您是工程師、技術人員或制造企業(yè)的所有者……使用SMC壓縮空氣系統(tǒng)。在出現(xiàn)問題之前，您是否對壓縮空氣能源生產(chǎn)系統(tǒng)的維護和維修感興趣？如果沒有，那么您應該閱讀這篇文章以了解為什么在系統(tǒng)出現(xiàn)故障之前進行維修很重要。如果是，您還應該閱讀更多壓縮空氣系統(tǒng)的 解決 方案。事實上，大多數(shù)使用壓縮空氣系統(tǒng)的生產(chǎn)單位都沒有注意能源消耗的浪費。但只對系統(tǒng)是否產(chǎn)生足夠的氣體使用感興趣。SMC本身曾經(jīng)是這樣的。SMC的壓縮空氣系統(tǒng)消耗的能源成本占整個車間能源消耗成本的10%左右。但在應用改進并實施工作后，浪費的成本已大大減少。讓我們來分析一下降低壓縮空氣系統(tǒng)的浪費成本的方法！

主目錄
壓縮空氣系統(tǒng)的成本評估
改善壓縮空氣系統(tǒng)的解決方案
解決方案一：有效改進現(xiàn)有的壓縮空氣系統(tǒng)
第 2 步：減少泄漏
步驟 3：修復系統(tǒng)中的壓降
第 4 步：檢查壓縮空氣罐
第 5 步：分離器、空氣過濾器、壓縮空氣干燥器和安全閥的維護
第六步：選擇合適容量的空壓機
解決方案 2：設計一個新系統(tǒng)
壓縮空氣系統(tǒng)的成本評估
壓縮空氣的生產(chǎn)成本不能以每小時消耗的量來計算。事實上，壓縮空氣生產(chǎn)過程中需要考慮冷卻成本。在生產(chǎn)壓縮空氣的過程中，以消耗量為99%，高達92%轉(zhuǎn)化為熱量。正是這種浪費的燃料使壓縮空氣的生產(chǎn)成本高出許多倍。

不包括廢熱再利用的壓縮空氣系統(tǒng)的估計運行成本為：

空壓機系統(tǒng)及安裝成本為12%
系統(tǒng)維護成本約占12%
用電成本約為76%

圖 1：10 年運行周期內(nèi)壓縮空氣系統(tǒng)的成本

圖表顯示了壓縮空氣系統(tǒng)運行約 10 年的成本，成本仍主要用于能源（73%）。如果不回收產(chǎn)生的熱量，浪費的成本太高。為了優(yōu)化壓縮空氣能源，企業(yè)需要對設計、安裝、運營和維護有一個全面的了解。一旦 確定了壓縮空氣系統(tǒng)的局限性s

改善壓縮空氣系統(tǒng)的解決方案
解決方案一：有效改進現(xiàn)有的壓縮空氣系統(tǒng)
第 1 步：評估對壓縮空氣的需求

在著手改造壓縮空氣系統(tǒng)之前，您需要確定系統(tǒng)中對壓縮空氣的需求。

– 消除不合適的設備：壓縮空氣是一種清潔的綠色能源，用途廣泛。使用SMC壓縮空氣為用戶帶來了許多好處、便利性、設備效率和安全性。然而，并非所有使用壓縮空氣的設備和工具都經(jīng)過優(yōu)化。如果您可以列出使用壓縮空氣的設備和工具，那么在使用其他更經(jīng)濟的能源減少不必要或合適的設備時，企業(yè)將取得驚人的成果。

使用壓縮空氣

使用的設備

解決方案

吹清潔空氣

噴槍和噴嘴

低壓風機、毛刷、毛刷。

冷卻

感應冷卻系統(tǒng)

空調(diào)系統(tǒng)、水冷系統(tǒng)、通風系統(tǒng)、冷卻風扇。

擦干產(chǎn)品上的水

噴槍和噴嘴

控制電磁閥、噴嘴

–規(guī)劃現(xiàn)在和未來：對于即將開展的項目，您可以總結當前和將來使用的壓縮空氣設備。使用以下標準識別使用相同氣體的設備類型：

壓力（千帕）
平均消耗量 (l/s)
壓縮空氣質(zhì)量（濕度、粉塵濃度、油量等）
– 空氣壓縮機的估計功耗。

第 2 步：減少泄漏
壓縮空氣系統(tǒng)的 定期 檢查 和 維護是減少浪費性泄漏的一種方法。由于泄漏造成的浪費可能高達產(chǎn)生的壓縮空氣的 50%。減少泄漏是降低壓縮空氣系統(tǒng)成本的關鍵。

–泄漏測量：這是一種使用流量計確定壓縮空氣流量消耗并根據(jù)理論方法計算的方法。

等效孔徑 (mm)

泄漏流量 (l/s)

年泄漏能量 (Kwh)

年泄漏成本 (€)

等效泄漏孔直徑、泄漏流量、年泄漏能量和成本之間的關系。

–尋找泄漏：為了減少泄漏，必須找到泄漏。容易發(fā)生泄漏的部位有：管道、接頭、調(diào)壓閥、泄壓閥、氣動閥、螺紋接頭等。

如果泄漏很大，則可以通過偵聽輕松檢測到泄漏。在許多嘈雜的環(huán)境中，可以通過在可疑位置涂抹肥皂來檢測泄漏，通過冒泡現(xiàn)象檢測到?；蛘吒旄鼫蚀_的可以使用超聲波檢測儀。

–泄漏修復：定期檢查、擰緊和更換接頭、氣動閥，修復或更換泄漏位置。需要更換的地方應更換為同步元器件和配件。參考：如何找到有信譽的工業(yè)設備供應商。

–制定泄漏管理計劃：需要定期執(zhí)行以下任務，以確保壓縮空氣系統(tǒng)的效率。

定期檢查和維護壓縮空氣設備；
檢查壓縮空氣管道、氣動閥、接頭和截止閥；
移除該管道上調(diào)節(jié)器未使用或未使用的部分；
定期監(jiān)測和綜合泄漏，有合理的處理方法。
步驟 3：修復系統(tǒng)中的壓降
對壓縮空氣系統(tǒng)造成嚴重問題的現(xiàn)象之一是壓降現(xiàn)象，壓力下降。當壓力下降時，輸出壓力，產(chǎn)生的壓縮空氣量不足以滿足生產(chǎn)需要。一個好的壓縮空氣系統(tǒng)是壓縮機和使用點之間的壓降值小于 10% 的系統(tǒng)。

– 使用SMC壓縮機出口處的壓力表監(jiān)測壓降。將每個壓力調(diào)節(jié)器設置為值。

壓降 = 壓縮機壓力 – 調(diào)節(jié)器壓力。
– 安裝合適的截止閥：常用的兩種閥門是球閥和閘閥。每種類型都有其適合在系統(tǒng)上使用的特性。

– 合理布置管道，限制收縮或彎曲。風管的彎曲也會導致壓降。壓縮空氣系統(tǒng)2種連接方式，以盡量減少彎曲的位置。

cach-noi-duong-ong-dan-khi-nen-trong-he-thong-khi-nen
分支系統(tǒng)。 帶分支電路的主環(huán)系統(tǒng)。

– 計算壓縮空氣需求以選擇合適的管道直徑。如果需求量大，用小管子在使用的時候會沒有足夠的氣壓。

– 壓力設置：壓縮機的標準壓力 = 設備所需的壓力 + 系統(tǒng)壓降導致的最小壓力。

第 4 步：檢查壓縮空氣罐
壓縮空氣罐的容量直接影響空壓機的運行，決定了空壓機的壽命?？紤]提高油箱容量和安裝位置，以減少能源使用，限度地減少壓降和磨損。

方法一：安裝一個更大的主水箱供整個系統(tǒng)使用。
方法二：在使用的設備附近安裝輔助水箱，以快速響應設備的需求。
第 5 步：分離器、空氣過濾器、壓縮空氣干燥器和安全閥的維護
– 分離過濾器用于將空氣中的油從壓縮機中分離出來，一個好的分離過濾器會增加空氣壓縮機的使用壽命。因此，過濾器的更換和定期維護非常重要，應按照制造商的說明進行更換。

– SMC空氣過濾器過濾掉空氣中殘留的灰塵和污垢，幫助氣體在放入容器時清潔并達到標準。物件應定期維護更換，不得堵塞過濾器，造成壓降，浪費機能。

– SMC壓縮空氣干燥器也是壓縮空氣系統(tǒng)中的重要組成部分。為系統(tǒng)使用合適的烘干機也將節(jié)省能源。

– SMC排水閥：集成在水箱、空氣干燥器和過濾器上。

第六步：選擇合適容量的空壓機
共享以上的步驟旨在限度地利用、分配、存儲和處理壓縮空氣。在這步中，SMC分享了更多關于選擇空氣壓縮機的信息。下表總結了市場上可用的空氣壓縮機類型的優(yōu)缺點。

空壓機類型

優(yōu)勢

缺點

往復式壓縮機 7.8 – 8.5 (Kw/m3/min)

壓縮壓力高、體積小、體積小、維護簡單、多級壓縮。

噪聲級高，維護成本高，適用于小型系統(tǒng)。

螺桿壓縮機 6.4 – 7.8 (Kw/m3/min)

操作簡單，運行時發(fā)熱量低，維護少，運行安靜，結構緊湊。

能源消耗大，空氣質(zhì)量差。

對流壓縮機

操作簡單、工作溫度低、噪音低、維護量少。

容量有限，空氣質(zhì)量低。

離心式壓縮機 5.8 – 7.0 (Kw/m3/min)

效率高、功率范圍寬、運行安靜、空氣質(zhì)量高。

初期投資高，產(chǎn)能低效率低，需要特殊維護。

根據(jù)系統(tǒng)的負載選擇更換空壓機或安裝另一臺壓縮機。

解決方案 2：設計一個新系統(tǒng)
帶有日立空壓機的簡單壓縮空氣系統(tǒng)
–評估和建立壓縮空氣需求 ，如解決方案 1 的第 1 步。

– 氣體管道和連接閥的設計

管道和連接位置對系統(tǒng)的壓力設定點有直接影響。提醒大家：運行良好的壓縮空氣系統(tǒng)必須確保壓縮機10% ：管徑、到各使用位置的管長應符合系統(tǒng)要求。適當位置的連接數(shù)量和類型，以及s

– 選擇位置并安裝壓縮空氣罐：將罐用于整個系統(tǒng)或在大容量使用位置附近安裝額外的輔助罐。

– 空氣過濾器、分離器和壓縮空氣干燥器的選擇： 壓縮空氣系統(tǒng)中的配件和設備需要保證質(zhì)量。使用的產(chǎn)品也是系統(tǒng)節(jié)省成本的一種方式。

| 查看更多：的設備制造商在越南亮相

使用分離器、空氣過濾器和壓縮空氣干燥器是提高壓縮空氣質(zhì)量的必要條件。因此，維護成本也更高。

+ 有必要計劃定期維護和更換，以盡量減少壓降。

+ 在排放閥上使用電子傳感器優(yōu)化壓力調(diào)節(jié)器、儲液罐、過濾器、空氣干燥器的打開和排放時間。

– 確定進風口和出風口

使用安裝在空氣壓縮機進氣歧管前面的冷卻器可提高壓縮機的效率。或者干脆把廠外的氣體引出來更干凈。

– 選擇壓縮機和控制系統(tǒng)

選擇壓縮機，壓縮機的工作范圍（壓縮機類型，容量…）?？紤]因素（步驟 6 – 解決方案 1）以確定適合您需求的壓縮機。

You are an engineer, a technician or the owner of a manufacturing business… using a compressed air system . Have you ever been interested in the maintenance and repair of the compressed air energy production system before there was a problem?

If not, then you should read the article to learn why it’s important to service before your system fails. If yes, you should also read for more optimal solutions for compressed air systems .

chi-phi-cho-he-thong-khi-nen
In fact, most production units that use compressed air systems do not pay attention to the waste of energy consumption. But only interested in whether the system produces enough gas to use or not. VCC TECH itself used to be like that. The cost of energy consumed by the compressed air system of VCC accounts for about 10% of the energy consumption cost of the whole workshop. But after applying Kaizen improvement and implementing 5S work, wasted costs have been significantly reduced. Let’s analyze the ways to reduce waste costs of compressed air systems with VCC !

Main Table of Contents
Cost assessment for compressed air systems
Solutions to improve compressed air systems
Solution 1: Effectively improve the existing compressed air system
Step 2: Reduce Leaks
Step 3: Fix the pressure drop in the system
Step 4: Examine the compressed air tank
Step 5: Maintenance of separators, air filters, compressed air dryers and relief valves
Step 6: Choose the right capacity air compressor
Solution 2: Design a new system
Cost assessment for compressed air systems
The cost of compressed air production cannot be calculated based on the amount of electricity consumed per hour. In fact, it is necessary to consider the cost of cooling during the production of compressed air. In the process of producing compressed air , considering the amount of electricity consumed as 99%, up to 92% is converted to heat. It is this wasted fuel that makes the production cost of compressed air many times more expensive.

The estimated operating cost of a compressed air system that does not include waste heat reuse is:

Cost of air compressor system and installation is 12%
System maintenance costs account for about 12%
The cost of electricity consumption is about 76%

Figure 1: Cost for a compressed air system in a 10-year operating cycle

The chart shows the cost of a compressed air system over about 10 years of operation, the cost is still mainly for energy (73%). Without recycling the generated heat, the cost of waste is too great. And to optimize compressed air energy, businesses need to have an overview of design, installation, operation and maintenance. Once the limitations of the compressed air system have been identified , we have the key to optimizing energy efficiency.

Solutions to improve compressed air systems
Solution 1: Effectively improve the existing compressed air system
Step 1: Assess the demａnd for compressed air

Before proceeding to renovate the compressed air system , you need to determine the demａnd for compressed air in the system.

– Eliminate unsuitable equipment : Compressed air is a clean green energy with many useful uses. Using compressed air brings many benefits, convenience, efficiency of equipment and safety for users. However, not all equipment and tools using compressed air are optimized. If you can make a list of equipment and tools using compressed air, businesses will have amazing results when reducing unnecessary or suitable equipment using other energy more economically.

Use compressed air

Equipment used

Solutions

Blow cleaning air

Guns and nozzles

Low pressure fan, brush, brush.

Cooling

Induction cooling system

Air conditioning system, water cooling system, ventilation system, cooling fan.

Dry the water on the product

Guns and nozzles

Control solenoid valve, nozzle

– Planning for the present and the future: With upcoming projects, you can summarize the compressed air equipment that is currently and will be used in the future. Identify types of equipment using the same gas with the following criteria:

Max pressure (kPa)
Average Consumption (l/s)
Compressed air quality (humidity, dust concentration, oil, etc.)
– Estimated power consumption of the air compressor.

Step 2: Reduce Leaks
Regular inspection and maintenance of compressed air systems is one way to minimize wasteful leaks. Waste due to leaks can be up to 50% of compressed air produced. Reducing leakage is the key to reducing the cost of the compressed air system.

– Leakage measurement : this is a way to determine the compressed air flow consumption using a flowmeter and calculate by based on theoretical methods.

Table 1: Relationship between equivalent leak hole diameter, leak flow rate, annual leak energy and cost.

– Find the leak : To reduce the leak, it is necessary to find the leak. Locations prone to leaks are: pipelines, joints, pressure regulating valves, pressure relief valves, pneumatic valves, threaded joints, etc.

Leaks can be easily detected by listening if the leak is large. In many cases of noisy environment, leaks can be detected by applying soap to the suspected location, detected by the phenomenon of bubbling. Or faster and more accurate can use ultrasonic detector.

– Leak repair : regularly check, tighten and replace joints, pneumatic valves, repair or replace leak locations. The places that need to be replaced should be replaced with synchronous genuine components and accessories. Reference : How to find a reputable industrial equipment supplier.

– Develop a leak management program : The following tasks need to be performed regularly to ensure the efficiency of the compressed air system.

Regularly check and maintain compressed air equipment;
Inspect compressed air pipelines, pneumatic valves, connectors and shut-off valves;
Remove the unused or unused part of the regulator on that pipeline;
Monitor and synthesize leaks regularly to have a reasonable treatment method.
Step 3: Fix the pressure drop in the system
One of the phenomena that causes serious problems for the compressed air system is the phenomenon of pressure drop, pressure drop. When the pressure drops, the output pressure decreases, the amount of compressed air produced is not enough to serve production needs. A good compressed air system is one where the pressure drop value is less than 10% between the compressor and the point of use.

– Monitor the pressure drop by using the pressure gauge at the compressor outlet. Set each pressure regulator to the maximum value.

Pressure drop = compressor pressure – pressure at regulator.
– Install suitable shut-off valves: Two types of valves commonly used are ball valves and gate valves. Each type has its own features suitable for use on the system.

• Arrange pipes reasonably, limiting shrinking or bending. Bending of the air duct can also cause pressure drop. There are 2 ways to connect the air pipeline for the compressed air system to minimize the position of the maximum bending.

cach-noi-duong-ong-dan-khi-nen-trong-he-thong-khi-nen
Branching system. Main ring system with branching circuits.

– Calculation of compressed air demａnd to choose the right pipe diameter. If the demａnd is large, using a small pipe will not have enough gas pressure when used.

– Pressure setting: Standard pressure at the compressor = Maximum required pressure of the device + Minimum pressure due to pressure drop of the system.

Step 4: Examine the compressed air tank
The capacity of the compressed air tank has a direct influence on the operation of the air compressor, which determines the life of the air compressor. Consider improving tank capacity and mounting location to reduce energy use, minimize pressure drop and wear.

Method 1: Install a larger main tank to use for the whole system.
Method 2: Install the auxiliary tank near the equipment used to quickly respond to the needs of the device.
Step 5: Maintenance of separators, air filters, compressed air dryers and relief valves
– Separation filter is used to separate the oil in the air from the compressor, a good separation filter will increase the life of the air compressor. Therefore, the replacement and periodic maintenance of the filter is very important, it should be replaced according to the manufacturer’s instructions.

– The air filter filters out dust and dirt left in the air, helping the gas when it is put into the container to be clean and up to standard. The object should be maintained and replaced periodically, the filter must not be clogged, which will cause pressure drop and waste machine energy.

– The compressed air dryer is also an important part in the compressed air system. Using the right dryer for the system will also save energy.

– Drain valve: Integrated on the tank, air dryer and filter.

Step 6: Choose the right capacity air compressor
The steps above the shared VCC are steps that aim to maximize the use, distribution, storage, and handling of compressed air. In this final step, VCC shares more about choosing an air compressor. The table below summarizes the advantages and disadvantages of the types of air compressors available on the market.

Air compressor type

Advantage

Defect

Reciprocating compressors 7.8 – 8.5 (Kw/m3/min)

High compression pressure, small size, small volume, simple maintenance, multi-stage compression.

High noise level, high maintenance cost, suitable for small system.

Screw compressors 6.4 – 7.8 (Kw/m3/min)

Simple operation, lower heat output when operating, less maintenance, quiet operation, compact.

High energy use, low air quality.

Convection compressor

Simple operation, lower operating temperature, low noise, less maintenance.

Limited capacity, low air quality.

Centrifugal compressor 5.8 – 7.0 (Kw/m3/min)

High efficiency, wide power range, quiet operation, high air quality.

High initial investment, inefficient at low capacity, special maintenance.

Depending on the load of the system to choose to replace the air compressor or install another compressor.

Solution 2: Design a new system
h? th?ng khí nén ??n gi?n v?i máy nén khí hitachi
– Evaluate and build compressed air demａnd like step 1 of solution 1.

– Design of gas pipelines and connection valves

Piping and the location of connections have a direct effect on the pressure setting point of the system. A reminder for everyone: A well-functioning compressed air system must ensure a pressure drop of less than 10% between the compressor outlet and the service outlet at all points. When designing pipelines and location of valves, attention should be paid to: Pipe diameter, pipe length to each use position should be in accordance with the requirements of the system. The number and type of connections at the appropriate locations, plus the distance between the compressor and the point of use how to minimize pressure drop.

– Select the location and install the compressed air tank: use the tank for the whole system or install an additional auxiliary tank near the location to be used with a large capacity.

– Selection of air filters, separators and compressed air dryers: The accessories and equipment in the compressed air system need to ensure quality. Using products of reputable big brands is also a way to save costs for the system.

| See more : The world’s leading prestigious equipment manufacturers are present in Vietnam

Using separators, air filters and compressed air dryers is a must to improve compressed air quality. As a result, maintenance costs are also higher.

• It is necessary to plan periodic maintenance and replacement, minimizing pressure drop.
• Using electronic sensors at the drain valve to optimize the opening and discharging time on the pressure regulator, reservoir, filter, air dryer.

– Determine the air inlet and outlet

Using a chiller mounted in front of the air compressor’s intake manifold increases the efficiency of the compressor. Or simply lead the gas from outside the plant to be cleaner.

– Select compressor and control system

Select the compressor, the operating range of the compressor (compressor type, capacity…). Consider the factors (step 6 – Solution 1) to determine the right compressor for your needs.