HANGZHOU NUZHUO TECHNOLOGY GROUP CO.,LTD.

In industrial production, the stable operation of deep cooling air separation equipment is crucial for the quality of gas products and production efficiency. The condition of consumables affects the performance of the equipment. For the NuZhuo deep cooling air separation equipment, the timing for replacing consumables such as molecular sieve adsorbents, filter cartridge filters, and lubricating oil needs to be determined by comprehensively considering the operating parameters of the equipment, working conditions, and professional detection data. This article analyzes how to scientifically determine the timing for early replacement of consumables from four dimensions and provides a reference for enterprise equipment maintenance.

1. Identify risks through abnormal performance parameters

The operating parameters of the equipment reflect the condition of the consumables. Deviations in key indicators indicate possible failure. For example, if the carbon dioxide in the purified air exceeds 1 ppm or the dew point temperature rises above -65℃, even if it is not at the predetermined cycle, one should be vigilant; if the inlet and outlet pressure difference of the precision filter cartridge exceeds 0.1 MPa or the downstream gas particle size exceeds the standard, it should be replaced in advance; if the viscosity change rate of the lubricating oil in the expander exceeds 15% or the acid value rises above 0.1 mgKOH/g, it also needs to be replaced in advance.

2. Adjust the replacement cycle based on operating conditions

The lifespan of consumables is affected by operating load, raw gas quality, and environmental conditions. During high-load operation, the replacement cycle of the molecular sieve adsorption tower should be shortened; when the air cleanliness of the raw gas is poor, the replacement cycle of the filter cartridge filter should be adjusted; when the environmental temperature is high, the oil change cycle of the lubricating oil should be shortened; for intermittent operation equipment, check the moisture content of the molecular sieve adsorbent before restarting after more than 72 hours.

3. Determine the condition through physical state inspection

Regular inspection of consumables’ physical state can detect potential problems. If there are powder or lumps on the surface of the molecular sieve adsorbent or the static water adsorption capacity is lower than 20%, it should be replaced in advance; if the filter cartridge filter material is damaged, it should be replaced immediately; if the lubricating oil of the expander is emulsified or has oil sludge, it should be completely replaced and the oil path should be cleaned.

4. Develop plans based on preventive testing

Professional preventive testing can detect risks in advance. If the BET specific surface area of the molecular sieve adsorbent decreases by more than 30% or the micropore volume decreases by more than 25%, it should be replaced; if the vibration value of the expander bearing exceeds the standard and there is abnormal noise, decide whether to change the oil based on the oil sample analysis; if the measurement error of the PLC control system sensor exceeds ±0.5%FS, it should be replaced in time.

5. Practical suggestions for establishing an early warning mechanism

Enterprises should establish a “parameter monitoring + regular testing + historical data comparison” three-level early warning mechanism. Use the DCS system to monitor key parameters and set alarm values; test the oil sample and downstream gas every quarter, and test the performance of the molecular sieve once a year; record the information on consumable replacements to form a database and predict the replacement cycle through trend analysis.

The NuZhuo technical team can provide customized consumable management solutions, combining equipment operation data and on-site conditions, to formulate personalized replacement plans for users and provide professional testing services. This is aimed at helping enterprises minimize maintenance costs while ensuring the stable operation of deep cooling air separation equipment and providing a reliable guarantee for gas supply in the chemical, metallurgical, and energy sectors.

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Contact person：Anna

Tel./Whatsapp/Wechat:+86-18758589723

Email :anna.chou@hznuzhuo.com