Health diagnosis method for compressed air supply facilities and leakage inspection method for compressed air piping

Abstract

To provide a compressed air supply facility health diagnosis method that enables simple and reliable determination of the presence or absence of compressed air leakage without requiring idling or the like of production facilities using compressed air.SOLUTION: A compressed air supply facility health diagnosis method is provided, comprising a first step of collecting operation information data of an air compressor 2, a second step of acquiring usage information data, a third step of sorting the operation information data into first operation information data corresponding to the idle periods and second operation information data corresponding to the operating periods, a fourth step of evaluating the need for maintenance of compressed air piping on the basis of the first operation information data, and a fifth step of identifying compressed air leakage points in the compressed air piping, where the fifth step comprises a first sub-step of forming a synthetic resin coating on surfaces of pipe joint portions of the compressed air piping, and a second sub-step of searching for leakage points by checking temporal changes in appearance of the coating.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a method for diagnosing the soundness of compressed air supply equipment and a method for inspecting compressed air transport pipelines for leaks. [Background technology]

[0002] In manufacturing facilities (factories), compressed air generated by air compressors is used as a power source for pneumatic equipment and tools used in the process of manufacturing intermediate and finished products. Within the facility, a network of compressed air transport pipelines (air piping) is laid out to distribute compressed air to numerous production lines and different production areas. In addition, multiple air compressors are often installed in different locations corresponding to the production lines and production areas.

[0003] As the years go by since the establishment of a business establishment, the pipelines become deteriorated, and compressed air leaks become more likely to occur from pipe joints and other parts. If compressed air leaks are left unchecked for a long period of time, the air compressor will waste more electricity, which will lead to higher manufacturing costs. Furthermore, if fossil fuels are used as the primary energy source for the electricity supply, this will also lead to an increase in carbon dioxide emissions. Therefore, it is desirable to regularly diagnose the soundness of the pipelines and, if necessary, perform maintenance such as repairing or replacing the pipelines.

[0004] For example, Patent Document 1 discloses a technique for injecting carbon dioxide as a leak detection gas into an air pipe and searching for a leak using a gas detector capable of detecting the leak detection gas. Patent Document 2 discloses a technique for supplying a non-flammable mixed gas consisting of 5% hydrogen and 95% nitrogen into a water supply / drainage pipe and searching for a leak by measuring the hydrogen gas concentration around the pipe. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2009-186238 A [Patent Document 2] International Publication No. WO2016 / 132517 Summary of the Invention [Problem to be solved by the invention]

[0006] When applying the technology of Patent Document 1 to diagnose the soundness of compressed air transport pipelines, attention must be paid to corrosion of the transport pipelines. In other words, if the compressed air into which carbon dioxide is injected is not sufficiently dehumidified, there is a concern that carbon dioxide will dissolve in the condensed water generated in the transport pipeline, resulting in the generation of acidic water. In addition, when applying the technology of Patent Document 2, a hydrogen gas generator and a nitrogen gas generator (or alternative gas cylinders) must be brought to the site, making the inspection work large-scale. In addition, since the compressed air in the transport pipeline is replaced with a mixed gas, the production equipment must be stopped during the inspection work.

[0007] In view of the above-mentioned problems, the present invention aims to provide a method for diagnosing the health of compressed air supply equipment and a method for inspecting compressed air transport pipelines for leaks, which can easily and reliably determine the presence or absence of compressed air leakage without requiring the suspension of production equipment that uses compressed air. [Means for solving the problem]

[0008] The health diagnosis method according to the present invention is a method for diagnosing the health of a compressed air supply facility including an air compressor that generates compressed air and a transport pipeline used to transport the compressed air to a compressed air utilization device, the method comprising the steps of: a first step of collecting operation information data including a discharge air volume and power consumption of the air compressor; a second step of acquiring usage information data including operation periods and suspension periods of the compressed air utilization device; and dividing the operation information data into first operation information data corresponding to the suspension periods and second operation information data corresponding to the operation periods by comparing the usage information data with the usage information data. a third step of selecting, based on the first operating information data, a fourth step of evaluating the need for maintenance of the transport pipeline based on the first operating information data, and a fifth step of identifying a location of a leak of the compressed air in the transport pipeline if it is evaluated in the fourth step that maintenance of the transport pipeline is necessary, wherein the fifth step includes a first sub-step of causing a mist of colored lubricating oil to be present in the compressed air, and a second sub-step of searching for the leak location by searching for the lubricating oil leaking from the inside to the outside of the transport pipeline.

[0009] According to this method, it is possible to easily and reliably determine the presence or absence of a compressed air leak without the need to shut down production equipment that uses compressed air, etc. Note that the "operating period" here refers to the period during which the compressed air utilization equipment operates and consumes compressed air, and the "stopping period" refers to the period during which the compressed air utilization equipment is stopped and does not consume compressed air.

[0010] More specifically, the method may further include a sixth step of evaluating the necessity of maintenance for the air compressor based on second operation information data. More specifically, the method may include a fourth step of calculating a waste power cost of the air compressor based on first operation information data, and evaluating that maintenance is necessary for the transport pipeline when the calculated waste power cost satisfies a predetermined condition, and a sixth step of calculating a specific energy of the air compressor based on second operation information data, and evaluating that maintenance is necessary for the air compressor when the calculated specific energy satisfies a predetermined condition.

[0011] The leakage inspection method according to the present invention is a method for inspecting leakage of compressed air generated by an air compressor in a pipeline for transporting the compressed air, and includes a first step of making a mist of colored lubricant oil exist in the compressed air, and a second step of searching for the location of the leakage by searching for the lubricant oil leaking from the inside to the outside of the pipeline. According to this method, it is possible to easily and reliably determine the presence or absence of leakage of compressed air without requiring the suspension of production equipment that uses the compressed air.

[0012] More specifically, the method may be such that the air compressor is an oil-lubricated air compressor, and in the first step, a coloring agent is contained in the lubricating oil circulated inside the body of the oil-lubricated air compressor. Also, more specifically, the method may be such that in the first step, the lubricating oil containing a coloring agent is sucked into the compressed air discharged from the air compressor. Also, more specifically, the method may be such that the coloring agent is a fluorescent or non-fluorescent oil-soluble dye. Effect of the Invention

[0013] According to the method for diagnosing the health of compressed air supply equipment and the method for inspecting compressed air transport pipelines of the present invention, it is possible to easily and reliably determine whether or not there is a compressed air leak, without requiring the suspension of production equipment that uses compressed air. [Brief description of the drawings]

[0014] [Figure 1] 1 is a configuration diagram of a health diagnosis system 100 according to a first embodiment and its peripheral elements. [Diagram 2] 1 is an explanatory diagram showing an example of the configuration of a communication system of a health diagnosis system 100. FIG. [Diagram 3] FIG. 2 is an explanatory diagram showing a more specific configuration example of the compressed air supply facility 1. [Figure 4] FIG. 2 is an explanatory diagram showing a schematic configuration example of an air compressor 2. [Diagram 5] 1 is a flowchart of a data collection operation. [Figure 6] 13 is a flowchart relating to a health evaluation operation. [Figure 7] 13 is a flowchart showing the work process of a field engineer. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] 1. Configuration of the health diagnostic system 1 shows a schematic configuration of a health diagnostic system 100 according to this embodiment and its peripheral elements. The health diagnostic system 100 is a system having first to fourth controllers 30a to 30d (hereinafter, sometimes collectively referred to as "controllers 30") and a server 500, and is a system for diagnosing the health of a compressed air supply facility 1.

[0016] The compressed air supply facility 1 is a facility having four air compressors, first to fourth, 2a to 2d (hereinafter sometimes collectively referred to as "air compressors 2") that generate compressed air, and a transport pipeline 3 used to transport the compressed air to compressed air utilization equipment 4, and supplies compressed air to the compressed air utilization equipment 4. The compressed air supply facility 1 is installed in a business establishment that uses compressed air, such as an industrial facility such as a factory.

[0017] In the compressed air supply facility 1, each air compressor 2 generates compressed air and sends it out to a transport pipeline 3. The compressed air sent out from each air compressor 2 is supplied to the transport pipeline 3, and then supplied to each compressed air utilization device 4 connected to the transport pipeline 3.

[0018] In the health diagnosis system 100, in the example of this embodiment, a first controller 30a is provided corresponding to the first air compressor 2a, a second controller 30b is provided corresponding to the second air compressor 2b, a third controller 30c is provided corresponding to the third air compressor 2c, and a fourth controller 30d is provided corresponding to the fourth air compressor 2d.

[0019] Each controller 30 is capable of controlling the operation of the corresponding air compressor 2. The server 500 is capable of communicating with each controller 30. Note that in this embodiment, one controller 30 is provided corresponding to one air compressor 2, but one controller 30 may be provided corresponding to a plurality of air compressors 2. In this case, the one controller 30 is set to control the operation of each of the plurality of air compressors 2.

[0020] 2 shows a more specific example of the configuration of a communication system connecting the controller 30 and the server 500 in the health diagnosis system 100. The health diagnosis system 100 is configured to include a LAN (Local Area Network) 300 and the server 500. The LAN 300 is configured to include a mesh-type wireless network 210.

[0021] Wireless network 210 is a communication network configured using communication devices (nodes) including first to fourth communication units 200a to 200d (hereinafter sometimes collectively referred to as "communication units 200"), a repeater 201, and a master unit 202. Communication units 200 are provided in one-to-one correspondence with each of a plurality of controllers 30, and correspond to slave units in wireless network 210.

[0022] The first communication unit 200a corresponds to the first controller 30a, the second communication unit 200b corresponds to the second controller 30b, the third communication unit 200c corresponds to the third controller 30c, and the fourth communication unit 200d corresponds to the fourth controller 30d. Each controller 30 can communicate with its own corresponding communication unit 200. The wireless network 210 allows wireless communication between multiple nodes arranged in a local area of ​​the business establishment, and when radio waves cannot reach directly, mutual communication is possible through relay by a node in between.

[0023] One feature of the communication protocol of the wireless network 210 is that it has a multi-hop function that sends a packet to a target node by passing through (hopping) multiple nodes. Therefore, even if the communication unit 200 is installed in a place where radio waves are difficult to reach due to distance or other reasons, mutual communication with other nodes is possible by providing a repeater 201. Furthermore, when a new communication unit 200 is added, the burden of wiring work is small, and the communication network can be easily expanded. Furthermore, by arranging the nodes in a mesh pattern, even if a failure occurs in a node, communication can be made possible via other normal nodes.

[0024] In the LAN 300, all communication units 200 are connected to a parent device 202 via a wireless network 210, and the parent device 202 is further connected to a server 500 via the Internet 400. This allows the server 500 to communicate with each communication unit 200. Information transmitted from each communication unit 200 is sent to the server 500 via the LAN 300 and the Internet 400. If necessary, it is also possible to connect another LAN to the server 500 via the Internet 400 to expand the scale of the health diagnosis system 100.

[0025] With the above-described configuration of the health diagnosis system 100, each controller 30 can transmit the device ID and operating information data M (described in detail later) of the air compressor 2 corresponding to the controller 30 to the server 500. The device ID is information that enables the air compressor 2 to be identified from other air compressors 2.

[0026] The server 500 is capable of diagnosing the health of the compressed air supply facility 1 based on the information received from each controller 30. The device IDs of all air compressors 2 are pre-registered in the server 500, and various information can be recorded for each device ID. The operation of the health diagnosis system 100 will be described in detail later.

[0027] 2. Compressed air supply equipment configuration, etc. 3 shows a more specific configuration example of the compressed air supply facility 1. The compressed air supply facility 1 includes the first to fourth air compressors 2a to 2d and the transport pipeline 3 described above.

[0028] The transport pipeline 3 is laid out in a network form within the business premises so that each air compressor 2 can be connected to each of the multiple compressed air utilizing devices 4. The transport pipeline 3 is composed of a large number of pipes configured to pass compressed air and a large number of pipe joints connecting the pipes to each other. Since the pipe joints are locations where compressed air leakage is relatively likely to occur in the transport pipeline 3, in this embodiment, consideration is given to making it easier to identify the location of compressed air leakage at the pipe joints. This point will be explained in detail later.

[0029] In this embodiment, the transport pipeline 3 has a loop-shaped main pipeline 7, four feed pipelines 8a-8d (hereinafter sometimes collectively referred to as "feed pipelines 8"), and three use pipelines 9a-9c (hereinafter sometimes collectively referred to as "use pipelines 9"). Each feed pipeline 8 and each use pipeline 9 branches off and extends from a different position of the main pipeline 7. In other words, one end of each feed pipeline 8 and each use pipeline 9 is connected to a different position of the main pipeline 7.

[0030] The other end of each use pipeline 9 is provided with a connection part 9x that can be connected to a compressed air utilization device 4. The connection part 9x may be in a form in which the compressed air utilization device 4 is fixedly connected, or in a form in which the compressed air utilization device 4 is detachably connected. The connection parts 9x of the use pipelines 9 can be installed in locations separated from each other.

[0031] Various devices that use compressed air can be applied as the compressed air utilization device 4. Specific examples of the compressed air utilization device 4 include an air gun or air spray that sprays compressed air, an air actuator such as an air cylinder that is operated by compressed air, and a blow molding machine that molds parts using compressed air. The compressed air utilization device 4 may also be a production facility that produces products using compressed air.

[0032] The first air compressor 2a is connected to a first feed pipe 8a and sends out the generated compressed air to the first feed pipe 8a. In the middle of the first feed pipe 8a, a first air dryer 19a and a first receiver tank 20a are provided in this order from the upstream side. The first air dryer 19a dehumidifies the compressed air sent out from the first air compressor 2a. The first receiver tank 20a temporarily stores the compressed air dehumidified by the first air dryer 19a.

[0033] The second air compressor 2b is connected to the second feed pipe 8b and sends out the generated compressed air to the second feed pipe 8b. In the middle of the second feed pipe 8b, a second air dryer 19b and a second receiver tank 20b are provided in this order from the upstream side. The second air dryer 19b dehumidifies the compressed air sent out from the second air compressor 2b. The second receiver tank 20b temporarily stores the compressed air dehumidified by the second air dryer 19b.

[0034] The third air compressor 2c is connected to a third feed pipe 8c and sends out the generated compressed air to the third feed pipe 8c. A third air dryer 19c and a third receiver tank 20c are provided in the third feed pipe 8c, in this order from the upstream side. The third air dryer 19c dehumidifies the compressed air sent out from the third air compressor 2c. The third receiver tank 20c temporarily stores the compressed air dehumidified by the third air dryer 19c.

[0035] The fourth air compressor 2d is connected to a fourth feed pipe 8d and sends out the generated compressed air to the fourth feed pipe 8d. A fourth air dryer 19d and a fourth receiver tank 20d are provided in the third feed pipe 8d, in this order from the upstream side. The fourth air dryer 19d dehumidifies the compressed air sent out from the fourth air compressor 2d. The fourth receiver tank 20d temporarily stores the compressed air dehumidified by the fourth air dryer 19d.

[0036] Each of the air dryers 19a to 19d (hereinafter sometimes collectively referred to as "air dryer 19") plays a role of dehumidifying the compressed air generated by the air compressor 2, and each of the receiver tanks 20a to 20d (hereinafter sometimes collectively referred to as "receiver tank 20") plays a role of suppressing sudden pressure fluctuations of the compressed air sent out from each of the air compressors 2. The compressed air sent out to each of the feed pipes 8a to 8d flows into the main pipe 7. Note that an opening / closing valve for opening and closing the flow path of the compressed air to the main pipe 7 may be provided in all or some of the feed pipes 8a to 8d.

[0037] The compressed air that has flowed into the main pipeline 7 further flows into each use pipeline 9. As a result, the compressed air sent out from each air compressor 2 is supplied via the transport pipeline 3 to the compressed air utilization equipment 4 connected to the connection part 9x of each use pipeline 9.

[0038] 3. Air compressor configuration, etc. Fig. 4 shows a schematic configuration example of the air compressor 2. As shown in the figure, the air compressor 2 includes a compression mechanism 21, an oil separator 22, an automatic temperature control valve 23, an oil cooler 24, an oil filter 26, an inverter 27, and a suction filter 28. The compression mechanism 21 includes a compressor body 21a and an electric motor 21b.

[0039] In this embodiment, the air compressor 2 is configured as an oil-lubricated air compressor, and is capable of compressing air Aa sucked in from the outside by the compressor body 21a to produce compressed air Ab, which can be discharged to the transport pipeline 3 (corresponding feed pipeline 8) described above. The specific form of the air compressor 2 is not particularly limited, and may be configured as an oil-free air compressor, for example.

[0040] In Fig. 4, the outline arrows show the paths of the air Aa and the compressed air Ab, and the thick arrows show the lubricant oil circulation circuit X in which the lubricant oil Lu circulates. In this embodiment, the compressed air Ab discharged from the compressor body 21a passes through an oil separator 22 and is then discharged to the transport pipeline 3. An air flow sensor (not shown) is provided in the discharge line of the compressed air Ab, and detects the discharge air amount Q (in this embodiment, the unit is [m 3 / min). This detection information of the discharge air volume Q is sent to the controller 30. This enables the controller 30 to continuously collect monitor data (described in detail later) of the discharge air volume Q based on the detection information.

[0041] 4 is a path for circulating the lubricating oil Lu through predetermined locations (such as the compressor body 21a) in the compression mechanism 21 where friction reduction and cooling are performed using the lubricating oil Lu. The lubricating oil circulation circuit X has a path through which the lubricating oil Lu flows from the compressor body 21a to the compressor body 21a, passing through the oil separator 22, the automatic temperature control valve 23, the oil cooler 24, and the oil filter 26 in this order. The lubricating oil circulation circuit X also has an auxiliary path Xa that connects a position between the oil cooler 24 and the oil filter 26 to the automatic temperature control valve 23.

[0042] The compressor body 21a is driven by an electric motor 21b and operates to compress the air Aa to generate compressed air Ab. In this embodiment, a rotary (screw) compressor is used as the compressor body 21a, and the compressor body 21a uses lubricating oil Lu to reduce friction and cool the screw rotor (remove compression heat and frictional heat). The compressed air Ab generated by the compressor body 21a contains the lubricating oil Lu.

[0043] The electric motor 21b is configured to be driven to rotate by AC power (commercial power source, etc.) supplied from the outside, and drives the screw rotor of the compressor body 21a. The air compressor 2 is provided with a power sensor (not shown), which is capable of continuously detecting the power consumption L (instantaneous power, in this embodiment, the unit is [kW] as an example) of the air compressor 2. If the inverter 27 is provided with a power sensing function, this function may be used instead of the power sensor to continuously detect the power consumption L. The detection information of the power consumption L is sent to the controller 30. This enables the controller 30 to continuously collect monitor data of the power consumption L based on the detection information (described in detail later).

[0044] The oil separator 22 has an element 21 (a filter for removing oil mist) as a demister, receives compressed air Ab from the compressor body 21a, and temporarily stores the lubricating oil Lu (oil mist) contained in the compressed air Ab by separating it using the element 21. Note that the oil mist here corresponds to foreign matter mixed in the compressed air Ab. The portion of the lubricating oil circulation circuit X that runs from the compressor body 21a to the oil separator 22 is the path for the lubricating oil Lu contained in the compressed air Ab.

[0045] The automatic temperature control valve 23 is a three-way valve that adjusts the temperature of the lubricating oil Lu. The automatic temperature control valve 23 in this embodiment operates to increase the amount of lubricating oil Lu passing through the auxiliary path Xa when the temperature of the lubricating oil Lu is lower than a predetermined reference value, for example. This reduces the amount of lubricating oil Lu passing through the oil cooler 24, making it possible to suppress a drop in the temperature of the lubricating oil Lu.

[0046] The oil cooler 24 has a water-cooled oil cooler that cools the lubricating oil Lu by water cooling, and an air-cooled oil cooler that cools the lubricating oil Lu by air cooling. The water-cooled oil cooler recovers the waste heat contained in the lubricating oil Lu, and primarily cools the lubricating oil Lu by heat exchange between the lubricating oil Lu and the cooling water while warming the cooling water. The warm water generated by the water-cooled oil cooler can be used, for example, as boiler feed water within the business establishment.

[0047] The air-cooled oil cooler is configured to pass the lubricating oil Lu after passing through the water-cooled oil cooler and to perform secondary cooling of the lubricating oil Lu by heat exchange between the lubricating oil Lu and the cooling air. The oil cooler 24 may include only one of a water-cooled oil cooler and an air-cooled oil cooler. The oil filter 26 is a filter that removes impurities such as iron rust and sludge from the lubricating oil Lu.

[0048] The lubricating oil Lu circulating through the lubricating oil circulation circuit X plays a role in reducing friction in the compressor body 21a, and then flows into the oil separator 22 to be separated from the compressed air Ab. This lubricating oil Lu is temporarily stored in the oil separator 22, passes through the automatic temperature control valve 23, and is cooled when passing through the oil cooler 24. After impurities are removed from the cooled lubricating oil Lu in the oil filter 26, it flows into the compression mechanism 21 to be used for reducing friction and cooling in necessary places, and then returns to the compressor body 21a.

[0049] The inverter 27 is a device that performs power conversion of AC power supplied from the outside to the electric motor 21b. The operation of the inverter 27 can be controlled by the controller 30, which can control the drive frequency of the electric motor 21b. The higher the drive frequency, the higher the rotation speed of the electric motor 21b, and the more compressed air Ab is generated in the compressor body 21a.

[0050] The suction filter 28 is a filter that is provided in the intake path (the primary side of the intake adjustment valve) of the air Aa to the compressor body 21a and removes dust. When the air Aa passes through the suction filter 28, dust is removed from the air Aa and the air Aa is sent to the compressor body 21a.

[0051] The controller 30 controls and monitors each part of the air compressor 2 so that the air compressor 2 operates normally. As already described, the controller 30 is capable of communicating with the corresponding communication unit 200. Note that each controller 30 corresponding to each air compressor 2 may be incorporated in a control box arranged inside the housing of the air compressor 2.

[0052] The controller 30 in this embodiment monitors the pressure of the corresponding receiver tank 20, and when a pressure drop that exceeds a predetermined reference value occurs in the receiver tank 20, controls the corresponding air compressor 2 to start, and when a pressure increase that exceeds a predetermined reference value occurs in the receiver tank 20, controls the corresponding air compressor 2 to stop. Note that a pressure sensor that detects the pressure of the compressed air in the transport pipeline 3 may be disposed, and the controller 30 may control the drive frequency of the electric motor 21b according to the detection value of the pressure sensor. As a result, the lower the pressure of the compressed air in the transport pipeline 3, the higher the drive frequency is so that more compressed air is generated, and the pressure of the compressed air in the transport pipeline 3 can be maintained within an appropriate range.

[0053] 4. Operation of the health diagnostic system The health diagnosis system 100 executes operations related to diagnosis of the health of the compressed air supply equipment 1. In the example of the present embodiment, the health diagnosis system 100 executes a data collection operation for causing the server 500 to collect various data, and a health evaluation operation for evaluating the health of the compressed air supply equipment 1 based on the collected data.

[0054] First, the data collection operation will be described below with reference to the flowchart shown in FIG. 5. Each controller 30 continuously collects and stores operation information data M of the corresponding air compressor 2, and transmits new operation information data M (after the data transmitted previously) together with the device ID of the air compressor 2 in question to the server 500 (step S11). The collection of operation information data M here may be limited to only those air compressors 2 that are powered on. The operation information data M includes the discharge air volume Q[m 3 / min] and power consumption L [kW].

[0055] These monitor data are all time series data (data at each time point at one-minute intervals) of values ​​detected synchronously at a predetermined period (one-minute period is used as an example in this embodiment), and all values ​​in each monitor data are accompanied by information on the date and time Ts at which the value was detected (for example, date and time in minutes such as "July 1st, 15:31"). In this way, the operation information data M includes information on both the discharge air volume Q and power consumption L at each time point at one-minute intervals. The device ID and operation information data M are transmitted from each controller 30 to the server 500 periodically (for example, at a period of 30 to 120 minutes) via the wireless network 210 described above.

[0056] Meanwhile, the server 500 waits to receive the driving information data M and the device ID from each controller 30 (step S21). Then, every time the server 500 receives the driving information data M and the device ID from any controller 30 (Yes in step S21), the server 500 records the received driving information data M as the driving information data M related to the device ID (step S22).

[0057] Furthermore, the server 500 waits for input of usage information data U (step S23). Here, the usage information data U is data that enables identification of the operation period Ta and the idle period Tb of the compressed air utilization equipment 4. The operation period Ta is a period during which at least one of the compressed air utilization equipment 4 operates and consumes compressed air, and the idle period Tb is a period during which all of the compressed air utilization equipment 4 is idle (not operating) and does not consume compressed air.

[0058] Examples of the usage information data U include operation day data representing operation days (days on which the compressed air utilization device 4 is operated) of the business establishment, holiday data representing holiday days (days on which the compressed air utilization device 4 is not operated), operation time period data representing operation time periods (time periods on which the compressed air utilization device 4 is operated) on operation days, and idle time period data representing idle time periods (time periods on which the compressed air utilization device 4 is not operated). The usage information data U may also be the setting information of a calendar timer used for ON / OFF control of the compressed air utilization device 4. The usage information data U may also be data representing only one of the operation period Ta and the idle period Tb, in which case, the period other than the one period may be regarded as the other period. For example, if the usage information data U is data representing only the operation period Ta, the period not represented by the usage information data U (i.e., the period other than the operation period Ta) may be regarded as the idle period Tb, and both the operation period Ta and the idle period Tb can be identified based on the usage information data U.

[0059] When usage information data U is input (Yes in step S23), the server 500 records the currently input information as the latest usage information data U (step S24). By performing such a series of data collection operations (steps S11 to S24), it is possible for the server 500 to collect the operation information data M and usage information data U related to each air compressor 2.

[0060] Next, the health evaluation operation will be described below with reference to the flowchart shown in Fig. 6. The health evaluation operation is periodically performed at a predetermined frequency (once a day, as an example in this embodiment). In addition, in one health evaluation operation, all air compressors 2 (device IDs) are set as processing targets once each, and a series of operations from steps S31 to S37, which will be described later, is performed on the processing targets. In other words, in one health evaluation operation, the series of operations from steps S31 to S37 are performed on each of the first to fourth air compressors 2a to 2d.

[0061] The server 500 compares the driving information data M to be processed with the latest usage information data U, and selects the first driving information data M1 corresponding to the downtime period Tb and the second driving information data M2 corresponding to the operating period Ta (step S31).

[0062] More specifically, the server 500 recognizes the downtime period Tb and the operating period Ta based on the usage information data U, and classifies, among all the monitor data in the operating information data M, the data whose date and time Ts belongs to the downtime period Tb into the first operating information data M1, and classifies the data whose date and time Ts belongs to the operating period Ta into the second operating information data M2. In this way, each of the monitor data of the discharged air volume Q and the power consumption L included in the operating information data M is divided into a part representing a value detected during the downtime period Tb and a part representing a value detected during the operating period Ta.

[0063] Next, the server 500 calculates the waste power cost C [¥] of the air compressor 2 based on the first operation information data M1 selected in the process of step S31 (step S32). More specifically, the server 500 calculates the waste power cost C per day using the collected monitor data of the power consumption L [kW] of the previous day. First, the power consumption amount P [kWh] for one day is obtained by multiplying the integrated value ΣL of each monitor data of the power consumption L by the number of collected monitor data N (corresponding to a fraction) (P=ΣL×N / 60). Then, the waste power cost C per day can be calculated by multiplying this power consumption P by the power unit price E [¥ / kWh] (Z=P×E). This power unit price E is the power unit price of the power company that supplies power to the air compressor 2, and is information that is registered in advance in the server 500. The power unit price E registered in the server 500 may be updated as needed to accommodate fluctuations.

[0064] Next, the server 500 calculates the specific energy W [kW / m 3 / min] (step S33). More specifically, the server 500 calculates the collected discharge air volume Q[m 3 The time series value of the specific energy W (specific energy W at each point in time at one-minute intervals) is calculated from the monitor data of the air consumption [kW] and the power consumption L [min]. Note that the specific energy W at each point in time can be calculated, for example, by dividing the power consumption L at the same point in time by the discharge air volume Q (W=L / Q).

[0065] Next, the server 500 determines whether the waste power cost C calculated in the current process of step S32 satisfies a predetermined reference condition Z1 (step S34). In this embodiment, the reference condition Z1 is set as a condition that is satisfied when the waste power cost C at any point in time exceeds a predetermined threshold.

[0066] During the downtime Tb when the compressed air utilization equipment 4 does not consume compressed air, the air compressor 2 should not be operating. However, if a wasteful power cost C occurs, it is revealed that a compressed air leak is progressing somewhere in the transport pipeline 3. For example, if the wasteful power cost C per day on non-working days is 2,000 yen / unit, this waste also occurs on working days, so the total wasteful power cost for the whole year is estimated to be 730,000 yen / unit. Therefore, as the predetermined threshold value for the wasteful power cost C, an amount at a level at which the total wasteful power cost for the whole year is about 50,000 yen / unit (for example, the wasteful power cost C per day is less than 150 yen / unit) is selected. If the wasteful power cost C satisfies the reference condition Z1 (Yes in step S34), the server 500 updates the transport pipeline corresponding flag F1 to ON (step S35).

[0067] That is, the server 500 stores information on the transport pipeline corresponding flag F1 (initial value is "OFF") in advance for each device ID, and the operation of step S35 updates the transport pipeline corresponding flag F1 corresponding to the current processing target to "ON." The transport pipeline corresponding flag F1 is information indicating whether or not maintenance is required for the transport pipeline 3, and when it is "ON," it indicates that maintenance is required for the transport pipeline 3, and when it is "OFF," it indicates that the necessity for said maintenance is low. When the transport pipeline corresponding flag F1 is updated to "ON" by the processing of step S35, it means that the server 500 has evaluated that maintenance is required for the transport pipeline 3.

[0068] Next, the server 500 determines whether or not the specific energy W calculated in the current process of step S33 satisfies a predetermined reference condition Z2 (step S36). In this embodiment, the reference condition Z2 is set as a condition that is satisfied when the specific energy W at any point in time exceeds a predetermined threshold value.

[0069] When the specific energy W exceeds a predetermined threshold value, it becomes apparent that some malfunction is occurring in the air compressor 2 (typically, clogging of filters such as the suction filter 28).

[0070] As the predetermined threshold value for the specific energy W, for example, the specific energy when all filters are unclogged and equivalent to a new product (for example, the specific energy on the day of commissioning of a new filter or the day of overhaul) is set as a base value B, and a numerical value is selected by multiplying this base value B by a predetermined multiplication rate (for example, 1.1 to 1.3). If the specific energy W satisfies the reference condition Z2 (Yes in step S36), the server 500 updates the air compressor compatible flag F2 to ON (step S37).

[0071] The reference condition Z2 may be set as a condition that is satisfied when the cost of replacing filters (e.g., the total of parts cost, labor cost, etc.) exceeds the excess power cost incurred by the increase in specific energy W relative to the above-mentioned base value B.

[0072] That is, the server 500 preliminarily records and holds information on the air compressor compatible flag F2 (initial value is "OFF") for each device ID, and the operation of step S37 updates the air compressor compatible flag F2 corresponding to the current processing target to "ON". The air compressor compatible flag F2 is information indicating whether or not maintenance is required for the air compressor, and when it is "ON", it indicates that maintenance is required for the air compressor, and when it is "OFF", it indicates that the necessity of said maintenance is low. When the air compressor compatible flag F2 is updated to "ON" by the processing of step S37, it means that the server 500 has evaluated that maintenance of the air compressor 2 is necessary.

[0073] The status of the transport pipeline corresponding flag F1 and the air compressor corresponding flag F2 for each device ID recorded and held in the server 500 can be confirmed by a business operator (facility management agent) contracted to perform maintenance work for the compressed air supply facility 1. This allows, for example, a field engineer performing maintenance work under the business operator to efficiently perform maintenance work for the compressed air supply facility 1 based on the status of the transport pipeline corresponding flag F1 or the air compressor corresponding flag F2. An example of a work process performed by a field engineer based on the status of these flags F1 and F2 will be described below with reference to the flowchart in FIG. 7.

[0074] The field engineer checks whether any of the transport pipeline flags F1 corresponding to all the device IDs is ON (step S41). If any of the transport pipeline flags F1 is ON (Yes in step S41), the field engineer forms a coating on the transport pipeline 3, and then uses the coating to search for and identify the location of the compressed air leak in the transport pipeline 3 (step S42). If all of the transport pipeline flags F1 are OFF (No in step S41), it is considered that maintenance of the transport pipeline 3 is not required at this time, so the field engineer proceeds to step S44, which will be described later.

[0075] To explain step S42 in more detail, first, the field engineer forms a coating R made of synthetic resin on the surface of the pipe joint of the transport pipeline 3. The thickness of the coating R is preferably 20 to 100 μm. Next, the field engineer searches for the location of compressed air leakage in the transport pipeline 3 by investigating the change in appearance of the coating R over time. That is, the field engineer visually determines whether or not there is any change in the appearance of the coating R, such as floating, rupture, peeling, or other changes due to compressed air leakage, and identifies the location of leakage. Alternatively, instead of visual determination, the location of leakage may be identified by periodically taking an image of the appearance of the coating and comparing the images over time.

[0076] One specific example of a method for forming the coating R is to apply a liquid coating agent K mainly composed of a synthetic resin to the surface of the pipe joint, and then dry the applied layer to form the coating (painted film) R. Examples of synthetic resins that are the main components of the liquid coating agent K used to form the coating R include epoxy resin, acrylic resin, urethane resin, silicone rubber, and styrene butadiene rubber. The liquid coating agent K is preferably colored with a pigment or dye of a different color (e.g., red or white) from the transportation pipe 3, and a coating agent (so-called paint) for painting the exterior of an object may also be used. The different colors of the coating R and the transportation pipe 3 make it easier to distinguish changes in appearance.

[0077] The liquid coating agent K may be prepared by including microcapsules containing a color former and a color developer. Specifically, the microcapsules containing a color former (leuco body) and the color developer (proton donor) are mixed with a resin-dissolved varnish (a synthetic resin such as styrene acrylic resin, styrene maleic acid resin, or acrylic resin dissolved in drying oil) together with a sensitizer and a retention agent to be used as the liquid coating agent K. The leuco body (leuco dye) is known as a compound that can reversibly change between a colorless molecular structure and a colored molecular structure by heat, light, or pH.

[0078] The liquid coating agent K thus prepared is applied to the surface of the pipe joint of the transport pipeline 3 and dried to form a film R that acts as a pressure-sensitive film. That is, the film R after drying can be made to act as a pressure-sensitive film. When the microcapsules of this pressure-sensitive film burst due to the pressure of compressed air leakage and the color former leaks out, the color former reacts with the color developer to develop a color. The color former may be either a fluorescent or non-fluorescent dye, but if it is desired to distinguish the colored state in a dark place, a fluorescent dye is preferred. When a non-fluorescent dye is used, one that exhibits a vivid red or blue color tone is preferred, and furthermore, the visibility during color development can be improved by applying a white paint to the base of the coating film in advance.

[0079] Another specific example of the method for forming the coating R is a method in which a heat-shrinkable film mainly composed of synthetic resin is wrapped around the surface of the pipe joint of the transport pipeline 3 and heated to tightly cover the surface, thereby forming the coating R. The specific form of this heating is not particularly limited, and examples thereof include heating with hot air from a dryer, heating with near-infrared rays from a halogen heater, and heating with the flame of a burner.

[0080] Examples of synthetic resins that are the main components of the heat shrinkable film (shrink film) used to form the coating R include polypropylene resin, polyethylene resin, polyvinyl chloride resin, polystyrene resin, and polyethylene terephthalate resin. The heat shrinkable film is desirably colored with a pigment or dye of a different color tone (e.g., red or white) from the transportation pipe 3. The coating R and the transportation pipe 3 having different colors make it easier to distinguish changes in appearance.

[0081] After performing the process of step S42, the field engineer performs maintenance on the transport pipeline 3 based on the information on the identified leak location (step S43). A specific example of the maintenance is repairing the transport pipeline 3 or replacing parts to stop the compressed air leak at the identified leak location. This eliminates the wasteful power consumption of the air compressor 2 caused by the increase in the amount of compressed air leaking.

[0082] Next, the field engineer checks whether any of the air compressor corresponding flags F2 corresponding to all the device IDs are ON (step S44). If any of the air compressor corresponding flags F2 are ON (Yes in step S44), the field engineer performs maintenance on the air compressor 2 (step S45).

[0083] Specific examples of such maintenance include cleaning and replacing filters such as the suction filter 28. The field engineer can check which air compressor 2 has the air compressor flag F2 set to "ON" and narrow down the targets for maintenance to those air compressors 2 with the flag F2 set to "ON." This reduces the time and cost required for maintenance work.

[0084] Through the above-described steps S41 to S45, the field engineer can appropriately perform maintenance of the compressed air supplying facility 1 by using the health diagnosis system 100. Note that for each of the flags F1, F2 that have been set to "ON," it is possible to have the health diagnosis system 100 perform the diagnosis of health again by updating the flags F1, F2 to "OFF" after performing maintenance on the compressed air supplying facility 1, for example.

[0085] 5.Other As described above, the health diagnosis method according to this embodiment is a method for diagnosing the health of a compressed air supply facility 1 including an air compressor 2 that generates compressed air and a transport pipeline 3 that is used to transport the compressed air to a compressed air utilization device 4, and includes a first step (steps S11, S21 to S22) of collecting operation information data M including information on the discharge air volume Q and power consumption L of the air compressor 2, a second step (steps S23 to S24) of acquiring usage information data U that enables the operation period Ta and the down period Tb of the compressed air utilization device 4 to be specified, and The method includes a third step (step S31) of sorting the operation information data M into first operation information data M1 corresponding to the downtime Tb and second operation information data M2 corresponding to the operation period Ta by comparing the operation information data M with the operation information data U, a fourth step (steps S32, S34 to S35) of evaluating the need for maintenance of the transport pipeline 3 based on the first operation information data M1, and a fifth step (steps S41 to S42) of identifying the location of the compressed air leak in the transport pipeline 3 if it is evaluated in the fourth step that maintenance of the transport pipeline 3 is necessary.

[0086] Furthermore, this fifth step includes a first sub-step of forming a coating R made of synthetic resin on the surface of the pipe joint of the transport pipeline 3, and a second sub-step of searching for the leakage location by investigating the change in appearance of the coating R over time. According to this soundness diagnosis method, by executing the first to third steps, the necessity of maintenance for the transport pipeline 3 can be evaluated in the fourth step, and the leakage location can be identified in the fifth step by using the coating R. Furthermore, according to this soundness diagnosis method, it is possible to easily and reliably determine the presence or absence of a compressed air leak without requiring the suspension of production equipment that uses compressed air.

[0087] In the fifth step, the coating R formed on the surface of the pipe joint of the transport pipeline 3 is used to facilitate identification of the location of the compressed air leak, and the quality of the compressed air is not affected. Therefore, the soundness diagnosis method can be used without problems even in an environment where the inclusion of impurities in the compressed air is avoided, such as a food factory. Furthermore, even if the compressed air utilization device 4 is a production facility, there is no need to stop the production facility.

[0088] The health diagnosis method of this embodiment further includes a sixth step (steps S33, S36 to S37) of evaluating the necessity of maintenance for the air compressor 2 based on the second operation information data M2. Therefore, the second operation information data M2 obtained in the third step can also be used to evaluate the necessity of maintenance for the air compressor 2. In this way, the health diagnosis method is extremely useful in the maintenance management of the compressed air supply facility 1 because it can efficiently and collectively perform not only the health diagnosis of the compressed air transport pipeline 3 but also the health diagnosis of the air compressor 2.

[0089] The fourth step is a process of calculating the wasted power cost C of the air compressor 2 based on the first operation information data M1, and evaluating that maintenance is necessary for the transport pipeline 3 when the calculated wasted power cost C satisfies a predetermined condition. The sixth step is a process of calculating the specific energy W of the air compressor 2 based on the second operation information data M2, and evaluating that maintenance is necessary for the air compressor 2 when the calculated specific energy W satisfies a predetermined condition.

[0090] The soundness diagnosis method according to this embodiment also includes a leakage inspection method (step S42) for the transport pipeline 3. This leakage inspection method is a method for inspecting leakage of the compressed air generated by the air compressor 2 in the transport pipeline 3, and includes a step of forming a coating R made of synthetic resin on the surface of the pipe joint of the transport pipeline 3, and a step of searching for a leakage occurrence point by investigating the appearance change of the coating R over time.

[0091] Furthermore, this leakage inspection method can be implemented even if a means for appropriately controlling the operation of generating compressed air in each air compressor 2 is provided instead of the controller 30, and the installation of the health diagnosis system 100 is omitted. This method can be implemented at any time, for example, during regular diagnosis such as annual diagnosis. In this case, it is not necessary to execute the data collection operation or health evaluation operation, and this method can be implemented even in the facility environment in which the operation information data M cannot be collected (for example, when the air compressor 2 does not have a function to output information on the discharge air volume or power consumption).

[0092] Although the embodiment of the present invention has been described above, the configuration of the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the invention. In other words, the above embodiment is an example in all respects and should be considered as not restrictive. The technical scope of the present invention is indicated by the claims, not the description of the above embodiment, and should be understood to include all modifications that fall within the meaning and scope of the claims. [Explanation of symbols]

[0093] 1. Compressed air supply equipment 2. Air Compressor 2a No. 1 air compressor 2b No. 2 air compressor 2c 3rd air compressor 2d 4th air compressor 3 Transport pipeline 4. Compressed air equipment 7 Main pipeline 8 Feed Pipe 8a First feed line 8b Second feed pipe 8c Third feed line 8d 4th feed line 9, 9a~9c Use Pipeline 9x connections 19a First Air Dryer 19b Second Air Dryer 19c 3rd Air Dryer 19d No. 4 Air Dryer 20 Receiver Tank 20a 1st receiver tank 20b Second receiver tank 20c 3rd receiver tank 20d 4th receiver tank 21 Compression mechanism 21a Compressor body 21b Electric motor 22 Oil separator 23 Automatic temperature control valve 24 Oil cooler 26 Oil filter 27 Inverter 28 Suction filter 30 Controller 30a First Controller 30b Second Controller 30c 3rd Controller 30d 4th Controller 100 Health diagnostic system 200 Communication Unit 200a First communication unit 200b second communication unit 200c Third communication unit 200d 4th communication unit 201 Repeater 202 Parent unit 210 Wireless Network 300 LAN 400 Internet 500 Servers

Claims

1. A method for diagnosing the health of a compressed air supply facility including an air compressor that generates compressed air and a transport pipeline that transports the compressed air to a compressed air utilization device, comprising: A first step of collecting operational information data including information on the discharge air volume and power consumption of the air compressor; a second step of acquiring usage information data that enables the identification of operating periods and downtime periods of the compressed air utilization equipment; a third step of classifying the driving information data into first driving information data corresponding to the suspension period and second driving information data corresponding to the operation period by matching the driving information data with the usage information data; A fourth step of evaluating the necessity of maintenance for the pipeline based on the first operational information data; and a fifth step of identifying a location of a compressed air leak in the transport pipeline when it is evaluated in the fourth step that maintenance of the transport pipeline is necessary, The fifth step is: A first sub-step of forming a coating made of a synthetic resin on a surface of a pipe joint portion of the transport pipeline; A second sub-step of searching for the location of the leak by investigating changes in appearance of the coating over time.

2. 2. The method of claim 1, further comprising a sixth step of evaluating a need for maintenance on the air compressor based on the second operating information data.

3. A fourth step is a process of calculating a wasteful power cost of the air compressor based on the first operation information data, and evaluating that maintenance is necessary for the transportation pipeline when the calculated wasteful power cost satisfies a predetermined condition, 3. The health diagnosis method according to claim 2, wherein the sixth step is a process of calculating a specific energy of the air compressor based on the second operating information data, and evaluating that maintenance is necessary for the air compressor when the calculated specific energy satisfies a predetermined condition.

4. A method for inspecting a compressed air leak in a pipeline for transporting compressed air generated by an air compressor, comprising the steps of: A first step of forming a coating made of a synthetic resin on a surface of a pipe joint of the transport pipeline; a second step of searching for the location of the leakage by investigating changes in appearance of the coating over time.

5. 5. The leakage inspection method according to claim 4, wherein in the first step, the liquid coating agent containing the synthetic resin as a main component is applied to the surface of the pipe joint, and then the applied layer is dried to form the coating.

6. 6. The leak inspection method according to claim 5, wherein the liquid coating agent is prepared by containing microcapsules encapsulating a color former and a color developer, and the coating after drying acts as a pressure-sensitive film.

7. 5. The leak inspection method according to claim 4, wherein in the first step, the coating is formed by wrapping a heat shrinkable film containing a synthetic resin as a main component around a surface of the pipe joint and tightly covering it by heating.

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