ONE、 Case background

        In industrial production, as an important facility for providing compressed air, the operational efficiency and stability of the gas pipeline system in the air compressor room directly affect production efficiency and product quality. With the advancement of technology and the improvement of environmental protection requirements, many enterprises have begun to upgrade and renovate the gas pipelines in their air compressor rooms. The following is a typical case of gas pipeline renovation service in an air compressor room.

TWO、 Case details

1. Project Overview

Enterprise name: A large automobile parts manufacturing enterprise

Project content: Renovation of air compressor station building and gas pipeline system

Pre renovation situation: The enterprise has multiple air compressor stations and supplies a total of 8 air compressors, including 7 110KW single frequency air compressors and 1 75KW single-stage frequency air compressor. These devices have been in use for 7-8 years and suffer from issues such as outdated equipment, low energy efficiency, chaotic operation, large pressure fluctuations, unprofessional management, high maintenance costs, unreasonable pipeline design, high pressure drop, and multiple leakage points.

2. Renovation plan

In response to the above issues, the company has decided to carry out a comprehensive renovation of the air compressor station building and gas pipeline system. The specific plan is as follows:

Equipment update: Three customized two-stage compression permanent magnet variable frequency air compressors have been introduced, each with a gas production capacity of 45m ³/min, totaling 135m ³/min, to meet production needs. Meanwhile, three 110KW air compressors with good energy efficiency will be retained as backup units, while the rest will be phased out.

Pipeline rectification: Change the pipe material to aluminum alloy super pipeline and redesign the pipeline layout to simplify and rationalize the pipeline layout, in order to reduce pressure drop and improve transmission efficiency.

Post processing equipment: Install new post-processing equipment to rationalize load usage and reduce pressure drop.

Monitoring equipment: Install compressed air flow meters, electricity meters, pressure sensors and other detection components to monitor gas production energy consumption and operating status in real time.

Smart gas source station: Establish a smart gas source station, conduct real-time big data analysis through a cloud management platform, and achieve online monitoring of energy consumption operation status.

3. Transformation effect

Energy conservation and consumption reduction: After the renovation, the comprehensive gas electricity ratio decreased from 0.1169 kW · h/m ³ to 0.09 kW · h/m ³, significantly reducing energy consumption.

Stable production: The pressure remains constant at 0.6 MPa, making production more stable and resulting in a higher yield rate.

Convenient management: The cloud management system makes the operation of each air compressor more reasonable, and the mobile and computer terminals can observe the operating status in real time, making management more convenient.

Intelligent matching: Smart gas source stations can dynamically match and meet the gas demand and energy-saving technology upgrades of enterprises based on changes in production capacity and working conditions.

After sales guarantee: During the cooperation period of the renovated gas station, all after-sales maintenance work is undertaken by the supplier, ensuring the smooth and safe use of the air compressor.

THREE、 Case analysis

        This case demonstrates the complete process and significant achievements of gas pipeline renovation in the air compressor room. By introducing efficient and energy-saving equipment, optimizing pipeline layout, installing monitoring equipment, and establishing smart gas source stations, not only has the operational efficiency and stability of the system been improved, but energy consumption and maintenance costs have also been significantly reduced. Meanwhile, the intelligent management system makes operation and maintenance work more convenient and efficient. These experiences have important reference significance for other enterprises that need to carry out gas pipeline renovation in air compressor rooms.

FOUR、 Summary

        The renovation of gas pipelines in air compressor rooms is one of the important means to improve production efficiency and product quality. Through scientific and reasonable renovation plans and strict construction management, system optimization and intelligent management can be achieved. In the future, with the continuous advancement of technology and the increasing demand for environmental protection, the renovation of gas pipelines in air compressor rooms will become an inevitable choice for more enterprises.