Common problems and Countermeasures of air supply pipeline in compressed air pipeline system

Common compressed air supply pipeline problems can be divided into two types:

The first is design. Insufficient gas supply caused by too fine pipe network and unreasonable layout; The other is failure in the process of use, such as leakage at the pipe joint, hose rupture, condensate accumulation, poor operation of air source processing elements such as filters, etc.

Design problems

1. Excessive pressure loss is accompanied by continuous changes in the production scale and production process of the factory, and the main pipe network of compressed air is also constantly changed. In actual operation, the original pipeline is often changed. Due to the technical ability of factory personnel, site conditions and other reasons, there are often problems such as insufficient estimation of actual consumption and unreasonable pipeline layout, resulting in excessive burden of local pipeline network, large pressure loss or severe pressure fluctuation of local pipeline network. In view of such problems, the common solutions are: the plant should appropriately enlarge the pipe network layout, arrange the annular main pipe network slightly larger than the large gas demand, the equipment gas is led out from the annular pipe network nearby, and the pulse gas equipment should be arranged with a buffer pipe nearby to reduce the local pressure fluctuation. There are generally two problems for the excessive pressure loss of local branch pipes. The first is that the gas consumption is too large and the pipeline cannot match. The second is that the end filter is not maintained properly and the pressure regulating valve fails, resulting in excessive pressure loss.

Solution: reasonably design the size of the branch pipe network, try to reduce the pipe parts with large pressure loss such as bends, reduced diameters and unnecessary valves. In addition, establish a maintenance system, regularly check and maintain the branch pipe valves, filters and other equipment, and timely repair and replace the parts with large pressure difference

PIPRO aluminum alloy pipe has unique sealing design, no leakage and strong compression resistance.

2. The water outlet problem of the pipeline is caused by the non-standard dew point of the gas produced by the air compressor station. When the gas temperature is lower than the dew point temperature, water will be discharged from the pipeline. Generally in the south, it appears when the temperature is low in winter and disappears after the temperature rises in spring; In the north, it occurs when the temperature difference between day and night is large or the humidity is large.

Solution: for this kind of problem, when the pipeline problem is serious, priority should be given to reducing the dew point temperature of the produced gas in the air compressor station, checking the dew point temperature at the outlet of the cold dryer, and adding an adsorption dryer if necessary; In case of slight performance, a gas water separator shall be added before the pipeline enters the workshop to separate the liquid water in the pipeline.

PIPRO aluminum alloy pipe low friction internal surface, high flow, low pressure drop, zero leakage

3. High oil content of pipeline

The oil content of the pipeline is high, which may damage the terminal equipment. The problem of pipeline oil discharge generally occurs when the oil lubricated air compressor is used. For plants with low requirements for oil content of gas, oil sludge like foreign matters often appear in the end pipeline. This problem basically occurs at the same time as the water outlet problem. Because the air compressor station can not handle the compressed air containing gaseous or liquid oil and water well, the oil-containing compressed air forms oil droplets in the pipeline, and then mixes with the rust caused by the compressed air containing water to form oil sludge. This kind of oil sludge is very easy to damage the end pipeline equipment and the on-site gas equipment.

Solution: a gas distribution water separator shall be added at the place where the pipeline enters the workshop, and a level C filter shall be added.

4. Pipeline leakage is an inevitable problem of the compressed air pipe network system. It is mainly found in the pipeline joints, flange gaskets, air source triplets, quick connectors, damaged hoses and other parts. It occurs occasionally or continuously due to the lack of attention of management personnel, inadequate maintenance and repair, maintenance costs and other reasons.

Solution idea: calculate the energy consumption cost to the gas consuming equipment, improve the energy-saving awareness of management and site personnel, improve the maintenance and repair system, adopt high-quality joints, pipe fittings and seals that are not easy to leak, apply pipe sealant to the seldom disassembled pipe joints, and replace or repair the hoses that have been found to be leaking.

5. The power pipe network with reserved flowmeter position shall not only be used as the transmission channel of compressed air, and shall be considered in the design

For the management of production energy consumption data in the future, it is necessary to reserve the joint position for measurement and test in the design.

PIPRO aluminum alloy pipeline is corrosion-resistant, flame-proof and UV resistant to prevent early aging of equipment due to pipeline corrosion.

6. Use problem

Common pneumatic pipeline failures include leakage at pipeline joints, hose rupture, condensate accumulation, poor operation of air source processing elements such as filters, etc. these problems will lead to pipeline pressure loss, insufficient supply air pressure, damage to components, and increase energy consumption of the air compressor. For this, the pipeline system needs regular inspection and fixed-point inspection.