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Screw compressors are important machines in industrial production. They are used in sectors like manufacturing, automotive, electronics, and food processing. These industries value the compressors' exceptional reliability and efficient air supply. Jinan Golden Bridge Precision Machinery Co. Ltd. is an experienced provider of industrial air solutions which makes quality screw compressors for varying industrial applications. The performance of screw compressors are linked to its surrounding conditions. This is because, poor conditions surrounding a screw compressor will result in a loss of operational efficiency, an increase of maintenance costs, a decrease of general lifespan, and a decrease of overall performance. This makes users wonder, what poor conditions specifically result on the performance of screw compressors? This article will attempt to address this inquiry in a multiple approached way, combined with product advantages from my company and valuable insights from the industry.
The ambient temperature has a strong influence on how screw compressors perform. One of the compressors' reap the benefits from the internal workings of the machine, however, the external temperature can cause the machine to not adequately expel the heat from compression since the heat will not dissipate as it does on colder days. This leads to a compression temperature rise. If the compressor temperature continues to rise and exceeds a theoretical safety temperature of 40 degrees Celcius, the compressor will enter its thermal protection shutdown which stops the machine and causes the facility to go off-line. This can be seen in the Jinan Golden Bridge screw air compressors when the air temperature rises above 35 degrees celcius, the oil cooling system can be even less efficient, and it causes the machine to work harder to maintain output and increases energy consumption. However, there is a safety thermal protection that will stop the compressor and facility from being operational. On the opposite end of the temperature spectrum, there is a theoretical low of 5 degrees Celcius. The oil becomes more viscous when it is colder and there will not be adequate lubrication which increases the wear of the rotor bearings. The company recommends installing the screw compressor in a well-ventilated and temperature-controlled room, and providing heat insulation when the unit is placed outdoors to protect from direct sunlight and cold air drafts.
High humidity presents threats to screw compressors of all types. When moist air enters a compressor, it can mix with the compressor's oil, forming emulsified oil that loses its lubricating and sealing competencies, fast-tracking the rotor and bearing's damage. Plus, the moisture can lead to internal corrosion of the compressor's air tank and pipelines, shortening the device's air compressor's lifespan. Golden Bridge's screw compressors feature moisture separators, but the separator gets used in places with relative humidity over 80% (coastal and rainy seasons). This moist environments require more frequent separator changing taken a toll on the compressor. For example, in a food processing plant with moisture, a screw compressor with no dehumidification device can find oil change intervals of 2,000 hours, instead of the suggested 4,000 hours. The company does advise customers to put in dehumidifiers in the moisture ridden sectors and to help to preserve the internal components of the screw compressor by frequently draining the condensed water held in the compressor's air tank.
Dust, sand, and other particulate matter found in the environment poses a severe threat to screws compressors. When compressors pull in air with particles, it scrapes the precision rotors and increases the volumetric efficiency loss due to bigger gaps in the rotors. Filtered particulates also clog the suction and oil filters, increasing suction resistance and oil flow reduction. Jinan Golden Bridge screw compressors are equipped with air filters that have a filtration efficiency of 1-5 microns. However, dusty environments, such as construction and cement plants, exacerbate the filtration efficiency to be as low as blocked filters in 2-3 months, rather than the 6-8 months in clean areas. Increased pressure on the filters causes the compressors to work harder, leading to a 10% increase in energy consumption. The company suggests to mitigate this with filter replacement and inspection on a regular basis, to take the screw compressors service life one step further. In extremely dusty environments, it is recommended to use pre-filtration systems.
Increased screw compressors rely upon voltage stability within the electric motors powering the device. Any overvoltage and undervoltage can jeopardize the motors and the control systems. Undervoltage of less than 90\% of the rated voltage makes the motor lag at lower speed and consequently prompts the screw compressor to drop its air output and consume a higher current intake, thus posing risk of overheating. At overvoltage higher than 110\% of the rated voltage, the motors winding and the PLC control modules can get burnt. Golden Bridge screw compressors integrate designs that are compatible with voltage stabilizers, such as their SBW series. Screw compressors have proven useful to even out compressor downtimes by 70\%. Golden Bridge screw compressors emphasize the right match with a voltage stabilizer screw compressor to optimize performance in regions with poor power quality.
When it comes to high altitudes, air density impacts air intake volume in screw compressors. Air density begins to decrease at altitudes above 1,000 meters, and every 1,000 meters gives off a decrease of about 10% to the compressor's air output. At 3,000 meters, Golden bridge's (Jinan) 100kW screw air compressor with an output of 15m³/min at sea level, can supply only 12m³/min. A longer time is also required to run the compressor in order to to meet the level of demand for production. This in turn, increases the expenditure of energy and wear. Because of the high altitude, the company compensates with… screw compressors designed for high altitudes. These compressors have increased the sizes of the intake valves and modified rotor profiles. This is to counter balance the lower air density. Therefore, mountain industrial parks users with high altitude should select these to minimize under performance.
Compressed air systems, with their screw compressors, need to be arranged in such a way that heat can be removed effectively from the systems. Lots of the time though, the arrangements of the systems are such that there is inadequate ventilation and space layout that can cause indirect negative impacts in the performance of the screw compressors. Installations that are crowded can cause a blockage in air circulation, and thus lead to overheating. An example; with a screw compressor in a smaller, unventilated, machine room, *exhaust temperatures can rise up to a 25% increase, leading to a 30% reduction in service life.* Something else that can happen in a poorly designed layout, is that working on the systems to do maintenance becomes an unneccessarily complicated task. This will further delay maintenance tasks such as filter changes, and oil inspections. Ventilation and space in the room are critical to the performance of the machine. This is just one example of the maintenance simplicity and cost reduction that can be achieved with a firm layout and unobstructed performance. The comprehensive installation manuals from Jinan Golden Bridge represent some of the best in the business, with such customer service and attention to detail.
Ambient temperature, humidity, dust levels, voltage stability, altitude, and the surrounding environment all influence the performance of screw compressors. Jinan Golden Bridge Precision Machinery Co. Ltd. takes these elements into consideration when engineering their screw compressors and provides tailored options (i.e., high-efficiency filters, voltage regulators, high-altitude versions) to suit different conditions. With these controlled surroundings, the screw compressors can operate maximum output and the user can achieve optimal efficient, reliability, and longevity of the compressors to ensure the compressors provide the steady output needed to suppert their industries. For the companies focused on the optimization of their screw compressors operations, Golden Bridge expertise combined with quality engineering procutcs allow them to achieve their operational productivity and cost savings.