How to diagnose compressor gearbox faults based on oil analysis?

In industrial production, compressor gearbox is one of the key equipment, and its stable operation is directly related to production efficiency and safety. As the core component of power transmission, the monitoring and diagnosis of the health of compressor gearbox is particularly important. As a non-invasive diagnostic technology, oil analysis plays an irreplaceable role in compressor gearbox fault diagnosis.

1. Basic principles of oil analysis
Oil analysis mainly evaluates the working status of the gearbox and predicts potential faults by means of physical and chemical performance analysis, pollutant monitoring, and wear particle detection of the lubricating oil used in the compressor gearbox. When the lubricating oil circulates inside the gearbox, it will carry and reflect the wear information, degree of contamination, and performance changes of the oil itself of components such as gears and bearings.

2. Main steps of oil analysis
1. Sample collection
Oil samples need to be collected from the lubricating oil system of the compressor gearbox in accordance with the specifications. When sampling, ensure that the oil sample is representative, avoid contamination, and record the equipment working conditions and oil usage at the time of sampling.

2. Visual inspection
Perform a visual inspection on the collected oil samples to observe the color, transparency, odor, etc. of the oil to preliminarily determine the degree of aging and contamination of the oil. For example, a darker color of the oil may indicate severe oxidation, while impurities may indicate severe contamination.

3. Physical and chemical performance analysis
Through laboratory tests, analyze the physical and chemical performance indicators of the oil, such as viscosity, acid value, moisture content, and flash point. Changes in these indicators can reflect the degree of deterioration of the oil and changes in lubrication performance. For example, a decrease in viscosity may to insufficient lubrication, while an increase in acid value indicates that the oil has oxidized.

4. Pollutant monitoring
Use spectral analysis, ferrography, and other methods to detect pollutants such as metal abrasive particles, particulate matter, moisture, and gas in the oil. The presence and quantity of these pollutants can reflect the wear and contamination of the internal components of the gearbox. For example, the number and morphology of metal abrasive particles can indicate the type and severity of wear of gears or bearings.

5. Wear particle analysis
The wear particles in the oil are analyzed for morphology, size, and composition through microscopic observation or automatic wear particle analyzer. The type and quantity of wear particles can directly reflect the wear condition of the internal components of the gearbox. For example, spherical particles may indicate fatigue wear of the rolling contact surface, while strip-shaped particles may indicate wear of the sliding contact surface.

3. Fault diagnosis and prevention
Based on the results of oil analysis, the health of the compressor gearbox can be comprehensively evaluated and potential faults can be predicted. For example, if the number of metal abrasive particles in the oil is found to increase sharply, and of them are large-sized flake or strip particles, it may indicate that the gear or bearing is seriously worn, and it is necessary to stop the machine for inspection and replace the damaged parts in time.

Oil analysis can also provide an important basis for the preventive maintenance of the compressor gearbox. By regularly monitoring the physical and chemical properties and contamination degree of the oil, potential problems can be discovered and dealt with in time to avoid the occurrence or expansion of faults.

As an effective means of fault diagnosis, oil analysis plays an important role in the health management and preventive maintenance of compressor gearboxes. Through scientific and standardized sampling, analysis and evaluation processes, wear and contamination problems inside the gearbox can be discovered and dealt with in time to ensure the stable operation of the equipment and extend its service life. Therefore, the attention and application of oil analysis should be strengthened in industrial production.