What does the compressed air system in the factory building determine the air volume based on?

Scientific allocation of the air volume of the compressed air system in the factory building is a key link to ensure production efficiency and reduce operating costs. The determination of gas volume requires comprehensive consideration of equipment requirements, usage characteristics and system losses. The core basis and methods are described below from a professional perspective:

1. Accounting for gas equipment demand

1. Equipment gas consumption statistics
   It is necessary to conduct classified statistics on the gas equipment used in the whole plant to clarify the rated gas consumption of various equipment. For example:
   • pneumatic tools: For wind cannons and spray guns, the air consumption of a single unit is about 0.2-0.6m³/min;
   • automation equipment: For example, pneumatic manipulators and conveying devices, the air consumption of a single machine is about 0.5-1.5m³/min;
   • process equipment: For example, spraying machines and bottle blowing machines, the air consumption of a single machine can reach 3-8m³/min.
2. Gas peak-valley analysis
   Through PLC data acquisition or electric energy meter monitoring, a 24-hour gas consumption curve is drawn to identify peak demand and valley demand, and provide data support for system selection.

2. Dynamic utilization factor correction

1. Simultaneous use factor (K value)
   Determine the simultaneous usage factor based on the equipment usage characteristics to avoid waste of resources caused by simple superposition based on the rated gas volume of the equipment:
   • Continuous production factory(such as chemical industry, food): K value is 0.7-0.8;
   • batch production factory(such as automobile parts): K value is 0.6-0.7;
   • Multi-shift factory: The K value needs to be calculated by time periods, such as 0.75 for day shift and 0.65 for night shift.
2. Gas fluctuation buffer design
   When configuring an air storage tank, it is necessary to ensure that its volume is ≥ 10%-15% of the total air demand to smooth fluctuations in air consumption and reduce frequent starts and stops of air compressors.

3. System loss compensation

1. Line pressure loss
   Factors such as pipeline length, pipe diameter, and number of elbows will cause pressure loss, which needs to be estimated according to the following formula:
   • Pressure loss (ΔP)= 1.6×(L/D)×Q²
     (L: pipeline length, D: pipe diameter, Q: flow)
   • A 5%-15% gas volume compensation is usually required.
2. Leakage control
   The leakage rate of compressed air systems is generally between 10% and 30%, which needs to be controlled through the following measures:
   • Carry out ultrasonic leak detection regularly to repair leakage points above DN10;
   • 10%-20% of the gas volume is reserved for leakage compensation during design.

4. Reserve for future expansion

1. Capacity expansion demand
   According to the enterprise development plan, a 20%-30% gas volume margin is reserved to avoid system transformation due to production capacity expansion.

2. Process upgrade space
   To reserve interfaces for automated upgrades and new process equipment, it is recommended to adopt modular design to facilitate later expansion.

5. Typical industry configuration cases

6. Intelligent monitoring and optimization

1. Energy Efficiency Management Platform
   Deploy a compressed air management system (CAMS) to monitor flow, pressure, and power in real time, and identify energy-saving potential through big data analysis.

2. dynamic speed control
   The frequency converter and pressure sensor are linked to automatically adjust the speed of the air compressor according to air demand, and the power saving rate can reach 15%-35%.

conclusion
The determination of the gas volume of the compressed air system in the factory building must follow the principle of “on-demand configuration, dynamic compensation, reservation and expansion”, and achieve accurate matching of the gas volume through scientific accounting and intelligent monitoring. Enterprises should establish an annual energy efficiency assessment mechanism to continuously optimize system configuration based on production changes, and reduce operating costs throughout the life cycle while ensuring production continuity.