The control of the valve adjusts the amount of air processed in the first line, and finally stops one line of air compressor under the condition of ensuring normal production, and reduces the cost of compressed air. When the pressure of the net exceeds the set pressure (0 75MPa), it can only be carried out by unloading the steel pipe. Join. In order to save investment and speed up the progress, we used the existing two float production lines of our company, which were put into operation in February 2003 and February 2005 respectively. Each has a compressed air station that provides the required compressed air. In operation, we found that the float two-line air compressor needs to vent some of the compressed air to ensure the stability of the system due to the characteristics of the equipment itself and the process operation, so there is a problem of compressed air waste. In response to this situation, it was decided to carry out pipeline network transformation of the air compressor stations of the two production lines, and transport the second-line air-storage compressed air to the first line, reduce the number of air compressors in the first-line air compressor, and reduce the consumption cost of compressed air under the condition of ensuring production.
1Reconstruction concept 11 The configuration status of the air compressor station equipment before the transformation The float first-line air compressor station is designed with three screw air compressors with a displacement of 20m3/min, which is produced by Beijing Fusheng Company. In production, equipment must be fully put into use to meet the gas consumption requirements. No spare equipment. The air compressor itself is designed to have a capacity adjustment function, that is, an air intake adjusting butterfly valve is provided, and the opening of the intake valve is adjusted by the servo cylinder to adjust the pressure of the pipe network. When the pipe network pressure exceeds the set pressure (0.75MPa), the intake butterfly valve can be gradually closed to reduce the amount of compressed air; when the pipe network pressure is lower than the set pressure (0.75MPa), the large inlet butterfly valve can be gradually opened to increase the compression. The amount of air. This achieves the goal of stabilizing the pressure on the pipe network and saving energy.
The float second-line air compressor station is designed as four 20m3/min screw air compressors, manufactured by Atlas, and used for production. Since the brand air compressor does not have an air intake regulating valve, when the solenoid valve and the diaphragm switching valve of the tube valve group directly turn off the intake valve opening degree by 90% and completely unload the oil cylinder pressure; when the pipe network pressure is low At the set pressure (0 75MPa), the intake valve opening is directly opened to 100% through the solenoid valve and diaphragm switching valve of the unloading valve group. The air load of the compressed air is often changed due to the float line. In actual operation, in order to avoid the frequent addition and unloading of the air compressor to the internal pressure of the air compressor itself (especially the frequent starting of the motor) and the stability of the electrical control system of the subsequent gas equipment, the tube must be emptied by venting part of the compressed air. The mesh pressure is controlled below 0 75MPa. This long-term operation caused a lot of waste of compressed air.
12 The purpose of the transformation is to transform the first and second-line compressed air pipelines, and to deliver the compressed air of the second-line venting to the first line, and adjust the air volume of the first-line processing through the capacity control function of the first-line air compressor and the valve control, and finally stop the production under the guarantee of production. One line of air compressors. Reduce the cost of compressed air. The two-line air compressor operates under full load and relatively stable conditions without frequent loading, unloading, or artificially venting compressed air, effectively utilizing resources and reducing waste.
2 Reconstruction situation Under the concept of this transformation, after careful research, it was decided to renovate the compressed air system pipe network of the float company under the premise of meeting the process requirements and ensuring production safety.
The first and second-line compressed air main pipelines are reinforced by a DN150 seamless plant protection gas pipe network support through the reinforcement of the compressed air pipeline, and the necessary valves are installed on the pipeline. After the network is completed, all the venting compressed air of the second line can be transported to the first line. Then, the opening degree of the intake valve is reduced by the capacity adjustment function of the first-line air compressor, and the processing air volume of the two production lines is adjusted and distributed.
After the completion of the network transformation, most of the first-line air compressor stations were changed from three air compressors to two air compressors. One air compressor that was stopped was only operated for 4 ~ 5h/d when the raw material was dust-removed. The second line still has three air compressors. Compared with before the transformation, without increasing any operating costs, it is equivalent to opening one power 132kW air compressor, and the energy saving benefit is very significant.
3 The progress of the transformation began in April 2005. After one month of reform and trial production, under repeated and meticulous adjustments, the operating conditions of the equipment gradually stabilized. In the case that the dust removal system of the raw material workshop is not open, the first-line air compressor station is changed from 3 air compressors to 2 and 1 equipment. The device is running normally.
4Reconstruction effect (excluding 740m3/d circulating water to disable electricity saving) After the completion of the transformation in April 2005, the current of three air compressors in the first-line air compressor station decreased from the average of 230A, 230A, 200A to an average of 190A. 190A, 0A. In May 2005, the actual electricity consumption of the first-line air compressor station KfkWh, the actual power saving of 7 104kWh in the month. Basically achieved the expected results.
5 Economic Benefit Analysis Analysis of Energy Saving and Consumption Reduction (This analysis refers to the actual consumption calculation in 2004): Reduce the number of spare parts (air filter, oil filter, air compressor lubricant, etc.) with less air compressor, and save 33 circulating water: A set of air compressors need to circulate water about 740m3 per day. According to the calculation of 2% loss, the daily water price of 14 tap water can be calculated by 221 yuan/m3. The total amount of 148m3/d or more can generate direct economic benefits of 65X104 yuan per year.
6 Conclusion This network transformation has basically reached the transformation goal of â€œone air compressor at the first line air compressor stationâ€. After the transformation, the equipment is operating normally, and the power consumption of the air compressor station is obviously reduced, which has produced good economic benefits. However, this is only the benefit from optimizing the rational configuration of the float company air compressor. The real key to energy saving in air compressors is to find the root cause of system waste and accurately analyze the value of the system's energy saving potential.
The problems and inefficiencies encountered when the compressed air system is running are always complicated and impossible to get started. Therefore, the correct evaluation of the compressed air system equipment, comprehensive dynamic management, the full performance of the compressed air system components, and further reduce the comprehensive energy consumption of the air compressor is the direction of our technological innovation.
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