When multiple air sources (such as different equipment or process links) need to be supplied by one air compressor, system design, equipment selection and operation management are required to ensure the stability, pressure balance and energy efficiency optimization of air supply. The following are specific solutions and key points:
1. System Design: Rational Planning of Gas Supply Network
- design of main pipeline and branch pipeline
- main pipe diameter matching: According to the air compressor displacement (such as flow unit: m & sup3;/min) and total gas consumption, select the main pipe with sufficient diameter (such as DN80-DN200) to reduce the pressure loss.
- branch pipeline branch optimization: Branch near the gas point to avoid long-distance series gas supply and reduce pressure attenuation. For example, a circular pipe network or parallel branch design is used in the workshop.
- Material Selection: Stainless steel or galvanized steel pipe is preferred to reduce the pressure loss and pollution risk caused by corrosion of the inner wall.
- Gas tank configuration
- buffer effect: Install an air storage tank at the outlet of the air compressor (the capacity is recommended to be 15%-30% of the exhaust volume of the air compressor) to balance the flow difference between the peak and trough of air consumption and stabilize the system pressure.
- multistage gas storage: If the gas point is far away, a secondary gas storage tank can be added near the gas end to further reduce pressure fluctuations.
- Pressure regulation and distribution
- pressure reducing valve installation: Install a pressure reducing valve before each gas point, and adjust the pressure according to the equipment requirements (such as from 7bar to 5bar) to avoid waste of high-pressure gas.
- Pressure Sensors and Controllers: Install pressure sensors in the main pipeline and key gas points, monitor the pressure in real time through PLC or intelligent control system, and automatically adjust the operating parameters of the air compressor (such as frequency conversion speed regulation).
2. equipment selection: matching gas demand and air compressor performance
- air compressor type selection
- frequency conversion screw air compressor: It is suitable for scenes with large fluctuations in gas consumption. By adjusting the speed to match the actual demand, it avoids waste of energy consumption caused by frequent start and stop.
- Centrifugal air compressor suitable for large-scale continuous gas supply (such as semiconductor and chemical industries), but it is necessary to ensure stable gas consumption and avoid the phenomenon of "big horse-drawn trolley.
- Oil-free air compressor: If the gas point requires high air quality (such as food and pharmaceutical industries), Class 0 oil-free models should be selected to prevent oil pollution.
- Capacity matching calculation
- calculation of total gas consumption: Statistics the instantaneous maximum gas consumption of all gas-consuming equipment (unit: m & sup3;/min), and consider the simultaneous use coefficient (such as 0.7-0.9).
- Selection of air compressor: Select a model with a displacement slightly larger than the total gas consumption (e.g. the total demand is 10m & sup3;/min, choose 12m & sup3;/min air compressor), reserve 10%-20% allowance.
- Alternate Scenario
- redundant design: If shutdown is not allowed at the key gas point, two air compressors (one for use and one for standby) can be configured to ensure the continuity of gas supply through an automatic switching device.
- Mobile air compressor: As a temporary backup, to deal with sudden failure or maintenance needs.
3. operation management: optimization of gas supply efficiency and maintenance
- pressure belt control
- set reasonable pressure range: According to the requirements of gas equipment, set the system pressure in a reasonable range (such as 6-7bar) to avoid excessive pressure leading to increased energy consumption.
- Unloading pressure optimization: Adjust the unloading pressure of the air compressor (e. g. from 8bar to 7.5bar) to reduce the unloading operation time and reduce energy consumption.
- Leak Detection and Repair
- regular inspection: Use ultrasonic leak detector or soapy water to check leakage points at pipes, valves and joints.
- Quick Fix: Mark the leakage point and repair it immediately to avoid insufficient pressure and waste of energy consumption caused by long-term leakage.
- Intelligent monitoring and maintenance
- remote monitoring system: Real-time monitoring of air compressor operating status (such as temperature, pressure, energy consumption) through the Internet of Things technology, early warning of failure.
- Preventive Maintenance: Regularly replace the filter element and lubricating oil, clean the cooler, and ensure the efficient operation of the equipment.
