The error-prone link in the installation process of the air compressor system is summarized for you!
1. Selection of installation sites
The selection of the installation site of the air compressor is most easily neglected by the staff. After the air compressor is purchased, it is easy to find a place. After the piping is used immediately, there is no prior planning. As a result of this sloppy result, it has formed the consequences of frequent air compressor failures, maintenance difficulties and poor air quality in the future, so proper installation site is a prerequisite for the correct use of the air compressor system.
(1) Choose a wide area with good lighting to facilitate the space and lighting required for operation, maintenance and repair.
(2) Dry environment: The place where the machine room is located should be kept dry, the ventilation conditions are good, the dust is small, and the air is fresh. Try to avoid dusty, oily, and humid environments to reduce damage to the screw air compressor and extend its service life. It is also incapable of inhaling the screw air compressor with corrosive gases, paint molecules and gases containing explosive or chemically unstable or steam to avoid jeopardizing the air compressor user or causing rapid damage to the unit.
(3) The screw air compressor room should pay attention to keep the floor clean and free of debris, especially flammable and explosive materials, and should be equipped with fire extinguishers and other facilities to ensure the safety of the machine room.
(4) According to the requirements of GB50029-2003 "Code for Design of Compressed Air Stations", the heating temperature between machines in compressed air stations should not be lower than 15 °C, and the temperature between machines in non-working hours should not be lower than 5 °C. When the air compressor suction port or the unit cooling air suction port is installed indoors, the indoor ambient temperature should not exceed 40 °C.
(5) The pressure pipeline is strictly prohibited from bumping: the pressure pipeline inside the screw air compressor room is strictly prohibited from bumping. It is strictly forbidden to disassemble under the condition of charged belt pressure.
(6) If the factory environment is poor and there is a lot of dust, pre-filtering equipment must be installed to ensure the service life of the air compressor system parts.
(7) When a single compressed air station with a displacement equal to or greater than 20m3 /min and a total installed capacity equal to or greater than 60m3/min, lifting equipment for maintenance should be provided, and the lifting capacity should be the most according to the air compressor unit. Heavy parts are determined.
(8) Do not cling to the wall. The placement of the air compressor should be careful not to be close to the wall surface, and a certain distance should be reserved to ensure a certain ventilation and maintenance space, which is also conducive to the maintenance and maintenance of the air compressor. According to the requirements of GB50029-2003 "Compressed Air Station Design Specification", the channel width between the air compressor unit and the wall is 0.8 to 1.5 m according to the displacement.
2. Compressed air piping should pay attention to the matters needing attention
(1) When piping the main pipe, the pipe must have an inclination of 1 ° ~ 2 ° to facilitate the discharge of condensed water in the pipeline.
(2) The pressure drop of the piping pipe shall not exceed 5% of the pressure of the air compressor. Therefore, it is better to use a pipeline larger than the design value when piping.
The air compressor is a complete system through pipes, valves, etc. and other equipment. Improper design calculation and installation of the pipeline will affect the economics and reliability of the entire system, and even lead to serious and damaging accidents.
The inner diameter of the pipe can be obtained from the preselected gas flow rate as follows:
Where di is the inner diameter of the pipe (mm); qv is the gas volume flow (m3/h); u is the average gas flow rate (m/s) in the pipe. The range of the average flow rate of compressed air is given in Table 1.
(3) The branch line must be taken from the top of the main line to prevent condensation from flowing into the working machine or back to the air compressor.
(4) Do not reduce or enlarge the pipeline arbitrarily. The pipeline needs to use a reducer. If the reducer is not used, there will be a spoiler at the joint, which will cause a large pressure drop and a pipeline. The life expectancy also has an adverse effect.
(5) If there is a purification buffer such as a gas storage tank and a dryer after the air compressor, the ideal piping sequence should be air compressor + air tank + dryer. The gas storage tank filters out part of the condensate and also reduces the temperature of the gas. By reintroducing the compressed air of lower temperature and less water into the dryer, the dryer load can be reduced.
(6) If the amount of air used is large and the time is very short, it is better to install a gas storage tank as a buffer, which can reduce the number of air compressors and the number of discharges, and has a great service life for the air compressor. benefit.
(7) Minimize the use of elbows and various valves in the pipeline.
(8) The ideal piping is that the main line surrounds the entire building so that compressed air in both directions can be obtained at any position. If the gas consumption suddenly increases in a branch line, the pressure drop can be reduced. In addition, an appropriate valve block should be placed on the annular main line to facilitate cutting during maintenance.
(9) When multiple air compressor air output pipes are connected in parallel, there is no need to install a check valve at the output of the air compressor.
3. The basis of the air compressor
The foundation of the air compressor should be built on hard soil and the foundation water level should be smoothed before installation to avoid vibration. If it is installed on the upper floor, anti-vibration measures must be taken. Otherwise, the vibration will be transmitted to the downstairs or a resonance phenomenon will occur, which will easily cause damage to the air compressor and the building. Generally, the vibration speed of the screw air compressor is below 11.2mm/s (belt drive) and 7.1 mm/s (coupling drive). It can be used without special treatment. It can be built up to a height of about 120mm and the length and width are slightly larger than the air pressure. The platform foundation of the bottom area is conducive to sewage discharge.
4. Cooling system
The water quality standard for cooling water for water-cooled air compressors shall comply with the provisions of GB5005 "Design Code for Industrial Circulating Cooling Water Treatment". When there is demineralized water available inside the enterprise and the system is economically reasonable, the circulating water in the system can be demineralized water.
The main reason is to prevent the calcium and magnesium ions in the water from reacting in the cooler due to the high temperature, and finally forming scale in the cooler, thereby affecting the cooling efficiency of the cooler. The cooling water pressure is generally between 0.15 and 0.4 MPa, and the cooling water outlet temperature should be maintained between 6 ° C and 10 ° C above the inlet temperature. A filter screen should be installed in the cooling water inlet pipe, and a pressure gauge, a thermometer and a shut-off valve should be installed separately for the inlet and outlet pipes.
The air-cooled air compressor must pay attention to its ventilation environment. The air compressor should not be placed in the vicinity of high-temperature machinery or in a poorly-ventilated enclosed space, so as to avoid high temperature and stop the exhaust. If it is placed in a closed space, it must be installed with air inlet and exhaust equipment. The air inlet is located at the lower part of the machine room, and the air outlet is located at the upper part of the machine room to facilitate the circulation of cold air. In general, the amount of air entering and leaving the air must be greater than the amount of air discharged from the air compressor.
5. Power system
When the air compressor is distributed, the correct voltage of the power supply must be ensured. According to the power of the air compressor used, choose the correct power cable diameter. Do not use a small power cable. Otherwise, the power cable will burn out due to high load and high temperature. The power cord must be a multi-strand copper core cable, and one of the three-phase four-wire system is the grounding wire. It is better to use a power system separately for the air compressor, especially to avoid parallel use with other large power consumption systems. Otherwise, the main motor of the air compressor may be overloaded due to excessive voltage drop or three-phase current imbalance. High-power air compressors must pay special attention.
And the power supply network load should be uniform, the voltage fluctuation is within ±5%, and the three-phase voltage imbalance is allowed to be ±1%. There must be no connection point between the power distribution cable from the power distribution cabinet to the air compressor. According to the power of the air compressor, select the appropriate air switch to maintain the safety of the power system and maintenance. The grounding wire of the power system should be erected, and the grounding wire should not be directly connected to the compressed air conveying pipe or the cooling water pipe.
