Leakage is one of the crucial issues to be dealt with to improve energy efficiency. After compressed air is discharged from the compressor, it needs to be transported through a pipeline. If there is a leakage problem in the pipeline at the use site, it will increase the air compressor’s energy consumption and cause unnecessary waste. Therefore, effective leak management is crucial for saving energy with screw air compressors. The following provides common pipeline leakage failures and solutions.
Safety Valve Leaks
Issue: The spring bearing surface of the safety valve is not perpendicular to the spring centerline. When the centerline of the valve spring is not perpendicular to the supporting surface and the spring valve is compressed, it will deflect. This will cause an uneven force on the disc of the safety valve, leading to warping, air leakage, oscillation, and possible failure of the safety valve.
Solution: Adjust the verticality of the spring support surface of the safety valve to the centerline of the spring. Keep them perpendicular to each other, then clean up the impurities and dirt between the safety valve and the valve seat. Re-grind if necessary to ensure a tight contact surface. The valve spring of the safety valve should be pressed tightly, the thread and sealing surface should be protected, and the damaged parts should be repaired and ground.
Air Leak in Piping System
Issue: The cause of air leakage is often due to inferior quality materials and accessories or the quality of the installation. The sinking of the bracket in the air compressor pipeline causes severe deformation and cracking of the pipeline. The accumulation of water in the pipeline will cause the pipe or fittings to crack and burst.
Solution: Repair or replace damaged pipe sections and fittings. Regularly remove the water in the pipeline to prevent freezing and cracking. When the pipeline supports sinks, the support should be repaired, and the slope of the pipeline adjusted to facilitate drainage.
Additionally, using too many elbows in the compression system can cause airflow resistance to increase, and additional work points are formed. Simultaneously, gas shocks are formed at the elbows, and the local pressure increases, making it continue to operate at high air pressure. For an easy uninstall, be sure to optimize the system piping by avoiding the use of elbows, which will also reduce energy consumption.
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