Exhaust silencer modification case

Project background

The exhaust muffler of a well-known brand compressor used at a chemical industry site was operated 24 hours a day and 24 hours a day. During this period, the connection between the inner cylinder and the outer cylinder of the exhaust muffler developed cracks and damage, which affected the normal use of the equipment and led to a decrease in production capacity.

After being disassembled by our maintenance engineers, some pictures of the process are as follows:

After inspection and analysis, it was determined that the main causes of equipment damage are as follows:

1. The connection between the inner cylinder and the outer cylinder is spot welded, and the welding is not strong enough. Especially thin-walled parts require higher welding process requirements;

2. The wall thickness of the guide cover connecting the inner cylinder and the outer cylinder is too thin and the stiffness is not enough. Resonance is easily formed at this position during the operation of the compressor, thereby aggravating damage;

3. The inner cylinder is suspended in the middle and lacks support, resulting in insufficient strength and prone to resonance;

4. The cover plates at both ends of the inner cylinder are connected by spot welding, and the welding is not strong enough.

solution

Based on the above reasons, the overall design of the inner cylinder has been redesigned and improved, mainly in the following aspects:

1. The inner cylinder punching mesh plate is thickened (changed from original design *** to ***);

2. The thickness of the guide cover (inlet and exhaust port) is increased. The guide cover is inserted into the outer cylinder for full circumferential welding. The intersection line between the guide cover and the inner cylinder punching screen is also flanged for internal and external welding to increase the welding strength;

3. The cover plates at both ends of the inner cylinder body are thickened, and flanges are added for internal and external welding to increase the welding strength;

4. In the middle part between the inner and outer cylinders, a fixed support structure is added to improve the overall rigidity and stability and reduce resonance.               

Schematic diagram of this plan

Our company's construction process

1. Open the muffler end cover and take out the internal wire mesh filler;

2. Take out the damaged inner cylinder;

3. New inner cylinder designed, improved and manufactured;

4. After the design is improved, the new inner cylinder is fixed into the muffler;

5. Check the reliability of all welding/connection positions;

6. Replace the end cover sealing gasket;

7. Press all fillings into the silencer as required;

8. Appearance treatment and touch-up paint;