What is a pneumatic high-pressure cleaner?

In flammable and explosive industrial environments such as petrochemicals, coal mining, and shipbuilding, traditional electric cleaning equipment is severely restricted due to the risk of electrical sparks. Pneumatic high-pressure cleaning machines, powered by compressed air, completely eliminate electrical hazards, making them the preferred cleaning solution in high-risk scenarios.

Pneumatic high-pressure cleaning machines are cleaning devices that utilize compressed air as a power source. They are widely used in cleaning operations in industries such as oil fields, chemicals, agriculture, mining, airports, railways, power generation, construction machinery, ports and docks, farms, textiles, food processing, paper manufacturing, electroplating, and automotive detailing. These machines employ three-cylinder ceramic plunger pumps, capable of handling various corrosive cleaning agents and chemical solvents, and are characterized by high efficiency and safety, making them particularly suitable for hazardous areas requiring explosion-proof equipment.

Common Methods for Detecting Gas Leaks in Pneumatic Systems of Equipment

1. Listening and Touching Method: This is very common in factories. Based on experience, leaks are located by listening and touching. It is simple and cost-effective. However, its drawback is that it cannot locate leaks unless the system has a large leak point.  For complex equipment with limited space, touching can be difficult and may even cause physical harm.

2. Soap Water Leak Detection Method: Soap water is applied to various parts of the system; bubbles indicate a leak point. This method is simple and easy to use, but the amount of soap water applied is difficult to control, making precise leak detection difficult. It can also contaminate the equipment and other systems. For complex equipment with limited space, it is difficult to apply soap water to all areas, making it difficult to detect all leak points.

3. Ultrasonic Leak Detection Method: This method uses visual and auditory leak localization to quickly identify leak points. It has a wide detection frequency range and can work in various environments. With appropriate filters, it can eliminate major interference in high-noise environments. With a suitable signal transmitter, it can find leaks even without pressure. It is a point inspection method, not a surface inspection method, and is convenient for applications with few leak points.

4. Acoustic Imaging Leak Detection Method: This method uses sound, numerical data, color bars, and automatic leak point display images. It allows for surface inspection, and the image technology is easy to understand and use. Images and videos are stored in a standard format for quick playback and reporting. It can detect leaks from a distance of 10m-30m, even leaks as small as 0.01mm. The adjustable frequency range is from 2KHz to 52KHz, and it can detect even the smallest leaks and automatically adjust sensitivity based on the environment.

What are some common problems in pneumatic systems?

1. Air Leaks

Air leaks are one of the most common problems in pneumatic systems. They can occur at various locations, including fittings, hoses, and valves. Even small leaks can lead to significant pressure drops, resulting in reduced efficiency and increased energy costs.

Common causes of air leaks:

Worn or damaged seals and gaskets: Over time, seals and gaskets can wear down due to constant pressure and movement, leading to leaks.

Loose fittings or connections: Vibration and thermal expansion can cause fittings to loosen, creating gaps for air to escape.

Cracked or worn hoses: Hoses can be damaged by wear and tear, exposure to chemicals, or extreme temperatures, resulting in leaks.

2. Insufficient Pressure

Insufficient pressure can severely impact the performance of a pneumatic system. When the pressure falls below the required level, actuators may not function correctly, leading to slow or erratic movement.

Common causes of insufficient pressure:

Compressor problems: If the compressor is not functioning properly, it may not be able to generate enough pressure to meet system demands.

System blockages: Dirt, debris, or moisture can clog filters and lines, restricting airflow and reducing pressure.

Leaks: Air escaping from leaks prevents the system from maintaining sufficient pressure.

3. Inconsistent Actuator Movement

Inconsistent or erratic actuator movement can be frustrating and may indicate underlying problems within the system. This issue can lead to production delays and affect the quality of the final product.

Potential causes:

Valve malfunction: If valves are not opening or closing properly, it can lead to inconsistent airflow to the actuators.

Pressure fluctuations: Variations in pressure due to leaks or compressor problems can cause erratic actuator behavior.

Incorrect component sizing: Using components that are not matched to the system requirements can lead to performance issues.

4. Noise and Vibration

Noise and vibration in pneumatic systems can indicate mechanical problems or improper operation. While some noise is normal, excessive noise may indicate a problem that needs addressing.

Common sources of noise and vibration:

Compressor operating outside its optimal range: If the compressor is overworked or undersized, it can generate excessive noise and vibration.

Loose fittings or components: Vibration of moving parts can cause loose fittings to rattle, leading to increased noise. Air leak: A leak will produce a hissing or whistling sound, indicating that air is escaping from the system.

Industrial Core Application Scenarios

Explosion-Proof Cleaning in the Petrochemical and Chemical Industries

In explosive gas environments such as refineries and tank farms, pneumatic high-pressure cleaning machines, driven by compressed air instead of electricity, can remove pipe scaling and reactor residue, preventing accidents caused by static electricity or electrical sparks.

Coal Mine and Tunnel Equipment Maintenance

Underground equipment is often covered with coal dust and oil stains, and electric tools can easily generate sparks. Pneumatic equipment, combined with explosion-proof nozzles, can be used to clean coal mining machines and conveyor belts deep in mine tunnels, ensuring production.

Ship and Offshore Platform Rust Removal

Ship cabins and decks are often damp and cramped. The explosion-proof performance and portable design (main unit weight less than 15kg) of pneumatic high-pressure cleaning machines are ideal for these areas, removing salt deposits and rust layers and extending equipment life.

Food Processing and Pharmaceutical Industries

In areas with a risk of dust explosions, such as flour mills and sugar factories, pneumatic equipment can be used to clean production lines, avoiding the risk of dust explosions caused by electric tools, while also meeting GMP sterile cleaning standards.

Usage Precautions

Pneumatic high-pressure cleaning machines consist of a pneumatic motor as the power source, a stainless steel frame, and a high-pressure cleaning pump head. The pneumatic motor uses compressed air as the power source, eliminating the risks of electric sparks, overheating, and explosions. It can be operated remotely and meets the requirements of safety regulations. It is especially suitable for use in environments with high safety and explosion-proof requirements, such as petroleum, chemical, coal mining, flammable, explosive, high-temperature, humid, and dusty environments. It can also be used for emergency fire fighting. What precautions should be taken when using a pneumatic high-pressure cleaning machine?

First, ensure the correct power supply and connection for the pneumatic high-pressure cleaning machine. The connected voltage must match the voltage specified on the machine. For example, industrial three-phase power requires a 380V power supply, while household power requires a 220V power supply. In addition, the power supply capacity should be 25% higher than the power required by the cleaning machine. If the equipment requires an extended power cord, choose a power cord of appropriate thickness or have it connected by the manufacturer to avoid burning or damaging the cleaning machine due to an undersized power cord. Furthermore, the equipment's power supply must have a protective switch, a thermal magnetic switch, or a power cord grounding device.

Second, ensure the water supply: The water source must be clean and free of impurities or acids and alkalis, such as tap water. Do not connect a container to supply water to the cleaning machine, especially for cleaning machines without a self-priming function. Ensure sufficient water supply to the high-pressure pump. The water supply volume should be at least 130% of the cleaning machine's water flow rate. If connecting a water tank for water supply, the relative height between the water tank and the cleaning machine should be no less than 5 meters.  Also, avoid using elbow or T-shaped connectors when connecting the water tank to the cleaning machine to ensure a smooth and sufficient water supply. If the water supply is insufficient or absent during operation, the high-pressure pump will be damaged in a very short time.

Third, the cleanliness of the fuel filter and the setting of the exhaust pipe: When using fuel, the cleaning machine will produce smoke. Therefore, attention should be paid to exhaust issues during use. If used indoors, the chimney for smoke emission should not exceed 5 meters and must be inclined. If the end of the chimney is outdoors, a rain cap must be installed. Fourth, sandblasting and pipe cleaning functions: When purchasing a pneumatic high-pressure cleaning machine, you should check whether the equipment has sandblasting and pipe cleaning functions.  Equipment with these functions can be equipped with sandblasting attachments for rust removal, degreasing, and paint removal; additionally, connecting a high-pressure hose and nozzle allows for pipe cleaning.