1. Compressed air use.
2. The minimum operating pressure.
3. The required air volume at the tip and off-peak. If the difference between the highest and lowest operating pressure reaches 3bar, the “high and low pressure split” must be considered, and then different types of air compressors should be selected according to the peak and off-peak load changes. For example, the “base load” uses a centrifugal type (single machine> 75CMM) or screw type (single unit <60CMM): “fluctuating load” uses high-pressure air machines and large air storage tanks to cope.
4. Choose and configure different types and grades of dryers and precision filters according to different air quality. Excessive quality wastes energy, and insufficient quality affects the process, so it must be carefully considered.
5. The control technology of air compressors is changing with each passing day. Technologies such as “multi-machine chaining”, “frequency conversion and speed change” and “remote monitoring” can effectively suppress the waste of centrifugal BOV and spiral empty vehicles (saving 25-40% of electricity costs) , reduce standby capacity and investment (15-30%), and stabilize gas supply pressure (plus or minus 0.1bar).
6. The operating efficiency should not only be compared with the nominal horsepower and air volume in the catalog, but the actual “performance curve” and “air volume per horse”.
7. The installation considers the size of the computer room space, ventilation conditions, noise isolation, waste heat, waste water recycling, etc. all affect the use of energy. In addition, “centralized” has lower installation, maintenance and control costs than “distributed”, and can also reduce peripheral equipment. regional market
8. As for the cooling method, there are two kinds of air cooling and water cooling. Air cooling does not require additional investment in cooling tower rainwater, but it must have good ventilation: water cooling means that the operating temperature is not affected by the environment, which is beneficial to the life of the air compressor. Disadvantages of icing bursting and blocking.
9. Power supply planning The voltage demand and the stability of the voltage drop must be required. The centrifuge is usually high-voltage and cannot be moved at all. It will cause impact on the power grid when it is started, and it should be kept in regular operation.
10. The maintenance machine room should have proper maintenance space and necessary lifting facilities and access channels. Engineering personnel and maintenance should also be given different maintenance professional training.

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1. Before using the air compressor, you should carefully read the air compressor manual. Don’t take it for granted that you have been in contact with many models and start to operate. If some details are ignored, it will often cause unnecessary losses.

2. In order to effectively save power, users must pay attention to the ventilation and heat dissipation of the air compressor room. If the ambient temperature of the air compressor room is too high, it is equivalent to reducing the efficiency of the air compressor, reducing the exhaust volume, and increasing energy consumption. Every 100°C increase in the ambient temperature is equivalent to a 3% reduction in the efficiency of the air compressor.

3. In addition, the air compressor room should be kept clean and tidy. The environment of the air compressor room is too dirty, which will easily cause the filter, oil filter, and oil-gas separator of the air compressor to be clogged, and the lubricating oil will accelerate pollution and be replaced frequently.

4. Carry out regular maintenance on the air compressor, try to use the original parts. If the air compressor is poorly maintained or not maintained for a long time, small problems will accumulate into major failures, and the life of the machine will be significantly shortened.

5. The air compressor should supply air as much as possible. If the air compressors are distributed in various parts of the plant and the pipelines are independent, it will not only increase the purchase cost, but also increase the pipeline cost and operation and maintenance costs. Especially if the pipeline leaks seriously and is not found in time, it is thought that the gas consumption is insufficient, and a newly purchased air compressor is used to supplement the insufficient gas consumption, resulting in waste. Calculated based on a 7kg/cm2g, 10mm leak point, assuming that the electricity cost is RMB 1 8,000 hours a year will waste 320,000 yuan in electricity bills.

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1. The intact rate of the equipment.

The intact rate of equipment is the most used indicator, but its role in promoting management is limited. The so-called intact rate refers to the ratio of intact equipment to the total number of equipment during the inspection period (equipment intact rate=number of intact equipment/total number of equipment). The indicators of many factories can reach more than 95%. The reason is very simple. At the moment of inspection, if the equipment is in operation and there is no failure, it is considered to be in good condition, so this indicator is very good. Looking good means that there is not much room for improvement, it means that there is nothing to improve, and it means that it is difficult to improve. For this reason, many companies propose to modify the definition of this indicator, for example, propose to check three times on the 8th, 18th, and 28th of each month, and take the average of the intact rate as the indicator of the intact rate for this month. This is certainly better than checking once, but it’s still a good rate reflected in dots. Later, it was proposed that the hours of the intact table be compared with the hours of the calendar table, and the hours of the intact table are equal to the hours of the calendar table minus the total table hours of faults and repairs. This indicator is much more realistic. Of course, there is an increase in the statistical workload and the authenticity of the statistics, and the debate on whether to deduct when encountering preventive maintenance stations. Whether the indicator of intact rate can effectively reflect the status of equipment management depends on how it is applied.

2. The failure rate of the equipment.

This indicator is easy to confuse, and there are two definitions: (1) if it is the failure frequency, it is the ratio of the number of failures to the actual start-up of the equipment (failure frequency = number of failure shutdowns / actual number of equipment startups); (2) if it is failure shutdown The rate is the ratio of the downtime of the fault to the time when the equipment is actually started plus the time of the downtime (the downtime rate = the time of the downtime/(the time when the equipment is actually started + the time of the downtime)). Obviously, the outage rate It can truly reflect the status of the equipment.

3. Equipment availability.

This is widely used in western countries, but in our country there are planned time utilization rate (planned time utilization rate = actual working time/planned working time) and calendar time utilization rate (calendar time utilization rate = actual working time/calendar time) two Different terms. Availability as defined in the West is actually calendar time utilization by definition. The calendar time utilization reflects the full utilization of the equipment, that is to say, even if the equipment is operated in a single shift, we calculate the calendar time according to 24 hours. Because no matter whether the factory uses this equipment or not, it will consume the assets of the enterprise in the form of depreciation. The planned time utilization reflects the planned utilization of the equipment. If it is operated in a single shift, the planned time is 8 hours.

4. The mean interval between failures (MTBF) of the equipment.

Another formulation of this is called the average trouble-free working time (average interval between failures of equipment = total time of trouble-free operation in the statistical base period/number of failures). Complementary to the downtime rate, it reflects the frequency of failures, that is, the health of the equipment. One of the two indicators is enough, and there is no need to use related indicators to measure a content. Another indicator that reflects maintenance efficiency is mean time to repair (MTTR) (average time to repair = total time spent on maintenance in the statistical base period/number of maintenance), which measures the improvement of maintenance work efficiency. With the advancement of equipment technology, its complexity, maintenance difficulty, fault location, average technical quality of maintenance technicians and equipment age, it is difficult to have a definite value for maintenance time, but we can measure its average status and progress based on this .

5. Overall Equipment Effectiveness (OEE).

With the increasingly fierce market competition, manufacturers want to continuously obtain high economic benefits, maximize excavation and improvement. The production efficiency of the production workshop is extremely important, and in some respects, it even becomes the decisive factor for whether the enterprise can make a profit. However, in the current manufacturing industry, the production workshop that seems to be working well is not actually working in the best state, and there is a lot of room for improvement in the value of equipment and operators, which has brought huge benefits to the enterprise virtually. Loss. In order to solve this problem, the international manufacturing industry put forward the concept of overall equipment effectiveness (OEE).

The overall equipment efficiency is Overall Equipment Effectiveness, referred to as OEE. Generally, each production equipment has its own theoretical production capacity, and to realize this theoretical production capacity, it must be guaranteed without any interference and quality loss. It is a strict measure of the overall performance of the machine, indicating where the time waste exists, and the purpose of counting various time wastes is to achieve improvement.

An indicator that reflects equipment efficiency more comprehensively, OEE is the product of the time operating rate, performance operating rate and qualified product rate. Just like a person, the time activation rate represents the attendance rate, the performance activation rate represents whether to work hard after going to work, and to exert due efficiency, and the qualified product rate represents the effectiveness of the work, whether frequent mistakes are made, and whether the task can be completed with quality and quantity . The simple OEE formula is: overall equipment efficiency OEE=qualified product output/theoretical output of planned working hours.

6. Total Effective Productivity TEEP.

The formula that best reflects equipment efficiency is not OEE. Total Effective Productivity TEEP=qualified product output/theoretical output of calendar time, this indicator reflects the system management defects of equipment, including upstream and downstream impacts, market and order impacts, unbalanced equipment capacity, unreasonable planning and scheduling, etc. come out. This indicator is generally very low, not good-looking, but very real.

7. Regarding maintenance and management.

There are relevant indicators to reflect, such as the one-time qualified rate of overhaul quality, repair rate and maintenance cost rate, etc.

(1) The one-time pass rate of the overhaul quality is measured by the ratio of the number of times the overhauled equipment meets the product qualification standard for one trial operation to the number of overhauls. Whether the factory adopts this indicator as the performance indicator of the maintenance team can be studied and deliberated.

(2) The repair rate is the ratio of the total number of repairs after equipment repairs to the total number of repairs. This is a true reflection of the quality of maintenance.

(3) There are many definitions and algorithms of maintenance cost ratio, one is the ratio of annual maintenance cost to annual output value, the other is the ratio of annual maintenance cost to the total original value of assets in the year, and the other is the ratio of annual maintenance cost to current year assets The ratio of the total replacement cost, another is the ratio of the annual maintenance cost to the total net asset value of the year, and the last is the ratio of the annual maintenance cost to the total production cost of the year. I think the last algorithm is more reliable. Even so, the magnitude of the maintenance cost rate cannot explain the problem. Because equipment maintenance is an input, which creates value and output. Insufficient investment and prominent production loss will affect output; of course, too much investment is not ideal, which is called overmaintenance, which is a waste. Appropriate input is ideal. Therefore, the factory should explore and study the optimal investment ratio. High production costs mean more orders and more tasks, and the load on the equipment increases, and the demand for maintenance also increases. Investing in an appropriate ratio is the goal that the factory should strive to pursue. If you have this baseline, the farther you deviate from this metric, the less ideal it is.

8. About spare parts management.

There are many indicators, and the turnover rate of spare parts inventory (the turnover rate of spare parts inventory = monthly consumption of spare parts cost / monthly average spare parts inventory fund) is a more representative indicator. It reflects the mobility of spare parts. If a large amount of inventory funds are backlogged, it will be reflected in the turnover rate. What also reflects spare parts management is the ratio of spare parts funds, that is, the ratio of all spare parts funds to the total original value of the enterprise’s equipment. The value of this value varies depending on whether the factory is in a central city, whether the equipment is imported, and the impact of equipment downtime. If the loss of equipment downtime is as high as tens of millions of yuan a day, or the failure has serious environmental pollution and personal safety hazards, and the supply cycle of spare parts is long, the inventory of spare parts will be higher. Otherwise, the funding rate of spare parts should be as high as possible. reduce. There is an indicator that is not noticed by people, but it is very important in contemporary maintenance management, that is, maintenance training time intensity (maintenance training time intensity = maintenance training hours/maintenance working hours). Training includes professional knowledge of equipment structure, maintenance technology, professionalism and maintenance management etc. This indicator reflects the importance and investment intensity of enterprises in improving the quality of maintenance personnel, and also indirectly reflects the level of maintenance technical capabilities.

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2. Control leakage. The average leakage of compressed air in factories is as high as 20-30%, so the primary task of energy saving is to control leakage. All pneumatic tools, hoses, joints, valves, a small hole of 1 square millimeter, under the pressure of 7bar, will lose almost 4,000 yuan a year. It is urgent to check the leakage of the air compressor pipeline and optimize the design of the pipeline.

3. Pressure drop management. Pressure gauges are installed at each section of the pipeline. Generally, when the air compressor is exported to the point of use in the factory, the pressure drop cannot exceed 1 bar, and more strictly, it cannot exceed 10%, that is, 0.7 bar. The pressure drop of the cold-drying filter section is generally 0.2 bar, check the pressure drop of each section in detail, and repair it in time if there is any problem. (Each kilogram of pressure increases the energy consumption by 7%-10%).

4. Evaluate the pressure requirements of gas equipment. In the case of ensuring production, the exhaust pressure of the air compressor should be lowered as much as possible. The cylinders of many gas-consuming equipment only need 3~4bar, and a few manipulators only need more than 6bar. (For every 1bar lower pressure, energy saving is about 7~10%).

5. Adopt high-efficiency compressor. For variable working conditions, high-efficiency permanent magnet variable frequency screw air compressors are used to save energy. At present, the leading high-efficiency permanent magnet frequency conversion screw air compressor in China, its permanent magnet motor can save energy by more than 10% compared with ordinary motors; it has the advantages of constant pressure air without causing pressure difference waste; it uses as much air as it needs, and does not need to be loaded and unloaded. . More than 30% energy saving than ordinary air compressors.

6. Centralized control. The centralized linkage control of air compressors can avoid the stepwise exhaust pressure rise caused by the parameter setting of multiple air compressors, resulting in waste of output air energy.

• Reduce the intake air temperature of the air compressor. Because the internal temperature of the general air compressor station is higher than the outdoor temperature, outdoor gas extraction can be considered. Do a good job of maintaining and cleaning the equipment, increasing the heat dissipation effect of the air compressor, the exchange effect of heat exchangers such as water cooling and air cooling, and maintaining oil quality, etc., all of which can reduce energy consumption.

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1. Turn on the air dryer first, then press the start button of the air compressor, the air compressor starts to unload and run, and the automatic operation indicator light is on.

2. After 10 seconds, the air compressor starts to switch to loading, and the display information on the display screen changes from automatic unloading to loading operation.

3. The air compressor and cold dryer are manually drained and the sundries in the unit are discharged.

4. Debug according to the operating pressure to the specified pressure range, and improve other debugging operating parameters.

5. Fill in the operation record form and record various parameters and related contents.

6. After running for 10 minutes, manually drain the bottom of the gas storage tank.

7. Normal startup, loading and unloading for half an hour to 1 hour, turn off the air compressor and the cold dryer button.

8. The boot is over.

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