The operation steps and precautions for the initial startup of a new air pump

The first start-up of the new air pump must strictly follow the standardized procedures. Through installation inspection, system preparation, operation monitoring and other links, the safe operation of the equipment should be ensured to avoid mechanical damage or electrical failure caused by improper operation. The following are the phased operation guidelines and core precautions:

First, check and prepare before startup

1. Installation compliance confirmation

Basic fixation:

Check the tightening torque of the connecting bolts between the air pump and the base (refer to the equipment manual. For example, the M16 bolt needs to be tightened to 320-380N·m).

Use a level to measure the axial/radial levelness of the air pump, with an error of no more than 0.1mm/m(to avoid intensified vibration during high-speed operation).

Pipeline connection:

Confirm that a 40μm grade pre-filter is installed at the air inlet (insufficient filtration accuracy will cause impurities to enter the cylinder), and the diameter of the pipe connected to the air storage tank at the exhaust port should be ≥ 1.2 times the diameter of the air pump's exhaust port.

Check the material of the gaskets at all flange connections (with a pressure resistance of ≥1.5 times the system pressure and a temperature resistance of ≥120℃), and apply silicone flat sealant.

Electrical wiring

Check the phase sequence of the three-phase power supply in the motor junction box (which can be detected by a phase sequence meter). Incorrect phase sequence will cause the air pump to reverse (manifested as no airflow at the exhaust port and the pressure gauge not rising).

Measure the insulation resistance of the motor (using a 500V megohmmeter), and the resistance of the winding to ground should be ≥5MΩ(≥1MΩ in a humid environment).

2. System preparation

Lubrication system

Add grease to the gearbox/bearing chamber to 1/2 to 2/3 of the oil level mirror (excessive grease will cause high-temperature leakage, while insufficient grease will accelerate wear).

Before the first start-up, manually rotate the coupling 3 to 5 times to ensure uniform rotational resistance (normal resistance ≤3N·m; abnormal resistance may result from bearing jamming or assembly interference).

Cooling system

For air-cooled air pumps, the gap between the heat dissipation fins needs to be cleaned (use compressed air to blow off burrs/cotton fluff). For water-cooled ones, the cooling water flow rate (≥0.5L/min) and the temperature difference between the inlet and outlet (normal ≤15℃) need to be checked.

Safety device:

Verify the take-off pressure of the safety valve (set at 1.1 times the working pressure, with an error of ≤±3%), and test the action value of the pressure switch (set at 90% of the rated pressure to trigger the alarm).

Second, start the operation process

1. Start without load

Step:

Close the intake valve of the air storage tank and open the bypass valve (to directly vent the exhaust).

Start the air pump and observe the pointer of the ammeter:

The starting current should be 5 to 7 times the rated current (lasting for less than 3 seconds). If the overload persists, the machine should be stopped immediately for inspection.

After the current stabilizes, record the no-load operation current (which should be ≤ 40% of the rated current).

Run without load for 5 to 10 minutes, during which monitor:

Bearing temperature (≤70℃, detected by infrared thermometer).

Vibration intensity (ISO 10816 standard: Vibration velocity ≤4.5mm/s when rotational speed ≤1500rpm).

Abnormal sounds (such as metal friction sounds, the machine needs to be shut down for inspection).

2. Loading test

Step:

Slowly close the bypass valve and simultaneously open the air intake valve of the air storage tank (each adjustment should be ≤10% opening, with an interval of 30 seconds).

Observe the pressure gauge:

The time for the pressure to rise from 0 to the rated value should conform to the equipment curve (for example, for a 0.8MPa air pump, it should be ≤90 seconds).

After reaching the rated pressure, check the pressure maintenance condition (the pressure drop within 10 minutes is ≤0.02MPa).

Record the full-load operation parameters:

Displacement (error from the nameplate value ≤±5%).

Exhaust temperature (≤ ambient temperature +80℃, if exceeded, the cooling system needs to be checked).

Motor temperature rise (temperature rise of B-class insulation motor ≤80K).

Third, precautions for the first startup

List of Prohibited behaviors

Absolutely prohibited:

Start under pressure (pressure relief is required first when the pressure of the gas storage tank is greater than 0.1MPa).

Frequent starts and stops (with an interval of ≥10 minutes between two starts to prevent the motor from overheating).

Overload operation (if the pressure exceeds the rated value by 5%, it is regarded as overload).

Risk example: A certain chemical plant directly started the air pump without pressure relief, causing the safety valve to frequently trip. Within 3 hours, the sealing gasket fatigued and failed, resulting in leakage.

2. Key parameter monitoring

Electrical parameters:

The three-phase current unbalance degree is ≤5%(unbalance will cause abnormal rotor heating).

Power factor ≥0.85(if it is too low, the capacitor compensation device needs to be checked).

Mechanical parameters:

Coupling alignment deviation (radial ≤0.05mm, axial ≤0.02mm).

Belt tension (measured by a tensiometer, the sagging of the loose edge is ≤15mm).

Pressure parameter:

Pressure difference alarm threshold setting (The filter element needs to be replaced when the pressure difference of the intake filter is greater than 0.03MPa).

3. Emergency Response Plan

Emergency situation:

Current overload: Immediately cut off the power supply and check the insulation of the motor windings and the load conditions.

Abnormal noise and vibration: After the machine stops, check the condition of the bearing balls/cage. Replace the SKF 6205-2Z bearing if necessary.

Temperature over-limit: Check the cooling water flow rate/cooling fan speed, and use a thermal imager to locate the high-temperature point.

Tool configuration:

The emergency toolkit should include: a torque wrench (10 to 200N·m), a thermometer (-50 to 300℃), and a vibration analyzer (HHT handheld).

Fourth, post-startup maintenance requirements

Check after the initial operation

Tighten all connecting bolts within 48 hours (as the thermal expansion and contraction of metals may cause loosening).

Change the lubricating oil (change the oil after the first 20 hours of operation, and then change it every 1000 hours thereafter).

Clean the intake filter (after the first 50 hours of operation, and then adjust the cycle according to the dust concentration).

Long-term preservation and preparation

If it is necessary to stop the machine for storage, perform the following operations:

Empty the gas storage tank to below 0.05MPa.

Apply anti-rust oil (MOLYKOTE 33) to the inner wall of the cylinder.

Rotate the coupling 1 to 2 turns every month to prevent the shaft from bending.

Through the above-mentioned standardized process, it can be ensured that the success rate of the first start-up of the new air pump is ≥99%, and the service life of the equipment is extended by more than 30%. It is suggested to establish a "First Inspection Record Sheet for Air Pumps", detailing the start-up parameters and abnormal conditions to provide data support for subsequent maintenance.