COMMON ISSUES FOUND IN COMPRESSED AIR SYSTEMS
Compressed air systems alone consume more than 10% of industrial electricity.
However, these systems can be plagued by several common issues found in gas production, transport, and utilization.
- Unloaded compressors
- Unstablized pressure supply
- Manually start/stop units
- Low operational efficiency
- Lack of a central control system
- Lack of after air treatment control
- Lack of system surveillance
- Lack of preventive maintenance
ENERGY OPTIMIZATION AND INTELLIGENT AIR COMPRESSOR STATION
Deep Energy Optimization and Intelligent Air Compressor Station:
Implemented through the integration of DeepBox, DeepLogic, and DeepSight, enabling comprehensive energy optimization and intelligent operation and maintenance for air compressor systems.
- Supply-Demand Balance Synchronization
- Multi-Unit Control Optimization
- Narrow Pressure Band
- Minimization of Unloading and Venting Losses
- Load Distribution Equalization Across Units
- Unit Parameter Optimization
- Post-Treatment System Diagnostics and Synchronization
- Preventive Maintenance and Condition Monitoring
- Advanced Data Analytics and Reporting
- Intelligent Maintenance and Operations Workflows
PRODUCT FEATURES
01. System Level - Gas Supply-Demand Balance
Monitor gas utilization: Gain direct insight into actual end use of compressed air (pressure valves, pressure sensors, operational status), and reduce operating pressure to lowest possible setting.
Pressure equilibrium among stations: Control and fine-tune air flow and pressure distribution among power stations by leveraging pipeline pressure and flow monitoring data.
02. Station Level - Efficient Control of A Compressed Air System
Optmize system control: Dynamically coordinate compressors operation based on pressure demand, ensuring that only necessary compressor units are brought online and operating at peak efficiency, and that the system pressure is kept within specified limits.
Minimize pressure fluctuation: Optimize pressure regulation to stablize the system.
Implement dryer control: Refrigerated air dryers-pressure dew point: 2°C to 10°C, pressure drop: 0.2bar; Desiccant air dryers-pressure dew point: -20°C to -40°C, pressure drop: 0.7bar
03. Station Level - Unit Load Balance
Reduce unloading and blow-off: Employ predictive modeling and control strategies to manage unit loading and unloading efficiently. Enhance the loading rate of fixed-speed air compressors, optimize the drive motor speed of VSD air compressors, decrease blow-off duration of centrifugal air compressors, and minimize the unloading time of screw air compressors.
Unit load balancing: Implement effective control to equalize unit loading and minimize blow-off occurrences.