Compressor Technology Compressed Air System Leakage Measurement and Control Qin Hongbo 12, Hu Shougen, Qi Shengkai. Shanghai University of Technology, Hai 200000; 2. Shanghai Energy Conservation Service Center, Shanghai 200040 method, Langshi, combined with on-site experiments to reduce the pressure of ç¼’ æ°” æ°” æ°” æ°” , , , , , , , , , , , , , , , , , , , , , Mei Mu suggested. 1 Introduction Due to its advantages of clean, safe, pollution-free and easy to use, compressed air is widely used in industrial systems and has become the fourth largest energy source in the industry. Its energy consumption accounts for 10,401 of its total energy consumption in most plants. At the same time, compressed air is also the most energy-intensive, because in the process of air-air compressor shrinkage, the 8093 power consumed by the air compressor is converted into heat, which means that only part of the air compressor consumption can be converted into Available work. In recent years, with the tight energy situation in the world and the severe competition of enterprises, enterprises have gradually realized that the compressed air system has an optimized space. Reduce the energy costs of the collapsed air system by means of a series of measures such as reducing the improper use of compressed air to reduce the use of system piping, technology and frequency conversion technology. However, the statistical analysis of the proportion of compressed air consumption by a large number of practical tests shows that the leakage often accounts for 2030 of the system's gas production. Taking a small hole with a hole diameter of 4.5 as an example, in the case where the pipe supply pressure is 61 gastric pressure, the annual fee paid by the enterprise for the compressed air leaking in the small hole is 31,200 yuan. In addition to wasting energy, the system price is 0.6 yuan kWhif, and system leakage will cause other operational losses. Leakage causes the pressure of the system to drop, causing the pneumatics to operate at a low efficiency, which adversely affects production. In addition, due to the low pressure caused by the leakage, the drive equipment requires more frequent work, so the leakage almost shortens the service life of all system equipment including the compressor unit itself; increasing the running time also leads to additional maintenance requirements and large unplanned parking time In the end, the leak will result in an unnecessary increase in compressor capacity. 2 Leakage measurement method For plants that are not produced all year round, the following two methods can be used to measure the leakage of the entire compressed air system without any gas load on the compressed air system. 2.1 Determination of the upper download cycle of the air compressor For the system with the compressor with the download function, the air compressor can be operated during the system shutdown, and the air compressor can be used to upload the download time or test the air compressor power. Received version, 1 system. 4 with a singular gamma 诎 1 shame tube legs, Lin 4 minus 6 than hot è£ r, medium pressure body æž³ flow t parent soil machine or time, heart 1 2.2 test system pressure drop this method to estimate the system vent, foot First of all, pleading for the calculation of the gas storage volume of the entire system. Include all the gas storage tank volume of the system and the system pipe. The air compressor monitors the system pressure to stop the air compressor operation when the system supply pressure is normal. The system pressure begins to drop to a lower pressure value. The elapsed time 7, usually the calculation formula of the system leakage amount is as follows t. System Leakage System System Gas Storage Volume Initial Pressure The final pressure test should be explained. It is impossible to use the above two methods to evaluate the leakage of the entire system for the gray air system that runs every day throughout the year. Any part of the system. The most common areas of leakage usually include couplings. Soft bamboo. Pipeline and pipe fittings adjust the opening of the condensing trap and shut-off valve 1 stomach head = 1 and thread å²” preparation. 1Pub T air compressor is running, between. 1 heart 2 is the air compressor power curve during normal production of a tobacco production enterprise and the power curve of the air compressor download cycle due to leakage when the system is shut down. It is not difficult to calculate from the cabinet that the leakage of the system accounts for about 13. Since the compressed air leak cannot be directly observed by the eye, it is one. Therefore, it is necessary to check the method to check the leak, and the leak is accompanied by a high frequency humming sound of air leakage. These portable devices include a microphone amplifier and a filter, and the chaos is usually equipped with a finger to detect the leak. In addition, the easiest way to detect leaks is to use soapy water to apply a brush to the area that may leak. Although this method is highly reliable, it takes a lot of time. 4 system leakage control technology 4.1 maintenance and application of gas-saving equipment because leakage often occurs in the joints and joints, sometimes only need to tighten the pipe joints to eliminate leakage, and sometimes need to replace the parts in question, such as the coupling pipe fittings section soft bamboo Joints are not trapped, etc., in many cases, leaks, 1 defective or incorrect thread seals, so select high quality pipe fittings to connect hoses and pipes, and use a combination of thread sealing materials Proper installation is very effective in preventing and eliminating leaks. In addition, a throttle type water conveyor with automatic control function can be used. The war can be achieved, and the purpose of condensing water in the passage can be eliminated, and excess air shrinkage can be prevented. 4.2 Cut off the unnecessary supply of gas. No more, the scoop gas is still set up. In the pavilion, the potential leak source should be removed. It should be isolated from the pipeline. The equipment of the sputum is in the state of corpse operation. When the gas is used to stop the transportation, the connection between the equipment and the gas supply should be cut off in time, so as to maximize the leakage inside the gas equipment. Some companies that implement the three-shift system often do not produce in some workshops during mid- or night shifts, but the pipelines in the workshop still maintain normal supply pressure. In this case, it is very likely that the air compressor will only run for leakage. 3 is the air flow to the small room measured by a workshop of an auto parts manufacturer; although the lotus root 400,600 does not contain any production, it seems that the air flow to the jade in the workshop still remains. As this is, 1 space machine 2 air compressor is the amount of leakage. For the production features described above, the electric valve can be installed on the pipeline leading to the workshop. The valve can be controlled locally or even remotely. If there is no production, the gateway will be The valve in the workshop is closed. A steam turbine factory used this control method to stop the 20 1 air compressor during night shifts. 4.3 Reducing and Stabilizing the System Supply Air Pressure The most effective way to reduce the leakage of the compressed air system is to reduce the system air supply pressure flashing. The lower the card force in the small hole (1), the less the compressed air flow through the small hole. This can be proved from an experimental data flow coefficient of 4 of 4. An effective way to reduce and stabilize the system supply pressure while ensuring smooth system production is to install a voltage regulator on the system mains. Haiming Chemical Fiber Co., Ltd. has adopted this method to reduce the supply pressure of the stable system and save 1.92 million. A tobacco company in Shanghai achieved an energy saving effect of 8.17. through the installation of a voltage stabilization system. Power curve, after the 928 voltage regulator is bypassed, the uploading time of the air compressor that regulates is significantly prolonged. This system flow passes through the anvil and is added after the voltage regulator loses its function. 5 Conclusions Through the above analysis, the following conclusions can be drawn: The leakage of compressed air system accounts for a large proportion of gas production, which not only wastes energy but also reduces production reliability; it can apply the method of testing the air compressor to download cycle and system pressure drop to system leakage. The quantity is measured; the control technology of the compressed air system includes maintenance and application of the throttle device to cut off the air supply and reduce and stabilize the supply pressure. On the basis of reducing the system leakage as much as possible, the system method is used to control the whole system. The strategy is optimized to finally get through the system efficiency and. Maximize production reliability. The project is engaged in the research of energy-saving potential testing technology and energy-saving potential analysis and optimization technology of compressed air system.
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