In winter, screw air compressors frequently encounter faults primarily triggered by low temperatures, which increase oil viscosity, cause moisture condensation and freezing, and lead to electrical instability. These issues often stem from a combination of "low temperature + inadequate maintenance." Proactive preventive measures can effectively avoid most problems.
The main faults include:
Excessive Oil Content in Compressed Air — Due to low temperatures increasing oil viscosity and reducing fluidity, the oil-gas separator core's efficiency in separating oil from air decreases. Handling methods include switching to low-temperature specialized compressor oil, appropriately raising the temperature, and replacing clogged filter elements. Prevention involves changing oil in advance and conducting regular inspections.
Icing in Pipelines and Air Storage Tanks — Water vapor in compressed air condenses into ice under low temperatures. Handling requires shutting down the unit, removing ice, and inspecting the dryer. Prevention includes daily drainage, checking the dew point meter, and wrapping pipes with insulation cotton.
Motor Starting Difficulty or Overload Tripping — Low temperatures increase the viscosity of motor lubricant grease, while high winter power loads cause voltage fluctuations. Handling involves checking voltage, replacing lubricant grease, and calibrating overload protector parameters. Prevention includes manually rotating the motor before startup and measuring voltage regularly.
Additionally, three key taboos in winter fault handling are highlighted. Most faults arise from low temperatures combined with poor maintenance; advance prevention can mitigate the majority of issues. The article concludes with technical consultation and related information.
Key Highlights
Excessive Oil Content Fault
This fault manifests as excessive oil contamination in downstream pneumatic components and clogged precision filter elements, affecting product quality. In winter, low temperatures cause compressor oil viscosity to rise, impairing the oil-gas separator core's ability to effectively separate oil and air; oil adhesion can also lead to "oil film blockage." Emergency handling: Switch to low-temperature dedicated compressor oil; if unavailable, raise the temperature while replacing clogged filter elements. Prevention: Change to suitable oil before cold conditions arrive and check oil viscosity weekly. For example, in the food processing industry, excessive oil content can directly contaminate products, making handling and prevention of this fault particularly critical.
Pipeline and Air Storage Tank Icing Fault
Symptoms include normal exhaust pressure but insufficient pressure at downstream air points, with icing on pipeline and tank exteriors, possibly accompanied by unusual noises or leaks. Water vapor in compressed air condenses into ice in winter cold, blocking pipelines and affecting valves and pressure gauges. Emergency handling: Shut down the unit, drain via sewage valves, and use warm water to thaw ice; inspect the dryer. Prevention: Drain water before daily startup, check the dew point meter weekly, and insulate pipelines with cotton wrapping. For instance, in northern winters, unprotected air compressor pipelines are highly prone to icing, disrupting normal production.
Motor Starting Difficulty or Overload Tripping FaultPhenomena include no response on startup, slow rotor speed, overload tripping during operation, and high motor housing temperature. Low temperatures thicken motor lubricant grease, increasing bearing resistance; concurrent high winter power demands cause voltage drops, reducing motor torque. Emergency handling: Verify and adjust voltage, replace lubricant grease, and match overload protector settings. Prevention: Manually rotate the motor before starting and measure voltage monthly. For example, simultaneous operation of heating equipment and air compressors in factories can easily cause voltage issues, leading to motor faults.
The Cause and Solution of `Tripping fault` for Air Compressors ...
Three Taboos in Winter Fault Handling
Avoid using open flames to bake pipelines or storage tanks — high heat can embrittle pipeline materials, and as pressure vessels, tanks risk safety accidents from flame baking; use warm water or low-temperature hot air blowers instead.
Do not ignore minor leaks — winter thermal expansion and contraction make pipeline joints prone to small leaks, where icing easily occurs; check weekly with soapy water and tighten as needed.
Always drain after shutdown — residual water in compressed air can freeze overnight, causing blockages the next day. For example, some factories have neglected minor leaks, leading to severe pipeline icing and production disruptions.
Implementing timely oil changes, insulation, drainage, and voltage monitoring can significantly reduce winter downtime risks for screw air compressors.