Case of gas pipeline transformation in air compressor room

1. Case background
In industrial production, the air compressor room, a critical facility for supplying compressed air, directly impacts production efficiency and product quality through the operational efficiency and stability of its gas pipeline system. With technological advancements and increased environmental standards, many companies are upgrading their air compressor rooms’ gas pipelines. The following is a typical case of air compressor room gas pipeline renovation services.
Case details
Project overview
Enterprise name: a large automobile parts manufacturing enterprise
Project content: air compressor station and gas pipeline system transformation
Before the renovation, the company operated multiple air compressor stations, supplying a total of 8 air compressors. Among these, 7 were 110KW single-unit industrial frequency compressors, and 1 was a 75KW single-stage industrial frequency compressor. These devices had been in use for 7 to 8 years, leading to issues such as outdated equipment, low energy efficiency, chaotic operation, significant pressure fluctuations, unprofessional management, high maintenance costs, and unreasonable pipeline design with high pressure drops and numerous leakage points.

2. Renovation plan

In view of the above problems, the enterprise decided to carry out a comprehensive transformation of the air compressor station and gas pipeline system. The specific plan is as follows:

Equipment update: 3 customized two-stage compression permanent magnet variable frequency air compressors are newly introduced, with a gas production capacity of 45m³/min per unit and a total of 135m³/min to meet the production demand. At the same time, three 110KW air compressors with good energy efficiency are retained as backup machines, while the rest are eliminated.

Pipe rectification: the pipe material is changed to aluminum alloy super pipe, and the pipeline layout is redesigned to simplify and rationalize the pipeline layout, so as to reduce pressure drop and improve transmission efficiency.

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

Monitoring equipment: Compressed air flowmeter, electricity meter, pressure sensor and other detection elements are installed to monitor gas production energy consumption and operation status in real time.

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

3. Transformation effect

Energy saving and consumption reduction: after the transformation, the comprehensive gas-electricity ratio is reduced from 0.1169kw·h/m³ to 0.09kw·h/m³, which significantly reduces energy consumption.

Stable production: the pressure is constant to 0.6MPa, which makes the production more stable and the yield higher.

Convenient management: The cloud management system makes the operation of each air compressor more reasonable, and the operation status can be observed in real time on mobile phone and computer, making management more convenient.

Intelligent matching: The intelligent gas source station can dynamically match the gas demand of enterprises and energy saving technology upgrading according to the changes of enterprise capacity and working conditions.

After-sales guarantee: during the cooperation period of the modified air station, all after-sales maintenance and maintenance work shall be undertaken by the supplier to ensure the smooth and safe use of the air compressor.

Case analysis

This case demonstrates the complete process and significant outcomes of gas pipeline renovation in an air compressor room. By introducing high-efficiency energy-saving equipment, optimizing the pipeline layout, installing monitoring devices, and establishing a smart gas source station, the system’s operational efficiency and stability have been significantly enhanced, while energy consumption and maintenance costs have been notably reduced. Additionally, the intelligent management system has made operation and maintenance more convenient and efficient. These experiences are valuable for other companies considering similar gas pipeline renovations in their air compressor rooms.

4. summary

The renovation of gas pipelines in air compressor rooms is a crucial method to enhance production efficiency and product quality. By implementing scientific and reasonable renovation plans and strict construction management, the system can be optimized and upgraded, leading to intelligent management. In the future, as technology advances and environmental standards become more stringent, the renovation of gas pipelines in air compressor rooms will become an inevitable choice for more companies.