How can you save gas and save energy when the tank of the oil-free air compressor is discharged?
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Author : Runningway
Update time : 2019-11-20 09:25:24
How can you save gas and save energy when the tank of the oil-free air compressor is discharged?
The discharge of oil-free air compressor tanks is an indispensable task in the maintenance of air compressor systems, but many companies have neglected this work, resulting in corrosion of storage tanks, reduction of tank volume, and frequent damage to air compressor systems. And other issues. Based on the author's experience, this paper puts forward some suggestions on how to use the compressed air storage tanks for scientific sewage disposal.
The role of compressed air storage tanks
Compressed air storage tanks have the following effects:
First, stabilize the air pressure. The air pressure of the air compressor is very unstable during operation and has great volatility. The air tank can be used to control the air pressure within a suitable range, eliminating the pulsation of the air flow in the pipeline. With the gas storage tank, the air compressor output compressed air has a buffer, so that the gas source can be well maintained at a set value, and the gas system can obtain a constant pressure.
Second, store the air. There is no place for the compressed air inside the air compressor. Once the compressed air is generated, it must be used. This way of working is not ideal. With the gas storage tank, the compressed air can be first driven into the gas storage tank to a certain pressure, and then the air pressure is reduced to a certain level, and the compressor is restarted, which can meet the demand for the sudden increase of gas consumption of the gas equipment, and ensure that the gas is increased. Use gas steadily.
Third, the energy saving effect. The frequent start and stop of the air compressor will cause the current consumption of the motor to be very large. With the gas storage tank, the automatic shut-off of the air compressor can be guaranteed. Under the set pressure, the gas cylinder will automatically stop when it is full of air compressor, so that the air compressor will not run until the air compressor is running.
Fourth, cooling and filtration. The temperature of the compressed air entering the gas storage tank is reduced to achieve the effect of initially cooling the compressed air. At the same time, it can precipitate the moisture and oil in the compressed air, so that the quality of the compressed air is higher.
Storage tank sewage disposal methods and common problems of sewage discharge
Gas storage tanks remember to release water
Generally, the outside air is humid, especially in the southern rainy days. The air from the air compressor will contain a lot of water. After the air enters the gas storage tank, the air molecules with higher temperature hit the wall of the lower temperature gas storage tank and condense into water. The water falls down the tank wall to the bottom, which accumulates a lot of water in the air compressor tank. At the same time, it also reduces the water content in the compressed air discharged from the tank, and improves the quality of the gas produced by the enterprise. Since the moisture and oil in the compressed air are precipitated at the bottom of the compressed air storage tank, if it is not discharged, the water in the storage tank will be more and more, and the rising water level will cause various problems, so the compressed air storage tank should be regularly discharged.
The compressed air storage tanks mainly include manual manual sewage discharge and automatic sewage discharge. Manual sewage discharge refers to manually opening the gas storage tank drain valve to regularly discharge sewage. A common problem with this method is that the operator is susceptible to external factors and forgets to discharge the gas storage tank. Some enterprises that are not properly managed do not even know that they need to discharge the gas storage tank.
Automatic draining means that the tank is drained with an automatically opened drain valve. Automatic drain valves are available in both electronic and physical. The principle of the electronic automatic drain valve is that the solenoid valve controls the opening and closing of the valve, and the time and period of automatic drain opening can be adjusted by setting the above switch. The electronic drainer is commonly used PSQ-002/15, which is mainly used for precision filters and oil-water separators and gas storage tanks, but this installation is troublesome and requires a connection circuit. The principle of a physical automatic drain valve (also known as a mechanical automatic drain valve) is similar to a steam trap. The common model is BK-315BP.
The installation is relatively simple, only need to connect an extension tube, the life is longer than the solenoid valve. Automatically open the valve automatically at regular intervals to regularly discharge the sewage. A common problem with this method is that, due to the small inner diameter of the valve, it is easy to block the valve after the rust is generated in the gas storage tank, causing the valve to fail and fail to discharge.
Problems caused by unscientific drainage of storage tanks
corrosion
Generally, the outside air is humid, especially in the southern rainy days. The air from the air compressor will contain a lot of water. The water molecules in the compressed air generally contain a certain amount of acidic or basic molecules. If the water condensed at the bottom of the gas storage tank is not discharged for a long time, the gas storage tank will corrode, which greatly reduces the service life of the gas storage tank and jeopardizes Safe operation of the tank.
Volume reduction and affecting air quality
Long-term failure to clean up the water so that the water level rises will cause the volume of the gas storage tank to become smaller and smaller, affecting the stability of the production gas, and will also carry a large amount of water vapor to the gas end, which will inevitably affect the quality of the compressed air. Some precision pneumatic valves have high requirements on the water content in the air, and the increase in water content may cause the pneumatic valve to work abnormally or even be damaged.
Cause damage to other equipment in the air compressor system
Long-term failure to clean up the accumulated water, the water level rises to a certain height, will cause water to enter the oil separator, dryer, compressor and other equipment of the air pressure system, the oil contains too much water will cause the emulsification of the lubricating oil, and the compressor Poor lubrication of the main engine caused the air compressor system to malfunction. Because a company does not often discharge air storage tanks, water enters the compressor interior, resulting in poor lubrication, and finally the compressor is damaged, and the compressor is repaired every two or three months.
Compressed air storage tank scientific sewage method
The unit of use of the compressed air storage tank should be combined with the humidity and temperature of the ambient air and the amount of gas used by the enterprise to reasonably determine the interval of the exhaust gas, and is divided into two working conditions before the drying machine and after the drying machine. The air tank after the dryer, because the dryer has dried the water, basically does not need to drain, and the air tank without the dryer before the dryer and in the air compressor system must be drained regularly. Taking the common 20m?/min, 0.7MPa air compressor and the 2m? compressed air storage tank before the dryer as an example, the discharge cycle of the two sewage modes is explained.
Manual manual sewage
When manual manual sewage is used, it is advisable to discharge the soil every 12 hours in the spring and autumn, and then drain the water. In the case of rainy weather, high temperature weather, and the air compressor running interval is less than 30 minutes, it is recommended to discharge the dirt every 8 hours, and then drain the water. Depending on the water level in the tank, multiple rows are appropriate.
Automatic sewage
When the automatic sewage discharge mode is adopted, the sewage valve should be checked regularly every half month for normal operation. If it is found that it cannot be discharged normally, it should be repaired or replaced immediately. The life of the general automatic drain valve is about 3-5 years, and should be replaced in time when it is long. It is advisable to add a bypass to the automatic drain valve line, and open the bypass every time to check if there is too much water in the tank.
Before installing the drain valve, first remove impurities such as copper chips and rust from the gas tank. It is recommended to empty the system for 3 to 5 minutes under full pressure before installing the automatic drain valve. When installing, install the drain valve at the bottom (lowest point) of the gas tank, and ensure that the direction of drainage is the same as the direction of the arrow on the valve body.
Graphic and unrelated
Special requirements for installing an electronic drain valve:
1. The supply voltage should match the voltage of the electronic drain valve.
2. The TEST membrane switch on the timer of the electronic drain valve is a manual test button. Each time the button is pressed, the drain valve is discharged once. This button is used to check the drainage conditions at any time during daily work.
3. The two knobs of the timer are to adjust the discharge time (how long each time is discharged) and the interval between the two discharges (how often it is discharged).
4. In addition to the connection function, the small screws on the junction box of the electronic drain valve have the function of pressing the seal to prevent water from entering the timer and the coil, so be sure to tighten.
5. For high-pressure system gas storage tanks, high-pressure electronic drain valves should be used.
Suggest
The author combines the experience of many years of air compressor inspection, the following recommendations for the use of compressed air storage tanks:
1. The unit using manual sewage discharge method is recommended to establish a regular sewage discharge system for gas storage tanks according to the requirements of this paper, and strictly follow the sewage discharge system, so as to avoid serious corrosion of the storage tank and damage of the machine caused by improper discharge.
2. The unit that uses the automatic sewage discharge method is recommended to establish a regular inspection system in accordance with the requirements of this article, and conduct regular inspections on solenoid valves and physical valves. Avoid damage to the valve, resulting in inability to drain, resulting in serious corrosion of the tank and damage to the machine.
3. The unit that uses the automatic sewage discharge method is recommended to increase the pipe diameter of the sewage outlet to the manufacturing unit at the time of purchase. Now most of the compressed air storage tank manufacturing units use the sewage pipe of DN15mm to DN25mm. When automatic sewage is used, Only DN8 to DN15 are left in the drain pipe after the sewage disposal equipment is installed. When there is rust in the sewage, the nozzle is easily blocked. Therefore, it is recommended to purchase a compressed air storage tank with a drain port of DN40 to DN50 to avoid the abnormal discharge due to the small diameter of the drain pipe.
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