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新莆京股份

CHINSC

节能环保 绿色科技 和谐发展 造福人类

19

2017

-

09

空压机变频节能改造方案

作者:


  一、空压机工作原理简述

  空压机工作原理是由一对相互平行齿合的阴阳转子(或称螺杆)在气缸内转动。使转子与齿槽之间的空气不断产生周期性的空积变化,空气则沿着转子轴线由吸入侧输送到输出侧,实现螺杆式空压机的吸气、压缩和排气的全过程。空压机的进气口和出气口分别位于壳体的两端,阴转子的槽和阳转子齿被主电机驱动而旋转,常见大中型空压机为螺杆式或活塞式压缩机。工作时由一台电动机带动螺杆或活塞停止压缩空气。压缩机的这种工作方式带来了下列问题:

  1、气压最高时电机卸载空转造成电能的大量浪费。

  2、出口压力随着用气量的大小而出现正弦波式的变化,这样就会影响气动

  设备的性能及工作效率。

  3、工作时,压缩机频繁的加卸载使设备的检修时间加长,使用寿命缩短。

  4、大功率压缩机电机的频繁卸载造成对电网的冲击

  根据以上空压机的工作特点,我们选用SVF-EV空压机专用一体化变频调速对空压机进行节电改造。

  二、变频改造设计要求

  针对空压机系统压力控制方式不能跟随负荷变化而调节系统运行参数和能量供应,造成系统效率降低、能源浪费大、机械磨损严重等问题,以变频调速控制,对空压机的压力系统和实行变频恒压节能控制,大大降低系统能耗。

  根据我司多年工作经验及现场采集数据,采用计算机技术和变频技术实现恒压控制,使压力恒定,同时优化主机运行环境,大幅度降低能源消耗,以节省电费开支。

  根据原工况存在的问题并结合生产工艺要求,空压机变频改造后系统应满足以下要求:

  (1)主电机变频运行状态保持储气罐出口压力稳定,压力波动范围不超过±0.02Mpa.

  (2)系统应具有变频和工频两套控制回路,确保变频出现异常跳保护时,不影响生产。

  (3)在用气量小的情况下,变频器处在低频运行时,应保障电机绕组温度和电机噪音不超过允许的范围。

  SVF-EV空压机一体化专用型变频器性能优良,可靠性高,内置PID调节器,各项参数灵活设置,能很好的满足控制要求。压力传感器选用美国MSP-100型,该型号传感器安装简便,线性好,信号变送精度高。

  三、系统功能

  该系统以压力为控制对象,压力值由变频器面板设定,可根据用气设备的实际需要,在空压机的最高允许工作压力内自由设定,调整便捷。压力传感器对供气管网压力实时监测,并通过变送器转换,输出标准的4-20mA的信号,送至变

  频器反馈,根据系统用气量的要求实施调整压缩机电机的转速,保证管网压力的恒定,对空压机实现自动软启动软停,当车间供气量不足或富余时,控制系统对空压机实现自动启停闭环控制,实现所需及所供,大大降低系统能耗,变频调速技术近年来发展迅速,并在许多领域发挥了重要的作用,空压机变频节能系统原理如下图所示:

  采用该系统改造后,压缩机的供气量与系统所需量动态匹配,压缩机电机转速会随着系统用气量的不同而进行调节,避免了电机空转以及频繁的加卸载所带来的能量损耗,电机的输入功率大大降低,节电效果显著,对于空气机来说,供气量Q与转速N成正比,气压F与转速N的二次方成正比,而轴功率与转速N的三次方成正比,见下表:

频率值Hz

50

45

40

35

30

25

供气量Q%

100

90

80

70

60

50

气压F%

100

81

64

49

36

25

轴功率P%

100

73

51

34

22

13

节电率N%

0

27

49

66

78

87

 

  一般来说,对于连续用气的空压机系统,随用气量的变化,电动机运行频率在25.00-50.00Hz之间动态调节,系统的节电率可达20%-35%。

  另外系统改造所带来的间接效益也不可低估,首先,压缩机电动机实现了软启停,软加减速,对电网的冲击大大减少,其次压缩机气缸内气阀片不再反复地开启和关闭,增加了设备的寿命,减少了系统维护时间,再次系统管网气压稳定,提高了气动设备的效率。

  四、注意事项

  1、螺杆机组不能反向运转。

  2、将加载压力(mpa)调到与设定压力相等,(因变频器设有下限频率)这样防止在卸载状态变频器加速作无用功。

  五、空压机变频改造的效益

  1、节约能源

  变频器控制压缩机与传统控制的压缩机比较,能源节约是最有实际意义的。

  2、运行成本的降低

  传统压缩机的运行成本由三项组成:初始采购成本,维护成本和能源成本。其中能源成本大约占压缩机成本的70%。通过降低能源成本30%以上,再加上变频起动后对设备的冲击减少。维护和维修量也跟随着降低,所以运行成本大大降低。

  3、提高压力控制精度

  变频控制系统具有精确的压力控制能力。使压缩机的空气压力输出与空气系统所需的气量相匹配。变频控制压缩机的输出气量随着电机转速的改变而改变。由于变频控制电机速度的精度提高,所以它可以使管网的系统压力变化保持在要求范围内,有效地提高了工况的质量。

  4、延长压缩机的使用寿命

  变频器从0.00Hz起动压缩机,它的启动加速时间可以调整,从而减少启动对压缩机的电器部件和机械部件所造成的冲击,增强系统的可靠性,使压缩机的寿命延长,此外,变频控制能够减少机组起动时的电流波动,这一波动电流会影响电网和其它设备的用电,变频器能够有效的将起动电流的峰值减少到最低程度。

  6、降低了空压机的噪音

  根据压缩机的工况要求,变频调整改造后,电机运转速度明显缓慢,因此有效的降低空压机运行时的噪音,据以往现场经验测定表明,噪音与原来系统比较下降5至15分贝。

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