Dry screw vacuum pumps are widely used in the chemical, pharmaceutical, and electronic industries due to their characteristics of being oil-free and highly efficient. However, many users report that the maintenance costs for dry screw vacuum pumps are relatively high, especially after long-term operation, where the cost of replacing core components and repairs can become a significant expense.
In fact, through scientific daily maintenance, the service life of the equipment can be effectively extended, reducing maintenance costs. This article will provide you with detailed daily maintenance tips for dry screw vacuum pumps, helping you save expenses and enhance equipment performance.
High replacement costs of high-precision components
Screw rotor: The screw rotor, a core component of the dry screw vacuum pump, requires extremely high machining precision, usually at the micron level. After long-term operation, the screw rotor is prone to wear, affecting the performance of the pump. Due to its complex manufacturing process, requiring specialized equipment and technology, the replacement cost of a set of screw rotors is high.
Bearings: The internal bearings of the pump need to withstand high speeds and loads, which makes them prone to wear. To ensure stable operation of the pump, high-precision, high-temperature-resistant, and wear-resistant high-quality bearings are often required. These bearings are inherently expensive, with additional labor and adjustment costs involved during replacement, further increasing maintenance costs.
Frequent replacement of seals
Special operating conditions: In the chemical and electronic industries, dry screw vacuum pumps often handle corrosive gases, high temperatures, or high vacuum requirements, imposing stringent demands on the seals.
Ordinary sealing materials cannot meet these demands, necessitating the use of special materials such as fluororubber or polytetrafluoroethylene. These materials are expensive, and due to harsh operating conditions, seals age and get damaged quickly, requiring frequent replacements.
High maintenance difficulty: The installation position of the seals is special, requiring partial disassembly of the pump body for replacement, which increases labor and time costs. Seal installation requires high precision; improper installation can affect the sealing performance, causing gas leaks and further impacting the pump's performance.
Complex maintenance of the lubrication system
Lubricating oil quality requirements: To ensure the efficient operation and component life of the pump, high-quality, specific-grade lubricating oils are required. Some also need special properties, such as oxidation resistance, wear resistance, and high-temperature tolerance. These lubricating oils are more expensive than ordinary lubricating oils, increasing usage costs.
Oil monitoring and maintenance: Regular comprehensive checks of the lubricating oil are required, including indicators such as viscosity, acid value, and moisture content. Based on the test results, lubricating oil should be replaced or added timely. Testing equipment and operations increase maintenance costs. Additionally, the lubricating system's filters also need regular replacement to ensure the cleanliness of the lubricating oil.
High technical requirements for fault diagnosis and repair
Professional knowledge and skills: The structure and working principle of the dry screw vacuum pump are complex, requiring professional knowledge and rich experience for fault diagnosis. Maintenance personnel need to understand not only mechanical principles and vacuum technology but also electrical control and other related knowledge. The high labor cost of professional maintenance personnel increases overall maintenance costs.
Specialized testing equipment: Specialized testing equipment, such as vibration analyzers, infrared thermal imagers, and vacuum testers, are often required for accurate fault diagnosis. These devices are expensive and need regular calibration and maintenance, increasing the company's equipment investment and maintenance costs.
High cost of downtime
Impact on production continuity: In industries with continuous production like chemicals and pharmaceuticals, downtime for repairs due to dry screw vacuum pump failures can interrupt the production line, causing significant economic losses. Not only is product output lost, but complex commissioning and testing may be required to restart the production line, adding further costs.
Emergency repair costs: To minimize downtime, companies might need to pay high rush fees, requiring maintenance personnel to respond quickly or use fast transportation methods like air freight to obtain parts, significantly increasing maintenance costs.
Startup and shutdown operations
When starting, first check whether the oil level, oil quality, and cooling water are normal, then turn on the power and slowly open the main intake valve.
When shutting down, first close the main intake valve, then turn off the power, and wait until the pump body temperature is below 35°C before turning off the cooling water.
Lubrication and inspection
Oil-free screw vacuum pumps use vacuum pump oil or high-temperature grease. It is recommended to check the oil usage daily, and based on the actual process and usage environment, change the lubricating oil every 2 to 3 months if necessary.
Equipment inspection
Arrange at least one inspection tour daily to check if the vacuum pump oil is reducing, emulsionizing (if reduced, stop the pump and add oil, and if reducing frequently, stop the pump for maintenance). Check if the cooling water flow and temperature are normal, and use an infrared thermometer to ensure the pump body temperature is below 40°C.
Cleaning and maintenance
Regularly clean the pump chamber weekly with appropriate cleaning agents to remove dirt and prevent rust and seizure.
Operation in special environments
If the equipment needs to stop running for a long time in winter, be sure to drain the cooling water from the pump to prevent freezing damage to the pump body. The packaging process is corrosive, it is recommended to use an independent dry screw vacuum pump pipeline and not connect it with other processes.
By following these measures, the normal operation of dry screw vacuum pumps can be effectively maintained, extending their service life and ensuring production continuity and efficiency.
Choose the appropriate model
Select a suitable dry screw vacuum pump model based on the actual operating conditions (such as gas type, flow rate, pressure range, etc.) to avoid overload operation.
Optimize the operating environment
Maintain a clean environment around the equipment to avoid dust and moisture affecting the pump body. For high humidity gases, it is recommended to install a gas-liquid separator.
Regular professional maintenance
Even with proper daily maintenance, it is recommended to have professional technicians perform a comprehensive inspection and maintenance once a year, including rotor clearance measurement and bearing condition assessment.
In summary, through scientific daily maintenance, the frequency of component replacement can be reduced, lowering parts costs; sudden failures causing downtime losses can be avoided; equipment service life can be extended, delaying the equipment renewal cycle; operating efficiency can be improved, reducing energy consumption.
