Tag: air compressor maintenance

Maintaining Your Compressed Air System

Published on by Jordan T ShouseLeave a comment

A poorly maintained compressed air system wastes energy, increases operational costs, and risks unexpected failures. Common issues include leaks, pressure loss, contamination (like moisture or oil). Studies suggest that up to 30% of compressed air is lost to leaks in an average system, while contaminants can damage downstream equipment or spoil products. Routine maintenance tackles these problems head-on, ensuring reliability and cost-effectiveness.

Key Maintenance Practices

  1. Monitor and Replace Intake Filters
    The air compressor draws in ambient air, which is often laden with dust, dirt, and water vapor. The intake filter is your first line of defense, protecting the compressor’s internals from wear. Over time, debris buildup increases pressure drop, forcing the compressor to work harder and reducing efficiency. Check the filter regularly—typically monthly—and replace it when the pressure differential exceeds the manufacturer’s recommended limit (often around 5-10 psid) or at least annually.
  2. Manage Moisture with Dryers and Drains
    Water vapor in compressed air condenses as it cools, leading to rust in pipes, damage to pneumatic tools, and quality issues in applications like painting or food processing. A dryer—whether refrigerated, desiccant, or membrane—is crucial. For smaller systems or point-of-use applications, inspect and clean dryer coils or replace desiccants as per the manual (usually every 1–2 years). Automatic drain traps should also be checked quarterly to ensure they’re removing condensate effectively.
  3. Audit for Leaks
    Leaks are silent efficiency killers. Even a small 1/8-inch hole at 100 psig can cost over $1,000 annually in wasted energy. Conduct a leak audit every 6–12 months using an ultrasonic leak detector. Focus on fittings, valves, and older piping sections, where vibration or corrosion often takes a toll. Repairing leaks promptly can save 20-30% on energy costs. EXAIR’s 9207 can help with this task.
  4. Optimize Pressure Settings
    Over-pressurizing the system to compensate for downstream losses wastes energy—every 2 psig increase adds about 1% to power consumption. Use pressure regulators at the point of use to deliver only what’s needed. Monitor system pressure monthly to ensure it aligns with demand, adjusting as equipment or processes change.

How EXAIR Products Enhance Maintenance and Efficiency

EXAIR’s Intelligent Compressed Air Products are engineered to complement these maintenance practices. Here’s how some specific items can help:

  • Ultrasonic Leak Detector (Model 9207)
    Pinpointing leaks in a noisy compressor room can feel like finding a needle in a haystack. EXAIR’s Ultrasonic Leak Detector uses sound wave detection to identify leaks with precision, even in high-decibel environments. Regular use during audits—say, every 6 months—helps maintenance teams catch and fix leaks early, slashing energy waste. Its portability and ease of use make it a must-have for proactive upkeep.
  • Automatic Drain Filter Separators
    Moisture and particulates in the air stream can clog tools or ruin products. EXAIR’s Automatic Drain Filter Separators (available in various port sizes, e.g., 1/4″ to 1-1/2″ NPT) feature a 5-micron filter and centrifugal separation to remove bulk liquids and debris. The auto-drain feature expels collected water without manual intervention, reducing maintenance time. Replace the filter element annually or when the pressure drop hits 10 psid to keep air quality high and downstream equipment safe.
  • Oil Removal Filter
    For applications requiring ultra-clean air—like electronics assembly or pharmaceutical production—the Oil Removal Filter takes filtration further. With a 0.03-micron coalescing element, it traps oil vapor and fine particles, coalescing liquids for gravity drainage. Pair it with a Filter Separator for a two-stage approach, and replace elements yearly to maintain performance. This ensures sensitive equipment stays contaminant-free with minimal upkeep.
  • Pressure Regulators
    Excessive pressure at the point of use is a common efficiency drain. EXAIR’s Pressure Regulators (included in many product kits) let you dial in the exact pressure needed—e.g., dropping from 100 psig to 80 psig can cut air usage by nearly 20%. Install them downstream of filters for accurate control, and check settings quarterly to match evolving process demands. They’re a simple, maintenance-free way to optimize demand-side efficiency.

A well-maintained compressed air system isn’t just about avoiding breakdowns—it’s about maximizing efficiency and minimizing costs. By pairing routine checks with EXAIR’s engineered solutions, you can tackle leaks, contamination, and over-pressurization head-on. The result? A system that runs smoother, lasts longer, and keeps your energy bill in check. Whether you’re blowing off parts, powering tools, or cooling processes, these strategies and tools ensure your compressed air works as hard as you do.

For more insights or help selecting the right EXAIR products for your system, reach out to an Application Engineer. Let’s keep your air flowing intelligently!

Jordan Shouse
Application Engineer

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Air Compressors: Maintenance and Optimization

Published on by John BallLeave a comment

In one of my previous jobs, I was responsible for the operation of the facility, and one of my biggest jobs was the operation of our air compressor.  Like with many industries, the compressor system is the lifeblood of the company.  If the compressor fails, the whole facility will stop.  In this blog, I will share some maintenance items and schedules for air compressors.

Because the cost to make compressed air is expensive, the compressed air system is considered to be a fourth utility.  With such an important investment, you would like to keep it operating as long and efficiently as possible.  To do this, it is recommended to get your air compressor a “checkup” every so often.  I will cover some important items to check.  Depending on the size and type, some items may or may not apply.  But please, always check with the manufacturer of your air compressor.

Intake filter: The intake filter is used to clean the air that is being drawn into the air compressor.  Better filtration results in less debris getting into your system.  Particles can damage the air pump mechanisms over time as well as plug filters and heat exchangers downstream.  If they are not properly monitored and cleaned, the air flow can be restricted.  This will cause the compressor motor to operate harder and hotter.

Compressor Oil: This would be for flooded screws and reciprocating compressors that use oil to lubricate the bearings and sleeves in the air pump.  Most systems have an oil sight to verify levels.  The oil can also be checked for acidity, which will tell the degree at which the oil is breaking down.  Just like the motor oil in your car, you will have to replace it after so many hours of operation.

Belts & couplings: These items transmit the power from the motor to the air pump.  Check their alignment, condition, and tension (belts only) as specified by the manufacturer.  You should have spares on hand in case of any failures.

Electric Motors: A mechanical device that turns electric energy into rotational energy.  It is the main component that uses a lot of energy to make compressed air.  So, some checks are required to foresee any potential issues and major shutdowns.  For the windings inside, the resistance should be measured with a multi-meter, and it should fall within the motor’s specifications.  Another check should be on the start capacitor.  The start capacitor stores energy to give the motor a powerful boost to get it turning.  One other item is the centrifugal switch.  Just like the name states, it will disconnect the start capacitor when the motor starts spinning.  One other item for large electric motors is the phase converter.  These are typically capacitors, and they are designed to keep the direction of three-phase motors going in the correct rotation.  Both types of capacitors can be checked with a multi-meter.

Air/Oil Separators: This filter removes as much oil from the compressed air before it travels downstream.  It returns the oil back to the sump of the air compressor.  If the Air/Oil Separator builds too much pressure drop, excess oil can travel downstream.  Not only will the air pump lose the required oil level, but it will affect the performance of downstream parts like air dryers and after-coolers.  Also, the pressure drop is a waste and can rob your air system of workable energy. 

Internal filters: Many air compressors will come with an attached refrigerated air dryer.   With this type of air compressor, they will place coalescing filters to remove any residual oil.  These filters should be checked for pressure drop.  If the pressure drop gets too high, then it will rob your compressed air system of pressure, and you will not get the required performance.  Some filters come with a pressure drop indicator which can help you to determine the time to change the element.   

Unloader valve: When the air compressor unloads, this valve helps to remove any of the compressed air that is trapped in the cavity.  When the air compressor restarts, it does not have to “work” against this air pressure.  If they do not fully unload, the air compressor will have to work harder to start, wasting energy.

Preventative maintenance is very important.  As for a schedule, I created a rough sequence to check, change, or clean certain items that are important to your air compressor.  You should also check with your local compressor representative for a more detailed maintenance schedule.

Daily:

  • After stopping, remove any condensate from the receiver tank.
  • Check the oil level.

Monthly:

  • Inspect the cooling fins on the air pumps.  Clean if necessary
  • Inspect the oil cooler. Clean if necessary

Quarterly:

  • Inspect the inlet air filter.  Clean or replace if necessary.
  • Check the belt for tension and cracks.  Tighten or replace.
  • Check differential pressure indicators on outlet compressed air filters.
  • Ohm check on the electric motor

Yearly:

  • Replace Air Inlet Filter
  • Replace the air-oil separator
  • Test safety valves and un-loader valve
  • Replace compressed air filters
  • Change oil
  • Grease bearings if required

Keeping your air compressor running optimally is very important for pneumatic operations.  But there is much more than an air compressor in your system.  To help, there are steps that can be used on the demand side.  EXAIR created a Webinar – “Optimizing Your Compressed Air System In 6 Simple Steps”.  With this combination, you can keep a healthy compressed air system.  You can always contact an Application Engineer at EXAIR to see how much money can be saved by energy reduction, safety, and monitoring.  

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Image courtesy of Compressor1 – Creative commons license

General Guidelines for Maintaining Your Compressed Air System

Published on by Tyler DanielLeave a comment

Performing regular maintenance on your compressor system helps to keep everything operating in peak condition and ensures you’re not wasting unnecessary energy. Just as you perform regular routine maintenance on your vehicles, a compressed air system also needs a little TLC to keep things running smoothly. Neglected maintenance items can lead to increased energy costs, high operating temperatures, and coolant carryover. Much of these issues can be eliminated simply by performing routine maintenance on the components of the system.

According to the Best Practices for Compressed Air Systems by the Compressed Air Challenge (1), components within the system that need maintained include: the compressor, heat exchanger surfaces, lubricant, lubricant filter, air inlet filter, motors, belts, and air/oil separators.  

The compressor and all surfaces of the heat exchanger need to be kept clean and free of contaminants. When these components are dirty, compressor efficiency is greatly reduced. Any fans and water pumps should also be regularly inspected to ensure that they’re functioning properly. The air inlet filter and piping should also be cleaned. The quality of the air in the facility will impact the frequency, refer to the manufacturer’s specifications for ideal intervals for performing scheduled maintenance.

The lubricant and lubricant filter must also be changed per manufacturer’s specifications. Old coolant can become corrosive, impacting useful life and damaging other components while reducing efficiency. While synthetic lubricants are available that have an extended life compared to standard coolants, this does not extend the life of the lubricant filter itself.

Belts should be routinely checked for tension (every 400 hours is reasonable) to alleviate bearing wear. Belts will stretch and wear under normal operation and must be adjusted periodically. It’s a good practice to keep some spares on hand in the event of a failure.

End use filters, regulators, and lubricators should also be periodically inspected and filter elements replaced as needed. If left unchecked, a clogged filter will increase pressure drop. This can cause both a reduction of pressure at the point of use or an increase in the pressure supplied by the compressor, leading to increased energy costs.

Another often overlooked maintenance item is leak detection and repair. Leaks contribute to unnecessary air usage, pressure drop, and increased energy costs. EXAIR offers an Ultrasonic Leak Detector that can be used to identify the leaks in your system and allow you to make the necessary repairs.

EXAIR Ultrasonic Leak Detector

In order to keep your system running in peak condition, regular maintenance is critical. By paying close attention to the manufacture’s recommendations, and implementing a regular maintenance schedule, you can ensure you’re getting the most out of your system components.

Tyler Daniel, CCASS

Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

(1) Scales, W. (2021). Best Practices for Compressed Air Systems : Second Edition (2nd ed.). The Compressed Air Challenge,.

Compressor system image courtesy of Compressor1 via Flickr Creative Commons License Attribution-NoDerivs 2.0 Generic

A-Z of Compressed Air Systems & Maintenance

Published on by bdwagesLeave a comment
Pic courtesy of Johan55 Pixaby License

To fully appreciate how impactful a properly functioning air compressor system is to your bottom line, it is foremost important to fully understand how much your compressed air costs. Compressed air is a self generated utility within your facility that is a top 3-4 utility expense for your company. This fact is often overlooked or misunderstood, because the expense is primarily linked to the electric and or gas bill. This can be a costly oversite. You will see an example below where a single common maintenance issue causes a 4psi reduction in performance and resulted in $1265 in additional annual cost to that company. Imagine when/if there are multiple issues…

In order to calculate the compressed air cost, some companies use an educated guess of @$0.25 per 1000 cubic feet of compressed air consumed, and others are more precise. The U.S. department of Energy performed an energy saving study in 2004 and they show a precise way to calculate your compressed air cost. Here is their sample calculation:

“Compressed air is one of the most expensive sources of energy in a plant. The overall efficiency of a typical compressed air system can be as low as 10%-15%. For example, to operate a 1-horsepower (hp) air motor at 100 pounds per square inch gauge (psig), approximately 7-8 hp of electrical power is supplied to the air compressor. To calculate the cost of compressed air in your facility, use the formula shown below:

Cost ($) = (bhp) x (0.746) x (# of operating hours) x ($/kWh) x (% time) x (% full-load bhp) ÷ Motor Efficiency
Where:
bhp = Motor full-load horsepower (frequently higher than the motor nameplate horsepower—check equipment specification)
0.746 = conversion between hp and kW
Percent time = percentage of time running at this operating level
Percent full-load bhp = bhp as percentage of full-load bhp at this operating level
Motor efficiency = motor efficiency at this operating level
Example:
A typical manufacturing facility has a 200-hp compressor (which requires 215 bhp) that operates for 6800 hours annually. It is fully loaded 85% of the time (motor efficiency = .95) and unloaded the rest of the time (25% full-load bhp and motor efficiency = .90). The aggregate electric rate is 0.05/kWh.
Cost when fully loaded =
(215 bhp) x (0.746) x (6800 hrs) x ($0.05/kWh) x (0.85) x (1.0) = $48,792
.95
Cost when unloaded =
(215 bhp) x (0.746) x (6800 hrs) x ($0.05/kWh) x (0.15) x (0.25) = $2,272
.90
Annual energy cost = $48,792 + $2,272 = $51,064″

Pic courtesy of Gunjan2021 Pixaby License

I encourage you to calculate this self generated utility cost for your facility. Also keep in mind that this example is using $0.05/kWh, this example was form 2004, today the average industrial sector cost in the US is $0.0747 (see more here). This annual cost puts so many things into perspective. First and foremost the importance of Maintenance. Even more specific, the preventative maintenance costs become much lower than the impact of even one small oversite. Here is an example from the Department of Energy that discusses a specific and common maintenance issue and it’s annual impact.

“A compressed air system that is served by a 100-horsepower (hp) compressor operating continuously at a cost of $0.08/kWh has annual energy costs of $63,232. With a dirty coalescing filter (not changed at regular intervals), the pressure drop across the filter could increase to as much as 6 psi, vs. 2 psi when clean. The pressure drop of 4 psi accounts for 2% of the system’s annual compressed air energy costs. (or an increase of $1,265 per year)”

The realization of the dollars spent for compressed air certainly pushes the priority of maintenance. If we extrapolate from the above filter example, we can see that a 4 psi pressure drop in that system increased the cost by $1265 per year. We need to then ask ourselves, what other areas could be causing a pressure drop or stressing the motor? And if there is an issue upstream to this issue, will it cause even more issues, or more pressure drops?

There are many tips, tools, websites, YouTube videos and more, out there that address the recommended maintenance of your compressor and system. Many of you already have specific guidelines for your precise system, and set maintenance schedules in place. Below is a sample checklist (not all-inclusive) of maintenance items to watch for with your compressor in case you need a starting point. If left unchecked and or uncorrected, any of these (if an issue) will cost your company money – over time, lots of money.

  • Visually Inspect Air Compressor
  • Check moisture traps
  • Change Air Filters
  • Change Oil Filters
  • Change Oil/Water Separators – could (should) be many of these on the lines
  • Change Oil Separator O-Ring if necessary
  • Inspect Couplers, Hubs and Shaft Seals
  • Check Drive Belts condition if applicable
  • Check and Log Drive Motor Bearing Temps
  • Check and Log Fan Motor Bearing Temps
  • Change Oil if necessary
  • Check and Log Oil Cooler Temps
  • Check and Log After Cooler Temps
  • Blow Out Coolers

I would be amiss if I finished this blog without mentioning the perils of pressure leaks. The Compressed Air and Gas Institute stated that a single 1/4″ leak, can cost you between $2500 and $8000 per year (CAGI article). Imagine the impact of several leaks!!!

How do I find leaks? I’m glad you asked. The first step is to walk your lines and check any or all of the following areas for leaks or damage.

  • Couplings
  • Hoses
  • Tubes
  • Fittings
  • Point-Of-Use Devices
  • Pipe Joints
  • Quick Disconnects
  • Filters
  • Regulators
  • Lubricators
  • Condensate Traps
  • Valves
Ultrasonic Leak Detector

A great way to identify leaks is to use our Ultrasonic Leak Detector to listen for leaks. Look for and ask the technicians if there seems to be a change in productivity. Install Pressure Regulators and gauges at each point of use in your facility – monitor and log these pressures often. Once you find an issue, no matter how small, correct it. A small leak adds up $$$ over the hours, weeks, and months.

EFC

In addition to leaks, there are many times that air is wasted by being blown on empty space (i.e. the space between items on your conveyor). you, please look at our Electronic Flow Control (EFC) product, this device gives you an out of the box automation solution that can be set up in minutes and save thousands. There are so many clogged and leaking pipes, bad hoses inside many plants, this coupled with using an poor performing Air Gun, or Air Nozzle all have large dollar impacts for your company. EXAIR has products that can help in all of these areas…

In parting, please keep in mind that many Utility companies offer incentives to companies that take an initiative to reduce their energy footprint. In our current time of inflation this is a real way to reduce costs, many times significantly. We are here to help. Please contact us for assistance in dramatically reducing both your utility costs, and your environmental impact.

Pic courtesy of PIRO4D Pixaby License

Thank you for stopping by. Please reach out if you have any questions about this Blog, or any of EXAIR’s amazing products.

Brian Wages
Application Engineer
E-mail: BrianWages@EXAIR.com
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