Analysis and Solutions to Common Problems of Nitrogen Generation Systems in Summer
As we all know, extreme weather poses a severe test to equipment stability, especially high temperatures in summer. This article lists frequent malfunctions occurring in nitrogen generation systems during summer. Feel free to leave a comment to supplement any missing issues.
A nitrogen generation system consists of an air compressor, air storage tank, purification assemblies (refrigerated air dryer, heat regenerative adsorption dryer and filters), purified air buffer tank, main nitrogen generator unit and nitrogen buffer tank. The entire system relies on the air compressor to supply compressed air.
High temperature is the primary culprit triggering system failures in summer. Rising ambient temperature directly affects the discharge temperature of the air compressor. Excessively high discharge temperature is a prevalent issue in hot seasons. If ignored, persistent overheating will reduce the air output efficiency of the compressor, accelerate equipment wear and shorten service life in mild cases; in severe cases, it may damage components of the whole system. Therefore, implementing effective overheating prevention measures is critical to ensuring stable operation of the entire nitrogen generation system.
Special attention should be paid to the following aspects to prevent overheating failures:
1. Excessively High Ambient Temperature
High heat is more prominent in factory workshops during summer, making good ventilation extremely important. Excessively high room temperature usually stems from unreasonable design of the compressor and nitrogen generator station with poor ventilation, trapping heat dissipated by air compressors inside the room. An air deflector can be installed on the air compressor to channel hot air from its exhaust fan directly outdoors.
Besides air compressors, refrigerated dryers and heat regenerative adsorption dryers also generate heat during operation. If the station has poor natural ventilation, additional exhaust fans are strongly recommended. Air intake and exhaust vents shall be installed on walls facing open outdoor spaces to expel hot air and lower indoor temperature.
No high-temperature heat sources shall be placed inside the station. High ambient temperature around the compressor leads to high intake air temperature, which in turn raises lubricating oil temperature and discharge temperature.
2. Overhigh Discharge Temperature of Air Compressor
When the ambient temperature is high, the compressor inhales hot air, resulting in elevated discharge temperature and frequent overheating alarms.
The optimal operating temperature range for air compressors is 30℃ ~ 40℃.
3. Lubricating Oil Level of Air Compressor
Check the oil level via the oil sight glass on the oil-gas separator tank. Shut down the unit immediately and replenish proper amount of lubricating oil if the level falls below the normal range to avoid unit overheating.
Degraded oil or expired lubricant suffers poor fluidity and weakened heat exchange performance, preventing full heat dissipation from the compressor head and eventually causing overheating.
4. Filter Element Performance
Blockage frequently occurs to air filter elements, oil filter elements and oil separator cores:
- Clogged air filter increases compressor load and causes overheating under long-term heavy-duty operation;
- Blocked oil filter reduces oil flow, resulting in incomplete heat dissipation and high temperature;
- Fouled oil separator leads to excessive internal pressure and temperature rise.
5. Cooler
Inspect the cooler for clogging. Blocked coolers directly degrade heat dissipation and trigger unit overheating. Clean residues and blockages on the cooler to prevent compressor overheating.
Verify the normal functioning of cooling fans and fan motors. For water-cooled air compressors, the inlet water temperature should generally not exceed 35℃ with water pressure maintained between 0.4~0.6 MPa. A cooling tower can be installed if these requirements cannot be met.
6. Temperature Sensors
A faulty temperature sensor may send false over-temperature alarms and trigger emergency shutdown. Malfunction of the thermostatic valve may allow lubricating oil to bypass the cooler and flow straight into the compressor head, failing to lower oil temperature and resulting in overheating.
7. Air Buffer Tank
When compressed air discharged by the compressor flows through the air storage tank, high-speed airflow impacts the tank wall to form confluence, rapidly reducing air temperature inside the tank. A large amount of water vapor condenses accordingly, removing most moisture and oil from compressed air. Adjust drainage duration and intervals according to water accumulation volume, and an automatic drain valve can be retrofitted as needed.
8. Purification Assemblies
Install automatic drain valves for filters. Adjust the electronic drain valves of refrigerated dryers by extending drainage time and shortening drainage intervals based on actual operating conditions.
In conclusion, minor routine adjustments can effectively prevent equipment failures. Only stable equipment operation can deliver efficient service and improve overall work efficiency.
