• 2025/3/5 10:55:29

Hazards of Long-term Low-load or Unloaded Operation of Screw Air Compressors

I. Decreased equipment performance

1. Reduced compression efficiency: Long-term low-load operation will lead to reduced compression efficiency of screw air compressors. Under low-pressure conditions, the compressor takes longer to complete the compression process, which affects the overall working efficiency. This will not only reduce the production capacity of the equipment, but also increase energy consumption.

2. Increased wear of mechanical parts: When the screw air compressor is unloaded or running at low load, its internal moving parts such as screws and bearings lack sufficient lubrication and cooling, which can easily lead to abnormal wear. This wear not only shortens the service life of the equipment, but may also cause more serious failures, such as screw jamming, bearing damage, etc.

3. Poor oil lubrication: Long-term unloading will cause the internal operating speed of the machine to decrease and the oil lubrication to be poor. This will increase the friction between the machine parts, further aggravate the wear, and may cause machine failure.

4. Oil deterioration and emulsification: Screw air compressors rely on lubricating oil for lubrication and cooling. Long-term low-load or unloaded operation will accelerate the deterioration process of the lubricating oil, especially under high temperature and no-load conditions, water analysis in the compressed air will cause the lubricating oil to emulsify, contaminate, and even fail. This will not only affect the overall performance of the air compressor, but also shorten the service life of the equipment.

II. Increased energy consumption

1. Rising energy consumption: Due to reduced compression efficiency, screw air compressors need to consume more energy to complete the same amount of work when running at low pressure or unloading. This not only increases the operating costs of the enterprise, but also reduces energy utilization efficiency.

2. Reduced energy efficiency: Long-term low-load operation will lead to reduced energy efficiency of screw air compressors. Even if the equipment is running in a seemingly normal working state, its actual energy efficiency will be greatly reduced due to wear and poor lubrication of internal components.

III. Decreased system stability

1. Increased pressure fluctuations: Frequent loading and unloading or long-term low-load operation of screw air compressors will cause unstable internal pressure in the system. This pressure fluctuation will not only affect the stability of the production process, but may also cause damage to the equipment.

2. Increased safety hazards: The decline in system stability may also cause some safety hazards, such as equipment overheating and electrical failure. These safety hazards will not only pose a threat to production safety, but also may harm personnel safety.

IV. Increased risk of equipment failure

1. Lubricating oil deterioration and failure: Due to low load or long unloading time, the lubricating oil temperature is too low (below 70-75 degrees Celsius); the risk of water condensation and precipitation in the compressed air is increased, causing the lubricating oil to emulsify and deteriorate, which in turn causes rotating parts such as bearings and rotors to rust or damage, and the rust residue has the risk of aggravating the blockage of oil filters and oil separators.

2. Failure of other components: Long-term low-load or unloading operation may also cause failures in other components of the screw air compressor, such as solenoid valve damage and oil separator blockage. These failures will not only affect the normal operation of the equipment, but also increase the maintenance cost of the enterprise.

V. Increased maintenance cost

1. Increased maintenance frequency: Due to the decline in equipment performance and increased risk of failure, screw air compressors require more frequent repairs and maintenance during long-term low-load or unloading operation. This will not only increase the maintenance cost of the enterprise, but also affect the reliability and stability of the equipment.

2. Frequent replacement of spare parts: Long-term low-load operation will accelerate the wear and aging of equipment components, resulting in an increase in the frequency of spare parts replacement. This will not only increase the spare parts cost of the enterprise, but also affect the normal operation and production efficiency of the equipment.

VI. Solutions and suggestions

1. Reasonable adjustment of operating parameters: Reasonably adjust the operating parameters of the screw air compressor, such as the outlet pressure setting value, etc. according to the actual situation, so that it can operate within the normal operating pressure range. This helps to avoid damage to the equipment caused by long-term low-load operation and frequent loading and unloading.

2. Adopt high-efficiency energy-saving technology: Introduce advanced energy-saving technologies, such as variable frequency speed regulation, to reduce the energy consumption of screw air compressors when running at low pressure or unloading. This can not only improve the energy utilization efficiency of the enterprise, but also help reduce operating costs.

3. Strengthen equipment inspection and maintenance: Regularly inspect and maintain the screw air compressor to ensure that it is in good working condition. This includes checking the oil level of the compressor, the filter element, and the tightening of each component. Timely discovery and resolution of problems that arise during the operation of the equipment will help ensure the stable operation of the equipment and extend its service life.

4. Operator training: Strengthen the training of screw air compressor operators to improve their skills and equipment maintenance awareness. This helps to promptly discover and solve problems that occur during the operation of the equipment and ensure the stable operation of the screw air compressor.

In summary, long-term low-load or unloaded operation of screw air compressors will cause a series of hazards to equipment performance, energy consumption, system stability, failure risk, and maintenance costs. Therefore, enterprises should take effective measures to avoid this situation, ensure the stable operation of screw air compressors and reduce operating costs.