Compressed Air Archives

Custom-engineered air compressor solutions

Written by Tami Matthews on January 3, 2020. Posted in Compressed Air, Compressed Air, Compressed air systems. Leave a Comment

Custom-engineered solutions are designed for the most demanding installations and harshest of environments. These complete systems are exceptionally reliable, simple to maintain, and have superior energy efficiency, no matter what the installation limitations may be. Space, weather, and accessibility constraints are eliminated with reduced construction, installation, and operating costs.

These custom-engineered solutions are completely turnkey, reducing onsite planning and installation costs, which save you time since there is no need to build a new compressor room or add onto an existing building. They can even be built to be moved from one site to another. Every component is selected with your installation and location in mind.

Plan and design

Whether you call it planning, designing, or even engineering, we start by partnering with you to determine what you need. We’ll ask a series of questions based on your environment to start spec-ing out the best solutions, including your enclosure or skid configuration. We’ll use that information to begin designing the necessary wiring, and power distribution to a single service connection.

Then, we add thermostatically controlled inlet louvers and exhaust ducting as well as supplemental heating as needed for reliable operation nearly anywhere on the planet. Based on your system requirement, we select the right compressors to meet your pressure and flow needs and mount them to the floor with vibration isolators. Air treatment comes next and includes dryers, filters, receiver tanks, and condensate management. We have options for every grade of compressed air quality from the shop to the instrument to oil-free and even breathing air.

Prepare and deliver

After that, we run piping throughout the package to a single connection that ties the entire system directly to your plant. To efficiently control air output and remotely monitor the system for preventative maintenance, planning, and troubleshooting we install Kaeser’s Sigma Air Manager 4.0. (SAM 4.0) also constantly measures and reports energy consumption. Your system will give you complete access for maintenance and repair.

Finally, we deliver your customized air system to you.

Don’t worry about site preparation, just provide a level surface capable of holding the weight of the system. Whether you need compressed air, blower, or vacuum systems give us your spec and we’ll deliver a complete system faster than you can budget, plan, permit, and build a new building or expand an existing facility.

Elevate works to design these custom-engineered solutions

We have experts who help design these custom-engineered solutions, working with Kaeser to get them to your location whether you’re in South Carolina, Ohio, or Michigan. We also provide services (such as preventive maintenance and emergency repairs) as well as traditional compressed air systems. When it comes to compressed air systems, we do it all.

common compressed air maintenance mistakes

7 common air compressor maintenance mistakes

Written by Tami Matthews on December 2, 2019. Posted in Air compressors, Compressed Air, Compressed Air, Featured. Leave a Comment

When it comes to your business, compressed air represents a significant operating cost. Between the compressor, system, installation, and maintenance, your compressed air system can cost tens of thousands or hundreds of thousands of dollars (depending on the size of your facility). But did you know you may be wasting money through common air compressor maintenance mistakes?

Mistake 1: not purchasing a cost-efficient, easy-to-maintain machine

A lot of factors go into the entire cost of compressed air systems, not just the initial price of the compressor. These factors include the lifespan of the compressor, maintenance costs, frequency of maintenance, and energy usage. These costs will far outweigh the price of the compressor, so it’s important to purchase a high-quality and reliable compressor that is easy to maintain.

Mistake 2: air leaks

Air leaks, whether you’re ignoring it or don’t know it, can cost you thousands. Your compressed air system will work overtime to keep up with demand, increasing wear and tear on your compressor as well as energy costs. Ensure you do not have air leaks by performing routine leak audits.

Mistake 3: infrequent inspections

Your compressor receives scheduled maintenance, but maintenance may not cover everything that happens to your compressor. Wear and tear, dirt, and broader maintenance needs may be causing your compressor to run longer to meet air demand. (Your expert service technicians should be recommending how often your compressor needs maintenance and other audits based on your environment and runtime.)

By performing inspections, variables such as temperature, humidity, dust, and wear and tear on your compressor will be managed which will improve efficiency.

Mistake 4: compressed air pipe

Certain piping materials can promote contamination, leaks, and pressure drops. Regardless of the material, the pipe will eventually need to be cleaned of debris and eventually replaced. Failure to clear this debris can lead to inefficiencies and additional issues for air tools and your compressor. SmartPipe+ by Kaeser does not promote contamination which increases the lifespan of the piping and system.

Mistake 5: air demand

It is very common for companies to overestimate or underestimate air demand. Often times this underestimation leads to needing new equipment. By performing a demand analysis you’ll able to identify the exact amount of air you need even across different departments. If your equipment has already been purchased and is not meeting demand, oftentimes you do not need to replace your compressor. Upgrading tank size and reducing inefficiencies with an air management system will provide additional air at a lower cost, helping you meet the required demand.

Mistake 6: training staff

At some facilities, machine operators are less experienced and less knowledgeable of the compressed air system than management. Providing additional training to operators will help provide more air at a lower price, help spot maintenance issues before they arise and reduce stress on your compressor.

Mistake 7: data collection

Being able to spot issues early will prevent issues from becoming worse, downtime repairing the machine, and time spent figuring out what went wrong in the first place. Collecting data on your compressed air system with help identify future issues. Once again having well-trained staff and collecting data will help identify potential issues before they get worse.

Elevated doesn’t make maintenance mistakes

Getting Elevated service means you won’t have these common mistakes. Instead, our team of experts will do everything necessary to keep your compressed air system running at peak efficiency. Our team is certified and can train your personnel as well as deliver just about any data you need. Plus, we work with energy companies to save you money. For an air demand analysis (ADA), ultrasonic leak audit, SmartPipe+ information, or maintenance, contact our team. We’d love to help!

Kaeser’s SmartPipe

Written by Tami Matthews on October 17, 2019. Posted in Compressed Air, Compressed air systems. Leave a Comment

Whether you know it as Kaeser’s SmartPipe+ or SmartPipe it’s the gold standard for piping in the compressed air systems industry. It’s why Elevated Industrial Solutions is an authorized vendor, installing this pipe throughout South Carolina, Michigan, and Ohio.

What is SmartPipe?

It’s the pipe used for air flow in compressed air systems, created by Kaeser. Installers (whether it’s your team or a vendor) will add that pipe when you create or expand your compressed air system.

Kaeser’s SmartPipe is available in sizes up to 8″ pipe diameter in aluminum, and available in stainless steel in 10″ pipe diameter. Connectors, to connect pipe, ensure it’s also leak-free.

Materials

Kaeser indicates SmartPipe+ components are nonflammable and 100% recyclable. The piping is constructed of alloy aluminum and it’s blue, powder-coated on the outside. Pipe, fittings, and valves are
guaranteed silicone free.

And a plug here – please don’t ever use PVC for compressed air installations. It’s a safety hazard.

Benefits

SmartPipe is popular with plant managers, facility managers, installers, and compressed air service technicians because it comes in a variety of sizes, is faster to install, and has lower long-term operating costs associated with it. Because of this flexibility, it works for small and large facilities. Plus, because SmartPipe has no rough surfaces or interior restrictions that accumulate contaminants, the airflow and quality of this pipe tend to be better. So, the higher the air quality standards your facility has, the more likely compressed air installation experts will be to recommend SmartPipe.

Kaeser lists the benefits of SmartPipe (at a glance) as the following:

Installs faster than other common piping
No specialized trades needed
No threading, welding, or brazing pipe
Simple mounting and connecting hardware
Can connect to existing systems with other pipe types
Easy to add on to or disassemble for your changing needs
Compression-style valves and fittings 2 1/2″ and below
Bolt-on style fittings 3″ and above
10-year warranty
ISO 4414/EN983 compliant

Read the Tech Specs

Elevated can help install SmartPipe

We have installers at each of our compressed air system facilities – in South Carolina, Ohio, and Michigan. If you want to learn more about SmartPipe or need an installer, we have an expert team who can do it. Our installations are turnkey, where we plan ahead of time with you, communicate along the way, and manage the project. That way, you’re focusing on the things you need to stay operational while we handle ensuring your compressed air system is up and running perfectly – on time and on budget.

Get your compressors ready after the holidays

Written by Kaeser Compressors on January 8, 2015. Posted in Compressed Air, Compressed Air, General, Industrial, Manufacturing, Metalworking, Signage, Woodworking. Leave a Comment

The holidays are over and for many plants that mean seasonal shutdowns or lower production demands are also a thing of the past. While everyone is gearing up to start this year with gusto, don’t forget to stop and take a breath before bringing your equipment back online.

coming back from winter holidays presents some challenges to air compressors

Here is a short list of points to check on your compressors to make sure they are ready to get back to work. The first three tips are important to check after any shutdown period. The last two apply to compressors that have been offline for an extended period of time.

Check the temp

Check the ambient temperature. If it is below 40°F, the compressor will need either a cabinet or ambient heater in order to start safely. If it’s too cold, the lubricant will not circulate through the unit properly, causing a cold start. Cold starts can cause unnecessary wear and tear on the motor and airend and sometimes even catastrophic failure.

Grease the motor bearings

Make sure the motor bearings are properly greased. Some compressors have external lubrication points which makes re-greasing easy. Otherwise, be sure to check the grease zerks (fittings) on the rear and front of the motor.

Valve off and start slowly

If you have any filtration in your compressed air system, valve off the compressors before starting and then slowly open the valve to the system. This will prevent the filter from being blasted with high-velocity air—which can cause damage to the filter elements and can also cause contaminants to enter the compressed air stream. To prevent this from happening in the future, consider installing an air main charging valve.

Prime with oil

If you have equipment that has been offline for an extended period of time (6-8 months), the airend will need to be primed with oil. This is typically done by removing the inlet valve and pouring oil directly into the airend. Check your service manual and consult the compressor manufacturer for specifics on the type and amount of oil to use. Don’t forget that during periods of shut down it is good practice to run the unit once a week for a least 30 minutes. This will help prevent corrosion—in particular on the airend and in the fluid separator tank.

Additional help for your compressors

For variable speed drive compressors that have been sitting for more than 12 months, they will need to have their capacitors re-formed before start-up to prevent severe damage to the electrical panel. Contact the manufacturer for help.

7 deadly sins of compressed air

Written by Kaeser Compressors on December 2, 2014. Posted in Compressed Air, Compressed Air, Compressed Air, General, Industrial, Manufacturing. Leave a Comment

When putting together a compressed air system, temptation is all around you. You want the best system, but having the best doesn’t mean grabbing whatever looks good. Build a system that meets your needs, not your wants. Focusing on your system’s needs and avoiding these seven deadly sins will keep you from needing to confess when your utility bill arrives.

1. Lust

Don’t lust after a variable-frequency drive compressor. Many utilities offer rebates for a VFD, but they are not always the best solution. Sellers often make blanket claims of huge savings, but if your compressor will run fully loaded more than 75% of the time, savings are very limited. Keep in mind that they are more expensive and have drive losses which need to be considered. If you have an application where the load varies between 40-80% of compressor capacity, then a VFD makes sense. Do the math before you buy one to make sure your system will benefit from using this technology.

2. Gluttony

Don’t be a glutton with your air treatment. Dry air sounds great, but there is such a thing as overkill. And overkill is expensive. This is especially true for larger, industrial compressed air systems supplying multiple processes. Take a hard look at your system and determine what level of filtration and dew point each segment needs. If you need a desiccant dryer for only part of your process, then size it for that part only. You’ll not only save by buying smaller capacity equipment, but also on pressure drop, air loss, and energy.

3. Greed

Don’t be greedy for air by oversizing your system. Bigger is not always better. Oversizing means you are paying for more energy than you need to. In some cases, if the compressor is too large for the demand, it may not come up to temperature, causing excess condensation. The machine will cycle on and off, which puts unnecessary wear and tear on the motor, valves, and seals. Figure out the amount of air you need for your system and select a compressor that will meet it. And, if you determine your load varies widely, consider using a VFD.

4. Sloth

Don’t be lazy attending to leaks. Leaks occur and reoccur and need to be continually monitored and repaired. The US Department of Energy estimates that as much as half of all compressed air is wasted, with an average of 25% lost to leaks. I’ve seen annual leak losses range from $3,000 for smaller systems and up to $600,000 for larger ones. Check for leaks and repair them once you find them. You’ll be putting money back on your bottom line every time you do.

5. Wrath

Beware the wrath of poorly controlled compressors. If you notice pressure spikes, disruptions in your air supply, or compressors cycling on and off, that means the compressors need to be controlled with a master system controller. A master controller monitors system demand and selects the right combination of units to meet it in the most efficient way possible. Don’t leave them to their own devices. Keep them under control.

6. Envy

Don’t be envious of other plants with the newest technology simply because it is new. Choose what is best for your application. Some installations are using the latest in remote monitoring and taking advantage of cloud-based solutions. Good for them. Don’t let the latest and greatest distract you from your system’s needs. Stay focused on what is right for your installation.

7. Pride

Don’t be so proud of your system that you fail to monitor its changing needs. You’ve worked hard to put together an efficient system and in the process, you’ve saved a lot of money in energy costs. Don’t rest on your laurels. A good way to stay on top of your system is by doing an annual compressed air audit. This will help you see trends and react to any changes that might be happening in your demand profile.

When putting together a compressed air system, temptation is all around you. You want the best system, but having the best doesn’t mean grabbing whatever looks good. Build a system that meets your needs, not your wants. Focusing on your system’s needs and avoiding these seven deadly sins will keep you from needing to confess when your utility bill arrives.

Embrace humility regarding your compressed air system

At Elevated Industrial Solutions, we have the expertise to help your air compressors or compressed air system reach peak efficiency. With air audits, maintenance, and a host of other tools, we can evaluate how to improve your system or whether it needs improvement.