Reciprocating compressor load regulation
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The unit is equipped with a compressor; at 100% load, the volume of air processed is around 12,000 cubic meters. Since the current processing volume is relatively low, the volume returning from the second stage outlet is about 6,500 cubic meters, meaning that only around 5,500 cubic meters of air is actually compressed. Therefore, I would like to ask the experts in the group: under such conditions, is it possible to adjust the compressor’s load to 50%? The load regulation of this compressor includes 0%, 50%, and 100%.
If it’s only half of the usual workload, then the machine needs to be checked!
It is possible to operate at 50% load, but running at this load level is generally not recommended, as one of the cylinders does not work at 50% load. The air valves are of the constant-open type, which has a significant negative impact on the lifespan of the valves and piston rings. At the same time, the compression and release of some gas will cause the inlet and outlet temperatures to rise by a few degrees on average. Furthermore, prolonged operation causes significant damage to components such as the compressor’s main shaft bearings and large-end bearings due to force imbalances. However, it is not impossible to use those designed to meet 50% of the requirements; in such cases, you need to make a choice based on power consumption and energy savings as well as the protection of the unit itself.
No, in your case, a variable air volume control system and a cylinder clearance adjustment system can be used.
What are the reasons why it’s not possible? Could you be more detailed? The other two are good approaches, but modifications are needed; I want to optimize the operations based on what already exists.
It was already clearly explained on the 3rd floor: a 50% load level results in an unbalanced load on one side of the device, which is definitely not acceptable. Therefore, it is recommended to use variable flow control; however, with such a system, the load level usually needs to be above 30%, and it cannot operate at low loads for long periods of time. But in your case, a 50% load level should be fine
There are many reasons; costs can be saved after one year of operation following the renovation. Two negatives and one positive can also be considered
The lifespan of the valve and piston rings has a significant impact. At the same time, the compression and release of some gas will cause changes in the inlet and outlet temperatures
Is the speed of the driving power not adjusted properly?
Prepare a modified plan without fixed limits for the leader’s approval. It’s very energy-efficient.
Check with the manufacturer; variable frequency should be an option.