How long can the screw air compressor work continuously?

Analysis of continuous operation ability of screw air compressor

Screw air compressors are widely used as compressed air equipment in the industrial field. Their continuous operation capability is affected by multiple factors such as equipment design, operating environment, maintenance level and load characteristics. From a professional perspective, combined with industry specifications and typical application scenarios, the continuous operation capabilities and guarantee measures of screw air compressors are systematically described.

1. Design standards and continuous operation capabilities

1. design continuous operating time
   • Industrial-grade standards: The designed continuous running time of the main engine and key components (such as bearings and screw rotors) of screw air compressors is usually 8,000 – 12,000 hours. Based on 16 hours of operation per day, the theoretical continuous running period can reach 1.5-2.5 years.
   • service life: Taking into account the motor, cooling system, electrical components and other components, the design life of the whole machine is generally 10-15 years, during which multiple maintenance and component replacement are required.
2. Manufacturer recommended operating mode
   • intermittent operation: Most manufacturers recommend a “run-stop” cycle mode, such as 1 hour shutdown after 8 hours of operation, to reduce component wear and energy consumption.
   • Continuous operating conditions: Under ideal conditions of ambient temperature ≤40℃, intake air dust content ≤1mg/m³, and cooling water temperature ≤32℃, screw air compressor can operate continuously for more than 72 hours, but requires enhanced maintenance and monitoring.

2. Key factors affecting continuous operation

1. environmental conditions
   • temperature: For every 10 ° C increase in ambient temperature, the oxidation rate of lubricating oil doubles and the bearing life is shortened by 40%. High temperature environments require enhanced cooling system maintenance.
   • dust: When the dust concentration exceeds 1mg/m³, a high-efficiency pre-filter needs to be equipped, otherwise the wear of the main machine will increase by 5 times and the continuous running time will be shortened by more than 50%.
   • humidity: In high-humidity environments, it is necessary to strengthen the protection of electrical components to prevent the risk of short circuit caused by condensation.
2. load characteristics
   • full-load operation: Continuous full-load operation will cause the main engine temperature to increase by 10-15 ° C and the viscosity of the lubricating oil to decrease. The oil change period needs to be shortened to 2000 hours.
   • variable load operation: The screw air compressor driven by frequency conversion can automatically adjust the speed according to the air consumption, reducing energy consumption and component wear, and is suitable for long-term continuous operation.
3. maintenance level
   • Three-level filtration maintenance: The pre-filter is replaced every 2000 hours, the oil filter is replaced every 4000 hours, and the oil and gas separator is replaced every 8000 hours, which can extend the life of the main engine by 30%.
   • lubrication management: Regularly test the viscosity, acid value and metal particle content of the lubricating oil, and replace it in time when it deteriorates to prevent major failures such as mainframe jamming.

3. Guarantee measures for continuous operation

1. Enhanced cooling system
   • air-cooled unit: Clean the cooling fins quarterly to ensure that the ventilation area is ≥90%; add axial fans in high temperature environments to enhance heat dissipation.
   • water-cooled units: Check the pH value (6.5-8.5) and conductivity (≤500μS/cm) of cooling water every six months to prevent the decline in heat exchange efficiency caused by fouling.
2. Intelligent monitoring and early warning
   • IoT systems: Deploy pressure, temperature, and current sensors, monitor equipment status in real time, and set high temperature (≥85℃) and high pressure (≥ rated pressure) alarm thresholds.
   • energy efficiency management system: Optimize operating parameters through data analysis, reduce energy consumption by 10%-15%, and extend continuous running time.
3. preventive maintenance program
   • monthly inspection: Check key parameters such as vibration intensity (≤7.1mm/s), bearing temperature (≤80℃), and lubricating oil level.
   • annual overhaul: Disassemble and check rotor clearance and bearing clearance, replace worn parts, and clean the cooling system to ensure that equipment performance is restored to more than 90% of its original state.

4. Continuous operation risks and prevention and control

1. risk analysis
   • components from overheating: Continuous operation will cause the temperature of the main engine, motor, bearings and other components to increase, accelerating lubrication oil oxidation and component wear.
   • Energy efficiency attenuation: After long-term operation, the specific power of the equipment (kW/m³/min) may increase by 10%-20%, and energy consumption will increase significantly.
   • security risk: Overtemperature and overpressure operation may cause safety accidents such as electrical faults and pipeline bursts.
2. prevention and control measures
   • temperature control: Set the main engine exhaust temperature alarm (≥100℃) and equipped with a backup cooling system to ensure temperature stability.
   • pressure monitoring: Monitor exhaust pressure in real time through pressure sensors to prevent overpressure operation.
   • emergency plan: Formulate emergency plans for high temperature and overpressure, including emergency shutdown procedures, pressure relief operation steps, personnel evacuation routes, etc.

5. Typical application scenarios

1. 24-hour continuous production scene
   • industry: Steel metallurgy, petrochemicals, food and beverage, etc.
   • configured: Multiple screw air compressors are used in parallel, equipped with standby units and intelligent control systems to achieve automatic switching and load distribution.
   • maintenance: Equipment inspections are carried out every shift and in-depth maintenance is carried out quarterly to ensure continuous operation stability.
2. Intermittent production scenarios
   • industry: Mechanical processing, automobile maintenance, furniture manufacturing, etc.
   • configured: A single screw air compressor is adopted, equipped with an air storage tank and a cold dryer to meet the intermittent gas demand.
   • maintenance: Conduct monthly equipment inspections and carry out comprehensive maintenance every year to extend the service life of the equipment.

conclusion

The continuous operation capability of screw air compressors requires comprehensive consideration of equipment design, environmental conditions, load characteristics and maintenance levels. By strengthening the cooling system, deploying intelligent monitoring, and implementing preventive maintenance, the continuous operation capability of the equipment can be significantly improved. Enterprises should establish an equipment operation management system, clarify continuous operation conditions, monitoring indicators and emergency response procedures, and regularly train operators to ensure that the equipment operates in a safe and efficient state and provide a stable and reliable compressed air supply for production.