Tag: planned maintenance

The Importance Of Planned Maintenance

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“If it ain’t broke, don’t fix it” is a common phase that we’ve all heard. It’s also a recipe for disaster. Think about it:

  • Corrective maintenance is ALWAYS more expensive. An oil change in your car might set you back $50 and an hour or so, but when (not if) emulsified, contaminated oil causes your engine to seize, that’s a four (if not five) figure repair bill.
  • Corrective maintenance is also ALWAYS more inconvenient. “If you don’t schedule time for maintenance, your equipment will schedule it for you.” ’nuff said.

Anything with moving parts is going to live its best life if you maintain it properly, and your air compressor has a LOT of moving parts that are CONSTANTLY under a good deal of mechanical stress. Your compressor’s manufacturer almost certainly has a published list of recommended maintenance items, with a schedule of when they should be performed. While that list is going to vary, depending on the type of compressor you have, some of the more common items include:

  • Intake Filter: This is what removes environmental contamination from the air that the compressor is drawing in. When (not if) it gets dirty, your compressor works harder. That means higher power consumption, which means higher operating costs. It also means more heat is generated, which can wear machinery out WAY faster than it should.
  • Lubricating Oil: If your compressor is oil lubed, that oil needs to be changed periodically. The schedule for this is always going to be a certain number of hours of operation, or a certain period of time, whichever comes first. That first one is because the amount of particulate contamination is going to be roughly proportional to the amount of time the lubricated parts spend in motion. The latter is because oil just loses some of its critical lubricating properties over time.
  • Drive Equipment: The two main methods of connecting a motor to a compressor are direct drive shaft coupling, or a system of pulleys and belts. Making sure they stay aligned is critical to their operation. Depending on the nature of the drive, lubrication, tension, and physical condition are all important maintenance points as well.
  • Safety (Pressure Relief) Valve: This valve releases excess pressure if the pressure switch fails and the compressor keeps running. At the very least, this keeps your operating costs in line — the higher the discharge pressure, the higher the power consumption. And, worst case, it makes sure you don’t over pressurize the system. If your receiver tank blows up, that’s a bad day.
  • Receiver Tank Condensate Drain: While there are a number of automatic condensate drains available for industrial air compressors, many owners choose to manually drain condensate from the wet receiver. This should be done AT LEAST once a day, with some manufacturers recommending it more frequently than that. This is critical because standing water can corrode the tank from the inside over time. It can also lead to moisture carryover into the header, and it reduces the volume of available air storage in the tank.
  • Keep Clean To Keep Cool: Air compressors generate heat, both from the friction between the moving parts, and the compression itself (Gay-Lussac’s Law states that the pressure of a given mass of gas is directly proportional to its temperature as long as the volume is constant.) Some compressors are air cooled; others are water cooled. Whichever yours is, keep the heat transfer surfaces — like the fins on the air end housing (air cooled) or fins of the heat exchanger (water cooled) — clean & free of debris to maximize the heat transfer, keeping your compressor as cool as possible.

Again, these are just some of the more common maintenance items for an air compressor. If you want yours to live its best life, keep up with the manufacturer’s recommendations. Oftentimes, maintenance records are required for warranty consideration, should something fail. If you have questions about getting the most out of your compressed air system, give me a call.

Russ Bowman, CCASS

Application Engineer
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Any Machine Is A Smoke Machine If You Operate It Wrong Enough

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While most folks think this old adage applies only to personnel not being familiar with the OPERATION of machinery, it’s also a reminder that ‘operating it right’ necessarily includes keeping up with regularly scheduled preventive maintenance. This includes pretty much anything with moving parts and components in a system that fluids might flow through. But today, I’m going to focus on certain parts of a typical industrial compressed air system. Failing to change oil in an industrial air compressor, for example, will “let the smoke out” just as fast (and sometimes faster) than anything a day-to-day operator can do to it.

The folks at Compressed Air Challenge are dedicated to (and this is right from their website) “helping you enjoy the benefits of improved performance of your compressed air system.” Their “Best Practices For Compressed Air Systems” stresses the importance of:

  • Proper maintenance as a means to ensure operational efficiencies and systems reliability.
  • Continuous checks for preventive maintenance items.
  • Implementing a detailed system maintenance program, including schedules of required maintenance, and records of its performance.

And that’s just from the introduction. It goes on to list the major components that should be included in this program: the compressor, heat exchanger surfaces, lubricant, lubricant filter, air inlet filter, motors, belts, and air/oil separators. The steps for properly maintaining these components range from standard housekeeping practices, to mechanical operations that are typically performed by trained operators, to services that might be best handled by qualified manufacturer’s representatives:

  • Cleaning: The air compressor itself, and any heat transfer surfaces, have to be kept clean & free of contaminants. Moving parts generate heat, and dirt, scale, corrosion, etc. are essentially insulation that’ll prevent that heat from being dissipated.
  • Lubrication: It’s critical to service the lubricant & any lubricant filtration per the manufacturer’s specifications. Again – not doing this is one of the best ways to “let the smoke out” of any machine.
  • Power transmission components: Regular inspection, including alignment checks, of belts & couplings is probably the 2nd best way (next to lubrication maintenance) of keeping the moving parts of the air compressor, and its drive, in good working order.
  • Intake filter: An air compressor will try to compress anything that’s drawn in with its air intake. If it pulls in particulate, that can damage internal surfaces, especially moving parts with tight tolerances to each other, like pistons & cylinders, scrolls & casings, rotary screws & chambers, impellers & volutes, etc., depending on the type of compressor. Plus, anything that makes its way into your compressed air header will also have a chance to foul up your pneumatic tools & devices, and get on anything that you use compressed air to blow off.
  • Motors & drives: Simply put, if you can’t turn the shaft of the compressor, it won’t compress any air. Periodic checks of electric motor windings, bearings, ‘soft start’ capacitors, phase converters, etc., are among the basic maintenance items that operators can inspect.

In addition to the compressor itself, the air distribution system should be properly maintained as well:

  • Filtration: The intake filter is there primarily to protect the compressor. Many times, the aforementioned tight tolerances between the moving parts in the air end will result in (hopefully) small amounts of particulate being carried over into the compressor discharge. There’s usually a main particulate filter, along with a dryer (for entrained moisture – the intake filter won’t do anything about that either), and possibly even a coalescing filter for oil & oil vapor. Good engineering practice calls for servicing those filters when the differential pressure across them reaches a certain value (5psid is a common one), but those elements, being relatively inexpensive, can also be replaced during regularly scheduled downtime as well.
  • Leak detection & repair: Leaks make the compressor run harder, so any reduction in the amount of compressed air leakage will, by definition, reduce the wear & tear on the compressor. EXAIR makes it easy to find them with the Ultrasonic Leak Detector.
  • Filtration Part 2: Don’t forget about contaminants that can enter the system downstream of the compressor, too. Iron pipe headers are subject to internal corrosion, which can result in rust particulate. Environmental pollution can enter if flanges or fittings are broken & made up during maintenance. Point of use filtration, like EXAIR Automatic Drain Filter Separators, can keep this debris (and any moisture that’s not removed by the compressor’s dryer) out of your pneumatic tools & products.
EXAIR has a number of Accessories and Optimization Products to help you get the most out of your compressed air system.

Compressed air is expensive enough without throwing in a bunch of easily preventable repair costs. Schedule time for maintenance, or it’ll schedule the time for you…and it may even send you a ‘smoke signal’ when it’s ready. If you’ve got questions about getting the most out of your compressed air system, we’ve got answers.

Russ Bowman, CCASS

Application Engineer
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The Importance Of Preventative Maintenance

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The first brand-new car I ever bought was a 1995 Ford Escort wagon. I was playing in a band pretty much every weekend (and the occasional weeknight), and my digital piano case fit perfectly in the back – I took it with me to make sure when I went to test drive it. Over eleven years, I put just shy of 200,000 miles on it, and, aside from gas, oil, and tires, had a little under $1,000 in repair costs.

There used to a legendary warning about not buying a car made on a Monday (since the auto workers were presumably recovering from the weekend) or a Friday (since they were equally presumably distracted by getting ready for the weekend). Some folks only buy a particular make of automobile (or shun another) because that’s the make their favorite race car driver (or least favorite) drives. I don’t know what day of the week that Escort was made, and I couldn’t tell you which race car drivers are loyal to the Ford Motor Company, but I CAN tell you that I followed the manufacturer’s recommended maintenance schedule to a “T”. And I’m pretty sure that had a LOT more to do with that little red wagon’s longevity than a bunch of auto workers’ attention to detail (or lack thereof) or who’s popular on the NASCAR circuit.

The same is true for many components that make up your compressed air system. You’re going to want to change the lubricating oil in your compressor on a regular basis (as recommended by the manufacturer) for the exact same reasons you change the oil in your car’s engine. You need to replace particulate elements in compressed air filters, same as you need to periodically replace your car’s air filter.

For point-of-use devices – like most EXAIR compressed air products – preventative maintenance largely comes down to replacing those particulate elements in your filters. Products like our Air Knives, Air Wipes, Air Amplifiers, E-Vac Vacuum Generators, Reversible Drum Vacs, and Vortex Tubes all have relatively small passages that the air has to flow through, so it’s critical to their performance to supply them with clean air. In fact, if you DO supply these products with clean air, they’ll run darn near indefinitely, maintenance free. That’s why all of our product Kits include a Filter Separator with a 5 micron particulate element, and a centrifugal element for moisture removal.

Good engineering practice calls for point of use filtration and moisture removal, such as that provided by EXAIR Filter Separators.

One question we get on a pretty regular basis is, how often do you have to change the particulate element in our Filter Separators. Good engineering practice calls for replacing that element when the differential pressure across the filter reaches 5psi. Now, you can measure the pressure on either side of the Filter Separator and change the element when the outlet pressure drops 5psi from the inlet. If you can shut down long enough to do so, that’s an efficient way to do it – that ensures you get the most ‘bang for your buck’ from that element.

Of course, those elements don’t cost all that much – but shutting down a production line, for even the few minutes it takes to replace an element, can get VERY costly. Facilities that run 24/7 will usually plan some downtime for periodic maintenance on SOMETHING…and they’ll just replace their Filter Separator’s particulate elements during those downtimes.

If you’ve got questions about getting the most out of our products – and, by extension, your compressed air system – give me a call.

Russ Bowman, CCASS

Application Engineer
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The Importance Of Preventative Maintenance

Published on by Russ BowmanLeave a comment

The first new car I ever bought was a 1995 Ford Escort Wagon. It got GREAT gas mileage (which was important for my 25 mile one-way commute to the day job), and had ample room to haul my keyboards & amplifier rig (which was just as important to my side hustle as a potential rock star). Since it only had four miles on the odometer – and, it was the first purchase I ever financed over a period of YEARS, I decided to follow the owner’s manual’s maintenance schedule religiously. And it paid off: I got eleven years and just shy of 200,000 miles out of one of the least expensive cars ever made. It was actually still running like a top when I sold it to “upgrade” to a minivan, which suited my needs at the time for a vehicle that fitted the car seats for our little boys (who are now a U.S. Marine and a hippie college student, respectively). I actually followed the maintenance schedule for that minivan too, and got 14 years & almost 180,000 miles out of it, without a major breakdown.

Whether you call it “preventive”, “preventative”, “scheduled”, or “planned” maintenance, there’s an old adage that applies in any case:

“If you don’t plan maintenance, it’ll plan itself without regard to your schedule.”

While following the proverbial “owner’s manual’s maintenance schedule” doesn’t guarantee against catastrophic failures, it’s awfully good insurance against them. For your privately owned vehicles, I encourage you to follow the owner’s guide as best you can. For your compressed air system – from the compressor to the devices it provided compressed to (and everything in between) – there’s likely similar documentation to follow, and for good reason. Consider:

  • Air compressor maintenance. Failure to properly maintain a compressor can increase energy consumption by not keeping it operating as efficiently as possible. For example, just like not periodically replacing your car engine’s air filter will impact your gas mileage, failure to do the same for your compressor’s intake air filter will impact its production of compressed air.
  • Air leaks are costly. Not only do they waste the money you spent on running the compressor (a leak that’s equivalent to a 1/16″ diameter hole costs you over $700.00 annually – let me know if you want to do the math on that), your system pressure takes a hit too. Pressure drop caused by those leaks (plural because there’s rarely just one) can create what’s known as “false demand”, which costs you money as well: every 2psi increase in compressor discharge pressure makes for a 1% increase in power consumption. So, it’s really important to stay on top of them. Regularly scheduled surveys with an instrument like EXAIR’s Model 9207 Ultrasonic Leak Detector allows you to quickly find – and then fix – those leaks.
EXAIR Model 9207 Ultrasonic Leak Detector comes with everything you need to find out if you have a leak (with the parabolic disc, lower right) and then zero in on its exact location (with the tubular extension, bottom).
  • Filters, part 1: I already mentioned the compressor intake filter above, but the rest of the filters in the system need attention from time to time as well. Filter manufacturers typically call for replacing the element in a filter when pressure drop reaches a certain point. I’ve seen published values of 2-5psi for that. Of course, that may not occur at a convenient time to shut down everything downstream of that filter, so lots of folks replace those elements as part of planned maintenance evolutions that require depressurization of that particular part of the system anyway. Dirty filters mean you have to increase their inlet pressure to maintain the same outlet pressure you had when they were clean – and the same 1% increase in power consumption for a 2psi pressure increase applies here too.
  • Filters, part 2: most compressed air operated products have small passages that the air has to flow through, and without filtration, those can get clogged with dirt that the intake filter doesn’t catch, solid particulate from compressor ‘wear & tear’, and rust from header pipe corrosion, just to name the “usual suspects”. An argument could be made that installation & upkeep of properly rated Filter Separators at the point of use of these devices is part of those devices’ planned maintenance. In any case, it’s akin to the awfully good insurance against catastrophic failures I mentioned earlier.
Good engineering practice calls for point of use filtration and moisture removal, such as that provided by EXAIR Filter Separators.

Again, many of the components that make up a typical industrial compressed air system will have a manufacturer’s recommended maintenance schedule, but if they don’t, how can you properly plan for it? Monitoring of certain system parameters can be a valuable tool for determining how often some planned maintenance should be performed:

  • Power consumption of the compressor. The benefit of measuring & logging this on a regular basis is, if you see sudden changes, you can start looking for what’s causing them. Maybe a bearing or belt is wearing out, some leaks have popped up, or a filter’s clogged. In any case, it’s an indication that SOMETHING needs attention. Large industrial compressors might even have power monitoring in their control scheme. If not, there ARE other parameters you can measure…like:
  • Pressure and flow. EXAIR’s Pressure Sensing Digital Flowmeters make monitoring these parameters quick and easy. Managing the readings can be done with our USB Data Logger, or you can get it on your computer, via a Zigbee Mesh Gateway, with our Wireless Models.
EXAIR Digital Flowmeters are made for iron, copper, or aluminum compressed air pipe in sizes from 1/2″ to 8″ diameters. Options include Pressure Sensing, Wireless Output, USB Data Logger, Hot Tap, and Metric display.

At EXAIR, we’re committed to helping you get the most out of your compressed air system. If you’d like our help with that, give me a call.

Russ Bowman, CCASS

Application Engineer
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Featured image courtesy of Compressor1 – creative commons license