Common Fault Analysis for Desiccant Air Dryers - CHANUN air compressor
Release time:
2025-06-25
Common Fault Analysis for Desiccant Air Dryers - CHANUN air compressor
Fault Types and Causes
Common faults in desiccant air dryers primarily fall into three categories: desiccant issues, regeneration system problems, and valve malfunctions:
Desiccant Failure: Degradation due to long-term saturation, oil contamination, or powdering, leading to elevated pressure dew points.
For instance: Desiccant powdering can block airflow channels, causing increased pressure differential and excessive noise.
Regeneration System Abnormalities: Includes insufficient heating temperature, excessively short cooling purge time, or inadequate regeneration gas flow.
For instance: Regeneration tower depressurization failure or blower filter blockage can reduce regeneration efficiency by over 50%.
Valve Malfunctions: Jamming of pneumatic angle seat valves or butterfly valves, solenoid valve cross-leakage, etc., resulting in failed adsorption tower switching or abnormal pressure.
For instance: For butterfly valves, the top indicator parallel to the cylinder indicates the OPEN position, while perpendicular indicates CLOSED. Manual testing is required for troubleshooting.
Diagnosis and Countermeasures
Addressing the above faults requires combining intelligent diagnostic technology with on-site troubleshooting:
Dew Point Monitoring & Parameter Calibration: Install online dew point meters and combined pressure/temperature sensors for real-time drying performance monitoring.
If dew point is abnormal, prioritize checking desiccant condition and regeneration temperature (Heating phase must reach 140-160°C; exhaust gas temperature >100°C).
Valve Actuation Testing: Manually press the solenoid valve test button in a de-energized state to check pneumatic valve reset. Clean the FRL unit (Filter-Regulator-Lubricator) filter monthly.
Desiccant Management: Employ layered filling technology (coarse-fine-coarse structure) to reduce powdering and schedule regular replacement.
Maintenance and Prevention
Extending dryer lifespan requires standardized maintenance procedures:
Daily Inspection: Record dew point and pressure fluctuations daily; listen for abnormal noise. Clean pre-filters and calibrate dew point meters weekly.
For instance: Replace the filter element if the post-filter pressure differential exceeds 0.5 kg/cm² (equivalent to approx. 7.1 psi).
Annual Overhaul: Replace desiccant, inspect valve sealing, and clean cooler scaling.
Energy Efficiency Enhancement: Optimize regeneration purge gas consumption, implement waste heat recovery systems, and apply dew point tiered control.
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