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preventive maintenance and audits for air compressors

Why frequent air compressor maintenance and audits

Written by Tami Matthews on December 11, 2020. Posted in Automotive, Compressed Air, Compressed Air, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

Air compressors are the lifeblood of many facilities – keeping your business going. They help you deliver your company’s products on time and on budget. Compressor Station Audits can assist too, in ensuring you’re using your equipment to the best of its ability.

Together, preventive maintenance and audits (air compressor service), keep a facility running.

Preventive maintenance

Did you know that you should be having your air compressors serviced at least once a year or for every 2,000 – 3, 000 hours of service? In addition, extreme weather conditions – caused during winter and summer – are great times to get your air compressor serviced.

At a minimum, compressors need a variety of routine maintenance:

Fittings and belts tightened and inspected
Oil changed
Filters changed
General inspections
Cleaning of all coolers and drains
Collection of oil samples for testing
Recording amp draw
Recording voltage
Checking for abnormal vibrations and noise
Injection and discharge oil temp
Lubricating drive motor bearings

If you’re behind on your maintenance or considering an audit, here are a few good reasons to invest in maintenance … before it’s too late.

Save money on replacing a compressor as well as get more efficiency

It probably goes without explaining that preventive maintenance can save money in the long term. A new air compressor, being replaced after not maintaining your old one, is costly.

What often happens, though, are air compressors being used inefficiently due to lack of maintenance. One auto shop couldn’t keep up with customer demand due to delayed maintenance.

Prevent shutting down your plant or handling costly repairs

When air compressors aren’t serviced regularly, they become more apt to break down or quit completely. Of course, when an air compressor breaks down, the facility could come to a halt. Shutting down operations costs your company time and money, even potentially impacting your customers.

But it goes beyond stopping or slowing operations. The labor costs for emergency repairs can be expensive, too. Although Compressed Air Technologies handles emergencies, including middle-of-the-night repairs, we don’t recommend customers wait for that scenario.

Prevent injured workers and fines

You also probably know that if compressors are mishandled or misused, they can be dangerous, causing serious issues. Those issues can vary wildly from hearing damage to killing a worker.

If a worker does become injured on the job, including his hearing damaged, they can file a worker’s compensation claim and potentially even sue your company. One law firm indicates their median settlement for hearing loss is around $55,000.

OSHA has standards for how air compressors are used in facilities, even where they’re used. Violations of those OSHA standards can be expensive; OSHA fines are up to $70,000 per violation.

Audits

Audits are an important part of the equation for keeping your facility running. Typically, managers ask for an audit before adding compressors. Audits provide a snapshot of overall controls, get an idea of peak usage and capacity, and more.

Audits are used for the following:

Weaknesses in your existing system, including leakage
Inefficiency in the compressors you’re using, including too much horsepower
Providing guidance on reconfiguring your current system for better airflow

Save money from buying another compressor

By receiving an audit, you can identify whether you really need an additional compressor. Compressed Air Technologies technicians often see managers ready to buy a new compressor when one isn’t necessary. Many times, air compressors aren’t being fully utilized. Technicians and engineers can help you reconfigure your setup to ensure maximum efficiency.

Not purchasing an additional – and unnecessary – air compressor could save thousands of dollars. For example, Kaeser has a case study on one audit, where they identified a furniture company that was wasting $600,000.

Save money on energy and energy consumption

Audits can point out leaks to reduce them as well as ensure energy is being used efficiently. Even if energy consumption isn’t an overall goal of your company (such as those seeking ISO certifications or meeting tight environmental standards), it can save money. After all, the more compressors you’re using, the more energy you’re consuming.

One Kaeser case study indicates one company saved (with a utility rebate) $78,031 in the first year alone. Audits are a fraction of that cost.

Audits + maintenance together

Audits + Maintenance – it’s the formula for running an efficient facility. Together they can save you money. They keep workers safe, prevent unnecessary fines and lawsuits, and keep your plant moving.

At Elevated Industrial Solutions, we enable you to meet customer demands on time and on budget. Our technicians have a combined 60+ years of experience. And although we handle late-night emergencies, we provide – and can help you schedule – regular maintenance to prevent catastrophes at your facilities.

Air compressors for the manufacturing industry

Written by Tami Matthews on August 4, 2020. Posted in Aerospace & defense, Compressed Air, Manufacturing. Leave a Comment

Compressed air plays an important role in the manufacturing industry. It powers your facility to make everything from car parts to consumer goods. So, getting the right compressor is important.

Among the manufacturing companies needing compressed air for industrial processes include:

Primary product industries (suppliers of semi-finished raw materials to manufacturers)
Heavy goods manufacturers
Consumer goods processing and packaging
Transportation
Construction
Aerospace
Automotive
Cement production

Here are some key considerations to incorporate into the decision-making process:

Power

Choose an air compressor that will drive tools and power your machines and processes with no hassles. Get a vendor that can provide recommendations to get just the right power (not too much or too little). Also, some vendors – such as Elevated Industrial Solutions – can provide ideas on how to save energy, working with energy companies to get you rebates.

Efficiency

The more power an air compressor requires, the higher the fuel cost, which is a significant operating expense. Ask for ideas on how to make your compressed air system more efficient for the manufacturing processes you’re running.

Maintenance requirements

Some compressors have higher maintenance costs than others. In addition, your manufacturing environment (such as a cement plant) could require more maintenance than others.

Choose an air compressor that requires as little maintenance as possible to ensure that your operations run smoothly. Also, ensure you’re working with an expert team certified in your compressor and who are available 24 x 7. Having people available, in case the worst happens (such as a shutdown) is imperative.

Warranty

Choose an air compressor manufacturer that stands behind their product with a strong warranty.

The right vendor: Elevated

When looking into compressed air systems, it’s important to have a compressed air audit to determine your specific needs. Our specialists can also help you check if there are tasks that can be done with less expensive options for a high-performing compressed air system. We have 24 x 7 repair service available to get your facility up and running during emergencies. And we warranty our compressors so you have peace of mind.

Buying an air compressor – what you need to know

Written by Tami Matthews on June 2, 2020. Posted in Compressed Air, Compressed air systems, General, Industrial, Industrial supplies, Manufacturing, Metalworking, Woodworking. Leave a Comment

Buying an air compressor is complicated and requires some expert knowledge. Not everyone involved in the buying process is a facility or plan engineer/manager, either. So we put together a guide to help you or help explain to others in your company what to look for.

Compressed air terms

To help you familiarize yourself with the terms concerning air compressors, turn to this shortlist of definitions that will be helpful for your next air compressor purchase:

Pounds per Square Inch (PSI) — the measurement of air pressure and force that is delivered by an air compressor. Higher numbers mean that a larger volume of air can be compressed in the tank.
Pounds per Square Inch Gauge (PSIG) — the measurement of air pressure and force that is delivered by an air compressor relative to our atmospheric pressure at sea level, which is 14.7 PSI. Most gauges are calibrated to read 0 at sea level so the 14.7 psi of the earth’s atmosphere is not measured.
Actual Cubic Feet per Minute (ACFM) — the actual volume of air pumped in one minute from a compressor running at its rated operating conditions of speed, pressure, and temperatures.
Standard Cubic Feet per Minute (SCFM) — the representation of the volume of air pumped in one minute at 60 degrees Fahrenheit (15.6 degrees Celsius). Some air compressors will be rated with SCFM to provide a more accurate working rating since air contracts and expands at different temperatures.
Horsepower (HP) — the measurement of power the motor produces. The higher the number, the more work the air compressor can do to deliver a greater PSI and ACFM.
Brake horsepower —Horsepower delivered to the output shaft of a motor or engine, or the horsepower required at the compressor shaft to perform work.
Indicated horsepower —The horsepower is calculated from compressor indicator diagrams. The term applies only to displacement-type compressors.
Intercooler — part of the air compressor that cools air between compression stages.
Aftercooler — a heat exchanger used for cooling air discharged from a compressor. The resulting condensation may be removed by a moisture separator following the aftercooler.
Pneumatic tools — tools that operate by air pressure.
Positive displacement compressors —Compressors in which successive volumes of air or gas are confined within a closed space and space is mechanically reduced, resulting in compression. These may be reciprocating or rotating.

Air compressor options

Here are three general categories that air compressors fall into.

Consumer-grade air compressors. These models are perfect for simple jobs like inflating tires, sporting goods, and other inflatables. Most have the power to operate small-load air tools.

Professional-grade air compressors. These are designed to power more demanding tools, making them perfect for contractors, woodworking shops as well as small garages.

Commercial/Industrial-grade air compressors. Redesigned to provide a steady flow of compressed air for extended periods of time. These compressors are built with high-quality components and come with additional features that use advanced technology to improve performance, energy efficiency and reliability.

Determine the work your compressor will do

Here are some questions that you will want to answer before buying an air compressor.

Where will you be using your air compressor?

The first thing you will need to choose is between performance and portability. The reason is that the wheeled design has less power than most stationary units. So If you’d like to roll it to different areas in your shop or building or transport it to different locations, you might need to sacrifice some performance to achieve it. Nevertheless, it is very important to make sure that the performance of the air compressor you choose covers your needs. If your compressor is too small, the air compressor will run more frequently, use more electricity and wear out quickly.

Is there a dependable electrical supply?

Another very important thing you need to take into consideration is your electrical supply. Because the fluctuations in power delivered can cause severe damage to your air compressor. Most manufacturers will also deem this as improper use and will void any warranty on the compressor. If that’s your case, you might want to choose a unit that works with gas instead.

What tools do you want to use with your compressor?

Determine what tools you will be using with your air compressor at one time. All air tools have an average CFM rating, so look at it to ensure you get an air compressor that will provide you with the power you need.

What is the maximum operating pressure (PSI) you’ll require?

To answer this question, you will need to check the specifications of the air tools you will be using, for example, if a blowgun with 2.5 CFM at 90 PSI is your tool with the highest requirements then you would want to get an air compressor with a minimum 90PSI rating.

Knowing this also will help you choose between a single-stage or two-stage design among piston models. Two-stage models will have a higher PSI than single-stage compressors since the second compression of air will increase the PSI.

What is the maximum air volume (CFM) you’ll require?

Pneumatic tools require different levels of air volume to operate properly. So it’s vital to be sure that your air compressor can give you the CFM needed, especially if you have more than one airline from your air compressor. In those cases be sure to get your minimum CFM rating from all tools that could be used at one time, so you don’t underestimate your airpower needs.

We recommend increasing the CFM total you get from the highest-rated tool (or the total number of highly-rated tools that could be used at the same time) by 30 to 50 percent to ensure that you have adequate performance under the most demanding applications you may encounter.

For example, if you had two airlines and your highly rated tools that could run at the same time are an impact wrench with a CFM of 7 and a spray gun with a CFM of 6 then you’d want to look for an air compressor that can deliver in the range of 16-20 CFM

7cfm+6cfm=13cfm

13×1.3 (30%)=16.9

13×1.5(50%)=19.5

What size tank will you need?

As a general recommendation, we would suggest you get the largest, practical-size tank you can afford within your CFM and PSI requirements.

The reason we recommend this is that it can affect the operation of some tools, especially the ones that require air continuously, like sanders and grinders.

Also if the tank is too small, it will strain the motor of your air compressor, because it will have to run more often than it was designed for, to keep your tank full, shortening the life of the compressor. The longer the air compressor can go without switching on again, the less strain on the motor and the better return you’ll get on your investment.

Finally, if your tank is too small for your needs, the compressed air might be used before it has the time to cool down. As a result, condensation will build up in your airlines damaging your tools as well as your compressor. Larger tanks and other features such as intercoolers and aftercoolers allow the air to be cooled before flowing through the airline.

What horsepower (HP) is needed for the motor of your air compressor?

The HP of the air compressor doesn’t affect the performance of the tools or the air delivery directly, but it’s an important factor to take into consideration. The HP is a rating for the motor or engine’s power. The engine creates the compressed air and delivers it into the tank. The higher the HP, the more efficiently the air tank will be filled, which reduces the recovery time.

Air compressor features explained

After answering all these questions probably you have a good idea of what air compressor to buy. Nevertheless, some of the features might still be unclear, making it hard to decide. Below are some of the common air compressor features with a brief explanation.

Belt drive or direct drive. The motor of most rotary screw-type air compressors can be either belt-driven or direct-driven. Direct drive models have the motor directly connected to the crankshaft of the compressor. They can operate at lower temperatures and high-energy efficiency but are usually more expensive, difficult to maintain, and noisier.

Belt-drive compressors have a belt that connects the motor to the air compressor pump with pulleys. They offer greater flexibility to adjust the airflow and pressure as needed. They are also less expensive to purchase and are easier to install and maintain. These models are not ideal for severe temperatures or harsh conditions.

Auto start/stop or continuous speed or dual control. These features deal with the operation of compressed air production. Auto start/stop means the air compressor is set with a pressure switch that automatically turns the motor on when the air is needed and turns it off when the tank is full. Continuous speed is for air compressors that constantly run and will adjust the airflow as the demand requires. Dual control offers the option to set the air compressor to either run in auto start/stop mode or continuous mode as needed.

Vertical or horizontal tanks. Vertical tanks take up less space, which could be a deciding factor for you. The biggest benefit of horizontal tanks is portability.

ASME parts. These parts or components have met the standards and codes set by the American Society of Mechanical Engineers.

Low oil protection. The air compressor is equipped with technology to shut itself down in the event of low oil levels, preventing downtime and expensive repairs due to low fluid levels.

Ball-valve tank drain allows safe and easy draining with a simple quarter turn in the tank for frequent removal of any moisture.

Need more help choosing the right air compressor?

We have sales engineers who can provide recommendations on the right compressor to use based on your circumstances. Understanding your budget and timing to bring in a compressor (especially with lead-time delays) can help, too.

Contact Elevated with any other questions you have about buying an air compressor or locate one of our sales and service reps near you.

Monthly air compressor maintenance

Written by Tami Matthews on February 6, 2020. Posted in Air compressors, Automotive, Compressed Air, General, Industrial. Leave a Comment

Maximize compressor efficiency and lifespan by performing monthly preventive maintenance checks. Or hire a certified service technician to handle your compressed air system to ensure you’re getting expert support.

Follow these 6 monthly steps to ensure your Kaeser compressed air system is running efficiently and properly.

1) Check belt tension

To make sure that your air compressor will function properly, check that the tension of the belt drives is optimal to avoid slipping and premature wear of the drive belts and pulleys.

2) Check the cooling oil level

Most air compressors require a certain amount of oil circulating throughout their system. If this amount is not enough, the internal temperature will rise, which will ultimately lead to the compressor overheating and shutting down. If the problem is not solved promptly, it will result in premature wear.

3) Cooler: check the filter mat

The filter mat helps to keep the cooler clean. If the filter mats are clogged, inadequate cooling of the components could result

4) Control cabinet: check the filter mat

A filter mat is placed behind every ventilation grille. Filter mats protect the control cabinet from the ingress of dirt. If the filter mats are clogged, clean or replace the filter mats.

5) Check the condensate drain

Condensation is an inevitable result of air compression. If the condensed liquid is not adequately drained off at all collection points, it will cause corrosion that will damage the compressed air system.

6) Log all maintenance tasks completed

Documenting all the maintenance work will determine if there is any deviation from the OEM’s recommendation. Remember: That only qualified and authorized personnel should be allowed to perform any maintenance task.

Elevated can help with preventive maintenance

Some compressors come from Elevated with a warranty, guaranteeing we’ll service your compressor. For others, you’ll need to ensure you get on a maintenance schedule. Luckily, Elevated makes it easy. When we sell you a compressor, we provide a maintenance schedule based on the make and model as well as the environment and runtime expected or experienced on your compressor. Plus, our team is certified.

Compressor life cycle cost

Written by Tami Matthews on January 27, 2020. Posted in Air compressors, Compressed Air, Compressed air systems. Leave a Comment

Many factors go into the total cost of investing in a compressed air system. Focusing on just the upfront expenses can hurt your company and cost thousands. For example, energy usage alone can outpace the initial price of the compressor in just a couple of years. These factors make up the overall return on investment (ROI) you’re getting when you think of budget costs.

Here are 4 categories to consider when thinking about the life cycle cost of your compressed air system. It’s especially important to consider as the purchase price is only a fraction of the overall cost — over the years — of your machine.

Purchase price

The initial cost of the compressor can vary greatly. Larger manufacturers may use more expensive equipment to reduce reliability issues and increase productivity. Getting the right machine for your environment is crucial – the durability needed, correct horsepower, etc. (The right vendor will never give you more horsepower than needed.)

Compressor parts and service

Getting a brand that’s known for its reliability is a good start. Some brands are definitely more durable than others. These high-performance machines will cost you less, generally, in parts and service.

But service is an important component, especially getting service in a timely manner. Vendors who are available 24/7, 365 days a year that you can rely on when you need them is crucial. You also want certified technicians who are experienced with your compressor, no matter the brand.

The most expensive issue comes from not servicing your compressor at all. It can cause additional wear and tear on your compressor, increasing operating costs (more parts and service). Worse, it can also potentially shut down your facility, halting production. (We’ve seen this happen!)

Energy costs

It’s no secret that industrial air compressors consume a lot of energy. Many modern compressors are highly efficient and will produce much more air for less money. Kaeser, for example, is known for its high performance. Considering energy is the largest cost, this should be a primary focus when purchasing a new compressed air system.

The right vendor will help you find ways to save money, even if you’re purchasing the most expensive brand.

Additional factors

Additional factors include load/unload cycle time, air leak losses, non-production operation, system pressure set points, and individual components that can make a difference in the cost of your compressor’s operation.

Elevated is there for the lifecycle of your compressor

Elevated has certified technicians available 24/7. Parts are in stock. We offer ultrasonic leak detections, air audits, and scheduled maintenance to save you time and money. In other words, we work to eliminate any downtime. Let us make recommendations on your compressed air system or service needed.