I. Installation Location
The proper installation location is a prerequisite for the correct operation of air compressor systems. The chosen location should ensure easy maintenance of the air compressor in the future, and avoid abnormal operation due to suboptimal environmental conditions.
Installation locations should have good lighting and sufficient illumination to facilitate operation and maintenance.
Low humidity, non-corrosive, free of metal shavings, minimal dust, clean air, and good ventilation.
If the factory environment is poor and dusty, an additional ventilation duct should be installed to direct the intake end towards a cleaner air area. The installation of the duct must be easy to disassemble for maintenance, with the installation size to be referenced from the external dimensions of the air compressor.
Compressed air generators must have sufficient space around them for other components to fit. The distance from the air compressor to the wall should be at least 1.5 meters. The space above the air compressor should be at least 2 meters.
If an air compressor is installed in an enclosed air compressor room, a exhaust fan must be set up to expel the heated gas outside as much as possible after heat exchange.
If the ambient temperature is too high (above 40℃), it is recommended to take cooling measures (such as avoiding direct sunlight, opening windows and doors, etc.) to prevent unnecessary downtime due to excessive heat; if the ambient temperature is low.
Pipe, Foundation, and System Precautions
Pipe fitting
Do not apply additional force to the after cooler during piping. It is strictly prohibited to let welding sparks fall into the air compressor to prevent damage to the internal components.
Managers must have a 1° to 2° downward slope for the pipeline to facilitate condensate drainage (the pipeline should be equipped with a drain plug for regular drainage).
The pipe diameter should be greater than or equal to the compressor exhaust port diameter. Minimize the use of elbows and various valves in the pipeline to reduce pressure loss.
Don't arbitrarily shrink or expand the supervisor's pipeline; if you need to shrink or expand, use a gradual reducer. Otherwise, turbulence will occur at the joints, leading to significant pressure loss. Additionally, due to the impact pressure of the gas, the lifespan of the pipeline will be greatly shortened.
Branch pipelines must be routed from the top of the main pipeline to prevent condensate from the main pipeline from flowing into the machine through the pipeline.
It is recommended to install an air storage tank after the compressor unit, which can reduce the frequency of loading and unloading operations of the air compressor, thereby extending the lifespan of the equipment and electrical components.
If an air compressor is followed by a gas storage tank and purification buffer facilities such as a desiccant, the ideal piping should be air compressor + gas storage tank + desiccant. The gas storage tank can reduce the temperature of the exhaust gas, remove most of the moisture, and allow cooler, drier air to enter the desiccant, thereby reducing the desiccant's load.
Compressed air below 1.5 MPa must have a flow rate of 15 m/s or less to prevent excessive pressure drop in the piping.
An ideal piping system involves wrapping the main pipeline around the entire factory and installing appropriate valves along the ring main. This way, any straight pipeline within the factory can access compressed air in both directions. In case the demand for gas in a branch line suddenly increases, it won't cause a significant pressure drop; additionally, valves can be used to cut off the pipeline for maintenance.
2. Basic
The foundation should be established on hard soil or concrete ground, ensuring a flat surface to avoid additional vibration caused by tilting.
If installed on an upper floor, an air compressor must be properly vibration-proofed (e.g., by placing a layer of 10mm thick rubber), to prevent the transmission of vibrations and the occurrence of resonance.
Cooling System
The water-cooled unit requires the construction of a cooling tower to carry away the heat from the cooler through the cooling water.
Using softened water for cooling to avoid calcium and magnesium ions in the water reacting at high temperatures, forming scale inside the cooler and affecting its heat transfer efficiency. If a tower recirculation system is used, the water must be regularly treated with softening agents to maintain water cleanliness.
The automatic补给 system for the cooling water recirculation system needs improvement, otherwise, after a few hours of operation, insufficient cooling water can cause the air compressor to shut down due to high temperatures.
The air compressor's cooling system operates independently to avoid sharing with other systems, thereby preventing water from affecting the cooling efficiency.
Cooling water towers must meet the required cooling water volume for the air compressor, select the correct power rating for the pump, be placed in a location with easy heat dissipation and good ventilation, and be securely mounted to prevent tipping.
Cooling water pressure should generally be maintained between 0.25~0.40 MPa, with a maximum not exceeding 0.5 MPa.
The cooling water export temperature should be maintained below 40°C.
b. The air-cooled unit utilizes fans to facilitate air convection, which carries away the heat from the cooler to control the unit's temperature.
