Problems with two air compressors operating together
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Our company has two air compressors; usually one is in use while the other serves as a backup. When the production facility starts up, there is a high demand for air, so both compressors need to be turned on. However, after some time, one of the compressors stops running due to being idling for too long. On the other hand, if only one compressor is in operation, the amount of air produced is not sufficient, forcing it to keep running at full capacity. Could you please advise on how to set the pressure levels for starting and stopping these two compressors, so that one of them does not have to stay idling for too long, and the other does not have to keep operating at full capacity? Thank you!
This can be achieved through a control loop, by setting the minimum and maximum loads for the two fans. For example, if the required amount is 1000, and the minimum load of each fan is 200+200, then the actual requirement is 600. The load can be distributed evenly, or one fan can have its load increased while the other operates at its minimum load.
I remember 60% each being the best. Adjustable separately.
If only one air compressor is used, the air volume is not sufficient, so it keeps running at full load
If there are two air compressors, with one in operation and one as a backup during design, it is necessary to carefully check for leaks at all points where air is used. Standby machines are all in hot standby and start up automatically in sequence.
Use the intake valves on both units manually, or reduce the flow by closing the shut-off valve on one of them
The pressure setting for operation is set low, while the backup pressure setting is set high.
It is most reasonable to have one unit operating under load while the other serves as a backup from an energy efficiency perspective; why run both units at reduced capacity?
1. The key is to ensure that the air consumption is optimized in terms of scheduling. 2. In the long term, it is possible to add another air compressor with a lower air delivery capacity. 3. Adjust the loading and unloading pressures of the air compressors: set the unloading pressure for the continuously operating compressors to be higher than that of the standby compressors, while setting the loading pressure to be lower than that of the standby compressors
Your situation is somewhat similar to ours. We have five air compressors, with three in operation and two as backups. There are two solutions: one is to install a control system that uses a computer to regulate the load on the two air compressors； Another way to save money, though it’s more labor-intensive, is to use experience to set slightly different outlet pressures for the two air compressors, thereby controlling the work done by each compressor so that it meets the operational requirements.