Compressor Maintenance: Steps to Minimize Wear

While I was still in college, I worked in a meat processing plant as a Project Engineer in the maintenance department. During my time in the maintenance department I learned the importance of proper maintenance on machines. A meat processing plant is one of the most taxing environments on machines as they will have to survive in extreme cold temperatures to extreme hot temperatures; they are also put through deep sanitation wash downs multiple times a day sometimes for periods of over an hour. The plant really put into perspective the importance of preventative maintenance of machines. This includes utilities such as a boiler and of course your air compressor.

Industrial Air Compressors
Neglected air compressors can cause a lot of issues ranging from expensive repairs to a decrease in efficiency. Wear and tear placed on the motor of an air compressor can cause the compressor to produce less compressed air (SCFM) at the same power consumption. This means you are paying the same amount of money for less compressed air.

A primary focus to prevent an increased amount of wear on your compressor motor is to seal up compressed air leaks. Leaks can cause the compressor to cycle more often and/or refill receiver tanks on a more frequent basis, causing the motor to run more often. With the motor having to run more often to keep the air present, it will wear down faster. Using EXAIR’s Ultra Sonic Leak detector, leaks can be found in the pipes so that they can be sealed up.

EXAIR Ultrasonic Leak Detector
Another important maintenance is to make sure that the compressor gets cleaned. As the motor runs excess heat is generated; the heat generated then needs to be dissipated which is done by exhausting air through vents. If these vents become dirty or blocked and the air cannot escape then the temperature of the motor and winding resistance will increase; this in turn will shorten the life of the motor and increase the energy consumption. Using one of EXAIR’s Super Air Nozzles is a sure way to keep your compressor vents clean and dust free in a quiet and efficient manner.
EXAIR Nozzles
There are many other items that require maintenance over time such as keeping belts in good condition and the drain traps clean. Good maintenance on any item whether it’s a production machine or  air compressor keeps it running a peak performance helping you save money and headaches in the long run. 

If you have any questions about compressed air systems or want more information on any EXAIR’s of our products, give us a call, we have a team of Application Engineers ready to answer your questions and recommend a solution for your applications.

Cody Biehle
Application Engineer
EXAIR Corporation
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Intelligent Compressed Air: Maintaining an Efficient Compressor System

compressor

The electrical costs associated with generating compressed air make it the most expensive utility in any industrial facility. In order to help offset these costs, it’s imperative that the system is operating as efficiently as possible. I’d like to take a moment to walk you through some of the ways that you can work towards making your compressed air system more efficient.

The first step you should take is to identify and fix any leaks within the distribution piping. According to the Compressed Air Challenge, up to 30% of all compressed air generated is lost through leaks. This ends up accounting for nearly 10% of your overall energy costs!! To put leaks in perspective, take a look at the graphic below from the Best Practices for Compressed Air Systems handbook.

air leaks cost

Compressed air leaks don’t just waste energy, but they can also contribute to other operating losses. If enough air is lost through leaks, this can also cause a drop in system pressure. This can affect the functionality of other compressed air operated equipment and processes. This pressure drop can affect the efficiency of the equipment causing it to cycle on/off more frequently or to not work properly. This can lead to anything from rejected products to increased running time. With an increase in running time, there’s also the need for more frequent maintenance and unscheduled downtime.

You can perform a compressed air audit in your facility using an EXAIR Model 9061 Ultrasonic Leak Detector. If you’d prefer someone come in and do this for you, there are several companies that offer energy audit services where this will be a focal point of the process.

ultrasonic_2
EXAIR Ultrasonic Leak Detector

Speaking of maintenance, proper compressor maintenance is also critical to the overall efficiency of the system. Like all industrial equipment, a proper maintenance schedule is required in order to ensure things are operating at peak efficiency. Inadequate compressor maintenance can have a significant impact on energy consumption via lower compressor efficiency. A regular preventative maintenance schedule is required in order to keep things in good shape. The compressor, heat exchanger surfaces, lubricant, lubricant filter, air inlet filter, and dryer all need to be maintained. This can be done yourself or through a reputable compressor dealer. The costs associated with these services are outweighed in the improved reliability and performance of the compressor. A well-maintained system will not cause unexpected shutdowns and will also cost less to operate.

The manner in which you use your compressed air at the point of use should also be evaluated. Inefficient, homemade solutions are thought to be a cheap and quick solution. Unfortunately, the costs to supply these inefficient solutions with compressed air can quickly outweigh the costs of an engineered solution. An engineered compressed air nozzle such as EXAIR’s line of Super Air Nozzles are designed to utilize the coanda effect. Free, ambient air from the environment is entrained into the airflow along with the supplied compressed air. This maximizes the force and flow of the nozzle while keeping compressed air usage to a minimum.

Another method of making your compressed air system more efficient is actually quite simple: regulating the supply pressure. By installing pressure regulators at the point of use for each of your various point of use devices, you can reduce the consumption simply by reducing the pressure. This can’t be done for everything, but I’d be willing to bet that several tasks could be accomplished with the same level of efficiency at a reduced pressure. Most shop air runs at around 80-90 psig, but for general blowoff applications you can often get by operating at a lower pressure. Another simple, but often overlooked, method is to simply shut off the compressed air supply when not in use. If you haven’t yet performed an audit to identify compressed air leaks this is even more of a no-brainer. When operators go to lunch or during breaks, what’s stopping you from just simply turning a valve to shut off the supply of air? It seems simple and minute, but each step goes a long way towards reducing your overall air consumption and ultimately your energy costs.

Tyler Daniel
Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

 

Image taken from the Best Practices for Compressed Air Systems Handbook, 2nd Edition