Can a double-acting cylinder compressor operating at 50% load push open one suction valve?
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This post was last edited by autuleaf on 2018-1-18 at 08:33. The unit is equipped with a reciprocating compressor of the symmetrically balanced type, double-acting, with 4 stages and 4 rows. The air volume of the compressor is regulated either by an intake valve that is opened by pressure or by a four-way pneumatic bypass system. The intake valve utilizes a pneumatically operated finger-type unloader for pressure relief, which is controlled by solenoid valves. The air volume control switch is located on the local control panel, and it offers three settings: 0%, 50%, and 100%. The four-way bypass system is regulated using a pneumatic diaphragm control valve, enabling air volume adjustment within the range of 60%–100%. Under the current operating conditions, the load is only 50% yet the motor operates at full capacity; voltage regulation is achieved through a four-way and one-return control valve, which results in significant waste of electrical energy. Could I use the 50% setting to push open the air valve on the side of the piston, thereby achieving energy savings? What impact will it have on the crew?
If your equipment is under such a load, it is recommended to install a variable air volume control system; this will enable you to recoup your costs quickly. Using load relief for adjustment over an extended period will severely affect the reverse angle of the compressor, and over time it can cause damage to the small-end bearings
What is the current load, what is the compressor speed setting, and what is the opening degree of the bypass valve?
It should be fine for a short period of time or occasionally, but using it in this way for a long time is likely to have an impact on the device
Is this just a four-stage piston compressor? Just add a one-to-one circulation valve. The production of a piece of equipment requires long periods of operation under variable loads; to save energy, the best solution is to upgrade the power system using variable-frequency motors.
Gear at 100%, four-way one-return valve at 60%
Right, Level 4 – can it be activated frequently, once per session?
It is possible to reach gear 50, and there is still room for adjustment with the bypass valve. Operating at low load levels for extended periods is not good for reciprocating machines; your units have too high energy consumption. As suggested for other floors, you could install a variable air volume control system, which can be manufactured in China – Wuxi has companies that offer such systems. Additionally, bypass control for reflux should be considered at each stage, but specific design details require calculations. This is just my personal suggestion, provided for your reference.
This is the main control valve used to adjust pressure and flow rate; it represents the first level of control. If it is necessary to further reduce pressure and flow rate, fine adjustments can be made using the four-way valve. Main body adjustment is done step by step, allowing for long-term use.