The unit is in poor operating condition. This problem is mainly manifested in the difficulty in meeting the design requirements of the compressor operation cycle, unstable operation in summer, and frequent failures. Some compressor equipments operate for a long time.
1. Problems in compressor operation
1.1: Low output and high energy consumption. Many industrial compressors limit the compressor power due to energy saving, resulting in compressor compression capacity lower than the design value, especially when the summer load increases, the delivery volume will be significantly reduced. Due to the limited heat dissipation capacity, other equipment in the production line cannot be filled. Operation reduces production efficiency.
The operation mode of the parallel operation of the compressor is not high, the stability is not good, and the two compressors work in parallel. Although the total flow can be significantly increased, the working flow of a single compressor is lower than that of the single machine, so each unit The efficiency of the compressor has dropped. The total compression flow of the parallel connection of the two machines is smaller than the flow of the independent operation, and the flow rate increases after the parallel connection, the loss of the pipeline resistance will increase, and the safety of the unit is also affected. Shandong cold storage installation
1.2: The unit is in poor operating condition. This problem is mainly manifested in the fact that the compressor operation cycle is difficult to meet the design requirements, the summer operation is unstable, and the faults are frequent. Some compressor equipments operate for a long time, and mechanical, electrical, and instrumentation components are frequently faulty. It is difficult to realize the captain by means of after-sales maintenance. The time runs without failure and is prone to failure, which causes the compressor to stop and affects production safety.
1.3: The operation and maintenance costs are high. The old compressor maintenance cost is very high. When the two machines are in parallel, the two sets of compressors must spare one set of faulty multiple parts, double backup cost, and also cause redundant and wasteful spare parts.
2. Compressor energy regulation and energy consumption
The compressor is generally selected according to the actual demand of the cooling capacity of the design working condition. Under normal circumstances, the compressor is working all year round, spanning the extreme weather in winter and summer, so it faces a relatively complicated external environment, and the actual working conditions and design schemes are inevitable. There is a certain deviation, so the compressor power should have a reasonable surplus. Shandong cold storage price
At this stage, the compressor energy adjustment mainly includes intermittent control operation, suction adjustment, cylinder unloading, bypass adjustment and infinitely variable speed regulation. Among them, the intermittent operation of the compressor is a relatively common operation mode. When the ambient temperature is higher than the set temperature, the compressor will start running, the ambient temperature will drop below the set temperature, and the compressor will stop working. This mode of operation is suitable for situations where the ambient temperature is relatively stable and the load is not large, but in actual use, the ambient temperature does not stabilize at any time. In extreme weather and complex working conditions, various production activities will cause changes in the cooling load, frequent temperature changes, frequent engine start and stop, resulting in greater energy waste. The instantaneous current of the generator will pollute the power grid, increase the fluctuation of the power grid, and the life of the compressor will also be affected. Therefore, frequency conversion technology has also gained more applications in compressors.
3, compressor frequency conversion energy saving
Under certain working conditions, the compressor cooling capacity is proportional to the mass flow. The basic idea of ​​frequency conversion regulation is to adjust the mass flow by changing the compressor motor "target=_blank> motor speed, thus changing the total unit cooling capacity.
The system power consumption is related to the characterization mode, and is also affected by the cooling capacity of the refrigeration unit. The thermal load of the refrigeration system is reduced. The cold storage control system will reduce the compressor speed through the inverter, thereby reducing the refrigerant mass flow and reducing the refrigerant condensation temperature. High evaporation temperature, which reduces total cooling. Moreover, the inverter motor speed decreases, the compressor friction work decreases, and the adiabatic efficiency also increases, which is also helpful for lowering the K value. Under partial load conditions, the compressor power "target=_blank> machine motor speed decreases, KQ decreases, which can greatly reduce system power consumption.
Compressor energy saving technology
1. Optimization of compressor control process parameters
1.1: Intake pressure adjustment. Choosing the right suction pressure can effectively reduce compressor power consumption. In general, the lower the suction pressure, the greater the energy consumption, especially the suction pressure of the compressor. Therefore, the suction pressure of the compressor can be appropriately increased, and the high-efficiency cyclone inlet separator can be added in one suction to further eliminate the resistance of the intake pipe network, and a higher suction pressure can be obtained while ensuring sufficient treatment gas volume. Small cold storage price
1.2: The pressure drop between compressor sections is reduced. The pressure drop across the compressor section is also an important cause of compressor power consumption. In order to reduce the pressure drop between the sections, a high-efficiency heat exchanger can be used instead of the interstage cooler to reduce unnecessary piping equipment and elbows, while improving operating conditions and reducing the degree of fouling of the cooler.
2. Optimization of compressor structure design
2.1: Three-way flow impeller. The ternary flow impeller is a form of impeller structure designed for gas flow, and large compressors generally adopt this type of structure. The existing impeller can also be characterized by a three-way flow impeller by appropriate modification, which significantly improves the performance of the impeller. Relevant theoretical research and trial operation prove that the use of the three-element flow impeller can improve the operating efficiency of the impeller by up to 10%, and the transformation cost of the original compressor impeller is lower. However, it is possible to significantly increase the production capacity of the equipment and improve the economic efficiency, and the energy-saving performance of the compressor will also be significantly improved.
2.2: Impeller polishing. There is a direct relationship between the surface roughness of the impeller and the loss of the wheel set. The smoothness of the impeller surface can be improved by means of precision casting, finishing and polishing. There are many methods for impeller polishing, including sand blasting, polishing wheel, liquid polishing, abrasive belt polishing, etc. Generally, a suitable polishing scheme is selected according to the actual structural form and material of the impeller. For the impeller with a relatively large surface area, the belt vibration can be ground and polished, and the impeller with complicated structure, multi-pit and boss can be liquid polished.
2.3: Compressor return flow control. In order to avoid the surge problem of the compressor during operation, the compressor is equipped with an anti-surge control mechanism. Under the normal process parameters, the state curve is drawn by monitoring the operating parameters of the unit, and the surge control line is calculated according to the surge line. Thereby, the surge flow control point is obtained, and the compressor return flow is controlled by the comparison with the inlet flow rate to ensure that the compressor can obtain sufficient working gas. The manual control of the compressor reflow can be modified to automatically control, and a more accurate anti-surge control system can be applied to reduce the energy consumption of the unit. Built cold storage price
2.4: Comprehensive optimization of piping layout. In order to further reduce the pressure drop in the pipeline, it is necessary to adjust the pipeline layout to improve the rationality of the layout of the pipeline. The pressure loss can be used to evaluate whether the pipeline layout scheme is reasonable. If the pressure difference between the inlet pressure and the outlet pressure does not exceed 5%, it indicates that the pipeline layout planning of the compressor system is relatively scientific. In the pipeline, the structural components of the equipment capable of causing pressure loss mainly include a desiccant, a cooler, a control valve, an elbow, and the like. Desiccant, control valve and cooler pressure loss can be measured according to the pressure loss standard. The elbow pressure loss is approximately 8~10 times equal pipe length pressure loss. Through the accurate calculation of the total pressure loss of the pressure loss equipment, the total pipeline loss is reduced. Pressure loss.
In addition to optimizing the design, the daily use and maintenance of the compressor has a great impact on the energy-saving effect of the compressor. In daily work, it is necessary to use scientific control methods to adjust the compressor, cooperate with preventive maintenance strategy, reduce the failure rate of the compressor, maintain the normal performance of the compressor, and fully utilize the energy-saving advantages of the compressor.
This article is organized by Shandong Dingsheng Refrigeration Equipment Co., Ltd.! If you have any enquiries, please pay attention to the WeChat public account "Dingsheng Refrigeration" or call 15725158383! ! !
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