In industrial production, the nozzle is small, but its performance directly affects production efficiency and product quality. However, many users tend to ignore the daily maintenance of nozzles and fault detection, until the problem seriously affects the production to realize. In fact, nozzle failure can be detected and prevented in advance. Today, Bevane will provide you with a detailed introduction to the practical methods of industrial nozzle fault detection to help you avoid unnecessary losses.

Problems with nozzles during use are usually minor and therefore easily overlooked. However, over time, wear and tear or corrosion of the nozzle throat can lead to a gradual change in spray characteristics, which ultimately affects production results. For example, problems such as larger spray particles, increased flow rates, and pressure drops, although not easily detected initially, can significantly reduce nozzle life and performance when accumulated over time.

There are various ways to detect nozzle failure. First, when a nozzle is worn or corroded, the flow rate increases, the pressure decreases, and the spray particles become larger. This change, while difficult to observe directly, can be detected by analyzing the actual effect of the spray. For example, if the particles in the area covered by the spray are noticeably larger, or if the spray is no longer uniform, this may mean that the nozzle is worn.

When multiple nozzles are mounted on the same spray hose, accurate positioning between the nozzles is critical. The spray from all nozzles should be parallel to each other and at an angle of 5° to 10° to the nozzle to achieve a uniform coverage area. If the nozzles are not positioned correctly, the spray will become uneven, compromising the overall effect.

Regular flow testing is also necessary. Wear on the nozzle throat can cause an increase in flow rate, especially in systems using centrifugal pumps. This change is not easy to detect, so it is advisable to check the flow rate regularly. The flow rate can be measured by flow meter readings or by the collection method (collecting the water spray for a certain period of time at a given pressure) and comparing it to the readings of a new nozzle. If a reciprocating pump is used, the flow rate usually stays the same as the throat wears out, but the pressure in the fluid line will drop.

Observing the spray shape is also an important way to detect nozzle failure. Changes in spray shape are a visual sign of nozzle failure. For example, when a fan nozzle throat is damaged or clogged, the spray shape may become uneven or even streaky or hollow. In the case of a fan nozzle with an oval throat, wear causes the spray angle to narrow and the water flow to concentrate in the center. Hollow cone nozzles have a liquid ring spray shape, while solid cone nozzles may concentrate liquid in the center area when the spray shape is uneven. If the internal vanes of the nozzle are clogged, the change in spray shape may be irregular.

Pressure changes are an important signal of nozzle failure. With centrifugal pumps, the spray pressure usually remains constant, but as the nozzle throat wears out, the liquid flow rate increases, which in turn leads to an increase in the amount of liquid used. If a reciprocating pump is used, the flow rate remains constant, but the spray pressure decreases as the nozzle wears or corrodes. A low injection pressure reduces the blowing power of the spray, while a clogged nozzle can cause the pressure to rise even beyond the maximum pressure allowed by the system, triggering equipment damage or a safety incident.

Nozzle failures are difficult to avoid completely, but the service life of a nozzle can be significantly extended by regular inspection and maintenance. It is recommended that you regularly check the spray effect, flow rate and pressure of the nozzle, and clean the impurities inside the nozzle in time. Choosing the right nozzle material and design can also effectively reduce the risk of wear and corrosion.

Nozzles may be small, but they play an important role in industrial production. By mastering the above inspection methods, you can detect potential problems with nozzles in time and avoid production losses due to nozzle failure. If you have any questions about nozzle inspection or maintenance, please feel free to contact Bevane and we will provide you with professional technical support and customized solutions to ensure that your equipment is always in optimal operating condition.