent tripping.

• Optimize system load management to reduce the impact of load fluctuations on air compressor operation.

• Strengthen the system heat dissipation management to ensure that the air compressor can operate at the appropriate temperature.

The frequent take-off of air compressor safety valve is a complicated problem, which involves many factors. To solve this problem, it is necessary to conduct in-depth analysis and investigation from multiple angles such as oil partial pressure difference, safety valve itself, machine loading and unloading control, air outlet patency, system design and operation. At the same time, it is also necessary to strengthen the daily maintenance and maintenance work of air compressors, and timely discover and deal with potential problems and hidden dangers. Only in this way can we ensure the safe and stable operation of the air compressor and extend the service life of the equipment.