• 2025/3/11 8:47:19

Air pipeline energy saving transformation

Compressed air is one of the power sources widely used in industrial production, and its energy consumption occupies a considerable proportion in the total energy consumption of many enterprises. However, due to the unreasonable design of the compressed air system, improper pipeline layout, serious leakage and other problems, resulting in a lot of energy waste. Therefore, the energy-saving optimization of the compressed air pipeline system can not only reduce the operating costs of enterprises, but also improve production efficiency and reduce carbon emissions.

First, the compressed air pipeline system status analysis

The following are common plumbing problems:

1.1 Unreasonable pipeline layout

Problem description: Improper pipeline layout results in a long compressed air delivery path, excessive pressure loss, and increased energy consumption.

1.2 Improper pipe diameter

Problem description: Improper selection of pipe diameter, too large or too small will affect the efficiency of the system.

Too large diameter: increase material costs and installation costs, and the flow rate in the pipeline is too low, easy to accumulate condensate.

Too small diameter: increase pipeline resistance, resulting in excessive pressure loss and increased energy consumption.

1.3 Serious pipeline leakage

Problem description: The compressed air leaks due to loose connection parts, loose flange sealing, and pipe corrosion.

1.4 Water accumulation in pipes

Problem description: The water in the pipeline is not discharged in time, resulting in pipeline corrosion and increased pressure loss.

1.5 Poor pipe insulation

Description of the problem: Pipe insulation material aging or damage, resulting in increased compressed air temperature, pressure loss.

 

Second, energy-saving optimization and transformation plan

In response to the above problems, the following are several common energy-saving optimization plans:

2.1 Optimize pipeline layout

1. Scheme description: Redesign the pipeline layout, shorten the conveying path, reduce the number of elbows and valves, and reduce pressure loss.

2. Implementation steps:

Scheme design: According to the site survey results, design a new pipeline layout scheme to shorten the conveying path as much as possible and reduce the number of elbows and valves.

3. Expected effect: reduce pressure loss, reduce energy consumption, improve system efficiency.

2.2 Reasonable selection of pipe diameter

1. Scheme description: According to the actual flow demand, the pipe diameter is reasonably selected to ensure that the flow rate is within a reasonable range (usually 15-25m/s).

2. Implementation steps:

Flow calculation: According to the compressed air flow requirements, calculate the appropriate pipe diameter.

Scheme design: Select the appropriate pipe diameter, and carry out pipeline transformation.

Construction and renovation: According to the design scheme, the construction and renovation are carried out to ensure that the pipeline is firmly connected and there is no leakage.

3. Expected effect: reduce pipeline resistance, reduce pressure loss, and reduce energy consumption.

2.3 Control pipeline leakage

1. Solution description: Regular leak detection and timely repair of leakage points.

2. Implementation steps:

Leak detection: Use ultrasonic leak detector and other equipment to carry out regular leak detection.

Repair leaks: Repair leaks in a timely manner, including tightening loose parts, replacing seals, and repairing corroded pipes.

3. Expected effect: reduce compressed air leakage, reduce energy consumption, extend equipment life.

2.4 Drain water from pipes

1. Solution description: Install automatic drainage valve to periodically remove water in the pipeline.

2. Implementation steps:

Install drainage valve: Install automatic drainage valve at the low point of the pipeline to ensure that water can be discharged in time.

Pipeline cleaning: Regularly clean the pipeline to remove internal dirt and impurities.

3. Expected effect: prevent pipeline corrosion, reduce pressure loss, and improve compressed air quality.

2.5 Strengthen pipe insulation

1. Solution description: Replace the aging or damaged insulation materials to ensure the insulation effect of the pipeline.

2. Implementation steps:

Check insulation materials: Check existing insulation materials to assess their insulation performance.

Replace thermal insulation materials: Replace aging or damaged thermal insulation materials with those with low thermal conductivity and high temperature resistance.

Construction and renovation: According to the design scheme, the construction and renovation are carried out to ensure that the insulation material is firmly connected and without gaps.

3. Expected effect: reduce compressed air temperature rise, reduce energy consumption, improve system efficiency.

 

Iii. Implementation steps

3.1 Make the renovation plan

1. Demand analysis: According to the analysis results of the current situation of the pipeline system, determine the transformation needs and objectives.

2. Scheme design: Formulate detailed renovation scheme, including pipeline layout adjustment, diameter selection, leakage control, water removal, insulation strengthening, etc.

3. Budget preparation: According to the renovation plan, prepare the budget and determine the renovation costs.

3.2 Construction and Renovation

1. Construction preparation: prepare construction materials and tools, arrange construction personnel, and make construction plans.

2. On-site construction: Construction shall be carried out according to the renovation plan to ensure the construction quality.

3. Quality inspection: Check the construction quality to ensure no leakage, solid connection and good insulation.

3.3 Commissioning and acceptance

1. System debugging: Debug the transformed pipeline system to ensure that all parameters meet the requirements.

2. Performance test: Perform performance test to evaluate the transformation effect.

3. Acceptance and handover: Organize acceptance and transfer the transformed pipeline system.

 

4. Effect evaluation

4.1 Comparison of Energy Consumption

Evaluation method: Compare the energy consumption data before and after the renovation to evaluate the energy-saving effect.

4.2 Pressure loss

Evaluation method: Measure the pressure loss before and after renovation, and evaluate the change of pipeline resistance.

4.3 Device Life

Evaluation method: Observe the operating state of the equipment and evaluate the life change of the equipment.

4.4 Production Efficiency

Evaluation method: Comparing the production efficiency before and after the transformation, evaluating the impact on production.

 

The energy saving and optimization transformation of compressed air piping system is an important way for enterprises to reduce energy consumption and improve production efficiency. Through the comprehensive analysis of the current situation of the pipeline system, the formulation of a reasonable transformation plan, and the transformation in strict accordance with the implementation steps, the problems of the pipeline system can be effectively solved, and the goal of energy saving and consumption reduction can be achieved.