How to judge whether the end of the air compressor is using gas

To judge whether the end of the air compressor is using gas, it is necessary to conduct a comprehensive analysis in combination with the equipment operating state, pressure change, sound and vibration, energy consumption data and professional testing tools. The following are the specific judgment methods and steps:

1. observation of air compressor running state

1. loading and unloading cycles
   • normal gas use: The air compressor is automatically loaded (started) and unloaded (stopped) according to the end gas demand, and the ratio of loading time to unloading time is reasonable (e.g. loading time accounts for 60%-80% of the total running time).
   • abnormal phenomenon:
     • frequent Load/Unload the air consumption at the end fluctuates greatly or there is leakage, resulting in frequent start and stop of the air compressor.
     • Long Unloading: No gas demand at the end, continuous unloading operation of the air compressor, may be caused by pipeline leakage or equipment shutdown.
     • Long time loading: The end gas consumption continuously exceeds the rated capacity of the air compressor, and it is necessary to check whether new gas equipment or pipeline is blocked.
2. Pressure gauge reading
   • normal range: The outlet pressure of the air compressor should be stable near the set value (such as 0.7-0.8MPa), and the end pressure is slightly lower than the outlet pressure (due to pipeline pressure drop).
   • abnormal phenomenon:
     • pressure continues to drop: Sudden increase in end gas consumption (e. g. equipment start-up) or pipeline leakage.
     • Pressure continues to rise: The end gas consumption is reduced (such as equipment shutdown) or the unloading valve of the air compressor fails.

2. check the terminal equipment status

1. operation of gas-using equipment
   • direct observation: Check whether pneumatic tools, spray guns, cylinders and other end equipment are operating normally. For example:
     • whether the pressure of spraying equipment is stable and the atomization effect of paint is good.
     • Whether the pneumatic valve is sensitive in action without jamming or air leakage.
   • indirect judgment: If the terminal equipment is shut down or the consumption is reduced (such as the production line is suspended), the air consumption of the air compressor will decrease accordingly.
2. Pipeline Leak Detection
   • listening method: At night or in a quiet environment, use your ears to close to the pipe to hear whether there is a "hissing" sound (leak point).
   • soapy water method: Apply soapy water to the pipe joints and valves suspected of leaking, and observe whether bubbles are generated.
   • Professional testing: Use an ultrasonic leak detector to locate small leaks.

3. analysis of air compressor energy consumption data

1. power and current monitoring
   • normal gas use: The power and current of the air compressor increase with the increase of air consumption, but remain within the rated range.
   • abnormal phenomenon:
     • abnormally high power: The end air consumption is too large or the efficiency of the air compressor is reduced (such as the filter element is blocked).
     • Abnormally low power: There is no air demand at the end or the air compressor is unloaded.
2. specific power calculation
   • formula: specific power (kW/(m & sup3;/min))= input power ÷ gas production.
   • Judgment standard: If the specific power is significantly higher than the nameplate value of the equipment, the efficiency may decrease due to unreasonable end gas consumption or aging of the air compressor.

4. use of professional testing tools

1. flowmeter
   • installation position: Install a flowmeter at the outlet of the air compressor or the main pipe at the end to monitor the gas consumption in real time.
   • Judgment basis: If the reading of the flowmeter is zero or continuously lower than the minimum gas production of the air compressor, it indicates that there is no gas demand at the end.
2. Pressure sensor
   • multi-point arrangement: Install pressure sensors at the outlet of the air compressor, the air storage tank and the end pipeline to monitor the pressure distribution.
   • Judgment basis: If the end pressure is close to the outlet pressure of the air compressor and is stable, the gas consumption is normal; if the end pressure fluctuates greatly or is far lower than the outlet pressure, there may be abnormal gas consumption or leakage.
3. Data Logger
   • long-term monitoring: Record the air compressor running time, loading/unloading times, pressure, temperature and other parameters, and analyze the gas consumption law.
   • Judgment basis: Identify sudden changes or abnormal periods of gas consumption by comparing historical data.

5. Comprehensive Judgment and Treatment Suggestions

6. preventive measures

1. regular inspection daily check the air compressor operating parameters, terminal equipment status and pipeline leakage.
2. Create gas usage file: Record the list of gas equipment, power, gas time, etc. to provide basis for optimizing gas supply.
3. INSTALLATION OF INTELLIGENT CONTROL SYSTEM: Through the functions of frequency conversion control and pressure linkage, the dynamic matching between the air compressor and the end gas is realized.