What should be done if the compressed air pipeline is blocked

1、 Common causes of blockage in compressed air pipelines

Various blockage problems may occur in compressed air pipelines during use, and understanding the causes of blockage is the first step to solving the problem. Common causes of blockage include:

Moisture accumulation: Compressed air contains a large amount of moisture, which can easily accumulate in low-lying areas of pipelines and cause water blockages. Especially at low temperatures, moisture may freeze and cause complete blockage.

Oil pollution deposition: After mixing oil and dust in compressed air, viscous deposits will form on the inner wall of the pipeline, gradually reducing the diameter of the pipe until it is completely blocked.

Corrosion products: After long-term use, the inner wall of metal pipelines will rust, and the detached rust pieces may accumulate at bends, valves, and other places, causing blockages.

Installation residue: When installing new pipelines, foreign objects such as welding slag and fragments of sealing tape may be left behind, which may cause blockages in the early stages of use.

Pipeline design defects: Insufficient slope of the pipeline, unreasonable setting of drainage points, and other design issues can lead to the accumulation of water and dirt that cannot be discharged smoothly.

2、 Method for determining the location of blockage

Accurately identifying the location of blockage is the key to efficiently handling problems:

Segmented inspection method: Starting from the outlet of the air compressor, close the valve section by section and observe the pressure changes. The section where the pressure suddenly drops is the location of the blockage.

Auscultation method: Use a stethoscope or metal rod to touch the pipeline, tap and listen for changes in sound. The sound in the blocked area will be noticeably dull.

Temperature detection method: The upstream pipeline of the blocked area will experience an increase in temperature due to the accumulation of compressed air, and an infrared thermometer can be used to assist in judgment.

Flow meter detection: Install temporary flow meters in each branch of the pipeline, and the branch with abnormally reduced flow may be blocked.

Visual inspection: For transparent or detachable pipeline parts, directly observe the internal situation.

3、 Steps for handling pipeline blockage

（1） Safety preparation work

Turn off the power of the air compressor and hang a warning sign to prevent accidental start-up.

Slowly release the residual pressure in the pipeline and confirm that the system is completely depressurized.

Prepare personal protective equipment: safety goggles, gloves, earplugs, etc.

Ensure good ventilation in the work area, especially when dealing with oil stains.

（2） Handling methods for different types of blockages

1. Moisture blockage treatment

(1) Find the drain valve from the pipeline to the low point and slowly open it to drain the accumulated water.

(2) For icing blockage, a hot air gun or hot water bag can be used to heat and melt the blockage area.

(3) Check if the automatic drain is working properly and clean or replace it if necessary.

(4) After processing, it is recommended to install or upgrade air drying equipment.

2. Oil pollution deposition treatment

(1) Dismantle the blocked section of the pipeline and soak it in a specialized cleaning agent.

(2) For minor sedimentation, high-pressure air can be used for reverse blowing.

(3) Stubborn oil stains can be cleaned using a pipeline cleaning ball combined with a cleaning agent for cyclic cleaning.

(4) Check the efficiency of the oil separator after processing and replace it if necessary.

3. Rust and blockage treatment

(1) Slight rust can be cleaned by circulating pipeline rust remover.

(2) It is recommended to replace this section of pipeline due to severe corrosion, and prioritize the use of corrosion-resistant materials.

(3) After processing, an appropriate amount of rust inhibitor can be added to the system.

(4) Consider replacing metal pipelines with stainless steel or engineering plastic materials.

4. Handling of foreign object blockage

(1) After determining the location of the foreign object, disassemble the nearby detachable connection.

(2) Use an endoscope to examine and attempt to remove foreign objects using a hook tool.

(3) Larger foreign objects may need to be removed by cutting the pipeline.

(4) Thoroughly clean the interior of the pipeline before reinstallation.

（3） System recovery and testing

Reconnect all pipelines to ensure good sealing.

Gradually increase pressure and check for leaks at all connections.

Observe the pressure gauge and confirm that the system pressure has returned to normal.

Test whether each gas point is working properly.

Record the processing and replacement of components, and establish maintenance records.

4、 Measures to prevent pipeline blockage

Regular drainage: Develop a strict drainage plan, especially increase the frequency of drainage during humid seasons.

Improve the filtration system: Install multi-stage filters (coarse filter, fine filter, activated carbon filter) at the outlet of the air compressor.

Pipeline design optimization:

Ensure that the pipeline has a slope of 0.5-1% and install drainage devices at low points

Reduce unnecessary bends and diameter changes

The main pipeline adopts a circular arrangement to increase the airflow velocity

Regular chemical cleaning: Use specialized cleaning agents to cycle and clean the entire system every 1-2 years.

Daily monitoring: Install pressure and flow monitoring devices to promptly detect abnormalities.

Material upgrade: Gradually replace ordinary steel pipes with aluminum alloy or stainless steel pipelines.

5、 Suggestions for handling special situations

Emergency situation handling:

When production cannot be stopped, a bypass pipeline can be temporarily installed

Using portable air compressors to supply gas to critical equipment

Underground pipeline blockage:

First, determine the precise location of the blockage to avoid extensive excavation

Consider adopting pipeline lining repair technology

Serious corrosion suggests replacing the entire line with PE pipes

High altitude pipeline blockage:

Ensure safety protection for high-altitude operations

Use long pole tools to assist in operation

Consider building a temporary work platform

6、 Professional maintenance suggestions

Establish a comprehensive maintenance plan for the compressed air system, including:

Daily drainage inspection

Monthly filter inspection

Quarterly pipeline condition assessment

Annual comprehensive inspection

Provide professional training for maintenance personnel, including:

Principles of piping systems

failure diagnosis method

Safety operating procedures

Emergency response process

Consider signing a maintenance contract with a professional compressed air service provider to conduct regular professional inspections and maintenance.

Through the above systematic processing methods, the problem of compressed air pipeline blockage can be effectively solved, and the probability of future blockage can be significantly reduced, ensuring the stability and reliability of production gas.