Compressed Air Archives

Get your compressors ready after the holidays

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.