What is the effect of increasing the pressure of the air compressor?

The high pressure of air compressor will have a multi-dimensional impact, which requires professional evaluation from four aspects: equipment operation, energy consumption efficiency, system stability and safety compliance:

1. equipment operation level

1. increased mechanical load: Pressure increase will directly increase the load of moving parts such as screw rotors and bearings. Experimental data show that for every 0.1MPa increase in pressure, the screw axial force increases by about 15%, and the bearing life may be shortened by 30%-40%.
2. Temperature Control Challenges: The heat generated during the compression process is positively correlated with the pressure, and the exhaust temperature may rise by 10-15°C. If the flash point of lubricating oil is exceeded (usually 200-220 ℃), it will cause oil carbonization and block the oil system.
3. Sealing performance test: Under high pressure conditions, the risk of leakage of pipeline flanges and valve gaskets increases, and sealing components with higher pressure levels are required.

2. energy efficiency level

1. power Demand Surges: According to the gas compression isothermal efficiency curve, the shaft power demand may increase by 25%-30% for every 20% increase in pressure. Taking 75kW air compressor as an example, the actual operating power may exceed 90kW after the pressure is increased.
2. Energy efficiency ratio decreases: Deviation from the optimal efficiency point of the equipment, resulting in a reduction in overall energy efficiency (specific power). Measurements show that 10% overpressure operation can reduce energy efficiency by 8%-12%.
3. Rising life cycle costs continuous high-pressure operation will shorten the life of wearing parts, such as air filter replacement cycle may be shortened by 40%, increasing maintenance costs.

3. system stability level

1. pressure fluctuation intensifies the buffer capacity of post-processing equipment such as air storage tank and dryer may be insufficient, resulting in pressure fluctuation of terminal air point exceeding ± 0.2MPa, affecting the accuracy of pneumatic equipment.
2. Condensate water increased: When the high-pressure gas is reduced in the pipeline, the temperature drops more, and the amount of condensed water may increase by more than 50%, which increases the burden on the drainage system.
3. Pipeline vibration risk: The gas flow rate increases with the increase of pressure, which may cause pipeline resonance. It is necessary to add fixed bracket or adopt flexible compensation joint.

4. security compliance level

1. supervision of special equipment if the rated pressure is lower than the pressure after the increase, the equipment will exceed the supervision scope of the Safety and Technical Supervision Regulations for Fixed Pressure Vessels, and the use registration and regular inspection shall be re-handled.
2. Safety valve calibration the setting pressure of the system safety valve shall be adjusted synchronously to ensure timely discharge in case of overpressure and avoid the risk of container explosion.
3. Revision of operating procedures it is necessary to update the equipment operation manual, specify the inspection frequency and parameter monitoring requirements under high-pressure working conditions, and train the operators to master the emergency disposal process.

Typical Risk Scenarios

• painting operation: Excessive pressure may lead to excessive atomization of the coating, resulting in orange peel defects, while increasing the rebound of paint mist and reducing the utilization rate of the coating.
• Pneumatic tools: Exceeding the rated pressure may cause the pneumatic wrench torque out of control, resulting in bolt overload fracture.
• Instrument air source: When supplying air to pneumatic instruments, pressure fluctuations may cause misoperation of the valve positioner, resulting in out-of-control of process parameters.

Technical recommendations
the pressure adjustment should follow the principle of "supply on demand", and realize flexible gas supply through frequency conversion control, gas tank expansion and other measures. If high pressure operation is necessary, the following should be carried out:

1. mechanical strength check (screw, bearing, shell)
2. heat balance calculation (lubrication system, cooler)
3. pipe Stress Analysis (Elbow, Tee)
4. safety accessories upgrade (pressure gauge, safety valve)

it is suggested to entrust professional institutions to carry out systematic evaluation to avoid equipment failure or safety accident caused by blind pressure regulation.