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ContiTech (China) Fabric Air Dispersion System

The central ventilation system of ContiTech (China) VC working shop

ContiTech (China) rubber and plastics technology limited company located in Changshu Southeast economic development zone. Built in 2008, it was the first sole proprietor corporation founded by Continental AG in China, which consists of air spring systems workshop, vibration control workshop, hose& pipe technology workshop and central office building.


ContiTech (China) fabric air dispersion system


(1) Project Background

The vibration control of the workshop (VC)is mainly responsible for the manufacturing vibration system, where plenty of modules are made by rubber products. The temperature would relatively high with small amount exhaust gas during the high-temperature injection molding phase in the manufacturing period. At the present stage, 27 work positions are provided in the workshop, and it will rise up to 40 wok position.


spiral ventilation ducting


(2) Design Scheme

For creating a better physical and mental health of operating personnel, the production environment needs to be improved. It was considered to increase fresh air amount during the design of the scheme, which could able to form a positive pressure air supply in the workshop and take advantage of the RTU to improve indoor air quality. Based on the 40 work position requirement cited by German technician, and each air velocity at the work position needs to reach 7±1 m/s. We also calculated the air amount at each work position needs to reach 1750CMH on the basis of the trend and range of each duct, which arranged near the work position. In this case, within the range of 1m near the operating personnel, the air velocity could be able to reach 7±1 m/s at the 1.7m height which people could feel. So we are able to count the total air amount could be around 70000CMH.


Design Scheme as followed

textile duct system


1. Type selection of equipment

Based on the condition of the worksite, the equipment only could be able to install on the outdoor platform. The equipment need to be designed to be around 3 meters wide, 6.5 meters long and the total weight could not be able to exceed 5000Kg on the basis of the square of the platform. At the same time, based on the condition of the workshop, the equipment needs to reserve a position for the FCU, Meanwhile, the position for future use of the medium efficiency filter also needs to be reserved.

According to the air volume, we can figure out the move towards ducts, resistance of the function section and pressure loss of the plenum chamber. The external static pressure need to reach around 350Pa when all condition meets the requirement.

Choose the ELCO series EKDM1719H50 combined AHU, the total air volume is about 70000CMH, ESP is about 350Pa, the weight of AHU is about 3722Kg, boundary dimension:3130*2180*6350(wide*height*length, mm)

2. System structure

AHU is installed on the outdoor platform, each plenum chamber is arranged for one production line. The elevation of main duct is about 7.5m and the elevation of branch duct is about 4.5m which supply the air the post site. Outdoor ducts and plenum chambers are made by galvanized steel sheet while the indoor ducts are applied by the DurkeeSox Air Dispersion system (DurkeeSox Duct).

 

 

3. Automatic control design

System is equipped with a control cabinet specially and installed Siemens inverter to control the revolving speed to meet the different air supply requirement at the worksite. Siemens main controller and PLC monitor could be able to achieve the automatic control for whole system.

1) The equipment would stop if the outdoor temperatures get too high in the summer.

2) The equipment would stop if the outdoor temperatures get too low in the winter.

3)  The inverter could able to run fully automatic on the basis of the pressure of the indoor duct.

4)  The inverter could able to run by frame on the basis of the setting frequency.

5)  The fresh air valves in the air inlet could able to open automatically before the power on, while the air valves could able to close automatically after power off.

6)  The PLC monitor could able to show the indoor and outdoor temperature with help of the temperature sensor.

7)  3 sets pressure difference transducer are installed at the primary filter, medium filter and front-back of AHU            

 

8)  The stopping switch is available, which could able to stop device to avoid the equipment trouble and guarantee the safety during the maintenance

9)  The volume valves are equipped on the air ducts of plenum chamber which could able to adjust the balance of the 3 main ducts.

10) The control system is connected with the factory fire control system, the system could able to automatically shutoff during the fire alarm.


(3) Reconstruction Effect

1. Installation effect

The whole equipment, air ducts and control system are arranged according to the design scheme.

ContiTech (China) textile ductwork

2. Ventilation test effect

1) On-site ventilation effect

ventilation sock system

2) Testing Data

The inlet of main duct behind the plenum chamber

Powercheck:


Frequenz

Current

Pressure

Position

50Hz

80A

430 Pa

The inlet of main duct behind the plenum chamber

 

47.5Hz

68A

400 Pa

The inlet of main duct behind the plenum chamber

 

45Hz

58A

385 Pa

The inlet of main duct behind the plenum chamber

 

42.5Hz

50A

353 Pa

The inlet of main duct behind the plenum chamber

 

40Hz

44A

330 Pa

The inlet of main duct behind the plenum chamber

 

37.5Hz

36A

315 Pa

The inlet of main duct behind the plenum chamber

 

35Hz

30A

297 Pa

The inlet of main duct behind the plenum chamber

 

30Hz

20A

232 Pa

The inlet of main duct behind the plenum chamber

 

25Hz

12A

180 Pa

The inlet of main duct behind the plenum chamber




Butterfly Damper Adjust, marking and tightening!

Explan found position: Based on the velocity at the nozzle position of the 3 production line, adjust the opening of 3 air valves, fix the opening of the air valves when the velocity became the same. Guarantee the air volume at the nozzle and air velocity reach the same level.

 

Test: Automatic: START/SHUTDOWN/RESTART

 

Test: Maintenance Signal:

Signal come:

Signal go:

 

Check Airspeed at the outlet valves:

25Hz(Setting Frequency)                             35Hz(Setting Frequency)


Position:

speed: outlet (m/s)

speed: height 1.7m  (m/s)

pressure: (Pa)

Position:

speed: outlet  (m/s)

speed: height 1.7m  (m/s)

pressure: (Pa)

1#-1

17~18

5~6

180

1#-1

20~21

7~8

285

1#-2

17~18

5~6

170

1#-2

20~21

7~8

285

1#-3

17~18

5~6

170

1#-3

20~21

7~8

285

1#-4

17~18

5~6

180

1#-4

20~21

7~8

285

2#-1

15~16

5~6

150

2#-1

20~21

7~8

285

2#-2

15~16

4~5

150

2#-2

20~21

7~8

285

2#-3

15~16

4~5

180

2#-3

20~21

7~8

285

2#-4

16~17

4~5

180

2#-4

20~21

7~8

285

2#-5

16~17

4~5

140

2#-5

19~20

6~7

270

2#-6

15~16

4~5

140

2#-6

20~21

7~8

285

2#-7

15~16

4~5

140

2#-7

20~21

7~8

285

2#-8

15~16

4~5

140

2#-8

20~21

7~8

285

2#-9

15~16

5~6

140

2#-9

20~21

7~8

285

2#-10

15~16

5~6

150

2#-10

20~21

7~8

285

3#-1

16

5~6

150

3#-1

20~21

7~8

285

3#-2

15~16

5~6

150

3#-2

20~21

7~8

285

3#-3

15

4~5

140

3#-3

20~21

7~8

285

3#-4

15~16

4~5

140

3#-4

19~20

6~7

270

3#-5

15~16

4~5

150

3#-5

20~21

7~8

285

3#-6

15~16

4~5

150

3#-6

20~21

7~8

285

3#-7

15~16

5~6

150

3#-7

20~21

7~8

285

3#-8

15~16

5~6

150

3#-8

20~21

7~8

285


50Hz(Setting Frequency)

Position:

speed: outlet (m/s)

speed: height 1.7m  (m/s)

pressure: (Pa)

Position:

speed: outlet  (m/s)

speed: height 1.7m  (m/s)

pressure: (Pa)

1#-1

22~23

9~10

400

2#-8

22~23

9~10

400

1#-2

22~23

9~10

400

2#-9

22~23

9~10

400

1#-3

22~23

9~10

400

2#-10

22~23

9~10

400

1#-4

22~23

9~10

400

3#-1

22~23

9~10

400

2#-1

22~23

9~10

400

3#-2

22~23

9~10

400

2#-2

22~23

9~10

400

3#-3

22~23

9~10

400

2#-3

22~23

9~10

400

3#-4

21~22

9

390

2#-4

22~23

9~10

400

3#-5

22~23

9~10

400

2#-5

21~22

9

390

3#-6

22~23

9~10

400

2#-6

22~23

9~10

400

3#-7

22~23

9~10

400

2#-7

22~23

9~10

400

3#-8

22~23

9~10

400


Due to the accuracy of test equipment and method of testing personnel, test data might have some discrepancy

 

3) Testing conclusion

1. Based on the testing data, the frequency of equipment runs faster, the air velocity is more close and the discrepancy is less.

2. When the frequency of equipment reached at 30~35Hz, the air velocity at the elevation of 1.7 meters could able to reach(7±1m/s)as expected

3. The automatic system could able to meet expected requirements that could achieve automatic start-stop control by temperature difference、failure warning、filth blockage warning and etc.,Meanwhile, the system could able to run automatically in accordance with the set frequency.

4. All the post site air supply could be achieved accurately by our system and could able satisfied the comfort level of all the operating personnel. Meanwhile, it do not have any side effect on the operating of the production equipment.

Conclusion of acceptance: ContiTech (China) VC workshop fresh air supply system operated functionally, all the air supply position are accurate, all the terminal air velocity are accurate, the system meet the expected technical requirement of the contract, which could able to satisfied the acceptance.

 

 

(4) Conclusion analysis

   The successful case of ContiTech (China) post air supply system, which attribute to the hard work of design personnel and engineering personnel. The whole team did a great contribution to the positioning on the worksite, the accuracy of the air-supply terminal, the accuracy of production control and the performance of the air supply. DurkeeSox Air Dispersion System achieved symmetrical ventilation at the post and the accuracy of the air-supply terminal velocity, which established the leading position of the accuracy of the post air supply.

   The successful case of the ContiTech (China) post air supply system, it showed the DurkeeSox Air Dispersion System could able to control the velocity at each post site, which means it would save abundant energy in the field of ventilation and air condition system. DurkeeSox Air Dispersion System has a great possibility to become a mainstream product of air dispersion system in machine industry in the future.

   


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