While we don’t sell, install, or service air compressors, EXAIR Intelligent Compressed Air Products run on compressed air, so helping you get the most out of your compressed air system is important to us. Today, we’re starting where it all begins: the compressor room.
Some of the mistakes that are commonly made in the compressor room are by design, and others are operational. My colleague Tyler Daniel wrote a great blog on design considerations recently, so I’m going to focus on the operational aspects, which include maintenance…and maybe some minor design stuff:
- Poor ventilation: Air compressors get hot. They’ve got a lot of moving parts, and many of those parts are moving under a great amount of force (pressure is literally defined as force per unit area), and at a high rate of speed. Add in the heat of compression (it takes energy to compress air, and that energy has to go somewhere, something another colleague, John Ball, explains here), to all that friction and you come up with a TREMENDOUS amount of heat. An industry thumbrule, in fact, states that over 2500 Btu/hr of heat is generated, PER HORSEPOWER, by a typical industrial air compressor. If the compressor room isn’t big enough, you’ll need an exhaust fan capable of removing all that heat.
- Lack of filtration: Take a good, full breath in through your nose, right now. Did you smell anything unpleasant or irritating? I hope not…clean air is a “must” for your lungs (and the rest of your body), and the same is true for your air compressor (and the rest of your compressed air system). Keeping up with the maintenance on the intake filter is literally “starting where it all begins”…from the 1st paragraph.
- Not removing moisture: Water & water vapor will have an adverse effect on many components of your compressed air system: it’ll cause rust in iron pipes, damage the seals in air cylinders, motors, tools, etc., and if you use it for blow off or conveying, it’ll contaminate your product. We’ve written…again and again…about the importance of dryers, and which type might be best for you.
- Tolerating leaks: The compressor room is loud, so leaks are going to be pretty big before you can hear them. And to add insult to injury, the vibration of a running compressor makes the compressor room a prime location for them to occur. Even one small leak that you couldn’t hear in a quieter area will cost you over $100 over the course of the year, and maybe only take minutes to fix. Good news is, even if you can’t hear them, they ALL make an ultrasonic signature, and we’ve got something for that.
- Ignoring maintenance. If you don’t schedule planned maintenance, your equipment will schedule corrective maintenance for you…oftentimes at greater expense, and with no regard to your schedule.
- Moving metal parts that make metal-to-metal contact (or that have very tight spacing tolerances) HAVE to be lubricated properly. If you run low on oil, or let it get dirty or emulsified, severe damage will follow. Keeping an eye on the oil level, and changing it (and the filter) at the manufacturer’s recommended intervals, is critical.
- Emulsified or otherwise contaminated oil can damage seals, gaskets, and o-rings. That’s obviously a big problem for the compressor, and when it carries over into the header, it’s a big problem for pneumatic cylinders & tools as well. Periodic sampling & analysis of your oil can provide timely notice of issues that can be corrected before they become catastrophic failures.
- Depending on the type of compressor, and its drive system, the manufacturer’s maintenance recommendations may also include:
- Checking coupling or belt alignment of the drive.
- Checking bolts for loosening due to vibration (a “necessary evil”, especially with reciprocating compressors).
- Adjusting the pistons to maintain valve plate clearance.
- Tightening or replacing the mounts & vibration pads.
If you’d like to find out more about how EXAIR Corporation can help you get the most out of your compressed air system, give me a call.
Russ Bowman, CCASS