Company Profile
The company is a large-scale locomotive manufacturing enterprise approved by the State-owned SASAC. It is a manufacturing base for high-speed trains in China, a leading design and manufacturing enterprise for railway high-grade passenger cars, a designated manufacturer for domestic subways, light-rail vehicles, and an export manufacturing base for national rail transit equipment. The existing 16 wholly-owned and holding subsidiaries, distributed in 10 provinces and cities across the country, employs more than 80,000 people. The construction object is the new compressed air system of the company.
Gas equipment
Pneumatic tools, sandblasting equipment, machining equipment, small wind tunnel test equipment, spraying equipment, etc.
problem analysis
1. Compressed air manufacturing process:
There are a total of two air compressor stations. The distance between the two air compressor stations is about 2,000 meters. There are 13 screw compressors of Atlas and Ingersoll-Rand. The East Railway Station has no special personnel to attend, take regular inspections, there are management risks; West Station output pressure fluctuations.
2. Compressed air delivery:
The partial pressure reformation has been carried out, but the lack of pressure regulation measures on the pressure of the high-pressure pipe network has resulted in large pressure fluctuations in the high-pressure part; the pipe network has been transported a long distance, resulting in an excessive pressure drop at the end.
3. Compressed air use:
The use of gas at the end is irrational; the piping configuration in the blasting plant is unreasonable; the equipment pressure at the same time when the workshop equipment is running is insufficient.
Renovation content
Aisai Science and Technology successfully implemented energy-saving reform for the plant. The energy-saving renovation includes the following contents
No.
Renovation content
function
1
Air compressor energy-saving monitoring system
Centralized control of air compressors, prediction of air usage based on historical operating data, optimization of air compressor fleet operation using intelligent algorithms, reduction of dead load time, resolution of continuous high pressure unloading, etc. Air supply is required to reduce power consumption in air compressor stations.
2
Pipeline network transformation
Realize on-demand gas supply and reduce the energy consumption of air compressors.
3
Air compressor energy-saving auxiliary control cabinet
Stabilize the pressure of the low-pressure mains network to eliminate pressure fluctuations; reduce the frequency of the air compressor motor and reduce the power consumption of the air compressor.
4
Pipeline gas supply energy management unit
Stabilize the pressure of the high pressure system
5
Gas flow measurement management system
Count the volume of gas in each workshop, discover abnormal gas use in time, and measure the gas production efficiency of air compressors
Energy saving principle
The air compressor energy-saving monitoring system controls the air compressors in a centralized manner and matches the gas requirements of the air terminals to provide on-demand air supply. And the use of intelligent algorithms to optimize the operation of the air compressor, the air compressor is in an optimal operating state.
For the air-pressure station to carry out pipe network renovation, according to the pressure demand of the workshop, the pressure is divided into three levels, and the pressure is divided and supplied.
Air compressor installed energy-saving auxiliary control cabinet to stabilize the pressure of the supervisory network. The local pressurization process pressurizes the equipment with higher pressure in the workshop, thereby reducing the air supply pressure in the air compressor room.
The gas flow measurement management system counts the gas volume of each workshop and discovers abnormal gas use in a timely manner.
Transformation effect
After installing the air compressor energy-saving monitoring system, it realized the information management of different brands of air compressor systems of different eras, stabilized the air supply pressure, matched the air compressor output air with the end-use air, and reasonably matched the air compressor's power on. Quantity, can automatically generate the air compressor operating record table, the history of the electricity consumption, compressed air cumulative flow, pressure, temperature, dew point, etc., as well as the air compressor maintenance status tips and air compressor abnormal alarm Improving the information level of the compressed air system and visually reflecting the operating status of the air compressor.
Types of
Renovation items
Energy-saving space
1
On-demand gas supply to improve the gas production efficiency of air compressors
7.5%
2
Optimize air compressor operation and fully monitor pneumatic system
After installing the air compressor energy-saving monitoring system, it realized the information management of different brands of air compressor systems of different eras, stabilized the air supply pressure, matched the air compressor output air with the end-use air, and reasonably matched the air compressor's power on. Quantity, can automatically generate the air compressor operating record table, the history of the electricity consumption, compressed air cumulative flow, pressure, temperature, dew point, etc., as well as the air compressor maintenance status tips and air compressor abnormal alarm Improving the information level of the compressed air system and visually reflecting the operating status of the air compressor.