Design your compressed air system

抿 抿 抿 Design Your Compressed Air System MM Electromechanical Information Total 221 2000 The 1st / 2nd Compressed Air System is a key facility of the factory. Meet the special needs of the application. In order to choose an efficient and optimized design, six basic factors must be considered in your design. These six factors are the demand for compressed air. quality. supply. store.

Distribution and control management. All six factors must be considered in order to achieve the best operating conditions.

What is your compressed air demand? It is very important and very difficult to determine the actual demand for the collapsed air system. The gas consumption often fluctuates greatly and exceeds the pre-estimated average gas consumption. If we can know the amount of gas used at any time, we can design the storage and distribution system without the need to install a new air compressor.

The most accurate way to test the demand-time relationship of an existing system is to monitor the air flow with a flow meter. The flow meter can be installed at many points in the system, but it is usually installed at the beginning of the main air system, recording data such as air flow and pressure, which can be used to map the flow. Pay special attention to the peaks and troughs of the demand and their time spans.

For small, less complex systems, the proportion of time that the jade is fully loaded and unloaded can account for the average demand over a longer period of time.

Leakage and false demand account for a significant proportion of the total demand. Leakage means that there are only two compressed air systems: less leakage and severe. Leaks can be tested in a number of ways, such as testing the tank pressure drop time, testing full load operation time, and testing gas point leaks, while shutting down all air compressors and running without pneumatic tools. Today's compressed air demand also includes false demand, which is caused by system pressure and the pressure required by the gas equipment. This can be adjusted by adding a pressure regulator at the point of use or at the beginning of the line.

When determining the compressed air demand for a new system, work pressure requirements, compressed air requirements, and the operating cycle of each equipment must be considered.

Each pneumatic unit has its optimum operating conditions, usually at rated flow and pressure. In this way, it is required to design a compressed air system that provides a single pressure and must ensure that all pneumatic tools and equipment work effectively. If not, you can choose to run the entire system at a helium pressure and then reduce the pressure as needed; use a booster to increase the pressure somewhere; or use two separate compressed air systems to run different qualities force.

What kind of air quality you need, different applications require different levels of compressed air quality. It is very important that the international standard IS08573-1 air system meets but does not exceed the required air quality level. If I: different parts of the plant require different air quality, it is more cost-effective to process only a small amount of pressurized air.

What is your supply demand, the compressed air supply is provided by the empty machine. Sufficient storage and assembly; pipeline allocation can be used to meet demand. If the supply y storage and piping are not properly arranged, it will cause excessive pressure fluctuations and increase operating costs - most air compressors are controlled by the point pressure. For example, the pressure drop indicates an increase in the amount of gas used, and the output is increased by the air compressor to IE:. The pressure rise indicates that the gas consumption is reduced, and the output of the air compressor is reduced. Air compressors use a variety of control systems to monitor pressure changes and adapt the air supply to their changing needs. A more efficient control is the loading/unloading control, which can be used to operate the air compressor in a fully loaded or empty state.

The gas supply of the factory can be selected from single or multiple air compressor stations, which can be centralized or decentralized. A single air compressor is best suited for systems that are smaller than 1:: small systems or almost run in the state of the load. Multiple air compressor stations have the following advantages: flexible application (changes in demand for different shifts, adjustment and improvement of gas supply efficiency); flexible maintenance; centralized and distributable gas supply; flexible floor space; high system reliability Optional PLC system controller.

It is a comparison between a single unit and a plurality of air compressor stations. The middle 1 shows the response of multiple air compressors to fluctuations in gas consumption. The five air compressors are controlled by the PLC system controller. The PLC selects the minimum air compressor to meet the corresponding air demand. This design saves operating costs compared to a single air compressor station (middle 2), and increases system reliability when other air compressors require maintenance or standby.

How much reserve you need, the compressed air reserve is made up of all the containment equipment in the system. Adequate reserves are very important and represent a release when needed! Flow diagram: The energy resources of the existing system with a single horse and multiple s presses and m or supplement.

Gas storage tanks usually indicate the size of the entire reserve. Due to the control of some air compressors (such as the addition/unloading control), depending on the reserve amount to limit the maximum number of shutdowns when the gas consumption is less than 100%, it is necessary to select a properly sized gas storage tank to prevent too frequent start and stop switching. .

A well-sized gas storage tank can provide sufficient reserves for any peak demand. At the peak, a poorly designed system can cause a drop in pipe network pressure. Because not all of the air compressor stations are loaded and running at all times, the actual air supply may be lower than the system design air supply. The stored compressed air can be used to prevent a drop in system pressure before another air compressor is started. The reserve quantity should be determined by considering the following aspects: excess demand, number of air compressor starts and stops, and time to replenish reserve gas.

Compressed air storage system. This system utilizes a flow controller and a rear air reservoir to prevent frequent starts and reduce pressure fluctuations during peak gas usage.

How to design the best piping system, and the needs.

The system provides the required volume and pressure for all points of use. A pipeline network is usually used to supply air to different locations. However, compressed air flows in the pipe, and the pressure drops due to friction. Ideally, the pressure drop of the pipe is within 0.1-0.15 bar.

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Reduce friction by increasing pipe size and removing unnecessary corners, valves, and other flow restrictions.

Minimize the pressure drop caused by system components.

In pipelines with long pipelines or small diameters, the friction loss is relatively large. In order to reduce the pressure drop, an effective method is to use a toroidal pipe to provide a two-way pipe for any node of the system, so that the flow rate through each pipe is halved, thereby reducing the flow rate of the compressed air.

What are the important factors to consider when making the system layout, the optimal placement of the compressed air system depends on the aspects discussed above, i compressed air demand, quality level, compressed air supply requirements, reserve requirements, and piping layout design.

Although information on the production and use of compressed air is readily available, most users must design and install their own piping systems. Due to the complexities involved and the many factors to consider, only professional air compressor suppliers can provide the information needed to design an effective system. Customers who need to make the most of compressed air can consult with these companies.

Important aspects of system layout include: adequate ventilation, foundation requirements, space requirements, and roadway materials.

The four basic ventilation methods include: natural ventilation, exhaust fan ventilation, exhaust duct exhaust, and heat recovery indoor exhaust.

There are two kinds of ventilation methods for the station of multiple air compressors: one is to regard it as an air compressor, and its horsepower is the sum of the horsepower of all air compressors. Another, better approach is to provide a separate air inlet for each air compressor. How to determine the size of the air inlet, add the horsepower of all air compressors to get the total cooling air flow and the required air inlet size. Then, according to the proportion of each air compressor in the total horsepower, the total import area is divided accordingly.

The foundation requirements depend on the size and type of air compressor. Cabinet-type screw air compressors and piston machines up to 25 horsepower do not require any special foundation.

A piston machine with more than 50 horsepower requires a special foundation.

The ground type screw machine also does not require special foundations.

It is a large and medium-sized air compressor. It should be placed in a dedicated air compressor station, and keep the room clean, dust-free, dry and cool. If conditions permit, place the air compressor on the north side of the building and isolate it from the heat pipes and machinery. To avoid frost and corrosion during condensation, the room temperature should not be lower than 5'C. Each air compressor should be easily accessible and well lit for maintenance and inspection. Air-cooled air compressors need sufficient cooling air, so the temperature of these rooms should not exceed 35C. For air compressors with less than 18.5kW power, natural ventilation can be used, but for large machine small rooms, forced ventilation must be used.

There are many ways to arrange compressed air ducts, which can be placed in ditches and large pipes to avoid building obstacles. However, this arrangement is more complicated and expensive than other methods, and is not easily accessible to the pipeline. Another method is to bury them underground, which is low in cost. However, repair and maintenance becomes extremely difficult, and rust-proof materials are also used to avoid corrosion. Another method is to install the pipeline above the ground with brackets or cantilever beams. This method is relatively costly but forms a building barrier. For outdoor installations, only the compressed air is dried until the pressure dew point is lower than the outdoor minimum temperature to ensure that no pipe freezing occurs.

The piping arrangement is very important for the reliability and efficiency of the entire compressed air system. Prior to piping, material selection, size, placement, site conditions, and future needs must be considered. The piping must be able to adapt to existing operating conditions, provide minimal pressure loss and leakage and be easy to maintain. The compressed air line can be galvanized, copper plated or stainless steel, in length: it should be carefully selected.

Six basic factors: demand, quality-supply, storage, distribution and control must be considered together to design a well-filled compressed air solution that meets the requirements. The compressed air supply is only reliable and efficient after weighing each factor.

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