• Air Compressor Emergencies and How to Handle Them

    Air compressor emergencies can be very serious, resulting in personal damage and the breakdown of equipment. It is crucial that anyone involved in the process of compressing air is trained and aware of potential dangers. If you are working in an area you are unfamiliar with while using an air compressor, then take some time to look around for potential hazards, ask the owner questions about what is in the area you will be working. When operating an air compressor, be sure to read the handbook before using it. Follow the instructions precisely as each unit can vary.

    When compressing air, keep the air pressure at the manufacturer recommended level. Check the gauge regularly and ensure it is working as intended so that you do not get a false reading. When operating an industrial air compressor it is important to use a hose reel, especially if your company has multiple air tools. This helps keep the work place more organized and efficient, essentially preventing wear and tear on the hoses. Hose reels also function to prevent tripping hazards, avoid air leaks and increase the overall productivity for the staff.

    Not only can air leaks present a safety hazard, but can also cost a company potentially thousands of dollars a year depending on the size and amount of leaks. Therefore, identifying them as quickly as possible is crucial. Some signs of an air leak are; hissing sounds, lack of air pressure, the gauge reading an amount that is not equal to the amount used, and/or lack of air flow.

    When dealing with an air compressor malfunctions, it’s crucial to be aware of back-ups and rentals available to you. Using qualified staff or sub-contractors to conduct regular maintenance on the air compressor units, a scheduled walk through and inspection of all the involved equipment can prevent leaks, fires and help make the units more efficient. There are many different condensate management devices, including zero loss drains, timed automatic drains, and oil/water separators that can help you lengthen the service life of your air receivers and lubricants by removing condensate efficiently, and keep you in compliance with regulations regarding condensate disposal. Make sure that repair technicians are up to date on the latest aspects of repairing, rebuilding and maintaining a wide range of equipment.

  • Used Air Compressors Might Be Better

    An industrial air compressor is a machine that is used to convert power into energy by pressurizing and compressing air, which is then released in quick bursts. There are numerous methods of air compression, divided into either positive displacement or negative displacement types.

    Compressed air is commonly used in industrial settings as a form of power output. It is used in equipment ranging from pneumatic equipment to engines. Most warehouses have their own air compressors, to speed equipment repair. Mechanical devices can be attached to an extended hose, and the power of compressed air is utilized to drive nails, run rotary gadgets, and even power forklift engines. For industrial applications, a small commercial grade compressor will not cut it. An industrial shop is going to want an industrial sized air unit, with a large air tank and powerful compressor.

    Unfortunately, top quality industrial sized air compressors can be quite pricy. This is where strategic thinking becomes important. Some businesses have the cash to afford huge and brand new models of industrial air compressors. An independent business will likely focus on economy, which would mean making do with smaller units or hunting down a used model.

    Pre-owned, or used, air compressors are a great way to save money. Not only will you be able to purchase an air compressor at an affordable price, but you will also be able to get a quality piece of equipment. Used or pre-owned equipment can be less expensive because it has already depreciated in value or is no longer required by the original owner. However, this reduction in price does not translate to a reduction in quality. Most pre-owned industrial air compressors are in great shape, run smoothly, contain all the necessary parts, and operate efficiently. In fact, many of these pre-owned models are still under warranty, which reduces risk to the buyers.

    Air compressors are not sensitive equipment, and it is still possible to find replacement parts for most models. Those made by a established reputable manufacturer can last for decades. Many used air compressor models will still operate to their original specifications. It is generally the accessories that need replacement or better maintenance. These accessory parts are easy to come across to replace some of the worn out, depreciated ones found on pre-owned industrial air compressors. Purchasing a pre-owned air compressor is a terrific way to save money on a great quality machine.

  • Energy Savings Using Refrigerated and Desiccant Air Dryers

    If you are searching for a way to get harmful moisture out of your compressed air system, a refrigerated air dryer may be the most efficient solution to your problem. Too much moisture in your compressed air system can slow the performance of your machine and potentially destroy it, costing you time and money. A refrigerated air dryer removes detrimental moisture from your compressed air system by cooling the moisture until it is compressed into droplets that are then drained away. Using the refrigeration system has several benefits that cut energy costs. Cycling and non-cycling refrigerated air dryers are available depending on if you have a small air system requiring less horse power or a larger system requiring more horse power.

    The desiccant air dryer is the most common air dryer because they have been around much longer than the newer energy saving ones. The desiccant dryer uses more energy by passing compressed air through a pressure vessel where the air is brought down in temperature so the water vapor does not condense. The refrigerated air dryer functions to reduce your energy cost, by using two heat exchangers. The two exchangers use cold incoming air to cool the hot incoming air, making it possible to use a smaller compressor, essentially reducing the energy consumption. A refrigerated dryer also takes a lot of the work load off of the desiccant dryer, saving on energy costs and giving the desiccant dryer an increased lifespan and greater reliability. Most compressed air systems do not come with a stand-alone refrigerated dryer; they are most commonly used to coincide with a desiccant dryer.

    Giving a desiccant air dryer a longer life span with the assistance of a refrigerated air dryer, may be ideal for your budget. If you are interested in cutting energy costs and managing a more energy efficient hybrid dryer that saves you money in the short and long term, you may want to appease your compressed air system by adding to it the latest and most innovative technology. The U.S. Department of Energy estimates that about ten percent of all energy generated in the United States is used by air compressors. These statistics also indicate that about half of this energy is in fact wasted. Refrigerated air dryers work to reduce the harmful effects on the environment by diminishing wasted energy. Reliability coupled with saving money, while lessening the impact of industrial waste, contributes to overall satisfaction.

  • Condensate Management for Industrial Air Compressors

    Anyone who owns an air compressor understands the importance of properly maintaining their machine. A crucial tool in this process is a condensate management system. So long as these systems are functional, they are very important components of all air compressor systems because they separate the small amount of oil from the condensate that gathers in the air compressors. This allows the caretakers of the air compressor to perform simple, ecological, and economical disposal of any leftover waste.

    Since unwanted and excess oil can be a serious problem in an air compressor system, oil and water separators or condensate managements systems are installed to reduce the waste oil concentration. However, before disposing of this oil into the sewer, you must make sure to reduce it to legal limits. If you do not do this, you could be harshly punished for disobeying the law and potentially poisoning the nearby environment. Most separators naturally reduce the oil to a level permitted for disposal, but always check with your local municipality to be sure everything is alright. It is also good practice to periodically send out a sample of the reduced oil for analysis, in order to be confident that you are correctly following the rules.

    In the past, people would use a waste management company to come and remove collected condensate from their site. This, however, came only at a considerable cost. Today there are a number of different types of condensate management systems which can used independently within a company, and can separate almost any compressor fluid from the condensate. This allows the 98% of the condensate that is solely water to be disposed on site. The small percentage of remaining oil can then be collected and recycled, or disposed of at a much cheaper rate than what was possible before.

    When one owns an industrial air compressor, there are many benefits of using a condensate management system to maintain and clean it. One of these benefits is that these systems will protect your air compressor from damage by removing harmful excess oils. You will also ensure that the compressed air that is being delivered to your company is clean, protecting your product from any possible harm. You will also be saving a great amount of money in waste removal and fines, because you can clean your air compressors without the help of a second party. Finally, condensate management systems allow companies to be environmentally conscious and safe during waste disposal by removing any toxic oils from water that could otherwise be safely drained into the environment.

  • Properly Maintaining an Industrial Air Compressor

    Industrial air compressors are a crucial and fundamental part of the plant's operation (so crucial, in fact, that compressed air is also known as the fourth utility). With so much emphasis on the lifetime of these machines, air compressor maintenance has become key to conserving a company’s funds. When properly maintained, industrial air compression systems decrease downtime, increase production rates, and improve the quality of the air being produced. Two system components that require routine maintenance are the compressor package and the compressor drives. A lot of minor problems can be attended to simply by cleaning, replacing parts as necessary, and doing away with harmful conditions that could hinder the compressor’s working ability. Using a professional air compressor maintenance service will reduce safety hazards and increase the reliability of the air compressor.

    Components that need to be maintained by the compressor package are the heat exchanger surfaces, the compressors, the air-lubricant separator, the air-inlet filter, the lubricant, and the lubricant filter. Heat exchanger surfaces should be kept clean; if they are not, the air compressor will be less efficient. Air lubricant separators usually perform at 2 or 3psid when new and working at full capacity. Manufacturer manuals suggest changing the air lubricant separators when it reaches a 10psid. Air compressor lubricant often becomes acidic and deteriorates the equipment, therefore decreasing system efficiency. Lubricant-injected rotary compressors require lubrication to be applied to bearings, gears, and contacting rotor surfaces. To prevent reduction of compressor capacity, air-inlet piping should also be cleaned regularly.

    The compressor drive must be maintained through lubrication and cleaning. It is necessary to keep the air passages clean and clear of obstruction due to the fact that motors require cleaning. All enclosed motor fins should be free of debris to allow the compressor drive to cool. For motors with bearing grease fittings, first clean the grease fitting and remove the drain plug. Then, add new high-quality grease, run the motor for an hour, and finish by replace the drain plug. Excessive bearing wear can be caused by tight belts; on the other hand, loose belts can slip and create wasted energy. It is efficient to check and adjust belts regularly to reduce stretching and deterioration.

    Lack of maintenance can cause excessive energy consumption, high operating temperatures, poor moisture control, and excessive contamination. Keep in mind that all industrial air compressor equipment should be maintained in accordance with the manufacturers recommendations. Depending on ambient conditions, it may be prudent to carry out maintenance more often than advised by compressor manufacturers.