Exhaust duct installation optimization guide: avoid problems and improve efficiency

Exhaust duct installation optimization guide: avoid problems and improve efficiency

In air compressor systems, the quality of exhaust duct installation directly affects equipment reliability and air quality, especially in hot seasons, the hidden dangers caused by improper installation are more prominent. This article will deeply analyze common installation errors, provide practical solutions and best practices, and help build an efficient and stable compressed air system.

I. Common errors and countermeasures in pipeline installation

(I) Pipeline size selection error

Error manifestation: Customers or installers often choose pipes with too small specifications to match the size of the compressor hot air exhaust port, which is the primary cause of system failure. For example, a factory had insufficient pipe diameter, which led to compressor exhaust obstruction, a 30% drop in operating efficiency, and a significant increase in energy consumption.

Solution: The cross-sectional area of the pipe should be consistent with the size of the compressor cooler, and can even be up to twice the area of the exhaust area to ensure smooth airflow.

(II) Design defects in long pipeline operation

Error manifestation: Long-distance pipelines are prone to air stagnation, and the impact of elbows and bends on airflow is often ignored during design, resulting in increased back pressure. In some large-scale factory projects, due to unreasonable long pipeline design, the air flow rate is reduced, and the equipment frequently has overheating alarms.

Solution: For long pipelines or high back pressure scenarios, add a booster fan to maintain stable airflow and ensure the normal operation of the system.

(III) Problems with multiple compressors sharing a common pipeline

Error: Connecting multiple air compressors to a common pipeline header will cause uneven airflow, causing backflow and equipment overheating. A company once connected multiple compressors to the same pipeline. During operation, the temperature of some equipment soared and was forced to shut down for maintenance.

Solution: Configure an independent pipeline system for each compressor and install shutters to prevent hot air from backflowing; when connecting multiple devices, be sure to seek guidance from professionals.

(IV) Disadvantages of sharp-angle pipeline design

Error: The sharp-angle structure in the pipeline seriously hinders the airflow, especially for small-sized pipelines, which doubles the resistance. The pipelines in some old factories have multiple sharp-angle bends, and the energy consumption is 20% higher than normal.

Solution: Use large-diameter pipelines or large-curvature elbows to reduce airflow resistance and improve transportation efficiency.

(V) Warm air circulation problem

Error: Warm air flows back to the compressor cooler, which will push up the operating temperature, increase maintenance costs and reduce efficiency. Insufficient spacing between the inlet and outlet of a data center caused frequent compressor failures, and maintenance costs increased by 150,000 yuan per year.

Solution: Ensure that the inlet and outlet are properly spaced to prevent hot air recirculation.

(VI) Risk of lack of temperature control

Error: Lack of constant temperature control in hot seasons can easily cause overheating. If there is no temperature control system in cold areas, there is a risk of equipment freezing. For example, in a construction site in the north, due to poor temperature control in winter, the pipes froze and the equipment was seriously damaged.

Solution: Install automatic blinds and fans and check them regularly; in cold areas, use a temperature control system to mix exhaust air and fresh air to maintain the optimal operating temperature of the equipment.

(VII) Insufficient ventilation of small compressors

Error: Small compressors are often placed in poorly ventilated spaces, resulting in a lack of cooling air. Small workshops place compressors in closed sheds, shortening the service life of the equipment by nearly half.

Solution: Install blinds to enhance ventilation, add fans when necessary, monitor room temperature in real time, and adjust ventilation facilities as needed.

2. Best Practices for Pipe Installation

(I) Professional Collaboration and Data Reference

Work with experienced HVAC contractors and refer to the installation data sheets provided by manufacturers, such as HPC KAESER's technical data, to accurately determine the pipe size and installation plan.

(II) Scientifically Calculate Pipe Size

Based on the cooling fan flow (CFM) and the maximum allowable back pressure (inches of water column), use professional formulas to calculate to ensure that the pipe size is adapted to the equipment operation requirements.

(III) Real-time Monitoring of Operating Temperature

Air-cooled screw compressors usually operate efficiently under the condition of a temperature difference of 105°F (about 39°C) between room temperature and internal host exhaust temperature (before aftercooler). Real-time monitoring of average operating temperature (ADT). If the temperature rises abnormally, promptly check the cooling system and pipe problems.

(IV) Regular Maintenance

Establish a regular inspection and maintenance mechanism for pipes, fans, and blinds, and promptly handle aging and damaged parts to ensure stable system operation.

3. Summary of key points

Pipeline specifications are the core: Appropriate pipe size and standardized installation are the basis for efficient operation of air-cooled screw compressors.

Communication and collaboration ensure quality: Customers and contractors maintain good communication to avoid installation errors caused by information errors.

Professional guidance is indispensable: With the guidance of HVAC professionals and manufacturers, ensure reliable equipment performance and reduce downtime losses.

Temperature control design needs to be comprehensive: take into account the needs of winter and summer seasons, make rational use of compression heat, and achieve a win-win situation of energy saving and equipment protection.

A carefully designed and installed piping system can not only ensure the stable operation of the compressed air system, but also save a lot of time and financial costs for enterprises by improving efficiency and reducing energy consumption. It is a key link in achieving efficient industrial production.

The above optimized content is clearer, easier to understand and more practical. If you think there are still areas that need to be adjusted, such as adding or removing cases or modifying expressions, please feel free to tell me.