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如何有效解决压缩空气泄露问题

新闻来源:杭州日丰空气处理设备有限公司    发布日期:2020.01.06

 空气是免费的,但压缩空气不是免费的!

 
压缩空气作为一种动力能源,当比较电力输入价值与交付价值时,一个不当的压缩空气系统,特别是后处理系统配置不合理造成的成本要高于水、电、蒸汽甚至天然气。
 
压缩空气泄露等同于把钱扔进水里!
 
还不冒泡的那种!
 
在当前我国企业的压缩空气系统中,能源浪费主要表现为泄漏偏大、压缩机配置及运行仅以保压为目的、供给压力不合理、气枪喷嘴低效、设备用气存在浪费、现场工人用气成本意识淡薄等等问题,而压缩空气含水值偏高也是导致腐蚀泄漏的重要原因,压力露点在-26℃td以上,都会存在腐蚀,加速用气设备老化,就会存在泄漏隐患!(模芯吸附式干燥机露点可持续稳定达到-40~-70℃td,可有效解决腐蚀问题。)
 
我国一般工厂中压缩空气系统的泄漏量通常占供气量的20-40%,而管理不善的工厂甚至可能高达50%!这意味着您每月空压机电费的一半都这样泄露掉了!
 
这绝非危言耸听!
 
泄漏在现场广泛存在,有时一个汽车焊装车间的泄漏点就有数万个。通过对这些泄漏点进行排查,发现泄漏主要产生在橡胶软管接头、三联件、快换接头、电磁阀、螺纹连接、气缸前端盖等处。泄漏不是与生俱来的,而是压缩空气品质不良导致着零部件的老化或破损而形成。而解决压缩空气品质不良的根本就是选择合适的干燥净化设备,模芯吸附式干燥机是最佳的选择。
 
现场泄漏量的60-70%是寿命泄漏,来自使用了5年以上的设备,10-30%是在使用了1-4年的设备中发现的,而在设备安装阶段由于安装不当或产品允许泄漏等造成的泄漏仅占全部泄漏的5-10%。
 
由此可见,泄漏的存在并不可怕,需要的是我们对泄漏的正确认识,以及由此所需采取的对设备的定期点检和维护。
 
在工厂,完全意义上的堵死泄漏不太现实,即使采取大规模的堵漏运动,半年后泄漏仍会重新出现。所以,对企业而言,堵漏工作应该常态化,必须将其作为一项日常工作来实施,这样才能将泄漏动态地控制在最低水平。俗话说“消除浪费就是增加效益”
 
公司真正需要的是对其维修人员进行压缩空气系统的使用和维护的培训,提高压缩空气的干燥度和洁净度,后处理设备最好选用模芯干燥机以达到深度干燥,避免腐蚀,以消除能源浪费并使工厂运行更有效率。
Air is free, but compressed air is not free!
 
 
 
As a kind of power energy, when comparing the input value and delivery value of electric power, the cost of an improper compressed air system, especially the unreasonable configuration of post-treatment system, is higher than that of water, electricity, steam and even natural gas.
 
 
 
Leakage of compressed air is equivalent to throwing money into the water!
 
 
 
The kind that doesn't bubble yet!
 
 
 
In the current compressed air system of Chinese enterprises, the main problems of energy waste are large leakage, compressor configuration and operation only for pressure maintaining, unreasonable supply pressure, low efficiency of air gun nozzle, waste of equipment gas, weak cost awareness of field workers, etc., and the high water content of compressed air is also an important reason for corrosion leakage. The pressure dew point is- Above 26 ℃ TD, there will be corrosion, accelerating the aging of gas equipment, there will be potential leakage! (the dew point of the core adsorption dryer can reach - 40 ~ - 70 ℃ TD, which can effectively solve the problem of corrosion.)
 
 
 
In China, the leakage of compressed air system usually accounts for 20-40% of the gas supply in general factories, and even 50% in poorly managed factories! This means that half of your monthly electricity charge for air compressor leaks out like this!
 
 
 
This is not alarmism!
 
 
 
Leakage is widespread in the field. Sometimes there are tens of thousands of leakage points in an automobile welding workshop. Through the investigation of these leakage points, it is found that the leakage mainly occurs in rubber hose joints, triplets, quick change joints, solenoid valves, threaded connections, cylinder front end covers, etc. Leakage is not inherent, but the poor quality of compressed air causes the aging or damage of parts. The key to solve the poor quality of compressed air is to choose the appropriate drying and purification equipment, and the core adsorption dryer is the best choice.
 
 
 
60-70% of the on-site leakage is life leakage, which comes from the equipment that has been used for more than 5 years, 10-30% of which is found in the equipment that has been used for 1-4 years, and only 5-10% of the total leakage is caused by improper installation or product allowable leakage in the equipment installation stage.
 
 
 
It can be seen that the existence of leakage is not terrible. What we need is our correct understanding of the leakage, and the regular spot inspection and maintenance of the equipment needed.
 
 
 
In the factory, it is not realistic to stop the leakage completely. Even if the large-scale plugging movement is adopted, the leakage will reappear six months later. Therefore, for enterprises, plugging work should be normalized and implemented as a daily work, so as to dynamically control the leakage at the lowest level. As the saying goes, "eliminating waste is increasing efficiency"
 
 
 
What the company really needs is to train its maintenance personnel on the use and maintenance of the compressed air system to improve the dryness and cleanliness of the compressed air. The core dryer is the best choice for the post-treatment equipment to achieve deep drying and avoid corrosion, so as to eliminate energy waste and make the plant operation more efficient.


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