Air compressor energy saving retrofit scheme and benefits

First, the feasibility of air compressor energy saving transformation Air compressor in the course of the energy consumption is obvious to all, Beijing Zhongtian Energy Company based on the principle of frequency developed Zhongtian high-pressure fan Saver for all motor-driven air compressor energy-saving transformation. The overall energy-saving effect is significant, saving rate of 20 to 50%. The actual transformation of Beijing Zhongtian Energy Saving Co., Ltd. as a limited company is illustrated as follows: Electric Company currently has 4 fully automatic production lines, another 80 injection molding machine to Taiwan, the required compressed air provided by a group of compressors. The factory gas supply system has a total of four 380V compressor, of which two 37KW always work, and the other 55KW and 45KW according to the situation in the gas supply in different time periods put into use. Due to the lack of design compressor and the uncertainties in the production process, the air compression system has the following defects: Waste of energy. Compressed air production line pressure requirements for the 3kgf / cm2, the gas manifold to maintain the pressure at 3.2kgf / cm2 more appropriate. As the air can not be constant, in fact, two 37KW air compressors can basically meet the requirements of operation, three air compressors operate, there are more frequent deflation phenomenon, more serious waste of energy. Moreover, the system pressure often fluctuates in a wide range from 3kgf / cm2 to 4kgf / cm2, to a certain extent, affecting the quality of the products in some processes. loud noise. Air compressor automatically deflated when the noise is very loud, resulting in environmental pollution. Power grid impact. As the three air compressors are frequency start, run, the machine's starting current up to 630A above, causing impact on the power grid. Gas volume fluctuations. As the system can not automatically adjust the air supply, air supply fluctuations in the quality of the product has a certain impact. In summary, the air compressor energy saving system can be used to transform the existing air compression system, the use of PID control frequency conversion technology to establish a constant pressure air supply system, so as to achieve energy saving, reduce noise, reduce equipment wear and tear, reduce the grid Impact, improve power factor, stable product quality and other effects. Air compression system energy-saving transformation principle 1, power saving principle introduction Energy-saving controller using frequency conversion technology and the latest PID control technology, the use of pressure sensor signals and related electrical control signals, according to set the compressed gas pressure control air compressor motor speed, the pressure maintained at the required pressure value, the usual Do not have to save the energy saved, so as to achieve the purpose of saving electricity. The system uses continuous program control, there is no frequent impact of large current impact, which can effectively protect the power grid. 2, transformation requirements The factory gas supply system has a total of four compressors, of which two 37KW always work, and the other 55KW and 45KW according to the gas supply in different time periods put into use. The factory requires that the air compressor be supplied with a constant pressure gas supply, the pressure range of the gas supply is 0 ~ 1MPa; in addition to the full frequency (power frequency) work of two 37KW air compressors, the other 55KW and 45KW can be switched into work, The operating frequency is controlled according to the required air pressure. 3, control methods The working principle of the control system is shown in the following figure. It can be seen from the figure that there are 1 55KW air compressor (1 # pump), 1 45KW compressor (2 # pump) and 2 37KW compressors (3 # and 4 # pumps) for system operation. Two 37KW frequency operation, can not speed, the other two by the inverter speed. According to the specific circumstances of the plant air compressor, motor drive equipment inverter selection 55KW inverter, 55KW and 45KW can adapt to the use of two air compressors. In order to realize constant pressure gas supply on the gas pipeline, a pressure transmitter is installed on the gas transmission pipe, and the pressure in the pipe network is transformed into a 4-20mA signal and sent to the intelligent self-tuning PID regulator. PID regulator 4 ~ 20mA input signal into a 0 ~ 10VDC electrical signal, control the inverter output frequency and output voltage, thereby changing the motor speed. System work, 3 #, 4 # pump running frequency, such as pipe network pressure is not enough, the inverter control 2 # pump to work, if work to the working frequency state pipe network pressure is still not enough, the inverter automatically switches to 1 # pump , The inverter will automatically switch to # 2 pump. If it is still too high, pump # 2 will stop working and only # 3 pump will stop working. When pump pressure is too high, , 4 # frequency operation can be. So that the main air pressure is basically constant, to achieve the purpose of constant pressure gas supply. When the compressed air consumption changes greatly, the system pressure reaches the set maximum or minimum value, installed in the gas main power contact pressure gauge will detect the signal sent to the logic switching controller, as the system into / One of the important conditions (but not the only) to cut out the MF unit. When the system needs to be put into the power frequency unit, the system first judges which unit is in a ready state (STANBY), and then sends out an alarm signal, and then executes the start command after the delay; when the pressure is too large, it must be stopped without human interference , The system directly issued a stop command, the unit downtime. Comprehensive benefit analysis Zhongtian high-pressure fan energy-saving controller to minimize the air compressor power consumption, due to the realization of the stepless speed regulation, air compressor power consumption and the use of pneumatic equipment is closely related. After the air compressor energy-saving controller is installed to save energy, we expect the overall energy saving effect will generally reach 20% ~ 50%, and some air compressors may reach a higher level. After the company's air compressor unit has been transformed, the following results have been achieved: Save electricity: After the constant pressure gas supply system is put into operation, the gas pressure in the gas tank can be kept within 2.5% of the set value, the energy lost automatically will be saved and saved. After measured, the electricity saving rate will reach 40% , While the power factor increased to COSÑ„> 0.95, reducing reactive loss; Reduce noise and reduce environmental pollution: constant pressure air supply system due to the realization of the frequency control, basically eliminating the situation of emptying deflated, thus improving the noise pollution of the environment; Extend the life of mechanical components: the use of air compressor power-saving system, the air compressor most of the time running under the power frequency, can significantly reduce the wear and tear of mechanical components, extend the life of the machine, reduce maintenance costs and reduce maintenance time; Realize the soft start: Reduce the unit starting current impact on the grid, and can be flexibly repeated many times to start, to avoid self-coupling buck start in this area; Constant pressure air supply: After the system is put into operation, it improves the air supply reliability and load capacity adjustment ability, ensures constant air supply pressure and further ensures the stability of product quality. Reliable operation, the failure rate is almost zero: the system is equipped with overload, loss of pressure, voltage, over current, lack of equal protection, reliable operation; Simple operation, failure does not affect the production: Energy-saving device fails, it can automatically shut down and send a fault signal, at the same time, can be converted to electricity to make the normal operation of air compressor, does not affect the production.

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